wsm L4100 Workshop Manual

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Page 1

WORKSHOP MANUAL

KiSC issued 08, 2012 A

TRACTOR

L4100

Page 2

TO THE READER

KiSC issued 08, 2012 A

This Workshop Manual tells the servicing personnel about the mechanism, servicing and

maintenance of the L4100. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing".

Q Information

This section contains information below.

• Safety First

• Safety Label

• Specification

• Dimension

Q General

This section contains information below.

• Engine Identification

• Model Identification

• General Precautions

• Maintenance Check List

• Check and Maintenance

• Special Tools

Q Mechanism

This section contains information on the structure and the function of the unit. Before you continue

with the subsequent sections, make sure that you read this section.

Refer to the latest version of Workshop Manual (Code No. 9Y021-01870 / 9Y021-18200) for the

diesel engine / tractor mechanism that this workshop manual does not include.

Q Servicing

This section contains information below.

• Troubleshooting

• Servicing Specifications

• Tightening Torques

• Checking, Disassembling and Servicing

All illustrations, photographs and specifications contained in this manual are of the newest

information available at the time of publication.

KUBOTA reserves the right to change all information at any time without notice. Since this manual includes many models, information or illustrations and photographs can show

more than one model.

January, 2009

Page 3

I INFORMATION

KiSC issued 08, 2012 A

Page 4

INFORMATION

KiSC issued 08, 2012 A

CONTENTS

1. SAFETY FIRST ............................................................................................................................. I-1

2. SAFETY DECALS .......................................................................................................................... I-4

3. SPECIFICATIONS.......................................................................................................................... I-6

4. TRAVELING SPEEDS.................................................................................................................... I-7

5. DIMENSIONS ................................................................................................................................. I-8

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L4100, WSM

SAFETY FIRST

DANGER

WARNING

CAUTION

IMPORTANT

NOTE

KiSC issued 08, 2012 A

INFORMATION

1. SAFETY FIRST

• This symbol, the industry's "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 or use this unit.

• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• Indicates that equipment or property damage could result if instructions are not followed.

• Gives helpful information.

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BEFORE YOU START SERVICE

• Read all instructions and safety instructions in this manual and on your machine safety decals.

• Clean the work area and machine.

• Park the machine on a stable and level ground, and set the parking brake.

• Lower the implement to the ground.

• Stop the engine, then remove the key.

• Disconnect the battery negative cable.

• Hang a "DO NOT OPERATE" tag in the operator station.

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START SAFELY

• Do not do the procedures below when you start the engine. – short across starter terminals – bypass the safety start switch

• Do not alter or remove any part of machine safety system.

• Before you start the engine, make sure that all shift levers are in neutral positions or in disengaged positions.

• Do not start the engine when you stay on the ground. Start the engine only from operator's seat.

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INFORMATION

OPERATE SAFELY

• Do not use the machine after you consume alcohol or medication or when you are tired.

• Put on applicable clothing and safety equipment.

• Use applicable tools only. Do not use alternative tools or parts.

• When 2 or more persons do servicing, make sure that you do it safely.

• Do not operate below the machine that only a jack holds. Always use a safety stand to hold the machine.

• Do not touch the hot parts or parts that turn when the engine operates.

• Do not remove the radiator cap when the engine operates, or immediately after it stops. If not, hot water can spout out from the radiator. Only remove the radiator cap when it is at a sufficiently low temperature to touch with bare hands. Slowly loosen the cap to release the pressure before you remove it fully.

• Released fluid (fuel or hydraulic oil) under pressure can cause damage to the skin and cause serious injury. Release the pressure before you disconnect hydraulic or fuel lines. Tighten all connections before you apply the pressure.

• Do not open a fuel system under high pressure. The fluid under high pressure that stays in fuel lines can cause serious injury. Do not disconnect or repair the fuel lines, sensors, or any other components between the fuel pump and injectors on engines with a common rail fuel system under high pressure.

• Put on an applicable ear protective device (earmuffs or earplugs) to prevent injury against loud noises.

• Be careful about electric shock. The engine generates a high voltage of more than DC100 V in the ECU and is applied to the injector.

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PREVENT A FIRE

• Fuel is very flammable and explosive under some conditions. Do not smoke or let flames or sparks in your work area.

• To prevent sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.

• The battery gas can cause an explosion. Keep the sparks and open flame away from the top of battery, especially when you charge the battery.

• Make sure that you do not spill fuel on the engine.

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INFORMATION

KEEP A GOOD AIRFLOW IN THE WORK AREA

• If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.

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DISCARD FLUIDS CORRECTLY

• Do not discard fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you discard oil, fuel, coolant, electrolyte and other dangerous waste.

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PREVENT ACID BURNS

• Keep electrolyte away from your eyes, hands and clothing. Sulfuric acid in battery electrolyte is poisonous and it can burn your skin and clothing and cause blindness. If you spill electrolyte on yourself, clean yourself with water, and get medical aid immediately.

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PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all times.

• Keep the emergency contact telephone numbers near your telephone at all times.

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INFORMATION

2. SAFETY DECALS

The following safety decals (pictorial safety labels) are installed on the machine. If a decal becomes

damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.

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INFORMATION

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NOTE

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INFORMATION

3. SPECIFICATIONS

L4100

Model

Model V2203-M-E2A

Type Indirect injection, Vertical, Water-Cooled 4 cylinder diesel

Number of cylinder 4

Total displacement 2.197 L (1.341 cu.in.)

Engine

Capacities

Dimensions

Weight (with ROPS) 1464 kg (3228 lbs) 1494 kg (3294 lbs)

Travelling system

Hydraulic unit

PTO

Bore and stroke 87 x 92.4 mm (3.4 x 3.64 in.)

Net power* 29.3 kW (39.8 PS) / 2300 min

PTO power* (factory observed)

Maximum torque 141.5 N·m (14.43 kgf·m, 104.4 lbf·ft)

Battery capacity 12V, RC: 133 min, CCA: 582 A

Fuel tank 42 L (11 U.S.gals, 9.2 Imp.gals)

Engine crankcase (with filter) 7.6 L (8.0 U.S.qts, 6.7 Imp.qts)

Engine coolant 6.5 L (6.9 U.S.qts, 5.7 Imp.qts)

Transmission case 40 L (11 U.S.gals, 8.8 Imp.gals)

Overall length (without 3P) 3005 mm (118.3 in.)

Overall width (min. tread) 1490 mm (58.86 in.)

Overall height (with ROPS) 2525 mm (99.41 in.) 2378 mm (93.62 in.)

Wheel base 1845 mm (72.64 in.)

Min. ground clearance 377 mm (14.8 in.)

Tread

Standard tire size

Clutch Dry type single stage

Steering Hydrostatic power steering

Transmission Gear shift, 8 forward and 4 reverse

Braking system Mechanical, Wet disk type

Min. turning radius (with brake)

Hydraulic control system Position control

Pump capacity 30.5 L/min (8.06 U.S.gals/min, 6.71 Imp gals/min)

Three point hitch Category 1

Max. lift force

System pressure 17.7 MPa (180 kgf/cm

Rear PTO SAE 1-3/8, 6-splines

PTO /Engine speed 540 / 2208 min

Front 1145 mm (45.08 in.)

Rear 1145, 1235, 1335, 1340 mm (45.08, 48.62, 52.56, 52.76 in.)

Front 8 - 16

Rear 13.6 - 26

At lift points 1300 kg (2866 lbs)

24 in. behind lift points

Rear mount type ROPS Mid mount type ROPS

Manual Transmission

4WD

-1

(rpm)

-1

25.7 kW (34.9 PS) / 2300 min

2.6 m (8.5 ft)

1053 kg (2321 lbs)

-1

(rpm)

, 2570 psi)

(rpm)

• *Manufacturer's estimate. The company reserves the right to change the specifications without notice.

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4. TRAVELING SPEEDS

Q Manual Transmission Type

Model L4100

Tire size (Rear) 13.6 - 26

Shuttle shift

lever

Forward

Reverse Reverse

Range gear

shift lever

Low

High

Main gear shift

lever

1 1.4 (0.87)

2 1.9 (1.2)

3 3.1 (1.9)

4 6.0 (3.7)

1 4.9 (3.0)

2 6.9 (4.3)

3 11.2 (6.96)

4 21.4 (13.3)

1 1.7 (1.1)

2 2.4 (1.5)

3 3.8 (2.4)

4 7.3 (4.5)

INFORMATION

(At rated engine rpm)

km/h (mph)

The company reserves the right to change the specifications without notice.

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5. DIMENSIONS

Rear mount type ROPS

INFORMATION

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Mid mount type ROPS

INFORMATION

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G GENERAL

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GENERAL

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CONTENTS

1. TRACTOR IDENTIFICATION ....................................................................................................... G-1

[1] MODEL NAME AND SERIAL NUMBERS .............................................................................. G-1

[2] CYLINDER NUMBER ............................................................................................................. G-2

2. GENERAL PRECAUTIONS.......................................................................................................... G-3

3. HANDING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ...................................... G-4

[1] WIRING .................................................................................................................................. G-4

[2] BATTERY ............................................................................................................................... G-6

[3] FUSE ...................................................................................................................................... G-6

[4] CONNECTOR ........................................................................................................................ G-6

[5] HANDLING OF CIRCUIT TESTER ........................................................................................ G-7

[6] COLOR OF WIRING ..............................................................................................................G-8

4. LUBRICANTS, FUEL AND COOLANT......................................................................................... G-9

5. TIGHTENING TORQUES ........................................................................................................... G-11

[1] GENERAL USE SCREWS, BOLTS AND NUTS .................................................................. G-11

[2] STUD BOLTS ....................................................................................................................... G-11

[3] METRIC SCREWS, BOLTS AND NUTS .............................................................................. G-12

[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF

THREADS ............................................................................................................................ G-12

[5] PLUGS ................................................................................................................................. G-12

6. MAINTENANCE.......................................................................................................................... G-13

7. CHECK AND MAINTENANCE ................................................................................................... G-15

[1] DAILY CHECK...................................................................................................................... G-15

[2] CHECK POINTS OF INITIAL 50 HOURS ............................................................................ G-15

[3] CHECK POINTS OF EVERY 50 HOURS ............................................................................ G-18

[4] CHECK POINTS OF EVERY 100 HOURS .......................................................................... G-21

[5] CHECK POINTS OF EVERY 200 HOURS .......................................................................... G-26

[6] CHECK POINTS OF EVERY 400 HOURS .......................................................................... G-27

[7] CHECK POINT OF EVERY 600 HOURS ............................................................................. G-29

[8] CHECK POINT OF EVERY 800 HOURS ............................................................................. G-29

[9] CHECK POINT OF EVERY 1500 HOURS ........................................................................... G-29

[10]CHECK POINT OF EVERY 3000 HOURS ........................................................................... G-29

[11]CHECK POINT OF EVERY 1 YEAR .................................................................................... G-29

[12]CHECK POINTS OF EVERY 2 YEARS ............................................................................... G-29

....

[13]OTHERS.......................................................................................................................

8. SPECIAL TOOLS ....................................................................................................................... G-35

[1] SPECIAL TOOLS FOR ENGINE .......................................................................................... G-35

[2] SPECIAL TOOLS FOR TRACTOR ...................................................................................... G-39

9. TIRES ......................................................................................................................................... G-48

[1] TIRE PRESSURE................................................................................................................. G-48

[2] TREADS ADJUSTMENT ...................................................................................................... G-48

(1) Front Wheels .................................................................................................................. G-48

(2) Rear Wheels................................................................................................................... G-49

[3] TIRE LIQUID INJECTION .................................................................................................... G-50

.... G-33

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1. TRACTOR IDENTIFICATION

[1] MODEL NAME AND SERIAL NUMBERS

When contacting your local KUBOTA distributor, always specify

engine serial number, tractor serial number and hour meter reading.

GENERAL

(1) Tractor Identification Plate (2) Tractor Serial Number (3) Engine Serial Number (4) ROPS Identification Plate

(ROPS Serial No.)

(5) ROPS Identification Plate

(ROPS Serial No.)

(6) Hour Meter

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[2] CYLINDER NUMBER

GENERAL

You can see the cylinder numbers of KUBOTA diesel engine in the figure. The sequence of cylinder numbers is No.1, No.2, No.3 and No.4 and it starts from the gear case side.

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2. GENERAL PRECAUTIONS

• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be installed in their original position to prevent reassembly errors.

• When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

• Before disassembling or servicing electrical wires, always disconnect the ground cable from the battery first.

• Remove oil and dirt from parts before measuring.

• Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety.

• Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before assembling. See the figure left side.

• When reassembling external snap rings or internal snap rings, they must be positioned so that sharp edge faces against the direction from which a force is applied. See the figure left side.

• When inserting spring pins, their splits must face the direction from which a force is applied. See the figure left side.

• To prevent damage to the hydraulic system, use only specified fluid or equivalent.

(1) Grease (2) Force (3) Sharp Edge (4) Axial Force (5) Rotating Movement

GENERAL

(A) External Snap Ring (B) Internal Snap Ring

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IMPORTANT

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3. HANDING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING

To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring.

• Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check and at the same time recommend the dealer to perform periodic check for a fee.

• Do not attempt to modify or remodel any electrical parts and wiring.

• When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.

(1) Negative Terminal (2) Positive Terminal

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[1] WIRING

• Securely tighten wiring terminals.

(1) Correct

(Securely Tighten)

(2) Incorrect

(Loosening Leads to Faulty Contact)

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GENERAL

• Do not let wiring contact dangerous part.

(1) Dangerous Part (Sharp Edge) (2) Wiring (Incorrect)

(3) Wiring (Correct) (4) Dangerous Part

• Securely insert grommet.

(1) Grommet (A) Correct

(B) Incorrect

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GENERAL

• Securely clamp, being careful not to damage wiring.

(1) Clamp

(Wind Clamp Spirally)

(2) Wire Harness

(3) Clamp (4) Welding Dent

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• Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

(1) Wiring (2) Clamp

(A) Correct (B) Incorrect

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• In installing a part, take care not to get wiring caught by it.

(1) Wiring (A) Incorrect

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• After installing wiring, check protection of terminals and clamped condition of wiring, only connect battery.

(1) Cover

(Securely Install Cover)

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CAUTION

KiSC issued 08, 2012 A

[2] BATTERY

GENERAL

• Take care not to confuse positive and negative terminal posts.

• When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first.

• Do not install any battery with capacity other than is specified (Ah).

• After connecting cables to battery terminal posts, apply high temperature grease to them and securely install terminal covers on them.

• Do not allow dirt and dust to collect on battery.

• Take care not to let battery liquid spill on your skin and clothes. If contaminated, wash it off with water immediately.

• Before recharging the battery, remove it from the machine.

• Before recharging, remove cell caps.

• Do recharging in a well-ventilated place where there is no open flame nearby, as hydrogen gas and oxygen are formed.

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[3] FUSE

[4] CONNECTOR

• Use fuses with specified capacity. Neither too large or small capacity fuse is acceptable.

• Never use steel or copper wire in place of fuse.

• Do not install working light, radio set, etc. on machine which is not provided with reserve power supply.

• Do not install accessories if fuse capacity of reserve power supply is exceeded.

(1) Fuse (2) Fusible Link

(3) Slow Blow Fuse

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• For connector with lock, push lock to separate.

(A) Push

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• In separating connectors, do not pull wire harnesses.

• Hold connector bodies to separate.

(A) Correct (B) Incorrect

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GENERAL

• Use sandpaper to remove rust from terminals.

• Repair deformed terminal. Make certain there is no terminal being exposed or displaced.

(1) Exposed Terminal (2) Deformed Terminal

(3) Sandpaper (4) Rust

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• Make certain that there is no female connector being too open.

(A) Correct (B) Incorrect

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• Make certain plastic cover is large enough to cover whole connector.

(1) Cover (A) Correct

(B) Incorrect

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[5] HANDLING OF CIRCUIT TESTER

• Use tester correctly following manual provided with tester.

