Kubota WSM L3540-II Workshop Manual
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Kubota WSM L3540-II Workshop Manual

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Table of Contents

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WORKSHOP MANUAL
TRACTOR
L3540-II,L4240-II,L5040-II,
L5240-II,L5740-II
KiSC issued 02, 2015 A

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Summary of Contents for Kubota WSM L3540-II

  • Page 1 WORKSHOP MANUAL TRACTOR L3540-II,L4240-II,L5040-II, L5240-II,L5740-II KiSC issued 02, 2015 A...
  • Page 2 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.
  • Page 3 INFORMATION KiSC issued 02, 2015 A...

  • Page 4: Table Of Contents

    INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-4 3. SPECIFICATIONS.......................... I-7 [1] HST MODEL..........................I-7 [2] GST MODEL ..........................I-9 [3] MANUAL TRANSMISSION MODEL ..................I-11 4. TRAVELLING SPEEDS........................ I-13 [1] HST MODEL........................... I-13 [2] GST MODEL .......................... I-14 [3] MANUAL TRANSMISSION MODEL ..................

  • Page 5: Safety First

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 1. SAFETY FIRST 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. •...
  • Page 6 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM 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.
  • Page 7 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM 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.

  • Page 8: Safety Decals

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 2. SAFETY DECALS The following safety decals 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. WSM000001INI0013US0 9Y1211167INI0001US0 KiSC issued 02, 2015 A...
  • Page 9 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 9Y1211167INI0002US0 KiSC issued 02, 2015 A...
  • Page 10 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 9Y1211167INI0003US0 CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth. 3.

  • Page 11: Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 3. SPECIFICATIONS [1] HST MODEL Model L3540-II L4240-II L5240-II L5740-II Model D1803-ME2-EU2 V2203-ME2-EU1 V2403-MTE3-EU2 V2403-MTE3-EU3 Type Indirect injection vertical, water-cooled, 4-cycle diesel Number of cylinders Total displacement 1.826 L (111.4 cu.in.) 2.197 L (134.1 cu.in.) 2.434 L (148.5 cu.in.) 87 ×...
  • Page 12 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION (Continued) Model L3540-II L4240-II L5240-II L5740-II Weight (with CAB) 1745 kg (3847 lbs) 1810 kg (3990 lbs) 1995 kg (4398 lbs) Front 7-16 8-16 9.5-16 Standard tire size Rear 12.4-24 13.6-24 13.6-28 Clutch Dry type single stage Steering...

  • Page 13: Gst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION [2] GST MODEL Model L5040-II Model V2403-M-TE3-EU1 Type Indirect injection vertical, water-cooled, 4-cycle diesel Number of cylinders Total displacement 2.434 L (148.5 cu.in.) Bore and stroke 87 × 102.4 mm (3.4 × 4.0 in.) 36.0 kW Net power* Engine...
  • Page 14 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION (Continued) Model L5040-II Weight (with CAB) 1960 kg (4321 lbs) Front 9.5-16 Standard tire size Rear 13.6-28 Clutch Dry type single stage Steering Hydrostatic power steering Travelling Transmission Glide shift transmission (12 forward and 8 reverse speeds) system Braking system Wet disk type...

  • Page 15: Manual Transmission Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION [3] MANUAL TRANSMISSION MODEL Model L4240-II L5040-II Model V2203-M-E2-EU2 V2403-M-TE2-EU1 Type Indirect injection vertical, water-cooled, 4-cycle diesel Number of cylinders Total displacement 2.197 L (134.1 cu.in.) 2.434 L (148.5 cu.in.) 87 × 92.4 mm 87 ×...
  • Page 16 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION (Continued) Model L4240-II L5040-II Weight (with CAB) 1775 kg (3913 lbs) 1960 kg (4321 lbs) Front 8-16 9.5-16 Standard tire size Rear 13.6-24 13.6-28 Clutch Dry type single stage Steering Hydrostatic power steering Travelling Transmission 8 forward and 8 reverse fully synchronized main and shuttle transmission...

  • Page 17: Travelling Speeds

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 4. TRAVELLING SPEEDS [1] HST MODEL Model L3540-II L4240-II L5240-II L5740-II Tire size (Rear) 12.4-24 13.6-24 13.6-28 Speed control Range gear H-DS lever km/h (mph) km/h (mph) km/h (mph) km/h (mph) pedal shift lever 3.4 (2.1) 3.5 (2.2)
  • Page 18 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION [2] GST MODEL Model L5040-II Creep gear shift lever High Tire size (Rear) 13.6-28 Shuttle shift Main gear km/h (mph) lever shift lever 1.71 (1.06) 0.19 (0.12) 2.42 (1.50) 0.27 (0.17) 3.12 (1.94) 0.35 (0.22) 3.92 (2.44) 0.44 (0.27)
  • Page 19 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION [3] MANUAL TRANSMISSION MODEL Model L4240-II L5040-II Creep gear shift lever High High Tire size (Rear) 13.6-24 13.6-28 Shuttle shift Range gear Main gear km/h (mph) lever shift lever shift lever 1.68 (1.04) 0.19 (0.12) 1.71 (1.06) 0.19 (0.12)
  • Page 20 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM INFORMATION 5. DIMENSIONS no caption I-16 KiSC issued 02, 2015 A...
  • Page 21 GENERAL KiSC issued 02, 2015 A...
  • Page 22 GENERAL CONTENTS 1. TRACTOR IDENTIFICATION....................... G-1 [1] MODEL NAME AND SERIAL NUMBERS ................G-1 [2] CYLINDER NUMBER ......................G-3 [3] EMISSION CONTROL INFORMATION ................. G-3 2. GENERAL PRECAUTIONS......................G-4 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ........G-5 [1] WIRING ..........................G-5 [2] BATTERY ..........................

  • Page 23: Tractor Identification

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 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. (1) Tractor Identification Plate (3) CABIN Identification Plate...

  • Page 24: Engine Serial Number

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows. Year of manufacture Alphabet or Alphabet or Year...

  • Page 25: Cylinder Number

    • When servicing or repairing the engine, use an only replacement parts for that meets with the specific emission regulations, designated by the appropriate Kubota Parts List and perform all maintenance services listed in the appropriate Kubota Operator's manual or in the appropriate Kubota Workshop Manual.

  • Page 26: General Precautions

    • When it is necessary to use special tools, use KUBOTA special tools. Refer to the drawings when you make special tools that you do not use frequently.

  • Page 27: Handling Precautions For Electrical Parts And Wiring

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, obey the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
  • Page 28 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US0 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

  • Page 29: Battery

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [2] BATTERY • Be careful not to confuse positive and negative terminal posts. • When you remove battery cables, disconnect negative cable first. When you install battery cables, check for polarity and connect positive cable first.

  • Page 30: Circuit Tester

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make sure that there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust WSM000001GEG0075US0 •...

  • Page 31: Color Of Wiring

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [6] COLOR OF WIRING • 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 Brown...

  • Page 32: Lubricants, Fuel And Coolant

    2 (with draft control) (if equipped) NLGI-1 (GC-LB) Lift rod Lift cylinder Battery terminal Moderate amount Throttle cable Oiling Engine oil NOTE • *KUBOTA UDT or SUPER UDT fluid: KUBOTA original transmission hydraulic fluid. G-10 KiSC issued 02, 2015 A...
  • Page 33 2 (with draft control) (if equipped) NLGI-1 (GC-LB) Lift rod Lift cylinder Battery terminal Moderate amount Throttle cable Oiling Engine oil NOTE • *KUBOTA UDT or SUPER UDT fluid: KUBOTA original transmission hydraulic fluid. 9Y1211167GEG0005US0 G-11 KiSC issued 02, 2015 A...
  • Page 34 • The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and to complete lubrication of the transmission, it is important that a multi-grade transmission fluid is used in this system. We recommend the use of KUBOTA UDT or SUPER UDT fluid for optimum protection and performance.

  • Page 35: Tightening Torques

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 5. TIGHTENING TORQUES Tighten screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual according to the table below. WSM000001GEG0116US0 [1] GENERAL USE SCREWS, BOLTS AND NUTS Indication on top of bolt No-grade or 4T Indication on top of nut No-grade or 4T...

  • Page 36: Plugs

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [3] PLUGS Material of opponent part Shape Size Ordinariness Aluminum N·m kgf·m lbf·ft N·m kgf·m lbf·ft 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 Tapered screw R1/4...