• Check for polarity and range.

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[6] COLOR OF WIRING

GENERAL

• Colors of wire are specified to the color codes.

• This symbol of "/" shows color with stripe(s).

(An example)

Red stripe on white color: W/R

Color of wiring Color code

Black B

Brown Br

Green G

Gray Gy or Gr

Blue L

Light Green Lg

Orange Or

Pink P

Purple Pu or V

Red R

Sky Blue Sb

White W

Yellow Y

(1) Wire Color (2) Stripe

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GENERAL

4. LUBRICANTS, FUEL AND COOLANT

No. Place Capacity Lubricants, fuel and coolant

1Fuel

2 Coolant

Engine crankcase

(with filter)

4 Transmission case

5 Front axle case

42.0 L

11.1 U.S.gals

9.24 Imp.gals

6.5 L

6.9 U.S.qts

5.7 Imp.qts

7.6 L

8.0 U.S.qts

6.7 Imp.qts

40.0 L

10.6 U.S.gals

8.80 Imp.gals

6.5 L

6.9 U.S.qts

5.7 Imp.qts

• No. 2-D diesel fuel

• No. 1-D diesel fuel if temperature is below –10 °C (14 °F)

Fresh clean water with anti-freeze

Engine oil

Refer to next page

• Below 0 °C (32 °F) SAE10W, 10W-30 or 15W-40

• 0 to 25 °C (32 to 77 °F) SAE20, 10W-30 or 15W-40

• Above 25 °C (77 °F) SAE30, 10W-30 or 15W-40

KUBOTA UDT or SUPER UDT fluid*

KUBOTA UDT or SUPER UDT fluid* or SAE 80-90 gear oil

Greasing

No. Place No. of greasing point Capacity Type of grease

Front axle support 2

5. TIGHTENING TORQUES

[1] GENERAL USE SCREWS, BOLTS AND NUTS

Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be

tightened according to the table below.

Indication on top of bolt

Indication on top of nut

Material of opponent part Ordinariness Aluminum Ordinariness Aluminum Ordinariness

Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft

7.9

0.80

M10

M12

M14

M16

M18

M20

9.3

108

125

167

191

246

284

334

392

0.95

1.8 to

2.1

4.0 to

4.6

6.4 to

7.4

11. 0 to

12.8

17.0 to

19.5

25.0 to

29.0

34.0 to

40.0

No-grade or 4T 7T 9T

No-grade or 4T

5.8

7.9

0.80

5.8

9.81

1.00

7.24

7.9

0.80

5.8

6.8

8.8

to 53–––

79.6 to

92.5

–––

123

–––

141

181

–––

209

246

–––

289

0.90

1.7 to

2.0

3.2 to

3.5

6.5

11. 2

124

147

197

225

275

318

368

431

1.15

2.4 to

2.8

4.9 to

5.7

7.9 to

9.2

12.6 to

15.0

20.0 to

23.0

28.0 to

32.5

37.5 to

44.0

8.31

91.2 to

108

145

166

203

235

272

318

8.8

0.90

1.8

2.1

4.0

4.5

6.4

7.4

–––

12.3

6.5

14.2

103

117

260

304

344

402

491

568

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1.25 to

1.45

3.0 to

3.5

6.2 to

7.2

10.5 to

12.0

17.0 to

20.0

26.5 to

31.0

35.0 to

41.0

50.0 to

58.0

9.05 to

10.4

76.0 to

86.7

123

144

192

224

254

296

362

419

[2] STUD BOLTS

Material of opponent part Ordinariness Aluminum

Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

1.2

8.7

M10

M12

M14

M16

M18

98.1 to

112

172

201

1.6

2.5 to

3.2

3.0 to

5.0

6.3 to

7.5

10.0 to

11. 5

17.5 to

20.5

8.9

to 3631 3.2 23

to 54–––

72.4 to

83.1

–––

127

–––

148

0.90 to

1.2

2.0 to

2.6

G-11

6.5 to

8.6

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[3] METRIC SCREWS, BOLTS AND NUTS

GENERAL

Grade

Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M8 24 to 27 2.4 to 2.8 18 to 20 30 to 34 3.0 to 3.5 22 to 25

M10 48 to 55 4.9 to 5.7 36 to 41 61 to 70 6.2 to 7.2 45 to 52

M12 78 to 90 7.9 to 9.2 58 to 66 103 to 117 10.5 to 12.0 76.0 to 86.7

M14 124 to 147 12.6 to 15.0 91.2 to 108 167 to 196 17.0 to 20.0 123 to 144

M16 197 to 225 20.0 to 23.0 145 to 166 260 to 304 26.5 to 31.0 192 to 224

Property class 8.8 Property class 10.9

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[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH

UNC OR UNF THREADS

Grade

Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

1/4 11.7 to 15.7 1.19 to 1.61 8.61 to 11.6 16.3 to 19.7 1.66 to 2.01 12.0 to 14.6

5/16 23.1 to 27.7 2.35 to 2.83 17.0 to 20.5 33 to 39 3.4 to 4.0 24 to 29

3/8 48 to 56 4.9 to 5.8 35.0 to 42.0 61 to 73 6.3 to 7.4 45 to 54

1/2 110 to 130 11 to 13 80 to 96 150 to 178 15.2 to 18.2 110 to 132

9/16 150 to 178 15.2 to 18.2 110 to 132 217 to 260 22.2 to 26.5 160 to 192

5/8 204 to 244 20.8 to 24.8 150 to 180 299 to 357 30.5 to 36.4 220 to 264

SAE GR.5 SAE GR.8

WSM000001GEG0082US0

[5] PLUGS

Material of opponent part

Shape Size

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

Tapered screw

Straight screw G1/4 25 to 34 2.5 to 3.5 18 to 25 – – –

R1/8 13 to 21 1.3 to 2.2 9.4 to 15 13 to 19 1.3 to 2.0 9.4 to 14

R1/4 25 to 44 2.5 to 4.5 18 to 32 25 to 34 2.5 to 3.5 18 to 25

R3/8 49 to 88 5.0 to 9.0 37 to 65 49 to 58 5.0 to 6.0 37 to 43

R1/2 58.9 to 107 6.00 to 11.0 43.4 to 79.5 59 to 78 6.0 to 8.0 44 to 57

G3/8 62 to 82 6.3 to 8.4 46 to 60 – – –

G1/2 49 to 88 5.0 to 9.0 37 to 65 – – –

Ordinariness Aluminum

WSM000001GEG0005US1

G-12

(EU)

Page 28

L4100, WSM

KiSC issued 08, 2012 A

6. MAINTENANCE

GENERAL

Service Interval

No. Item

1 Engine start system Check ,,,,,,,,,,,,,,

2 Wheel bolt torque Check ,,,,,,,,,,,,,,

3 Greasing — ,,,,,,,,,,,,,,

4 Battery condition Check ,,,,,,,

5 Fan belt Adjust ,,,,,,,

6 Brake pedal Adjust ,,,,,,,

7 Clutch pedal Adjust +,,,,,,,

Primary

Air cleaner element

[Double type]

9 Fuel line

10 Fuel filter element

11 Parking brake (cable)

12 Engine oil Change ,,,

13 Engine oil filter Replace +,,,

Toe-in Adjust +,,,

15 Power steering oil line

16 Radiator hose and clamp

17 Intake air line

18 Hydraulic oil filter Replace +,

19 Transmission fluid Change ,

20 Front axle case oil Change ,

21 Front axle pivot Adjust ,

22 Engine valve clearance Adjust

element

Secondary element

Clean ,,,,,,,

Replace

Check ,,,,,,,

Replace

Clean ,,,,,,,

Replace

Adjust ,,,,,,,

Replace

Check ,,,

Replace

Check ,,,

Replace

Check ,,,

Replace

50 100 150 200 250 300 350 400 450 500 550 600 650 700

After

since

every

50 hr

every

50 hr

every

50 hr

every

100 hr

every

100 hr

every

100 hr

every

100 hr

every

100 hr

every

1 year

every

1 year

every

100 hr

every

2 years

every

100 hr

every

400 hr

every

100 hr

every

2 years

every

200 hr

every

200 hr

every

200 hr

every

200 hr

every

2 years

every

200 hr

every

2 years

every

200 hr

every

2 years

every

400 hr

every

400 hr

every

400 hr

every

600 hr

every

800 hr

Refer-

ence page

G-18

G-19

G-20

G-21 *4

G-23

G-15

G-24 *1

G-29 *2

G-29

G-24

G-29

G-25

G-27

G-25

G-29

G-27

G-

G-26

G-29

G-27

G-29

G-27

G-29

G-27

G-28

G-29

G-13

(EU)

Page 29

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

GENERAL

No. Item

Fuel injection nozzle injection

pressure

24 Injection pump Check

25 Cooling system Flush

26 Coolant Change

27 Fuel system Bleed

28 Clutch housing water Drain G-33

29 Fuse Replace G-34

30 Light bulb Replace G-34

Check

50 100 150 200 250 300 350 400 450 500 550 600 650 700

Service Interval

1500 hr

3000 hr

2 years

Service

quired

After since

every

as re-

Refer-

ence page

G-29

1-S15

G-30

G-33

• The jobs indicated by + must be done after the first 50 hours of operation.

• *1: Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2: Every year or every 6 times of cleaning. *3: Replace only if necessary. *4: When the battery is used for less than 100 hours per year, check the battery condition by reading the indicator annually.

9Y1210278GEG0076US0

G-14

(EU)

Page 30

L4100, WSM

CAUTION

KiSC issued 08, 2012 A

GENERAL

7. CHECK AND MAINTENANCE

• Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels.

9Y1210278GEG0010US0

[1] DAILY CHECK

To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items

before starting.

9Y1210278GEG0011US0

Checking

• Check areas where previous trouble was experienced.

• Walk around the machine.

1. Check the tire pressure, and check for wear and damage.

2. Check for oil and water leak.

3. Check the engine oil level.

4. Check the transmission fluid level.

5. Check the coolant level.

6. Check the condition of seat belt and ROPS attaching hardware.

7. Check the clean the radiator screen and grill.

8. Check the nuts of tires are tight.

9. Care of damage, warning and caution labels.

10. Clean around the exhaust manifold and the muffler of the engine.

11. Clean the evacuator valve.

12. Check and clean of electrical wiring and battery cables.

• While sitting in the operator's seat,

1. Check the brake pedals and clutch pedal.

2. Check the parking brake.

3. Check the steering wheel.

• Turning the key switch

1. Check the performance of the Easy Checker™ lights.

2. Check the lights, turn signal lights, hazard lights and other light equipment. Clean if necessary.

3. Check the performance of the meters and gauges.

• Starting the engine,

1. Check to see that the lights on the Easy Checker™ go off.

2. Check the color of the exhaust gas.

3. Check the brakes for proper operation.

9Y1210278GEG0012US0

[2] CHECK POINTS OF INITIAL 50 HOURS

Adjusting Clutch Pedal Free Travel

1. Slightly depress the clutch pedal (4) and measure free travel on top of clutch pedal.

2. If the measurement is not within the factory specifications, loosen the lock nut (2), remove the cotter pin (3) and the clevis pin, then adjust the length of rod (1) within acceptable limits.

3. Retighten the lock nut, reinstall the clevis pin, the cotter pin and split the cotter pin.

Clutch pedal free travel on top of clutch pedal

Factory specification

20 to 30 mm

0.8 to 1.2 in.

(1) Clutch Pedal Rod (2) Lock Nut (3) Cotter Pin

G-15

(4) Clutch Pedal

L: Clutch Pedal Free Travel

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(EU)

Page 31

L4100, WSM

CAUTION

IMPORTANT

CAUTION

IMPORTANT

KiSC issued 08, 2012 A

GENERAL

Changing Engine Oil

• Before changing oil, be sure to stop the engine.

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.

4. Screw in the drain plug (1).

5. Fill new oil up to upper hole on the dipstick (3).

• When using an oil of different manufacture or viscosity from the previous one, remove all of the old oil.

• Never mix two different types of oil.

• Use the proper SAE Engine Oil according to ambient temperatures.

• Refer to "LUBRICANTS, FUEL AND COOLANT". (See page G-9).

Engine oil (with filter)

Capacity

7.6 L

8.0 U.S.qts

6.7 Imp.qts

(1) Drain Plug (2) Oil Inlet Plug (3) Dipstick

(A) Oil lever is acceptable within this

range.

9Y1210278GEG0013US0

Replacing Engine Oil Filter Cartridge

• Be sure to stop the engine before changing oil filter cartridge (1).

• Allow engine to cool down sufficiently, oil can be hot and can burn.

1. Remove the engine oil filter cartridge (1).

2. Put a film of clean engine oil on rubber seal of new filter.

3. Tighten the filter quickly until it contacts the mounting surface. Tighten filter by hand an additional 1/2 turn only.

4. After the new filter has been replaced, the engine oil normally decreases a little. Make sure that the engine oil does not leak through the seal and be sure to check the oil level on the dipstick. Then, replenish the engine oil up to the prescribed level.

• To prevent serious damage to the engine, use only a KUBOTA genuine filter.

(1) Engine Oil Filter Cartridge

9Y1210278GEG0014US0

G-16

(EU)

Page 32

L4100, WSM

CAUTION

IMPORTANT

KiSC issued 08, 2012 A

GENERAL

Replacing Hydraulic Oil Filter

• Be sure to stop the engine before changing the oil filter.

• Allow engine to cool down sufficiently, oil can be hot and can burn.

1. Remove the drain plugs at the bottom of the transmission case and drain the oil completely into the oil pan.

2. After draining reinstall the drain plugs.

3. Remove the oil filter.

4. Wipe off metal filings from the magnetic filter with a clean rag.

5. Put a film of clean transmission oil on the rubber seal of the new filter.

6. Quickly tighten the filter until it contacts the mounting surface, then tighten it by hand an additional 1/2 turn only.

7. Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick.

8. After running the engine for a few minutes, stop the engine and check the oil level again, add oil to the prescribed level.

9. Make sure that the transmission fluid does not leak past the seal on the filter.

• To prevent serious damage to the hydraulic system. Use only a KUBOTA genuine filter.

• Do not operate the tractor immediately after changing the transmission fluid. Run the engine at medium speed for a few minutes to prevent damage to the transmission.

(1) Drain Plug (2) Filling Plug (3) Gauge (4) Hydraulic Oil Filter (5) Magnetic Filter

A: Oil level is acceptable within this

range.

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G-17

(EU)

Page 33

L4100, WSM

CAUTION

KiSC issued 08, 2012 A

[3] CHECK POINTS OF EVERY 50 HOURS

Checking Engine Start System

To avoid personal injury:

• Do not allow anyone near the tractor while testing.

• If the tractor does not pass the test do not operate the tractor.

Q Preparation before testing

1. Place all control levers in the "NEUTRAL" position.

2. Set the parking brake and stop the engine.

Q Test 1: Switch for the range gear shift lever

1. Sit on the operator's seat.

2. Shift the PTO clutch control lever to "OFF" position.

3. Shift the range gear shift lever to "L", "H" or "R" position.

4. Depress the clutch pedal fully.

5. Turn the key to "START" position.

6. The engine must not crank.

7. If it cranks, consult your local KUBOTA Dealer for this service.

Q Test 2: Switch for the PTO clutch control lever

1. Sit on the operator's seat.

2. Shift the PTO clutch control lever to "ON" position.

3. Depress the clutch pedal fully.

4. Shift the range gear shift lever to the neutral position.

5. Turn the key to "START" position.

6. The engine must not crank.

(1) Clutch Pedal (2) Range Gear Shift Lever (3) PTO Clutch Control Lever

GENERAL

(4) Parking Brake Lever (5) Operator's Seat

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G-18

(EU)

Page 34

L4100, WSM

CAUTION

KiSC issued 08, 2012 A

GENERAL

Checking Engine Start System and OPC System (OPC Model)

To avoid personal injury:

• Do not allow anyone near the tractor while testing.