  • Page 37: Maintenance

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 6. MAINTENANCE Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 1 Engine start system Check G-24  ...
  • Page 38 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 22 Front axle case oil Change G-38  400 Hr every 23 Front axle pivot Adjust...
  • Page 39 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL (Only the Check Points for Tractor with CABIN) Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page 1 Air conditioner condenser screen Clean Daily G-20...

  • Page 40: Check And Maintenance

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 7. CHECK AND MAINTENANCE WARNING • Park the machine on firm and level ground. • Set the parking brake. • Lower the implement to the ground. • All residual pressure of the hydraulic system released. •...
  • Page 41 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Engine Oil Level WARNING • Be sure to stop the engine before checking the oil level. 1. Park the machine on a flat surface. 2. Check engine oil before starting the engine or 5 minutes or more after the engine has stopped.
  • Page 42 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Dust Indicator 1. If the red signal (3) on the dust indicator (2) is visible, clean the element immediately. 2. After cleaning, reset the red signal by pushing the reset button (1).

  • Page 43: Check Points Of Initial 50 Hours

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Seat Belt 1. Always check condition of seat belt attaching hardware before operating tractor. 2. Replace if damaged. 9Y1211167GEG0021US0 [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil WARNING • Be sure to stop the engine before changing the oil. •...
  • Page 44 Then, replenish the engine oil up to the prescribed level. IMPORTANT • To prevent serious damage to the engine, use only a KUBOTA genuine filter. (1) Engine Oil Filter 9Y1211167GEG0023US0 Checking Clutch Pedal Free Travel 1. Stop the engine and remove the key.

  • Page 45: Check Points Of Every 50 Hours

    IMPORTANT • 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.
  • Page 46 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Engine Start System (GST / Manual Transmission Model) WARNING • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test, do not operate the tractor.
  • Page 47 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Engine Start System (HST Model) WARNING • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test, do not operate the tractor.  Test 1 : Switch for the speed control pedal. 1.

  • Page 48: Lubricating Grease Fitting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Lubricating Grease Fitting 1. 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. 2.

  • Page 49: Check Points Of Every 100 Hours

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Oiling WARNING • Be sure to stop the engine and remove the key before oiling. 1. Apply a small amount of engine oil to the hand throttle cable (1) and foot throttle cable (2). (1) Hand Throttle Cable (2) Foot Throttle Cable 9Y1211167GEG0030US0...
  • Page 50 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Cleaning Air Cleaner Primary Element 1. Remove the air cleaner cover and primary element. 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).
  • Page 51 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Adjusting Fan Belt Tension WARNING • 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.
  • Page 52 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Battery Condition DANGER To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below. • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
  • Page 53 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL (Continued)  Battery Charging WARNING • 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.

  • Page 54: Check Points Of Every 200 Hours

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Adjusting Parking Brake Lever WARNING • 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.
  • Page 55 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM 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 are loose or water leaks, tighten bands securely. 2.
  • Page 56 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Adjusting Toe-in 1. Park the tractor on the flat place. 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.
  • Page 57 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Intake Air Line 1. Check to see that hose 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) Hose [A] L3540-II, L4240-II (2) Hose Clamp...

  • Page 58: Check Points Of Every 400 Hours

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Cleaning Air Filter  Fresh Air Filter 1. Remove the knob bolts (3) and pull out the fresh air filter (1). 2. Blow air from the opposite direction to the filter's normal air flow. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm , 30 psi).
  • Page 59 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. (Refer to "4. LUBRICANTS, FUEL AND COOLANT"...

  • Page 60: Check Point Of Every 600 Hours

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Changing Front Axle Case Oil 1. To drain the used oil, remove the right and left drain plugs (3) and filling plug (2) at the front axle case and let out the oil completely into the oil pan.

  • Page 61: Check Points Of Every 3000 Hours

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [10] CHECK POINTS OF EVERY 3000 HOURS Checking Injection Pump 1. Refer to "1. ENGINE" servicing section. 9Y1211167GEG0056US0 Checking Turbocharger (L5040-II, L5240-II, L5740-II) 1. Refer to "1. ENGINE" servicing section. 9Y1211167GEG0057US0 [11] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1.

  • Page 62: Check Points Of Every 2 Years

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [12] CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Hose 1. Replace the fuel hoses and clamps, if necessary. Refer to "Checking Fuel Line". (See page G-29.) 9Y1211167GEG0061US0 Replacing Parking Brake Cable 1.
  • Page 63 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Flushing Cooling System and Changing Coolant WARNING • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1.
  • Page 64 The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. Freeze Point...

  • Page 65: Others

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [13] OTHERS Bleeding Fuel System Air must 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. Bleeding procedure is as follows.
  • Page 66 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM 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.
  • Page 67 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 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 : Remove the lens and replace the bulb. Light Capacity Head lights...
  • Page 68 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Checking Refrigerant (Gas) WARNING • Liquid contact with eyes or skin may cause frostbite. • In the event of a leakage, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. •...

  • Page 69: Special Tools

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No. • 07916-09032 Application • Use exclusively to pull out bearing, gears and other parts with ease. WSM000001GEG0011US0 Piston Ring Compressor Code No.
  • Page 70 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Oil Pressure Tester Code No. • 07916-32032 Application • Use to measure lubricating oil pressure. (1) Gauge (5) Adaptor 2 (2) Cable (6) Adaptor 3 (3) Threaded Joint (7) Adaptor 4 (4) Adaptor 1 (8) Adaptor 5 WSM000001GEG0015US0 Valve Seat Cutter...
  • Page 71 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Engine Hook 1 Application • Use to fix the engine when hooking, instead of the original hook with hook 2 as a set. 17 mm (0.67 in.) 9 mm (0.35 in.) 129 mm (5.08 in.) 10.8 to 11.2 mm (0.426 to 0.440 in.) 40 mm (1.6 in.) 20 mm (0.79 in.)
  • Page 72 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Engine Hook 2 Application • Use to fix the engine when hooking, instead of the original hook with hook 1 as a set. 217 mm (8.54 in.) 140 mm (5.51 in.) 49 mm (1.9 in.) 44 mm (1.7 in.) 20 mm Hole (0.79 in.
  • Page 73 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL NOTE • The following special tools are not provided, so make them referring to the figure. 9Y1211167GEG0079US0 Socket Wrench for Crank Pulley Nut (46 mm Deep Socket Wrench) Application • Use to loosen and tighten the fan drive pulley mounting nut. 100 mm (3.94 in.) 25.0 mm (0.98 in.) 27.0 mm (1.06 in.)
  • Page 74 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL (Continued) Application • Use to fix the crankshaft sleeve of the diesel engine. 42.0 mm (1.6535 in.) 30.5 to 30.6 mm (1.2008 to 1.2047 in.) 23.0 mm (0.9055 in.) 20.0 mm (0.7874 in.) 2.0 mm (0.0787 in.) 31.911 to 31.950 mm dia.
  • Page 75 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL NOTE • The following special tools are not provided, so make them referring to the figure. 9Y1211167GEG0082US0 Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. 20 mm dia.
  • Page 76 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa (300 kgf/cm 4267 psi) Copper gasket Flange (Material : Steel) Hex.
  • Page 77 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Flywheel Stopper Application • Use to loosen and tighten the flywheel screw. 200 mm (7.87 in.) 20 mm (0.79 in.) 30 mm (1.18 in.) 8 mm (0.31 in.) 10 mm dia. (0.39 in. dia.) 9Y1211167GEG0086US0 Crankshaft Bearing 1 Replacing Tool Application...
  • Page 78 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Balancer Metal Replacing Tool (for Removing) Application • Use to remove the metal bearing. 25 mm (0.98 in. dia.) 41.934 to 41.950 mm dia. (1.6509 to 1.6516 in. dia.) 10 mm (0.39 in.) 24.959 to 24.980 mm dia.
  • Page 79 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Balancer Metal Replacing Tool (for Fitting) Application • Use to press fit the metal bearing. 0.52 rad (30 °) 5 mm (0.20 in.) 10 mm (0.39 in.) 3.3 to 3.7 mm (0.130 to 0.146 in.) Chamfer 0.3 mm (0.01 in.) 43.934 to 43.950 mm dia.