• If the tractor does not pass the test do not operate the tractor.

Q Preparation before testing

1. Place all control levers in the "NEUTRAL" position.

2. Set the parking brake and stop the engine.

Q Test 1: Switch for the range gear shift lever

1. Sit on the operator's seat.

2. Shift the PTO clutch control lever to "OFF" position.

3. Shift the range gear shift lever to "L", "H" or "R" position.

4. Depress the clutch pedal fully.

5. Turn the key to "START" position.

6. The engine must not crank.

7. If it cranks, consult your local KUBOTA Dealer for this service.

Q Test 2: Switch for the PTO clutch control lever

1. Sit on the operator's seat.

2. Shift the PTO clutch control lever to "ON" position.

3. Depress the clutch pedal fully.

4. Shift the range gear shift lever to the neutral position.

5. Turn the key to "START" position.

6. The engine must not crank.

Q Test 3: Switch for the operator's seat

1. Sit on the operator's seat.

2. Start the engine.

3. Engage the PTO clutch control switch or lever.

4. Release the parking brake.

5. Stand up. (Do not get off the machine.)

6. The engine must not shut off after approximately 1 second.

(1) Clutch Pedal (2) Range Gear Shift Lever (3) PTO Clutch Control Lever

(4) Parking Brake Lever (5) Operator's Seat

9Y1210278GEG0088US0

Checking Wheel Mounting Bolts and Nuts Tightening Torque

• Never operate tractor with a loose rim, wheel or axle.

• Any time bolts and nuts are loosened, retighten to specified torque.

• Check all bolts and nuts frequently and keep them tight.

1. Check the wheel mounting bolts and nuts regularly especially when new. If there are loosened, tighten as follows.

124 to 147 N·m

Front wheel mounting bolt

Tightening torque

Rear wheel mounting bolt

(1) Front Wheel Mounting Bolt (2) Rear Wheel Mounting Bolt and Nut

G-19

12.6 to 15.0 kgf·m

91.2 to 108 lbf·ft

196 to 225 N·m

20.0 to 23.0 kgf·m 145 to 166 lbf·ft

9Y1210278GEG0017US0

(EU)

Page 35

L4100, WSM

NOTE

KiSC issued 08, 2012 A

GENERAL

Greasing

1. Apply a grease to the following position as figures.

• Apply a small amount of multipurpose grease to the following points every 50 hours. If you operated the machine in extremely wet and muddy conditions, lubricate grease fittings more often.

• When applying a grease to the front axle support, remove the breather plug and apply a grease until grease overflows from breather plug. After greasing reinstall the plug.

(1) Grease Fitting (Front Axle Support) (2) Grease Fitting (Front Axle Support) (3) Breather Plug (4) Grease Fitting (Top Link) (5) Grease Fitting (Lifting Rod RH)

(6) Grease Fitting (Top Link with Draft

Control, if Equipped)

(7) Battery Terminal

9Y1210278GEG0018US0

G-20

(EU)

Page 36

L4100, WSM

CAUTION

NOTE

KiSC issued 08, 2012 A

[4] CHECK POINTS OF EVERY 100 HOURS

Checking Battery Condition

• Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion. Check the fluid level regularly and add distilled water as required so that the fluid level is between the UPPER and LOWER levels.

• Never remove the vent plugs while the engine is running.

• Keep electrolyte away from eyes, hands and clothes. If you are splashed with it, wash it away completely with water immediately and get medical attention.

• Wear eye protection and rubber gloves when working around battery.

• The factory-installed battery is of non-refillable type. If the indicator turns white, do not charge the battery but replace it with new one.

1. Mishandling the battery shortens the service life and adds to maintenance costs.

2. The original battery is maintenance free type battery, but needs some servicing. If the battery is weak, the engine is difficult to start and the lights will be dim. It is important to check the battery periodically.

3. Check the battery condition by reading the indicator. State of indicator display: Green: Specify gravity of electrolyte and quality of electrolyte are both in good condition. Black: Need to charge the battery. White: battery needs to be replaced. Check the battery condition by reading the indicator.

State of indicator display

Green

Black Needs to charge the battery.

White Battery needs to be replaced.

Specific gravity of electrolyte and quality of electrolyte are both in good condition.

GENERAL

(1) Battery (2) Indicator

G-21

9Y1210278GEG0019US0

(EU)

Page 37

L4100, WSM

CAUTION

KiSC issued 08, 2012 A

GENERAL

Battery Charging

• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

• When charging the battery, ensure the vent caps are securely in place (if equipped).

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

1. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the standard fashion.

2. A boost charge is only for emergencies. It will partially charge the battery at a high rate and in a short time. When using a boost-charged battery, it is necessary to recharge the battery as early as possible. Failure to do this will shorten the battery's service life.

3. The battery is charged if the indicator display turns green from black.

4. When exchanging an old battery into new one, use battery of equal specification shown in table 1.

Table 1

Battery Type Volts (V)

80D26R 12 133 582 6.5

Reserve

Capacity

(min.)

CCA (SAE)

Normal

Charging

Rate (A)

CCA: Cold Cranking Ampere

Q Direction for Storage

1. When storing the tractor for long periods of time, remove the battery from tractor, adjust the electrolyte to the proper level and store in a dry place out of direct sunlight.

2. The battery self-discharges while it is stored. Recharge it once every three months in hot seasons and once every six months in cold seasons.

(1) Battery

9Y1210278GEG0020US0

G-22

(EU)

Page 38

L4100, WSM

CAUTION

IMPORTANT

NOTE

KiSC issued 08, 2012 A

GENERAL

Adjusting Fan Belt Tension

• Be sure to stop the engine before checking fan belt tension.

1. Stop the engine and remove the key.

2. Apply moderate thumb pressure to belt between pulleys.

3. If tension is incorrect, loosen the alternator mounting bolts (2), and using a lever placed between the alternator and the engine block, pull the alternator out until the deflection of the belt falls within the factory specifications.

4. Replace fan belt if it is damaged.

A deflection is 12 mm

Fan belt tension Factory specification

(0.47 in.) when the belt is pressed (68.6 N (7 kgf)) in the middle of the span

(1) Bolt (2) Alternator Mounting Bolt

(A) To Check the Fan Belt Tension (B) To Tighten the Fan Belt

9Y1210278GEG0021US0

Adjusting Brake Pedal Free Travel

• Stop the engine and remove the key, then chock the wheel before checking brake pedals.

1. Release the parking brake.

2. Slightly depress the brake pedals and measure free travel "A"

at top of pedal stroke.

3. If the measurement is not within the factory specifications, loosen the lock nut (1) and turn the turnbuckle (2) to adjust it within the factory specifications.

Brake pedal free travel

"A"

Factory specification

15 to 20 mm

0.59 to 0.78 in.

• Keep the free travel in the right and left brake pedals equal.

• The difference between the right and left pedal free travels must be less than 5 mm (0.20 in.)

• After checking brake pedal free travel, be sure to engage the parking brake lock fully and check to see that the brake pedals are securely locked.

(1) Lock Nut (2) Turnbuckle

A: Free Travel

9Y1210278GEG0077US0

G-23

(EU)

Page 39

L4100, WSM

NOTE

IMPORTANT

CAUTION

NOTE

KiSC issued 08, 2012 A

GENERAL

Cleaning Air Cleaner Element

1. Remove the air cleaner cover (3) and primary element (2).

2. Clean the primary element:

• When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air

must be under 205 kPa (2.1 kgf/cm

, 30 psi).

• When carbon or oil adheres to the element, soak the element in detergent for 15 minutes then wash it several times in water, rinse with clean water and dry it naturally. After element is fully dried, inspect inside of the element with a light and check if it is damaged or not.

3. Replace the air cleaner primary element (2): Once a year or after every sixth cleaning, whichever comes first.

• Check to see if the evacuator valve (4) is blocked with dust.

• The air cleaner uses a dry element, never apply oil.

• Do not run the engine with filter element removed.

• Be sure to refit the dust cup with the arrow ↑ (on the rear of cover) upright. If the dust cup is improperly fitted, evacuator valve will not function and dust will adhere to the element.

Q Evacuator Valves (4)

Open the evacuator valve once a week under ordinary

conditions or daily when used in a dusty place to get rid of large particles of dust and dirt.

(1) Secondary Element (2) Primary Element

(3) Cover (4) Evacuator Valve

9Y1210278GEG0022US0

Checking Fuel Line

• Stop the engine when checking or replacing the fuel line.

• Remember to check the fuel line periodically. The fuel line is subject to wear and aging, fuel may leak out onto the running engine, causing a fire.

1. Check to see that all line and hose clamps are tight and not damaged.

2. If hoses and clamps are found worn or damaged, replace or repair them at once.

• If the fuel line is removed, be sure to properly bleed the fuel system. Refer to "Bleeding Fuel System". (See page G-33.)

(1) Fuel Line (2) Clamp Band

9Y1210278GEG0023US0

G-24

(EU)

Page 40

L4100, WSM

CAUTION

KiSC issued 08, 2012 A

GENERAL

Cleaning Fuel Filter

This job should not be done in the field, but in a clean place.

1. Close the fuel cock (1).

2. Unscrew the screw ring (6), remove the filter bowl (5), and rinse the inside with kerosene.

3. Take out the element and dip it in the kerosene to rinse.

4. After cleaning, reassemble the fuel filter, keeping out dust and dirt.

5. Bleed the fuel system. (See page G-33.)

(1) Fuel Cock (2) O-ring (3) Filter Element (4) Spring

(5) Filter Bowl (6) Screw Ring

(A) "CLOSE" (B) "OPEN"

9Y1210278GEG0024US0

Adjusting Parking Brake Lever

• Stop the engine and chock the wheels before checking parking brake.

1. Raise the parking brake lever to the parking position while counting the ratchet sound made by the parking brake lever.

2. If adjustment is needed, loosen the lock nut (2) and adjust the parking brake cable (1) length with in acceptable limit.

3. Retighten the lock nut (2).

Proper parking brake lever free travel 1 notch (Ratchet sound 1)

(1) Parking Brake Cable (2) Lock Nut

9Y1210278GEG0025US0

Adjusting Clutch Pedal Free Travel

• Refer to G-15.

9Y1210278GEG0026US0

G-25

(EU)

Page 41

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

[5] CHECK POINTS OF EVERY 200 HOURS

Toe-in

1. Park the tractor on flat ground.

2. Inflate the tires to the specified pressure.

3. Turn steering wheel so front wheels are in the straight ahead position.

4. Lower the implement, lock the parking brake and stop the engine.

5. Measure distance between tire beads at front of tire, hub height.

6. Measure distance between tire beads at rear of tire, hub height.

7. Front distance should be 2 to 8 mm (0.08 to 0.3 in.) less than rear distance.

8. If the measurement is not with in the factory specifications, adjust by changing the tie-rod length.

Toe-in ((B) - (A)) Factory specification

Q Adjusting

1. Detach the snap ring (3).

2. Loosen the tie-rod lock nut (1).

3. Turn the outer tube to adjust the tie-rod length until the proper toe-in measurement is obtained.

4. Retighten the tie-rod lock nut (1).

5. Attach the snap ring (3).

Tightening torque Tie-rod lock nut

GENERAL

2 to 8 mm

0.08 to 0.32 in.

167 to 196 N·m

17.0 to 20.0 kgf·m 123 to 144 lbf·ft

• A right and left tie-rod joint is adjusted to the same length.

(1) Tie-rod Lock Nut (2) Tie-rod Joint (3) Snap Ring

(A) Wheel to Wheel Distance at front (B) Wheel to Wheel Distance at rear (C) Front

9Y1210278FAS0004US0

Checking Power Steering Oil Line

1. Check to see that all lines and hose clamps are tight and not damaged.

2. If hose and clamps are found worn or damaged, replace or repair them at once.

(1) Power Steering Pressure Hose

9Y1210278GEG0027US0

G-26

(EU)

Page 42

L4100, WSM

KiSC issued 08, 2012 A

GENERAL

Checking Radiator Hose and Hose Clamp

Check to see if radiator hoses are properly fixed every 200

hours of operation or six months, whichever comes first.

1. If hose clamps (2) are loose or water leaks, tighten hose clamps (2) securely.

2. Replace hoses (1) and tighten hose clamps (2) securely, if radiator hoses (1) are swollen, hardened or cracked. Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.

Q Precaution at Overheating

Take the following actions in the event the coolant temperature

be nearly or more than the boiling point, this is called "Overheating".

1. Stop the machine operation in a safe place and keep the engine unloaded idling.

2. Don't stop the engine suddenly, but stop it after about 5 minutes of unloaded idling.

3. Keep yourself well away from the machine for further 10 minutes or while the steam blown out.

4. Checking that there gets no danger such as burn, get rid of the causes of overheating according to the manual, see "TROUBLESHOOTING" section, and then start again the engine.

(1) Radiator Hose (2) Clamp

9Y1210278GEG0028US0

Checking Intake Air Line

1. Check to see that hoses and hose clamps are tight and not damaged.

2. If hoses and clamps are found worn or damaged, replace or repair them at once.

(1) Hose (2) Hose Clamp

9Y1210278GEG0029US0

Replacing Engine Oil Filter Cartridge

• Refer to G-16.

Changing Engine Oil

• Refer to G-16.

[6] CHECK POINTS OF EVERY 400 HOURS

Replacing Fuel Filter Element

• Refer to G-25.

Replacing Hydraulic Oil Filter

• Refer to G-17.

G-27

9Y1210278GEG0030US0

9Y1210278GEG0031US0

9Y1210278GEG0032US0

9Y1210278GEG0033US0

(EU)

Page 43

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

GENERAL

Changing Transmission Fluid

1. Place an oil pan underneath the transmission case.

2. Remove the drain plugs (1), (2).

3. Drain the transmission fluid.

4. Reinstall the drain plugs (1), (2).

(When refilling)

• Fill up new oil from the oil filling port (3) up to the upper line of the oil level gauge (4).

• After running the engine for few minutes, stop it and check the oil level again, add oil to prescribed level, if necessary.

40.0 L

Transmission fluid Capacity

10.6 U.S.gals

8.80 Imp.gals

• Use only multi-grade transmission fluid. Use of other fluids may damage the transmission or hydraulic system. Refer to "LUBRICANTS, FUEL AND COOLANT". (See page G-9.)

• Never work the tractor immediately after changing the transmission fluid. Keeping the engine at medium speed for a few minutes to prevent damage to the transmission.

• Do not mix different brands oil together.

(1) Drain Plug (2) Drain Plug (3) Oil Filling Port (4) Oil Level Gauge

A: Oil level is acceptable within this

range.

9Y1210278GEG0072US0

Changing Front Axle Case Oil

1. Place the oil pans underneath the front axle case.

2. Remove the drain plug (3) both sides and filling port plug (2) to drain the oil.

3. After draining, reinstall the drain plugs (3) and filling port plug (2).

(When reassembling)

• Remove the filling port plug (2) and right and left check plugs (1).

• Fill with the new oil.

• After filling, reinstall the port plug (2).

6.5 L

Front axle case oil Capacity

6.9 U.S.qts

5.7 Imp.qts

• Use KUBOTA SUPER UDT fluid or SAE 80, 90 gear oil. Refer to "LUBRICANTS, FUEL AND COOLANT". (See page G-9.)

(1) Check Plug (2) Filling Port Plug

(3) Drain Plug

9Y1210278GEG0073US0

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Page 44

L4100, WSM

KiSC issued 08, 2012 A

[7] CHECK POINT OF EVERY 600 HOURS

Adjusting Front Axle Pivot

1. Loosen the lock nut (2), tighten the adjusting screw (1) all the way, and then loosen the adjusting screw (1) by 1/6 turn.

2. Retighten the lock nut (2).

(1) Adjusting Screw (2) Lock Nut

[8] CHECK POINT OF EVERY 800 HOURS

Checking Valve Clearance

• See page 1-S10.

[9] CHECK POINT OF EVERY 1500 HOURS

Checking Fuel Injection Nozzle Injection Pressure

• See page 1-S16.

GENERAL

9Y1210278GEG0034US0

9Y1210278GEG0035US0

9Y1210278GEG0036US0

[10] CHECK POINT OF EVERY 3000 HOURS

Checking Injection Pump

• See page 1-S15.

[11] CHECK POINT OF EVERY 1 YEAR

Replacing Air Cleaner Element

• See page G-24.

[12] CHECK POINTS OF EVERY 2 YEARS

Replacing Fuel Hose

1. Replace the fuel hoses and clamps.

• Refer to G-24.

Replacing Parking Brake Cable

1. Replace the parking brake cable.

• Refer to G-25.

Replacing Power Steering Hose

1. Replace the hoses and clamps.

• Refer to G-26.

Replacing Radiator Hose and Hose Clamp

1. Replace the hoses and clamps.

• Refer to G-27.

Replacing Air Hose

1. Replace the hoses and clamps.

• Refer to G-27.

9Y1210278GEG0037US0

9Y1210278GEG0038US0

9Y1210278GEG0039US0

9Y1210278GEG0040US0

9Y1210278GEG0041US0

9Y1210278GEG0042US0

9Y1210278GEG0043US0

G-29

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Page 45

L4100, WSM

CAUTION

IMPORTANT

KiSC issued 08, 2012 A

GENERAL

Flush Cooling System and Changing Coolant

• Do not remove the radiator cap when the engine is hot. Loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (3) and remove radiator cap (1). The radiator cap (1) must be removed to completely drain the coolant.

3. After all coolant is drained, close the drain plug (3).

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the radiator cap. Install the radiator cap (1) securely.

7. Fill with coolant up to the "FULL" mark of recovery tank.

8. Start and operate the engine for a few minutes.

9. Stop the engine. Check coolant level and add coolant if necessary.

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator. When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap (1). If the cap is loose or improperly fitted, water may lead out and the engine could overheat.

Coolant (With recovery tank)

Capacity

6.5 L

6.9 U.S.qts

5.7 Imp.qts

(1) Radiator Cap (2) Recovery Tank (3) Drain Plug

(A) "FULL" (B) "LOW"

(To be continued)

G-30

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L4100, WSM

CAUTION

KiSC issued 08, 2012 A

(Continued)

GENERAL

Q Anti-Freeze

• When using antifreeze, put on some protection such as rubber gloves (Antifreeze contains poison.).

• If should drink antifreeze, throw up at once and take medical attention.

• When antifreeze comes in contact with the skin or clothing, wash it off immediately.

• Do not mix different types of Antifreeze. The mixture can produce chemical reaction causing harmful substances.

• Antifreeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze.

• When draining fluids from the engine, place some container underneath the engine body.

• Do not pour waste onto the grounds, down a drain, or into any water source.

• Also, observe the relevant environmental protection regulations when disposing of antifreeze.

If it freezes, coolant can damage the cylinders and radiator. If

the ambient temperature falls below 0 °C (32 °F) or before a long-term storage, let out cooling water completely, or mix fresh water with long-life coolant and fill the radiator and reserve tank with the mixture.

1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol (EG) type for this engine.

2. Before employing LLC-mixed cooling water, fill the radiator with fresh water and empty it again. Repeat this procedure 2 or 3 times to clean up the inside.

3. Mixing the LLC Put the LLC in cooling water in the percentage (%) for a target temperature. When mixing, stir it up well, and then fill into the radiator.

4. The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature. Refer to SAE J1034 standard, more specifically also to SAE J814c.

(To be continued)

G-31

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Page 47

L4100, WSM

IMPORTANT

NOTE

KiSC issued 08, 2012 A

(Continued)

GENERAL

• When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50 %.

Vol %

Anti-freeze

40 −24 −12 106 222

50 −37 −34 108 226

Freezing Point Boiling Point*

°C °F °C °F

* At 1.013 x 1000000 Pa (760 mmHg) pressure (atmospheric).

A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

5. Adding the LLC a) Add only water if the mixture reduces in amount by

evaporation.

b) If there is a mixture leak, add the LLC of the same

manufacturer and type in the same mixture percentage. **Never add any long-life coolant of different manufacturer. (Different brands may have different additive components, and the engine may fail to perform as specified.)

• The above date represent industry standards that necessitate a minimum glycol content in the concentrates anti-freeze.

• When the coolant level drops due to evaporation, add water only. In case of leakage, add anti-freeze and water in the specified mixing ratio.

• Anti-freeze absorbs moisture. Keep unused anti-freeze in a tightly sealed container.

• Do not use radiator cleaning agents when anti-freeze has been added to the coolant. (Anti-freeze contains an anti-corrosive agent, which will react with the radiator cleaning agent forming sludge which will affect the engine parts.)

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L4100, WSM

CAUTION

IMPORTANT

NOTE

KiSC issued 08, 2012 A

[13] OTHERS

GENERAL

Bleeding Fuel System

Air must be removed:

1. When the fuel filter or lines are removed.

2. When tank is completely empty.

3. After the tractor has not been used for a long period of time.

• Do not bleed the fuel system when the engine is hot.

Bleeding procedure is as follows:

1. Fill the fuel tank with fuel.

2. Open the air vent cock (1) on the fuel injection pump.

3. Close the air vent cock (1) after 30 seconds.

• Always close the air vent cock (1) except for bleeding fuel lines. Otherwise, Engine runs irregularly or stalls frequently.

(1) Air Vent Cock (A) CLOSE

(B) OPEN

9Y1210278GEG0045US0

Draining Clutch Housing Water

• The tractor is equipped with split pin plug (1) under the clutch housing.

• After operating in rain, snow or tractor has been washed, water may get into the clutch housing.

1. Check it by pushing in the split pin (1).

2. If water enters into the clutch housing, remove the plug (1) and drain the water, then reinstall the plug.

(1) Split Pin (Plug)

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L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

GENERAL

Replacing Fuse

1. The tractor electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system.

2. If any of the fuses should blow, replace with a new one of the same capacity.

• Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the tractor electrical system. Refer to troubleshooting section of this manual. If any of them should below, replace with a new one of the same capacity.

Fuse No. Capacity (A) Protected circuit

(1) 10 Work light

(2) 10 Panel

(3) 5 Lamp relay

(4) 5 Glow lamp

(5) 5 Starter relay

(6) 25 Head light

(7) 20 Flasher

(8) 5 Key stop

(9) 10 Beacon lamp

(10) 20 Hazard

(11) Slow blow fuse

Check circuit against wrong battery connection.

9Y1210278GEG0047US0

Replacing Light Bulb

1. Head lights and rear combination lights: Take the bulb out of the light body and replace with a new one.

2. Other lights: Detach the lens and replace the bulb.

Light Capacity

Head lights 45 W / 40 W

Tail light 10 W

Hazard and turn signal light (rear) 21 W

Hazard and turn signal light (front) 21 W

Side marker light 5 W

Instrument panel light 1.7 W

Brake stop light 21 W

Number plate light 10 W

9Y1210278GEG0048US0

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Page 50

L4100, WSM

KiSC issued 08, 2012 A

8. SPECIAL TOOLS

[1] SPECIAL TOOLS FOR ENGINE

Special Use Puller Set

Code No.

• 07916-09032

Application

• Use exclusively for pulling out bearing, gears and other parts with ease.

Piston Ring Compressor

Code No.

• 07909-32111

Application

• Use exclusively for pushing in the piston with piston rings into the cylinder.

GENERAL

WSM000001GEG0011US0

WSM000001GEG0012US0

Piston Ring Tool

Code No.

• 07909-32121

Application

• Use exclusively for removing or installing the piston ring with ease.

WSM000001GEG0013US0

Diesel Engine Compression Tester (for Injection Nozzle)

Code No.

• 07909-30208 (Assembly)

• 07909-30934 (A to F)

• 07909-31211 (E and F)

• 07909-31231 (H)

• 07909-31251 (G)

• 07909-31271 (I)

• 07909-31281 (J)

Application

• Use to measure diesel engine compression and diagnostics of need for major overhaul.

(1) Gauge (2) L Joint (3) Adaptor A (4) Adaptor B (5) Adaptor C (6) Adaptor E

(7) Adaptor F (8) Adaptor G (9) Adaptor H (10) Adaptor I (11) Adaptor J

WSM000001GEG0014US0

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KiSC issued 08, 2012 A

GENERAL

Oil Pressure Tester

Code No.

• 07916-32032

Application

• Use to measure lubricating oil pressure.

(1) Gauge (2) Cable (3) Threaded Joint (4) Adaptor 1

(5) Adaptor 2 (6) Adaptor 3 (7) Adaptor 4 (8) Adaptor 5

WSM000001GEG0015US0

Valve Seat Cutter

Code No.

• 07909-33102

Application

• Use to reseat valves.

Angle

• 0.79 rad (45 °)

• 0.26 rad (15 °)

Diameter

• 28.6 mm (1.13 in.)

• 31.6 mm (1.24 in.)

• 35.0 mm (1.38 in.)

• 38.0 mm (1.50 in.)

• 41.3 mm (1.63 in.)

• 50.8 mm (2.00 in.)

WSM000001GEG0016US0

Radiator Tester

Code No.

• 07909-31551

Application

• Use to check of radiator cap pressure, and leaks from cooling system.

Remarks

• Adaptor (1) BANZAI Code No. RCT-2A-30S.

(1) Adaptor

WSM000001GEG0017US0

Connecting Rod Alignment Tool

Code No.

• 07909-31661

Application

• Use to check the connecting rod alignment.

Applicable range

• Connecting rod big end I.D. 30 to 75 mm dia. (1.2 to 2.9 in. dia.)

• Connecting rod length

65.0 to 300 mm (2.56 to 11.8 in.)

WSM000001GEG0020US0

Nozzle Tester

Code No.

• 07909-31361

Application

• Use to check the fuel injection pressure and spray pattern of nozzle.

Measuring range

• 0 to 50 MPa (0 to 500 kgf/cm

, 0 to 7200 psi)

WSM000001GEG0021US0

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L4100, WSM

KiSC issued 08, 2012 A

GENERAL

Plastigauge

Code No.

• 07909-30241

Application

• Use to check the oil clearance between crankshaft and bearing, etc..

Measuring range

• Green: 0.03 to 0.07 mm (0.001 to 0.003 in.)

• Red: 0.05 to 0.1 mm (0.002 to 0.006 in.)

• Blue: 0.1 to 0.2 mm (0.004 to 0.009 in.)

WSM000001GEG0022US0

Red Check

Code No.

• 07909-31371

Application

• Use to check cracks on cylinder head, cylinder block, etc..

WSM000001GEG0023US0

Socket Wrench for Crank Pulley Nut (46 mm Deep Socket Wrench)

Application

• To loosen and tighten the mounting nut of fan drive pulley.

A 100 mm (3.94 in.)

B 25.0 mm (0.984 in.)

C 27.0 mm (1.06 in.)

D 45.0 mm dia. (1.77 in. dia.)

E 35.0 mm dia. (1.38 in. dia.)

F 62.5 mm dia. (2.46 in. dia.)

G 46.0 mm (1.81 in.)

M00000003GEG0062US1

Auxiliary Socket for Fixing Crankshaft Sleeve

Application

• To fix the crankshaft sleeve of the diesel engine.

A 80.0 mm (3.15 in.)

B 60.10 to 60.30 mm (2.367 to 2.374 in.)

C 80.0 mm dia. (3.15 in. dia.)

D 85.0 mm dia. (3.35 in. dia.)

E 60.10 to 60.30 mm dia. (2.367 to 2.374 in. dia.)

F 26.30 to 26.40 mm (1.036 to 1.039 in.)

G 25.85 to 25.90 mm (1.018 to 1.019 in.)

H 15.0 mm (0.591 in.)

I 5.0 mm (0.20 in.)

(1) Stopper (2) Sleeve Guide

G-37

(3) Auxiliary Socket for Pushing

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L4100, WSM

KiSC issued 08, 2012 A

GENERAL

Valve Guide Replacing Tool

Application

• To press out and press fit the valve guide.

A 225 mm (8.86 in.)

B 70 mm (2.8 in.)

C 45 mm (1.8 in.)

D 20 mm dia. (0.79 in. dia.)

E 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.)

F 7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.)

G 25 mm dia. (0.98 in. dia.)

H 7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)

I 5 mm (0.2 in.)

J 20 mm dia. (0.79 in. dia.)

K 13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.)

L 8.90 to 9.10 mm (0.351 to 0.358 in.)

C1 Chamfer 1.0 mm (0.039 in.)

C2 Chamfer 2.0 mm (0.079 in.)

C0.3 Chamfer 0.3 mm (0.01 in.)

M00000003GEG0058US1

Bushing Replacing Tools

Application

• To press out and press fit the bushing.

1) For small end bushing

A 162 mm (6.38 in.)

B 35 mm (1.4 in.)

C 27 mm (1.1 in.)

D 35 mm dia. (1.4 in. dia.)

E 27.90 to 27.95 mm dia. (1.099 to 1.100 in. dia.)

F 25.00 to 25.01 mm dia. (0.9843 to 0.9846 in. dia.)

2) For idle gear bushing

A 175 mm (6.89 in.)

B 40 mm (1.6 in.)

C 38 mm (1.5 in.)

D 45 mm dia. (1.8 in. dia.)

E 41.90 to 41.95 mm dia. (1.650 to 1.651 in. dia.)

F 37.950 to 37.970 mm dia. (1.4941 to 1.4948 in. dia.)

Flywheel Stopper

Application

• To loosen and tighten the flywheel screw.

A 20 mm (0.79 in.)

B 15 mm (0.59 in.)

C 10 mm dia. (0.39 in. dia.)

D 30 mm (1.2 in.)

E 8 mm (0.3 in.)

F 200 mm (7.87 in.)

M00000003GEG0059US1

M00000003GEG0060US1

G-38

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L4100, WSM

KiSC issued 08, 2012 A

GENERAL

Crankshaft Bearing 1 Replacing Tool

Application

• To press out and press fit the crankshaft bearing 1.

[1] Extracting tool

A 135 mm (5.31 in.)

B 72 mm (2.8 in.)

C 40 mm radius (1.6 in. radius)

D 10 mm (0.39 in.)

E 20 mm (0.79 in.)

F 20 mm dia. (0.79 in. dia.)

G 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

H 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

[2] Inserting tool

A 130 mm (5.12 in.)

B 72 mm (2.8 in.)

C 40 mm radius (1.6 in. radius)

D 9 mm (0.4 in.)

E 4 mm (0.2 in.)

F 20 mm (0.79 in.)

G 20 mm dia. (0.79 in. dia.)

H 68 mm dia. (2.7 in. dia.)

I 59.80 to 59.90 mm dia. (2.355 to 2.358 in. dia.)

J 64.80 to 64.90 mm dia. (2.552 to 2.555 in. dia.)

[2] SPECIAL TOOLS FOR TRACTOR

Relief Valve Pressure Tester

Code No.

• 07916-50045

Application

• This allows easy measurement of relief set pressure.

(1) Gauge (07916-50322) (2) Cable (07916-50331) (3) Threaded Joint (07916-50401) (4) Threaded Joint (07916-50341) (5) Adaptor B (M18 × P1.5)

(07916-50361)

Tie-rod End Lifter

Code No.

• 07909-39051

Application

• Use for removing the tie-rod end with ease.

M00000003GEG0061US1

(6) Adaptor C (PS3/8) (07916-50371) (7) Adaptor D (PT1/8) (07916-50381) (8) Adaptor E (PS3/8) (07916-50392) (9) Adaptor F (PF1/2) (07916-62601) (10) Adaptor 58 (PT1/4) (07916-52391)

WSM000001GEG0027US0

WSM000001GEG0029US0

G-39

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L4100, WSM

KiSC issued 08, 2012 A

GENERAL

Steering Wheel Puller

Code No.