  • Page 80: Special Tools For Tractor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [2] SPECIAL TOOLS FOR TRACTOR Tie-rod End Lifter Code No. • 07909-39051 Application • Use to remove the tie-rod end with ease. WSM000001GEG0029US0 Steering Wheel Puller Code No. • 07916-51090 Application • Use to remove the steering wheel without damage to the steering shaft.
  • Page 81 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Rear Axle Cover Puller Code No. • 07916-51041 Application • Use to remove a rear axle cover from rear axle. WSM000001GEG0035US0 Relief Valve Pressure Tester Code No. • 07916-50045 Application • This allows easy measurement of relief set pressure. (1) Gauge (07916-50322) (6) Adaptor C (PS3/8) (07916-50371) (2) Cable (07916-50331)
  • Page 82 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Pinion Locking Tool Code No. • 07916-55311 Application • Use to prevent the shaft from turning when you remove or tighten a staking nut of a bevel pinion shaft. WSM000001GEG0039US0 Rear Axle Nut Wrench 71 Code No.
  • Page 83 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Front Axle Rocking Restrictor Application • Use for lock the rolling of the front axle. 70 mm (2.8 in.) 11 mm (0.43 in) M8 × P1.25 18 mm (0.71 in.) M14 × P1.5 R5 mm (R0.2 in.) R15 mm (R0.59 in.) 22 mm (0.87 in.)
  • Page 84 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Draft Control Test Bar Application • Use for checking the lift range and floating range of hydraulic draft control. 1045 mm (41.14 in.) 1000 mm (29.37 in.) 20 mm dia. (0.79 in. dia.) 30 mm dia.
  • Page 85 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Cylinder Safety Valve Setting Pressure Adaptor Application • Use for setting the safety valve to the nozzle tester to measure cracking pressure and check oil tightness of the safety valves. 45 mm (1.77 in.) 10 mm dia.
  • Page 86 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL NOTE • Special tools for R134a refrigerant air conditioning system below are available from DENSO CO. LTD. M00000002GEG0111US1 Air-Conditioner Service Tool Code No. • DENSO 95048-00063 Application • Use for charge, test or discharge of the air conditioning system. (1) Manifold Gauge Assembly (95048-10090) (2) Charging Hose (Red: HI) (95948-10270) (3) Charging Hose (Blue: LO) (95948-10280)
  • Page 87 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Stopper Magnet Clutch (For A/C Compressor) Application • Use for loosen and tighten the magnet clutch mounting nut. (Use radius C) NOTE • This special tool is not provided, so make it referring to the figure. 125 mm (4.92 in.) 4.52 rad (120 °) 40 mm dia.
  • Page 88 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Stopper Bolt (for A/C Compressor) Application • Use with the stopper magnet clutch. NOTE • This special tool is not provided, so make it referring to the figure. 12 mm (0.47 in.) 35 mm (1.38 in.) 7 mm (0.28 in.) 0.4 mm (0.016 in.)
  • Page 89 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Pump Adaptor Application • Use for checking the main hydraulic pump. NOTE • When using, attach with following parts. O-ring : 04811-00180 • This adaptor is modified from Adaptor 61 of flowmeter adaptor set (see page G-59). (Reference) •...

  • Page 90: Tires

    IMPORTANT • Do not use tires other than those approved by KUBOTA.  Inflation Pressure 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.

  • Page 91: Treads Adjustment

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL [2] TREADS ADJUSTMENT WARNING • 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. •...

  • Page 92: Rear Wheels

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL (2) Rear Wheels 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. IMPORTANT •...

  • Page 93: Tire Liquid Injection

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL WARNING To avoid personal injury or death: • Before jacking up the tractor, park it on a firm and level ground and chock the front wheels. • Fix the front axle to keep it from swinging. •...
  • Page 94 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL 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...
  • Page 95 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Injection CAUTION • 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).
  • Page 96 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM GENERAL Draining Water or Solution 1. Lift the rear tires off the ground. 2. Turn the tire so that the air valve is at the bottom. 3. Remove the air valve, and drain liquid (liquid can only be drained to the level of the valve and liquid under that level remains inside).
  • Page 97 ENGINE KiSC issued 02, 2015 A...
  • Page 98 MECHANISM CONTENTS 1. FEATURES..........................1-M1 2. EGR (EXHAUST GAS RECIRCULATION) SYSTEM (IF EQUIPPED)........1-M2 [1] EGR VALVE ......................... 1-M3 [2] EGR COOLER........................1-M3 KiSC issued 02, 2015 A...