• 07916-51090

Application

• Use for removing the steering wheel without damaging the steering shaft.

WSM000001GEG0030US0

Injector CH3

Code No.

• 07916-52501

Application

• Use to put calcium chloride solution into a rear wheel and to remove it.

WSM000001GEG0031US0

Clutch Center Tool (For B and L Series Tractors)

Application

• The clutch center tool can be used for all B and L series tractors with a diaphragm clutch by changing tip guides. Center piece diameter is 20 mm (0.79 in.).

WSM000001GEG0032US0

Toe-in Gauge

Code No.

• 07909-31681

Application

• This allows easy measurement of toe-in for all machine models.

WSM000001GEG0034US0

Rear Axle Cover Puller

Code No.

• 07916-51041

Application

• Use for removing a rear axle cover from rear axle.

WSM000001GEG0035US0

G-40

(EU)

Page 56

L4100, WSM

KiSC issued 08, 2012 A

GENERAL

Flow Meter

Code No.

• 07916-52791 (Flow Meter)

• 07916-52651 (Hydraulic Test Hose)

Application

• This allows easy testing of hydraulic system.

(1) Flow Meter (2) Hydraulic Test Hose

WSM000001GEG0036US0

Adaptor Set for Flow Meter

Code No.

• 07916-54031

Application

• Use for testing the hydraulic system.

(1) Adaptor 52 (2) Adaptor 53 (3) Adaptor 54 (4) Adaptor 61 (5) Adaptor 62 (6) Adaptor 63 (7) Adaptor 64

(8) Adaptor 65 (9) Adaptor 66 (10) Adaptor 67 (11) Adaptor 68 (12) Adaptor 69 (13) Hydraulic Adaptor 1

WSM000001GEG0037US0

Power Steering Adaptor

Code No.

• 07916-54021

Application

• Use for measuring the relief valve setting pressure for power steering.

WSM000001GEG0038US0

Pinion Locking Tool

Code No.

• 07916-55311

Application

• Use for preventing the shaft from turning when removing or tighten a bevel pinion shaft staking nut.

WSM000001GEG0039US0

Relief Valve Setting Pressure Adaptor G

Code No.

• 07916-52751

Application

• This offers easy measurement of relief valve setting pressure from the hydraulic coupler. This is available with the relief valve setting pressure tester.

WSM000001GEG0041US0

G-41

(EU)

Page 57

L4100, WSM

NOTE

KiSC issued 08, 2012 A

Pump Adaptor

Application

• Use for checking the main hydraulic pump.

GENERAL

• When using, attach with following parts. O-ring: 04811-00180

• This adaptor is modified from Adaptor 61 of flowmeter adaptor set (see page G-41).

A 22 mm (0.872 in.) H 10 mm dia. (0.39 in. dia.) O 61.5 mm (2.42 in.)

B 11 mm (0.437 in.) I G 3/8 P 24 mm (0.94 in.)

C 24 mm dia. (0.94 in. dia.) J 89 mm (3.50 in.) Q 27.7 mm (1.09 in.)

D 18 mm dia. (0.71 in. dia.) K 135 mm (5.31 in.) R 0.244 rad (14 °)

E 12 mm dia. (0.47 in. dia.) L 7 mm dia. (0.28 in. dia.) S 40 mm (1.57 in.)

F 1.7 to 1.9 mm (0.067 to 0.075 in.) M 8.5 mm dia. (0.33 in. dia.) T 60 mm dia. (2.36 in. dia.)

G 30 mm Round (1.18 in. Round) N 37 mm (1.46 in.)

(Reference)

• Compared with adaptor 61, the followings are different. a) Dimensions S, T and number of holes M. b) Direction of pipe I.

9Y1210278GEG0049US0

G-42

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Page 58

L4100, WSM

NOTE

KiSC issued 08, 2012 A

GENERAL

Rear Propeller Shaft Tool

Application

• For installing bearing, oil seals and sleeves on rear propeller shaft.

A 40.0 mm dia. (1.57 in. dia.)

B 26.0 mm dia. (1.02 in. dia.)

C 36.0 mm dia. (1.42 in. dia.)

D 200 mm (7.87 in.)

E 40.0 mm (1.57 in.)

F 250 mm (9.84 in.)

G 10.0 mm (0.39 in.)

H 22 mm dia. (0.87 in. dia.)

I 25 mm dia. (0.98 in. dia.)

J 25 mm (0.98 in.)

K 45.0 mm (1.77 in.)

L 36.0 mm dia. (1.42 in. dia.)

(1) Bearing and Oil Seal (2) Sleeve

9Y1210278GEG0050US0

• The following special tools are not provided, so make them referring to the figure.

Pinion Shaft Remover

Application

• Use for removing a pinion shaft.

A 106 mm (4.17 in.)

B 350.0 mm (13.78 in.)

C 6.0 mm (0.24 in.)

D 90.0 mm (3.54 in.)

E 10.0 mm (0.39 in.)

F 40.0 mm (1.57 in.)

G 10.0 mm (0.39 in.)

H 35.6 mm (1.40 in.)

I 36.0 mm (1.42 in.)

J 41.6 mm (1.64 in.)

K Part code No. 3A201-4130 nut

L M27 x 1.5

M M10 x 1.25

9Y1210278GEG0051US0

9Y1210278GEG0052US0

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Page 59

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KiSC issued 08, 2012 A

GENERAL

Hydraulic Arm Shaft Bushing Press-Fitting Tool

Application

• Use for replacing the hydraulic arm shaft bushings in the hydraulic cylinder body.

Right Left

54.7 to 54.9 mm

(2.154 to 5.161 in.)

24.5 to 25.5 mm

(0.965 to 1.00 in.)

C 40.0 mm (1.57 in.) 40.0 mm (1.57 in.)

D 32.0 mm (1.26 in.) 32.0 mm (1.26 in.)

49.70 to 49.90 mm

(1.957 to 1.964 in.)

F 70.0 mm dia. (2.76 in. dia.)

G 40.0 mm dia. (1.57 in. dia.)

H 50.0 mm (1.97 in.)

I 10.0 mm (0.39 in.)

a 6.3 µm (250 µin.)

b 6.3 µm (250 µin.)

c 6.3 µm (250 µin.)

d 6.3 µm (250 µin.)

49.7 to 49.9 mm (1.957 to 1.964 in.)

21.5 to 22.5 mm (0.847 to 0.885 in.)

44.70 to 44.90 mm (1.760 to 1.767 in.)

9Y1210278GEG0053US0

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Page 60

L4100, WSM

NOTE

KiSC issued 08, 2012 A

GENERAL

Draft Control Test Bar

Application

• Use for checking the lift range and floating range of hydraulic draft control.

• When checking and adjusting the draft control rod by using the draft control test bar, about 50 kg (490 N, 110 lbf) of weight is needed.

A 1000 mm (39.37 in.)

B 25 mm (0.984 in.)

C 140 mm (5.51 in.)

D 200 mm (7.87 in.)

E 50 mm (1.97 in.)

F 25 mm (0.984 in.)

G 90 mm (3.54 in.)

H 25 mm (0.984 in.)

I 21 mm dia. (0.827 in. dia.)

J 30 mm dia. (1.18 in. dia.)

K 12 mm (0.47 in.)

9Y1210278GEG0086US0

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Page 61

L4100, WSM

KiSC issued 08, 2012 A

Balancer Metal Replacing Tool (for Removing)

Application

• Use to remove the metal bearing.

GENERAL

A 25 mm dia. (0.98 in. dia.) L 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.)

B 10 mm (0.39 in.) M 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.)

C Chamfer 0.3 mm (0.01 in.) N 21.947 to 21.960 mm dia. (0.8641 to 0.8646 in. dia.)

D 0.52 rad (30 °) O 28 mm (1.10 in.)

E 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.) P 29 mm (1.14 in.)

F 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.) Q 5 mm (0.20 in.)

G 41 mm (1.61 in.) R 36 mm (1.42 in.)

H 32.5 mm (1.28 in.) S 195.25 to 195.75 mm (7.687 to 7.707 in.)

I 148.5 mm (5.85 in.) T 145 mm (5.71 in.)

J 46.50 to 46.75 mm dia. (1.831 to 1.841 in. dia.) U 384.75 to 385.25 mm (15.148 to 15.167 in.)

K 44.950 to 44.975 mm dia. (1.7697 to 1.7707 in. dia.)

9Y1210278GEG0083US0

G-46

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Page 62

L4100, WSM

KiSC issued 08, 2012 A

Balancer Metal Replacing Tool (for Fitting)

Application

• Use to press fit the metal bearing.

GENERAL

A 0.52 rad (30 °) O 5 mm (0.20 in.)

B 10 mm (0.39 in.) P 3.3 to 3.7 mm dia. (0.130 to 0.146 in. dia.)

C Chamfer 0.3 mm (0.01 in.) Q 43.934 to 43.950 mm dia. (1.7297 to 1.7303 in. dia.)

D 182 mm (7.17 in.) R 140 mm (5.51 in.)

E 140 mm (5.51 in.) S 36 mm (1.42 in.)

F 35 mm dia. (1.38 in. dia.) T 60 mm dia. (2.36 in. dia.)

G 60 mm dia. (2.36 in. dia.) U 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)

H 37 mm (1.46 in.) V 44.950 to 44.975 mm dia. (1.7697 to 1.7707 in. dia.)

I 21.947 to 21.960 mm dia. (0.8641 to 0.8646 in. dia.) W 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.)

J 24.959 to 24.980 mm dia. (0.9826 to 0.9835 in. dia.) X 145 mm (5.71 in.)

K 8.8 to 9.2 mm (0.346 to 0.362 in.) Y 195.25 to 195.75 mm (7.687 to 7.707 in.)

L 25 mm dia. (0.98 in. dia.) Z 29 mm (1.14 in.)

M 60 mm dia. (2.36 in. dia.) a 36 mm (1.42 in.)

N 46.950 to 46.975 mm dia. (1.8484 to 1.8494 in. dia.)

G-47

9Y1210278GEG0084US0

(EU)

Page 63

L4100, WSM

WARNING

CAUTION

IMPORTANT

KiSC issued 08, 2012 A

9. TIRES

[1] TIRE PRESSURE

GENERAL

Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it everyday and inflate as necessary.

Recommended inflation pressure

Maintain the pressure shown below.

Tire sizes Inflation Pressure

Rear 13.6-26, 4PR 100 kPa (1.0 kgf/cm

Front 8.00-16, 4PR 160 kPa (1.6 kgf/cm

, 16 psi)

, 23 psi)

To avoid personal injury:

• Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment.

• Always maintain the correct tire pressure. Do not inflate above the recommended pressure shown in the operator's manual.

(1) Ground (A) Insufficient

(B) Standard (C) Excessive (D) Bad

9Y1210278GEG0055US0

[2] TREADS ADJUSTMENT

• When working on slopes or working with trailer, set the wheel tread as wide as practice for the job for maximum stability.

• Support tractor securely on stands before removing a wheel.

• Do not work under any hydraulically supported devices. They can settle, suddenly leak down, or be accidentally lowered. If necessary to work under tractor or any machine elements for servicing or adjustment, securely support them with stands or suitable blocking beforehand.

• Never operate tractor with a loose rim, wheel, or axle.

9Y1210278GEG0056US0

(1) Front Wheels

Front tread can not be adjusted.

Tire 8 – 16 Farm

Tread

1145 mm

(45.1 in.)

• Do not turn front discs to obtain wider tread.

• When re-fitting or adjusting a wheel, tighten the bolts to the following torques then recheck after driving the tractor 200 m (200 yards) and 10 times of shuttle movement by 5 m (5 yards), and thereafter according to service interval.

G-48

9Y1210278GEG0057US0

(EU)

Page 64

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

(2) Rear Wheels

Models

GENERAL

13.6 – 26 Farm

1145 mm

(45.1 in.)

1235 mm

(48.6 in.)

1335 mm

(52.6 in.)

1340 mm

(52.8 in.)

Rear tread width can be adjusted as shown with the standard

equipped tires.

To change the tread width

1. Remove the wheel rim and / or disk mounting bolts.

2. Change the position of the rim and / or disk (right and left) to the desired position, and tighten the bolts.

• Always attach wheels as shown in the drawings

• If not attached as illustrated, transmission parts may be damaged.

124 to 147 N·m

Front wheel mounting bolt

Tightening torque

Rear wheel mounting bolt and nut

(1) Tread (2) Front Wheel Mounting Bolt

(3) Rear Wheel Mounting Bolt and NUt

12.6 to 15.0 kgf·m

91.2 to 108 lbf·ft

197 to 225 N·m

20.0 to 23.0 kgf·m 145 to 166 lbf·ft

9Y1210278GEG0079US0

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Page 65

L4100, WSM

IMPORTANT

CAUTION

KiSC issued 08, 2012 A

GENERAL

[3] TIRE LIQUID INJECTION

Auxiliary weights can be used to increase traction force for plowing in fields or clayey ground.

Another way is to inject water or another liquid, such as a calcium chloride solution in the tires. Water must not be used in winter since it freezes at 0 °C (32 °F). The calcium chloride solution will not freeze and moreover, affords higher effect than water since its specific gravity is higher than that of water by about 20 %. Below is an explanation of calcium chloride solution injection.

• Do not fill the front tires with liquid.

9Y1210278GEG0059US0

Preparation of Calcium Chloride Solution

• When making a calcium chloride solution, do not pour water over calcium chloride since this results in chemical reaction which will cause high temperature. Instead add a small amount of calcium chloride to the water at a time until the desired solution is achieved.

Freezing temp.

−5 °C (23 °F) 12 kg (26.4 lbs)

−10 °C (14 °F) 21 kg (46.3 lbs)

−15 °C (5 °F) 28 kg (61.7 lbs)

−20 °C (−4 °F) 34 kg (75.0 lbs)

−25 °C (−13 °F) 40 kg (88.2 lbs)

−30 °C (−22 °F) 44 kg (97.0 lbs)

−35 °C (−31 °F) 49 kg (108 lbs)

−40 °C (−40 °F) 52 kg (114.6 lbs)

−45 °C (−49 °F) 56 kg (123.5 lbs)

−50 °C (−58 °F) 61 kg (134.5 lbs)

Weight of CaCl

(26.5 U.S.gals, 22.0 Imp.gals) of water

to be dissolved in 100 L

(a) Water (b) CaCl

(Calcium Chloride)

A: Bad B: Good

9Y1210278GEG0080US0

Attaching Injector

1. Lift the rear tires off the ground.

2. Turn the tire so that the air valve is at the top.

3. Remove the air valve, and attach the injector. (Code No. 07916-52501)

(1) Injector (2) Hose

9Y1210278GEG0081US0

G-50

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Page 66

L4100, WSM

CAUTION

NOTE

KiSC issued 08, 2012 A

GENERAL

Injection

• When a calcium chloride solution is used, cool it before pouring it into the tire.

• Do not fill tires with water or solution more than 75 % of full capacity (to the valve stem level).

The following four ways can be used to inject water or a calcium

chloride solution into tires.

1. Gravity injection (Fig. 1)

2. Pump injection (Fig. 2)

3. Pressure tank injection (Fig. 3)

4. Injection directly from top (only when water is being used).

• Once injection is completed, reset the air valve, and pump air into the tire to the specified pressure.

Weight of Calcium Chloride Solution Filling 75 % of Full

Capacity of a Tire.

Tire sizes 13.6 – 26

Slush free at −10 °C (14 °F) Solid at −30 °C (−22 °F) [Approx. 1 kg (2 lbs) CaCl (1 gal.) of water]

Slush free at −24 °C (−11 °F ) Solid at −47 °C (−52 °F) [Approx. 1.5 kg (3.5 lbs) CaCl (1 gal.) of water]

Slush free at −47 °C (−52 °F) Solid at −52 °C (−62 °F) [Approx. 2.25 kg (5 lbs) CaCl of water]

per 4 L

per 4 L (1 gal.)

172 kg

(379 lbs)

181 kg

(399 lbs)

192 kg

(423 lbs)

(1) Pump (2) Pressure Tank (3) Compressor (4) Air (5) Water

(A) Correct: 75 %

Air Compresses Like a Cushion

(B) Incorrect: 100 % Full

Water Can Not Be Compressed

9Y1210278GEG0082US0

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Page 67

1 ENGINE

KiSC issued 08, 2012 A

Page 68

MECHANISM

KiSC issued 08, 2012 A

CONTENTS

1. LUBRICATING SYSTEM ...........................................................................................................1-M1

2. COOLING SYSTEM ................................................................................................................... 1-M2

3. FUEL SYSTEM........................................................................................................................... 1-M3

Page 69

L4100, WSM

KiSC issued 08, 2012 A

1. LUBRICATING SYSTEM

ENGINE

(1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Governor Shaft (6) Idle Gear (7) Crankshaft (8) Oil Pump (9) Oil Strainer (10) Relief Valve (11) Oil Filter Cartridge (12) Push Rod (13) Tappet (14) Camshaft (15) Piston (16) Connecting Rod

A lubricating system consists of an oil strainer (9), oil pump (8), relief valve (10), oil filter cartridge (11) and oil

pressure switch (2).

The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the oil filter cartridge where it is further filtered. Then the oil is forced to crankshaft (7), connecting rods (16), idle gear (6), governor shaft (5), camshaft (14) and rocker arm shaft (3) to lubricate each part thorough the oil gallery.

9Y1210278ENM0001US0

1-M1

(EU)

Page 70

L4100, WSM

KiSC issued 08, 2012 A

2. COOLING SYSTEM

ENGINE

Bottom bypass system is introduced in 03-M Series

for improving the cooling performance of the radiator.

While the temperature of coolant in the engine is low, the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.

When the temperature exceeds the thermostat valve opening level, the thermostat fully opens itself to prevent the hot coolant from flowing through the bypass into the engine.

In this way, the radiator can increase its cooling performance.

(1) Thermostat (A) Thermostat Closed

(B) Thermostat Open

9Y1210278ENM0002US0

1-M2

(EU)

Page 71

L4100, WSM

KiSC issued 08, 2012 A

3. FUEL SYSTEM

ENGINE

(1) Fuel Overflow Pipe (2) Injection Nozzle (3) Injection Pipe

(4) Fuel Tank (5) Injection Pump Air Vent Pipe (6) Injection Pump

(7) Fuel Filter (8) Fuel Feed Pump (9) Fuel Filter Air Vent Pipe

a: Feed Fuel Flow b: Injected Fuel Flow c: Returned Fuel Flow

The fuel system of this tractor is shown in the diagram above. Fuel from the tank flows in the passage as shown by the arrows, and is injected from the nozzle via the fuel

injection pump. Overflow fuel returns to the tank.

The system includes filters and other concerns to protect it from entrance of air, water and dust.

While the engine is running, fuel is fed into the injection pump (6) by the fuel feed pump (8) after passing through the fuel filter (7). The fuel camshaft actuates the injection pump and force-feeds fuel to the injection nozzle (2) through the injection pipe (3). Fuel is then sprayed through the nozzle into the combustion chamber. The fuel discharged after lubricating and cooling the injection nozzle is returned to the fuel tank (4) automatically through the overflow pipe (1).

9Y1210278ENM0003US0

1-M3

(EU)

Page 72

SERVICING

KiSC issued 08, 2012 A

CONTENTS

1. TROUBLESHOOTING.................................................................................................................1-S1

2. SERVICING SPECIFICATIONS ..................................................................................................1-S4

3. TIGHTENING TORQUES ............................................................................................................1-S8

4. CHECKING, DISASSEMBLING AND SERVICING .....................................................................1-S9

[1] CHECKING AND ADJUSTING.............................................................................................. 1-S9

(1) Compression Pressure .................................................................................................... 1-S9

(2) Valve Clearance ............................................................................................................1-S10

(3) Top Clearance ...............................................................................................................1-S11

(4) Engine Oil Pressure....................................................................................................... 1-S12

(5) Fan Belt .........................................................................................................................1-S12

(6) Radiator ......................................................................................................................... 1-S13

(7) Fuel Injection Pump....................................................................................................... 1-S15

(8) Injection Nozzle .............................................................................................................1-S16

[2] PREPARATION................................................................................................................... 1-S17

(1) Separating Engine and Clutch Housing......................................................................... 1-S17

(2) Separation Engine from Front Axle Frame .................................................................... 1-S24

[3] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S25

(1) Cylinder Head and Valves ............................................................................................. 1-S25

(2) Timing Gears, Camshaft and Fuel Camshaft ................................................................ 1-S29

(3) Piston and Connecting Rod...........................................................................................1-S34

(4) Crankshaft .....................................................................................................................1-S38

(5) Thermostat ....................................................................................................................1-S40

(6) Injection Nozzle .............................................................................................................1-S40

[4] SERVICING.........................................................................................................................1-S41

(1) Cylinder Head and Valves ............................................................................................. 1-S41

(2) Timing Gears, Camshaft and Fuel Camshaft ................................................................ 1-S46

(3) Piston and Connecting Rod...........................................................................................1-S50

(4) Crankshaft .....................................................................................................................1-S52

(5) Cylinder .........................................................................................................................1-S56

(6) Oil Pump........................................................................................................................1-S57

Page 73

L4100, WSM

KiSC issued 08, 2012 A

1. TROUBLESHOOTING

ENGINE

Symptom Probable Cause Solution

Engine Does Not Start

Starter Does Not Run Battery discharged Charge G-22

Engine Revolution Is Not Smooth

No fuel Replenish fuel G-9

Air in the fuel system Bleed G-33

Water in the fuel system Change fuel and

repair or replace fuel system

Fuel pipe clogged Clean G-24

Fuel filter clogged Change G-27

Excessively high viscosity of fuel or engine oil at low temperature

Fuel with low cetane number Use specified fuel G-9

Fuel leak due to loose injection pipe retaining nut Tighten nut 1-S26

Incorrect injection timing Adjust 1-S15

Fuel camshaft worn Replace –

Injection nozzle clogged Clean 1-S16

Injection pump malfunctioning Repair or replace 1-S29

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder Replace head gasket,

Improper valve timing Correct or replace

Piston ring and cylinder worn Replace 1-S35,

Excessive valve clearance Adjust 1-S10

Starter malfunctioning Repair or replace 9-S12,

Main switch malfunctioning Repair or replace 9-S7

Safety switches defective Replace 9-S9

Starter relay defective Replace 9-S13

Wiring disconnected Connect –

Fuel filter clogged or dirty Change G-27

Air cleaner clogged Clean or change G-24

Fuel leak due to loose injection pipe retaining nut Tighten nut 1-S26

Injection pump malfunctioning Repair or replace 1-S29

Incorrect nozzle injection pressure Adjust 1-S16

Injection nozzle stuck or clogged Repair or replace 1-S16

Governor malfunctioning Repair –

Use specified fuel or engine oil

Repair or replace –

tighten cylinder head screw, glow plug and nozzle holder

timing gear

Reference Page

–

G-27

1-S27,

1-S28

1-S46

1-S56

9-S22

1-S1

(EU)

Page 74

L4100, WSM

KiSC issued 08, 2012 A

ENGINE

Symptom Probable Cause Solution

Either White or Blue Exhaust Gas Is Observed

Excessive engine oil Reduce to specified

level

Piston ring and cylinder worn or stuck Repair or replace 1-S35,

Reference Page

G-9

1-S56

Incorrect injection timing Adjust 1-S15

Deficient compression Adjust top clearance 1-S11

Either Black or Dark Gray Exhaust Gas Is Observed

Overload Loosen load –

Low grade fuel used Use specified fuel G-9

Fuel filter clogged Change G-25

Air cleaner clogged Clean or replace G-24

Deficient nozzle injection Repair or replace

1-S16

nozzle

Deficient Output Incorrect injection timing Adjust 1-S15

Engine's moving parts seem to be seizing Repair or replace –

Uneven fuel injection Repair or replace

1-S15

nozzle

Deficient nozzle injection Repair or replace

1-S15

nozzle

Compression leak Replace head gasket,

tighten cylinder head

1-S27,

1-S28 bolt, glow plug and nozzle holder

Excessive Lubricant Oil Consumption

Piston ring's gap facing the same direction Shift ring gap

direction

1-S35

Oil ring worn or stuck Replace 1-S35

Piston ring groove worn Replace the piston 1-S35,

1-S51

Valve stem and valve guide worn Replace 1-S43

Oil leaking due to defective seals or packing Replace –

Fuel Mixed into Lubricant Oil

Injection pump's plunger worn Replace pump

element or pump

Deficient nozzle injection Repair or replace

–

1-S15 nozzle

Injection pump broken Replace 1-S29

Water Mixed into Lubricant Oil

Head gasket defective Replace 1-S28

Cylinder block or cylinder head flawed Replace –

1-S2

(EU)

Page 75

L4100, WSM

KiSC issued 08, 2012 A

ENGINE

Symptom Probable Cause Solution

Reference Page

Low Oil Pressure Engine oil insufficient Replenish G-16

Oil filter clogged Clean G-16

Relief valve stuck with dirt Clean –

Relief valve spring weaken or broken Replace –

Excessive oil clearance of crankshaft bearing Replace 1-S54,

1-S55

Excessive oil clearance of crankpin bearing Replace 1-S53

Excessive oil clearance of rocker arm Replace 1-S45

Oil passage clogged Clean –

Different type of oil Use specified type of

G-9

oil

Oil pump defective Repair or replace 1-S33,

1-S57

High Oil Pressure Different type of oil Use specified type of

G-9

oil

Relief valve defective Replace –

Engine Overheated Engine oil insufficient Replenish G-9

Fan belt broken or elongated Replace or adjust 1-S12

Coolant insufficient Replenish G-30

Radiator net and radiator fin clogged with dust Clean –

Inside of radiator corroded Clean or replace –

Coolant flow route corroded Clean or replace –

Radiator cap defective Replace 1-S13

Overload running Loosen load –

Head gasket defective Replace 1-S28

Incorrect injection timing Adjust 1-S15

Unsuitable fuel used Use specified fuel G-9

1-S3

9Y1210278ENS0001US0

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Page 76

L4100, WSM

KiSC issued 08, 2012 A

ENGINE

2. SERVICING SPECIFICATIONS

CYLINDER HEAD AND VALVES

Item Factory Specification Allowable Limit

Piston Top Clearance 0.55 to 0.70 mm

0.0217 to 0.0276 in.

Cylinder Head Surface Flatness – 0.05 mm / 500 mm

Valve Recessing Protrusion

0.050 mm

0.0020 in.

–

0.0020 in. /

19.69 in.

–

Recessing

Valve Stem to Valve Guide

• Valve Stem

• Valve Guide

Valve Seat Width 2.12 mm

Valve Spring Tilt

Rocker Arm to Rocker Arm Shaft

Clearance

O.D.

I.D. (Intake and Exhaust)

Free length

Setting Load / Setting Length

Clearance

0.15 mm

0.0059 in.

0.040 to 0.070 mm

0.0016 to 0.0028 in.

7.960 to 7.975 mm

0.3134 to 0.3139 in.

8.015 to 8.030 mm

0.3156 to 0.3161 in.

0.0835 in.

–

41.7 to 42.2 mm

1.65 to 1.66 in.

117.6 N / 35.0 mm

12.0 kgf / 35.0 mm

26.4 lbf / 1.3780 in.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

0.40 mm

0.016 in.

0.10 mm

0.0039 in.

–

1.0 mm

0.039 in.

41.2 mm

1.62 in.

100 N / 35.0 mm

10.2 kgf /

35.0 mm

22.5 lbf / 1.3780 in.

0.10 mm

0.0039 in.

• Rocker Arm Shaft

• Rocker Arm

Push Rod Alignment – 0.25 mm

Tappet to Tappet Guide Clearance

O.D.

I.D.

O.D.

I.D.

1-S4

13.973 to 13.984 mm

0.55012 to 0.55055 in.

14.000 to 14.018 mm

0.55119 to 0.55188 in.

0.020 to 0.062 mm

0.00079 to 0.0024 in.

23.959 to 23.980 mm

0.94327 to 0.94409 in.

24.000 to 24.021 mm

0.94489 to 0.94570 in.

–

0.0098 in.

0.070 mm

0.003 in.

–

9Y1210278ENS0116US0

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Page 77

L4100, WSM

KiSC issued 08, 2012 A

TIMING GEARS, CAMSHAFT AND FUEL CAMSHAFT

Item Factory Specification Allowable Limit

Timing Gear

• Idle Gear to Crank Gear

Backlash

0.04150 to 0.1122 mm

0.001634 to 0.004417 in.

ENGINE

0.15 mm

0.0059 in.

• Idle Gear to Cam Gear

Backlash

0.04150 to 0.1154 mm

0.001634 to 0.004543 in.

• Idle Gear to Injection Pump Gear

Backlash

0.04150 to 0.1154 mm

0.001634 to 0.004543 in.

• Crank Gear to Oil Pump Gear

Backlash

0.0484 to 0.2455 mm

0.001906 to 0.009665 in.

Idle Gear Side Clearance 0.15 to 0.25 mm

0.0059 to 0.0098 in.

Camshaft Side Clearance

0.070 to 0.22 mm

0.0028 to 0.0086 in.

Alignment

Idle Gear Shaft to Idle Gear Bushing Clearance

0.025 to 0.066 mm

–

0.00099 to 0.0025 in.

O.D.

37.959 to 37.975 mm

1.4945 to 1.4950 in.

I.D.

38.000 to 38.025 mm

1.4961 to 1.4970 in.

Cam Height

(Intake / Exhaust)

Camshaft Journal

Clearance

33.90 mm

1.335 in.

0.050 to 0.091 mm

0.0020 to 0.0035 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.30 mm

0.012 in.

0.90 mm

0.035 in.

0.30 mm

0.012 in.

0.01 mm

0.0004 in.

0.10 mm

0.0039 in.

–

33.85 mm

1.333 in.

0.15 mm

0.0059 in.

• Camshaft Journal

• Cylinder Bearing

O.D.

I.D.

Balancer Shaft Side Clearance

Alignment

Balancer Shaft Journal 1 to Balancer Shaft

Clearance

Bearing 1

• Balancer Shaft Journal 1

• Balancer Shaft Bearing 1

O.D.

I.D.

39.934 to 39.950 mm

1.5722 to 1.5728 in.

40.000 to 40.025 mm

1.5748 to 1.5757 in.

0.07 to 0.22 mm

0.0028 to 0.0087 in.

–

0.030 to 0.111 mm

0.00118 to 0.00437 in.

43.934 to 43.950 mm

1.72969 to 1.73032 in.

43.980 to 44.045 mm

1.73150 to 1.73406 in.

–

0.30 mm

0.0118 in.

0.02 mm

0.0008 in.

0.20 mm

0.0079 in.

–

1-S5

(EU)

Page 78

L4100, WSM

KiSC issued 08, 2012 A

Item Factory Specification Allowable Limit

Balancer Shaft Journal 2 to Balancer Shaft Bearing 2

Clearance

0.051 to 0.132 mm

0.00201 to 0.00520 in.

ENGINE

0.20 mm

0.0079 in.

• Balancer Shaft Journal 2

O.D.

41.934 to 41.950 mm

1.65095 to 1.65158 in.

• Balancer Shaft Bearing 2

I.D.

41.980 to 42.045 mm

1.65276 to 1.65532 in.

Balancer Shaft Journal 3 to Balancer Shaft Bearing 3

• Balancer Shaft Journal 3

Clearance

O.D.

0.020 to 0.094 mm

0.00079 to 0.00370 in.

21.947 to 21.960 mm

0.86406 to 0.86457 in.