  • Page 99: Features

    The engine model shown in the table below is adopted in the L40 series tractor. These are 03-M series engine. In order to meet the strict emission regulations. Kubota has adapted the Exhaust Gas Recirculation (EGR) system on the V2403-M-TE3 for L5240 and L5740. Tractor Model...

  • Page 100: Egr (Exhaust Gas Recirculation) System (If Equipped)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 2. EGR (EXHAUST GAS RECIRCULATION) SYSTEM (IF EQUIPPED) (1) Boost Compensator (2) Thermo Valve (3) Exhaust Manifold (4) Crankcase (5) EGR Cooler (6) EGR Valve (7) Water Flange (8) Inlet Manifold (A) Boost Pressure (B) EGR Gas (C) Coolant The EGR (Exhaust Gas Recirculation) system is used to lower the combustion temperature and efficiently cool...

  • Page 101: Egr Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [1] EGR VALVE When the temperature of coolant rises above 65 °C (149 °F), the thermo valve (1) opens and boost pressure (B) flows to EGR valve. This boost pressure (B) pushes down EGR valve's diaphragm (5), and opens valve (16).
  • Page 102 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S10 [1] CABIN MODEL ........................1-S10 [2] ENGINE..........................1-S11 4. CHECKING AND ADJUSTING....................1-S12 [1] ENGINE BODY........................1-S12 [2] LUBRICATING SYSTEM.....................1-S14 [3] COOLING SYSTEM ......................1-S14 [4] FUEL SYSTEM........................1-S17 [5] TURBOCHARGER (IF EQUIPPED) ..................1-S21 5. PREPARATION .........................1-S22 [1] SEPARATING ENGINE FROM TRACTOR.................1-S22 6.

  • Page 103: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not 1. No fuel Fill fuel G-18 Start 2. Fuel leak due to loose injection pipe retaining Tighten nut 1-S38 3. Air in the fuel system Bleed G-43 4.
  • Page 104 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Reference Symptom Probable Cause Solution Page Either Black or Dark 1. Overload Decrease the load – Gray Exhaust Gas Is 2. Low grade fuel used Use the specified fuel G-10 Observe 3. Air cleaner clogged Clean or change G-28 4.
  • Page 105 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Overheated 1. Overload running Loosen the load – 2. Engine oil insufficient Fill G-21 3. Coolant insufficient Fill G-41 4. Unsuitable fuel used Use the specified fuel G-10 5.

  • Page 106: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 3.6 to 4.0 MPa 2.5 MPa (When Cranking with Starting Motor) 36 to 41 kgf/cm 26 kgf/cm 520 to 580 psi 370 psi •...
  • Page 107 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Item Factory Specification Allowable Limit Tappet to Tappet Guide Clearance 0.020 to 0.062 mm 0.07 mm 0.00079 to 0.0024 in. 0.003 in. • Tappet O.D. 23.959 to 23.980 mm – 0.94327 to 0.94409 in. •...
  • Page 108 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Item Factory Specification Allowable Limit Idle Gear Shaft to Idle Gear Bushing Clearance 0.025 to 0.066 mm 0.10 mm 0.00099 to 0.0025 in. 0.0039 in. • Idle Gear Shaft O.D. 37.959 to 37.975 mm –...
  • Page 109 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Item Factory Specification Allowable Limit Crankpin to Crankpin Bearing Oil Clearance 0.025 to 0.087 mm 0.20 mm 0.00099 to 0.0034 in. 0.0079 in. • Crankpin O.D. 46.959 to 46.975 mm – 1.8488 to 1.8494 in. •...
  • Page 110 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Item Factory Specification Allowable Limit Radiator Cap Pressure Falling 10 seconds or more for – Time pressure falling from 88 to 59 kPa (from 0.9 to 0.6 kgf/cm from 13 to 9 psi) Radiator Water Tightness No leaks at...
  • Page 111 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump [L3540-II, L4240-II] Injection Timing 0.30 to 0.33 rad – (17 to 19 °) before T.D.C. [L5040-II] Injection Timing 0.13 to 0.15 rad – (7.5 to 9.0 °) before T.D.C.