• Balancer Shaft Bearing 3

I.D.

21.980 to 22.041 mm

0.86535 to 0.86776 in.

PISTON AND CONNECTING ROD

Item Factory Specification Allowable Limit

Piston Pin Bore I.D. 25.000 to 25.013 mm

0.98426 to 0.98476 in.

Piston Pin to Small End Bushing

Clearance

0.014 to 0.036 mm

0.00056 to 0.0014 in.

•Piston Pin

O.D.

25.004 to 25.011 mm

0.98441 to 0.98468 in.

–

0.20 mm

0.0079 in.

–

9Y1210278ENS0117US0

25.05 mm

0.9862 in.

0.15 mm

0.0059 in.

–

• Small End Bushing

I.D.

25.025 to 25.040 mm

–

0.98524 to 0.98582 in.

Piston Ring Gap Top Ring

Second Ring

Oil Ring

Piston Ring to Groove Second Ring

Oil Ring

0.25 to 0.40 mm

0.0099 to 0.015 in.

0.30 to 0.45 mm

0.012 to 0.017 in.

0.25 to 0.45 mm

0.0099 to 0.017 in.

0.0930 to 0.128 mm

0.00367 to 0.00503 in.

0.020 to 0.060 mm

0.00079 to 0.0023 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

0.20 mm

0.0079 in.

0.15 mm

0.0059 in.

Connecting Rod Alignment – 0.05 mm

0.002 in.

9Y1210278ENS0118US0

1-S6

(EU)

Page 79

L4100, WSM

KiSC issued 08, 2012 A

CRANKSHAFT

Item Factory Specification Allowable Limit

Crankshaft Side Clearance

0.15 to 0.31 mm

0.0059 to 0.012 in.

ENGINE

0.5 mm

0.02 in.

Crankpin to Crankpin Bearing

Alignment

Clearance

0.025 to 0.087 mm

–

0.00099 to 0.0034 in.

• Crankpin

O.D.

46.959 to 46.975 mm

1.8488 to 1.8494 in.

• Crankpin Bearing

I.D.

47.000 to 47.046 mm

1.8504 to 1.8522 in.

Crankshaft Journal to Crankshaft Bearing 1

Clearance

0.0400 to 0.118 mm

0.00158 to 0.00464 in.

• Crankpin

O.D.

46.959 to 46.975 mm

1.8488 to 1.8494 in.

• Crankpin Bearing1

I.D.

59.980 to 60.039 mm

2.3615 to 2.3637 in.

Crankshaft Bearing 1 Dimension 59.921 to 59.940 mm

2.3591 to 2.3598 in.

Crankshaft to Crankshaft Bearing 2

Clearance

0.0400 to 0.104 mm

0.00158 to 0.00409 in.

0.02 mm

0.0008 in.

0.20 mm

0.0079 in.

–

0.20 mm

0.0079 in.

–

0.20 mm

0.0079 in.

• Crankshaft Journal

O.D.

59.921 to 59.940 mm

2.3591 to 2.3598 in.

• Crankshaft Bearing 2

I.D.

59.980 to 60.025 mm

2.3615 to 2.3631 in.

CYLINDER

Item Factory Specification Allowable Limit

Cylinder Bore

• Standard

I.D.

87.000 to 87.022 mm

3.4252 to 3.4260 in.

• Oversize

I.D.

87.250 to 87.272 mm

3.4351 to 3.4359 in.

OIL PUMP

Item Factory Specification Allowable Limit

Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm

0.0012 to 0.0055 in.

Outer Rotor to Pump Body Clearance 0.11 to 0.19 mm

0.0044 to 0.0074 in.

Inner Rotor to Cover Clearance 0.105 to 0.150 mm

0.00414 to 0.00590 in.

–

9Y1210278ENS0119US0

87.170 mm

3.4319 in.

87.420 mm

3.4417 in.

9Y1210278ENS0120US0

0.20 mm

0.008 in.

0.25 mm

0.0098 in.

0.20 mm

0.008 in.

1-S7

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NOTE

KiSC issued 08, 2012 A

ENGINE

3. TIGHTENING TORQUES

Tightening torques of screws, bolts and nuts on the table below are especially specified.

(For general use screws, bolts and nuts: See page G-11.)

9Y1210278ENS0123US0

PREPARATION

Item N·m kgf·m lbf·ft

Oil pressure switch 14.7 to 19.6 1.50 to 2.00 10.9 to 14.4

Steering wheel mounting nut 48 to 55 4.9 to 5.7 36 to 41

Independent PTO delivery pipe joint bolt 35 to 39 3.5 to 4.0 26 to 28

Power steering delivery hose joint bolt 49 to 58 5.0 to 6.0 37 to 43

Starter B terminal mounting nut 7.9 to 9.8 0.80 to 1.0 5.8 to 7.2

Main delivery hose retaining nut 47 to 50 4.8 to 5.2 35 to 37

Right and left delivery hoses retaining nut 25 to 29 2.5 to 3.0 18 to 21

Engine and clutch housing mounting screw and nut 78 to 90 7.9 to 9.2 58 to 66

Engine and clutch housing mounting stud bolt 40 to 49 4.0 to 5.0 29 to 36

Clutch mounting screw 24 to 27 2.4 to 2.8 18 to 20

Muffler mounting screw 32 to 39 3.2 to 4.0 24 to 28

Front axle frame mounting M10 screw 61 to 70 6.2 to 7.2 45 to 52

Front axle frame mounting M12 screw 103 to 122 10.5 to 12.5 76.0 to 90.4

9Y1210278ENS0124US0

ENGINE BODY

Item

Dimension ×

Pitch

N·m kgf·m lbf·ft

*Cylinder head screw M11 × 1.25 93.2 to 98.0 9.50 to 10.0 68.8 to 72.3

Cylinder head cover screw M6 × 1.0 6.87 to 11.2 0.700 to 1.15 5.07 to 8.31

Injection pipe retaining nut M12 × 1.5 25 to 34 2.5 to 3.5 18 to 25

Nozzle holder assembly M20 × 1.5 49 to 68 5.0 to 7.0 37 to 50

Overflow pipe assembly retaining nuts – 20 to 24 2.0 to 2.5 15 to 18

Glow plug M10 × 1.25 20 to 24 2.0 to 2.5 15 to 18

*Rocker arm bracket screw M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20

Hi-idling body M8 × 1.25 45 to 49 4.5 to 5.0 33 to 36

Fan drive pulley mounting nut – 138 to 156 14.0 to 16.0 102 to 115

Camshaft set screw M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20

Balancer shaft set bolt M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20

*Connecting rod screws M8 × 1.0 45 to 49 4.5 to 5.0 33 to 36

*Flywheel screw M12 × 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5

*Bearing case cover screws M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20

*Main bearing case screw 2 M10 × 1.25 69 to 73 7.0 to 7.5 51 to 54

*Main bearing case screw 1 M9 × 1.25 46 to 50 4.7 to 5.2 34 to 37

Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28

• For * marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.

• The letter "M" in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the normal distance in mm between two threads.

1-S8

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NOTE

KiSC issued 08, 2012 A

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Compression Pressure

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine and disconnect the 2P connector from the stop

solenoid in order to inject fuel.

3. Remove the air cleaner, the muffler and all injection nozzle.

4. Set a compression tester (Code No. 07909-30208) with the adaptor to the nozzle hole.

5. Keep the engine stop lever at "Stop Position".

6. While cranking the engine with the starter, measure the compression pressure.

7. Repeat steps 4 through 6 for each cylinder.

8. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the nozzle hole and measure the compression pressure again.

9. If the compression pressure is still less than the allowable limit, check the top clearance, valve cylinder.

10. If the compression pressure increases after applying oil, check the cylinder wall and piston rings.

ENGINE

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variance in cylinder compression values should be under 10 %.

Compression pressure

Factory specification

Allowable limit

3.53 to 4.02 MPa 36 to 41 kgf/cm 512 to 583 psi

2.55 MPa 26 kgf/cm 370 psi

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IMPORTANT

NOTE

KiSC issued 08, 2012 A

(2) Valve Clearance

ENGINE

Valve Clearance

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the head cover, the glow plugs and the timing window cover on the clutch housing.

2. Align the "TC" mark line on the flywheel and center or timing window so that the No.1 piston comes to the compression or overlap top dead center.

3. Check the following valve clearance marked with "," using a feller gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Finally turn the flywheel 6.28 rad (360 °), and align the "TC" marking line and the center of timing window. adjust all the other valve clearance as required.

Valve clearance Factory specification

0.18 to 0.22 mm

0.0071 to 0.0086 in.

• The "TC" marking line on the flywheel is just for No.1 cylinder. There is no "TC" marking for the other cylinders.

• No. 1 piston comes to the T.D.C. position when the "TC" marking is aligned with center of timing window on clutch-housing. Turn the flywheel 0.26 rad (15 °) clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position. Now referring to the table below, readjust the valve clearance. (The piston is at the compression top dead center when both the IN. and EX. valves do not move; it is at the overlap position when both the valves move.)

Condition

When No. 1 piston is compression top dead center

When No. 1 piston is overlap position

No. of

cylinder

1st ,,

2nd ,

3rd ,

4th

1st

2nd ,

3rd ,

4th ,,

IN. Valve EX.Valve

(1) TC Mark Line (2) Timing Window

1-S10

A: Valve Clearance

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NOTE

KiSC issued 08, 2012 A

(3) Top Clearance

ENGINE

Top Clearance

1. Remove the cylinder head.

2. Move the piston and place a trip of fuse on the piston head at three positions with grease.

3. Lower the piston, and install the cylinder head. (Use a new cylinder head gasket and tighten with a specified tightening torque.)

4. Turn the flywheel until the piston through the T.D.C..

5. Remove the cylinder head, and measure the thickness of the fuses.

6. If the measurement is not within the factory specifications, check the oil clearance between the crankpin and bearing and between the piston pin and bushing.

• After checking the top clearance, be sure to assemble the cylinder head with a new cylinder head gasket.

Top clearance Factory specification

0.55 to 0.70 mm

0.0217 to 0.0276 in.

Tightening torque Cylinder head screws

(1) Piston (2) Fuse

93.2 to 98.0 N·m

9.50 to 10.0 kgf·m

68.8 to 72.3 lbf·ft

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KiSC issued 08, 2012 A

(4) Engine Oil Pressure

ENGINE

Engine Oil Pressure

1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No. 07916-32032). (Adaptor screw size: PT 1/8)

2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.

3. If the oil pressure is less than the allowable limit, check the following.

• Engine oil insufficient

• Oil pump defective

• Oil strainer clogged

• Oil filter cartridge clogged

• Oil gallery clogged

• Excessive oil clearance

• Foreign matter in the relief valve

More than 98 kPa

1.0 kgf/cm 14 psi

49 kPa

0.50 kgf/cm

7.1 psi

294 to 441 kPa

3.00 to 4.50 kgf/cm

42.7 to 64.0 psi

245 kPa

2.50 kgf/cm

35.6 psi

Engine oil pressure

At idle speed

At rated speed

Factory specification

Allowable limit

Factory specification

Allowable limit

(5) Fan Belt

(When reassembling)

• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

14.7 to 19.6 N·m

Tightening torque Oil pressure switch

1.50 to 2.00 kgf·m

10.9 to 14.4 lbf·ft

9Y1210278ENS0007US0

Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway

between the fan drive pulley and alternator pulley at specified force 68.6 N (7.00 kgf, 15.4 lbf).

2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.

Deflection (A) Factory specification

(A) Deflection

12 mm

0.471 in.

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CAUTION

KiSC issued 08, 2012 A

(6) Radiator

ENGINE

Fan Belt Damage and Wear

1. Check the fan belt for damage.

2. If the fan belt is damaged, replace it.

3. Check if the fan belt is worn and sunk in the pulley groove.

4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.

(A) Good (B) Bad

9Y1210272ENS0018US0

Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat.

2. Heating the water gradually, read the temperature when the valve opens and leaves the string.

3. Continue heating and read the temperature when the valve opens approx. 6 mm (0.236 in.).

4. If the measurement is not within the factory specifications, replace the thermostat.

Thermostat's valve opening temperature

Temperature at which thermostat completely opens

Factory specification

69.5 to 72.5 °C

157.1 to 162.5 °F

85 °C 185 °F

9Y1210278ENS0008US0

Radiator Cap Air Leakage

• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people.

1. Set a radiator tester (Code No. 07909-31551) and an adaptor (BANZAI Code No. RCT-2A-30S) on the radiator cap.

2. Apply the specified pressure 88 kPa (0.90 kgf/cm

, 12 psi), and

measure the time for the pressure to fall to 59 kPa (0.60 kgf/cm

8.6 psi).

3. If the measurement is less than the factory specification, replace the radiator cap.

More than 10 seconds for pressure fall

Pressure falling time Factory specification

1-S13

from 88 to 59 kPa (from 0.90 to 0.60 kgf/cm, from 12 to 8.6 psi)

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KiSC issued 08, 2012 A

ENGINE

Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Set a radiator tester (Code No. 07909-31551) with an adaptor (BANZAI Code No. RCT-2S-30S) and raise the water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. If any leaks are detected, replace the radiator or repair with the radiator cement. Of the water leak is excessive, replace the radiator.

No leak at Radiator water leakage test pressure

Factory specification

137 kPa

1.40 kgf/cm

19.9 psi

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NOTE

KiSC issued 08, 2012 A

(7) Fuel Injection Pump

ENGINE

Injection Timing

1. Remove the stop solenoid.

2. Remove the injection pipes and nozzle.

3. Set the speed control lever to maximum fuel discharge position.

(Reference)

• Turn the flywheel with screwdriver.

4. Turn the flywheel counterclockwise (facing the flywheel) until the fuel fills up to the hole of the delivery valve holder for 1st cylinder.

5. Turn the flywheel further and stop turning when the fuel begins to flow over, to get the present injection timing.

6. (The flywheel has mark 1TC and four lines indicating every

0.09 rad (5 °) of crank angle from 0.17 rad (10 °) to 0.44 rad (25 °) before mark 1TC) Calculate the angle which the center of the window points out. If the calculation differs from specified injection timing, add or remove the shim to adjust.

(Injection Timing)

Injection timing Factory specification

0.30 to 0.33 rad 17 to 19 ° before T.D.C.

• The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.175 mm (6), 0.20 mm (3), 0.25 mm (4) and 0.30 mm (5). Combine these shims for adjustments.

• The 0.175 mm thick shim is coated only on the lower face. Therefore, do not use the 0.175 mm thick shim as the top shim of the combination (injection pump side), because this cause oil leakage.

• Addition or reduction of shim (0.05 mm, 0.002 in.) delays or advances the injection timing by approx. 0.009 rad (0.5 °).

• In disassembling and replacing, be sure to use the same number of new gasket shims with the same thickness.

(1) Delivery Valve Holder (2) Timing Mark (3) 2-Holes: 0.20 mm (Shim)

(4) 1-Hole: 0.25 mm (Shim) (5) Without Hole: 0.30 mm (Shim) (6) 2-Holes: 0.175 mm (Shim)

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CAUTION

KiSC issued 08, 2012 A

ENGINE

(8) Injection Nozzle

• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction of the injected fuel.

• If the injected fuel from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.

9Y1210278ENS0012US0

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

9Y1210278ENS0013US0

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.025 mm (0.00098 in.) difference of adjusting washer thickness. Approx. 590 kPa (6.0 kgf/cm

Fuel injection pressure Factory specification

, 85 psi)

13.73 to 14.70 kPa

140.0 to 150.0 kgf/cm 1992 to 2133 psi

(1) Adjusting Washer

9Y1210278ENS0014US0

Valve Seat Tightness

1. Set the injection nozzle to a nozzle tester.

2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm 1849 psi) for 10 seconds.

3. If any fuel leak is found, replace the nozzle piece.

No fuel leak at

Valve seat tightness Factory specification

12.75 MPa

130.0 kgf/cm 1849 psi

9Y1210278ENS0015US0

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L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

[2] PREPARATION

(1) Separating Engine and Clutch Housing

Draining Engine Oil

1. Start and warm up the engine for approx. 5 minutes.

2. Place an oil pan underneath the engine.

3. Remove the drain plugs (1) to drain oil.

4. Reinstall the drain plugs (1).

(When refilling)

• Fill the engine oil up to the upper line on the dipstick (3).

• Never mix two different type of oil.

• Use the proper SAE Engine Oil according to ambient temperatures. Refer to "LUBRICANTS, FUEL AND COOLANT". (See page G-9.)

Engine Oil Capacity

ENGINE

7.6 L

8.0 U.S.qts

6.7 Imp.qts

(1) Drain Plug (2) Oil Inlet Plug (3) Dipstick

A: Oil level is acceptable within this

range.

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IMPORTANT

CAUTION

KiSC issued 08, 2012 A

ENGINE

Draining Transmission Fluid

1. Place an oil pan underneath the transmission case.

2. Remove the drain plugs (1), (2).

3. Drain the transmission fluid.

4. Reinstall the drain plugs (1), (2).

(When refilling)

• Fill up new oil from the oil filling port (3) up to the upper line of the oil level gauge (4).

• After running the engine for few minutes, stop it and check the oil level again, add oil to prescribed level, if necessary.

40.0 L

Transmission fluid Capacity

10.6 U.S.gals

8.80 Imp.gals

• Use only multi-grade transmission fluid. Use of other fluids may damage the transmission or hydraulic system. Refer to "LUBRICANTS, FUEL AND COOLANT". (See page G-9.)

• Never work the tractor immediately after changing the transmission fluid. Keep the engine at medium speed for a few minutes to prevent damage to the transmission.

• Do not mix different brands oil together.

(1) Drain Plug (2) Drain Plug (3) Oil Filling Port (4) Oil Level Gauge

A: Oil level is acceptable within this

range.

9Y1210278ENS0109US0

Draining Coolant

• Never remove the radiator cap until coolant temperature is well below its boiling point. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.

1. Stop the engine and let cool down.

2. Loosen the drain plug (1) to drain the coolant.

3. Remove the radiator cap (2) to completely drain the coolant.

4. After all coolant is drained, retighten the drain plug (1).

(When refilling)

• Fill the coolant between the "FULL" and "LOW" marks of recovery tank.

Coolant (with recovery tank)

(1) Drain Plug (2) Radiator Cap (3) Recovery Tank

Capacity

(A) FULL (B) LOW

6.5 L

6.9 U.S.qts

5.7 Imp.qts

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KiSC issued 08, 2012 A

ENGINE

Bonnet and Front Cover

1. Disconnect the battery negative cable (1).

2. Disconnect the connector to head light (3), horn (2) and the head light wiring.

3. Remove bonnet (4) and side covers (5) on both sides.

4. Remove the front cover (6).

(1) Battery Negative Cable (2) Horn (3) Head Light

(4) Bonnet (5) Side Cover (6) Front Cover

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KiSC issued 08, 2012 A

ENGINE

Steering Wheel and Rear Bonnet

1. Remove the steering wheel (1) with steering puller.

2. Remove the throttle grip (4).

3. Disconnect the hourmeter cable from engine.

4. Remove the meter panel (2).

5. Disconnect 4P connector (7) to main switch.

6. Disconnect 8P connector (6) to combination switch.

7. Disconnect 4P connector to starter relay (8), 4P connector to engine stop solenoid relay (10) and 4P connector to glow relay (9).

8. Disconnect the fuel tank wiring (11).

9. Remove the rear bonnet (3).

(When reassembling)

48 to 55 N·m

4.9 to 5.7 kgf·m 36 to 41 lbf·ft

Tightening torque

Steering wheel mounting nut

(1) Steering Wheel (2) Meter Panel (3) Rear Bonnet (4) Throttle Grip (5) Steering Wheel Mounting Nut (6) 8P Connector (Combination Switch) (7) 4P Connector (Main Switch)

(8) 4P Connector (Starter Relay) (9) 4P Connector (Glow Relay) (10) 4P Connector

(Engine Stop Solenoid Relay) (11) Fuel Tank Wiring (12) OPC Timer (OPC Model)

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KiSC issued 08, 2012 A

ENGINE

Wiring, Pipes and Rods

1. Disconnect 1P connector (1) to coolant temperature sensor.

2. Disconnect glow plug terminal (9).

3. Disconnect accelerator cable (7), 2P connector to engine stop

solenoid (8) and then set aside the wiring harness.

4. Disconnect power steering delivery hose (5), power steering return hose (2).

5. Disconnect pump inlet hose (6), I-PTO delivery pipe (4) and 3P delivery pipe (3).

(When reassembling)

Independent PTO delivery pipe joint bolt

Tightening torque

Power steering delivery hose joint bolt

35 to 39 N·m

3.5 to 4.0 kgf·m 26 to 28 lbf·ft

49 to 58 N·m

5.0 to 6.0 kgf·m 37 to 43 lbf·ft

(1) 1P Connector

(Coolant Temperature Sensor)

(2) Power Steering Return Hose (3) 3P Delivery Pipe (4) I-PTO Delivery Pipe (5) Power Steering Delivery Hose

(6) Pump Inlet Hose (7) Accelerator Cable (8) 2P Connector

(Engine Stop Solenoid)

(9) Glow Plug Terminal

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KiSC issued 08, 2012 A

ENGINE

Wirings

1. Disconnect 1P battery connector (1) and remove slow blow fuse

boxes (3).

2. Disconnect 2P connector (4) to alternator and wings (5).

3. Disconnect 1P connector (8) to starter motor and B terminal (7).

4. Disconnect 1P connector (6) to engine oil pressure switch, then

set aside the wiring harness.

5. Disconnect the combination lamp connector (9)

7.9 to 9.8 N·m

0.80 to 1.0 kgf·m

5.8 to 7.2 lbf·ft

Tightening torque

Star te r B terminal mounting nut

(1) 1P Connector (Battery) (2) Flasher Unit Connector (3) Slow Blow Fuse Box (4) 2P Connector (Alternator) (5) Wiring (Alternator)

(6) 1P Connector (Engine Oil Pressure

Switch)

(7) B Terminal (Starter) (8) 1P Connector (Starter Motor) (9) Combination Lamp Connector

9Y1210278ENS0022US0

Hydraulic Hoses

1. Disconnect the right delivery hose (3) and the left delivery hose (4).

Main delivery hose retaining nut

Tightening torque

Right and left delivery hoses retaining nut

47 to 50 N·m

4.8 to 5.2 kgf·m 35 to 37 lbf·ft

25 to 29 N·m

2.5 to 3.0 kgf·m 18 to 21 lbf·ft

(1) Main Delivery Hose (2) Return Hose (3) Right Delivery Hose (4) Left Delivery Hose (5) Relief Valve Plug (Engine Side)

1-S22

(A) Steering Controller Viewing from

the Bottom

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KiSC issued 08, 2012 A

ENGINE

Propeller Shaft

1. Slide propeller shaft front cover (1) and rear cover (2) after removing screws (3).

2. Tap out spring pins (4), (5), slide couplings (6), (7), and then remove propeller shaft together with propeller shaft covers.

(When reassembling)

• Apply grease to the splines of the propeller shaft.

• Tap in spring pin (4), (5) as shown in figure.

(1) Propeller Shaft Front Cover (2) Propeller Shaft Rear Cover (3) Screw (4) Spring Pin

(5) Spring Pin (6) Coupling (7) Coupling

9Y1210278ENS0024US0

Separating Engine from Clutch Housing

1. Place the disassembling stand under the engine and clutch housing case.

2. Remove the steering support plates connecting steering support and rear bonnet support.

3. Remove the engine and clutch housing mounting screws and nuts.

4. Separate the engine and clutch housing.

(When reassembling)

• Apply grease to the spline of clutch shaft.

• Apply liquid gasket (Three Bond 1206C or equivalent) to joint face of the flywheel housing and clutch housing.

Engine and clutch housing mounting screw and nut

Tightening torque

Engine and clutch housing mounting stud bolt

78 to 90 N·m

7.9 to 9.2 kgf·m 58 to 66 lbf·ft

40 to 49 N·m

4.0 to 5.0 kgf·m 29 to 36 lbf·ft

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IMPORTANT

NOTE

KiSC issued 08, 2012 A

Clutch Assembly

1. Insert the clutch center tool.

2. Remove the clutch assembly together with the clutch center tool.

(When reassembling)

• Direct the shorter end of the clutch disc boss toward the flywheel.

• Apply molybdenum disulphide (Three Bond 1901 or equivalent) to the splines of clutch disc boss.

• Insert the pressure plate, noting the position of straight pins.

• Be sure to align the center of disc and flywheel by inserting the clutch tool set.

• Do not allow grease and oil the clutch disc facing.

Tightening torque Clutch mounting screw

(1) Clutch Disc (2) Pressure Plate Assembly

(2) Separation Engine from Front Axle Frame

Fuel Tank

1. Disconnect the fuel pipe (4) and drain the fuel.

2. Disconnect fuel return tubes (2).

3. Remove rear bonnet support mounting screws (3) on both sides.

4. Remove fuel tank (1) together with rear bonnet support (6) and shutter plate (5).

(1) Fuel Tank (2) Fuel Return Tube (3) Bonnet Support Mounting Screw

ENGINE

24 to 27 N·m

2.4 to 2.8 kgf·m 18 to 20 lbf·ft

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(4) Fuel Tube (5) Shutter Plate (6) Rear Bonnet Support

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Radiator Hose, Recovery Tank, Muffler

1. Disconnect radiator hose (1), (3) and air cleaner hose (4).

2. Disconnect recovery tank hoses (5) and then remove recovery tank (6), recovery tank stay (7).

3. Remove muffler (8).

(When reassembling)

Tightening torque Muffler mounting screw

(1) Radiator Hose (2) Radiator Cap (3) Radiator Hose (4) Air Cleaner Hose

(5) Recovery Tank Hose (6) Recovery Tank (7) Recovery Tank Stay (8) Muffler

1-S24

32 to 39 N·m

3.2 to 4.0 kgf·m 24 to 28 lbf·ft

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(EU)

Page 97

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

ENGINE

Separating Engine from Front Axle Frame

1. Remove one of the two engine hooks (1) and mount it on the right rear side of the engine.

2. Hoist the engine by the chain at the engine hook (2), (3).

3. remove the front axle frame mounting screws.

4. Separate the engine from the front axle frame (4).

(When reassembling)

• Remove engine hook (3) and return in to the original position.

Front axle frame mounting screw (M10)

Tightening torque

Front axle frame mounting screw (M12)

61 to 70 N·m

6.2 to 7.2 kgf·m 45 to 52 lbf·ft

103 to 122 N·m

10.5 to 12.5 kgf·m

76.0 to 90.4 lbf·ft

(1) Engine Hook (2) Engine Hook (Left Side)

[3] DISASSEMBLING AND ASSEMBLING

(1) Cylinder Head and Valves

External Components

1. Set the engine to the disassembling stand.

2. Remove the cooling fan (1).

3. Remove the alternator (3) and fan belt (2).

4. Remove the starter motor (4).

(3) Engine Hook (Right Side) (4) Front Axle Frame

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• After reassembling the fan belt, be sure to adjust the fan belt tension. (See page 1-S12.)

(1) Cooling Fan (2) Fan Belt

1-S25

(3) Alternator (4) Starter Motor

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Page 98

L4100, WSM

KiSC issued 08, 2012 A

ENGINE

Cylinder Head Cover

1. Remove the lead (1).

2. Remove the breather hose (2).

3. Remove the head cover screws (3).

4. Remove the cylinder head cover (4).

(When reassembling)

• Check to see if the cylinder head cover gasket is not defective.

6.87 to 11.2 N·m

Tightening torque Cylinder head cover screw

0.700 to 1.15 kgf·m

5.07 to 8.31 lbf·ft

(1) Lead (2) Breather Hose (3) Head Cover Screw (4) Cylinder Head Cover

(5) Cylinder Head Cover Gasket (6) Breather Valve (7) Plate

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Injection Pipes

1. Loosen the screws on the pipe clamps (1).

2. Detach the injection pipes (2).

3. Remove the inlet manifold (3).

(When reassembling)

• Blow out dust inside the pipes.

25 to 34 N·m

Tightening torque Injection pipe retaining nut

(1) Pipe Clamp (2) Injection Pipe

(3) Inlet Manifold

2.5 to 3.5 kgf·m 18 to 25 lbf·ft

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Hydraulic Pump and Other External Components

1. Remove hydraulic pump mounting screws and detach hydraulic pump (1).

2. Remove the accelerator cable (2), hour meter flexible cable (3).

(1) Hydraulic Pump (2) Accelerator

(3) Hour Meter Flexible Cable

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1-S26

(EU)

Page 99

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

ENGINE

Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe assembly (5).

2. Remove the nozzle holder assemblies (2) using a 21 mm deep socket wrench.

3. Remove the copper gasket and heat seal (3).

4. Remove the glow plugs (1).

(When reassembling)

• Replace the copper gasket and heat seal with new one.

49 to 68 N·m

Tightening torque

Nozzle holder assembly

Overflow pipe assembly retaining nut

Glow plug

5.0 to 7.0 kgf·m 37 to 50 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m 15 to 18 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m 15 to 18 lbf·ft

(1) Glow Plug (2) Nozzle Holder Assembly (3) Heat Seal

(4) Lead (5) Overflow Pipe Assembly

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Nozzle Heat Seal Service Removal Procedure

• Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx.

6.0 mm (0.24 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heat seal (4) out together with the injection nozzle gasket (3).

4. If the heat seal drops, repeat the above procedure

(When reassembling)

• Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.

(1) Plus Screw Driver (2) Injection Nozzle

(3) Injection Nozzle Gasket (4) Heat Seal

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Rocker Arm and Push Rod

1. Remove the rocker arm bracket screws.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

(When reassembling)

• When putting the push rods (2) onto the tappets (3), check to see if their ends are properly engaged with the grooves.

• After installing the rocker arm, be sure to adjust the valve clearance.

Tightening torque Rocker arm bracket screw

(1) Rocker Arm Assembly (2) Push Rod

(3) Tappet

1-S27

24 to 27 N·m

2.4 to 2.8 kgf·m 18 to 20 lbf·ft

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Page 100

L4100, WSM

IMPORTANT

KiSC issued 08, 2012 A

ENGINE

Cylinder Head

1. Loosen the pipe clamp, and remove the water return pipe (1).

2. Remove the cylinder head screw in the order of (18) to (1).

3. Lift up the cylinder head to detach.

4. Remove the cylinder head gasket.

(When reassembling)

• Replace the cylinder head gasket with a new one.

• Tighten the cylinder head screws after applying sufficient oil.

• Tighten the cylinder head screws in diagonal sequence starting from the center.

• Tighten them uniformly, or the head may deform in the long run.

93.2 to 98.0 N·m

Tightening torque Cylinder head screw

9.50 to 10.0 kgf·m

68.8 to 72.3 lbf·ft

(1) Return Pipe

A: Gear Case Side B: Flywheel Side

(18) to (1): To Loosen (1) to (18): To Tighten

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Tappets

1. Remove the tappets (1) from the crankcase.

(When reassembling)

• Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets.

• Before installing the tappets, apply engine oil thinly around them.

• Do not change the combination of tappet and tappet guide.

(1) Tappet

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Valves

1. Remove the valve caps (2).

2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1)

3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).

4. Remove the valve (7).

(When reassembling)

• Wash the valve stem seal and valve guide hole, and apply engine oil sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.

• Do not change the combination of valve and valve guide.

(1) Valve Spring Replacer (2) Valve Cap (3) Valve Spring Collet (4) Valve Spring Retainer

(5) Valve Spring (6) Valve Stem Seal (7) Valve

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1-S28

(EU)