  • Page 112: Tightening Torques

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 3. TIGHTENING TORQUES [1] CABIN MODEL Item N·m kgf·m lbf·ft Alternator B terminal 5.9 to 9.8 0.6 to 1.0 4.4 to 7.2 Starter B terminal 7.4 to 9.8 0.75 to 1.0 5.5 to 7.2 Seat Bracket mounting bolts and nuts 23.5 to 27.5 2.4 to 2.8...

  • Page 113: Engine

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [2] ENGINE Dimension × Item N·m kgf·m lbf·ft Pitch Alternator mounting screw (M10) – 40 to 44 4.0 to 4.5 29 to 32 Alternator mounting screw (M8) – 18 to 20 1.8 to 2.1 13 to 15 Clutch mounting screw –...

  • Page 114: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 4. CHECKING AND ADJUSTING [1] ENGINE BODY 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 not to inject fuel. 3.
  • Page 115 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Valve Clearance IMPORTANT • 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.

  • Page 116: Lubricating System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [2] LUBRICATING SYSTEM Engine Oil Pressure 1. Remove the engine oil pressure switch, and set a oil pressure tester (Code No. 07916-32032). (Adapter screw size: PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
  • Page 117 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM 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.
  • Page 118 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 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.

  • Page 119: Fuel System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [4] FUEL SYSTEM 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. NOTE •...
  • Page 120 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. 13.7 MPa...
  • Page 121 12.8 MPa (140 to 130 kgf/cm , 1990 to 1850 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a KUBOTA-authorized pump service shop. 10 seconds 13.7 → 12.8 MPa Factory specification 140 →...
  • Page 122 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE CAUTION • Check the injection pressure and condition after Be carefuling that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly injects the human body, cells may be destroyed and blood poisoning may be caused.

  • Page 123: Turbocharger (If Equipped)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [5] TURBOCHARGER (IF EQUIPPED) Turbine Side 1. Check the exhaust port (1) and inlet port (4) side of the turbine housing (3) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (5) with new one.

  • Page 124: Preparation

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 5. PREPARATION [1] SEPARATING ENGINE FROM TRACTOR NOTE • When separating the engine from the tractor, there is no need to release refrigerant from air conditioner system. 9Y1211167ENS0019US0 Draining Engine Oil WARNING •...
  • Page 125 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Draining Coolant WARNING • Do not remove the radiator cap when the engine is hot. 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.
  • Page 126 10.8 U.S.gals L5740-II 9.0 Imp.gals IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. (Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-10.) • Do not mix different brands of fluid together.
  • Page 127 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Battery, Front Grill, Skirt and Bonnet 1. Open the bonnet and disconnect the battery negative cable (5). 2. Disconnect the head light connector (6) and remove the front grill (4). 3. Remove the left and right side skirts (3). 4.
  • Page 128 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Clutch Rod, Brake Pedal Rod and Electric Wiring 1. Disconnect the brake pedal rod (6) and clutch rod (4). 2. Disconnect the wiring connectors for alternator (1), coolant temperature sensor (9), oil pressure switch (2), fuel unit (3), starter motor (7) and battery (10).

  • Page 129: Hst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Seat, Seat Bracket and Lever Grips 1. Remove the seat switch connector. 2. Remove the seat (1). 3. Remove the seat bracket (2). 4. Remove the front wheel drive lever (3). (HST Model) 5.
  • Page 130 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Steps and Wiring Harness 1. Remove the step LH (2) and step RH (6). 2. Disconnect the ground cable (3). (HST Model) 3. Remove the solenoid cover (1). 4. Remove the solenoid connector (4). 5.
  • Page 131 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Cables and Wiring Harness 1. Disconnect the PTO connector (1). 2. Disconnect the PTO speed change switch connector (7) (Manual Transmission Model only). 3. Disconnect the speed sensor connector (2). 4. Remove the stay (5) and disconnect the position control cable (4).
  • Page 132 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Differential Lock Rod and Lowering Speed Adjusting Knob 1. Remove the lowering speed adjusting lever (2). 2. Remove the differential lock rod (1) and range gear shift rod (4). 3. Disconnect the range gear shift sensor connector (3). (1) Differential Lock Rod (3) Range Gear Shift Sensor Connector (2) Lowering Speed Adjusting Lever...
  • Page 133 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Mats, Panel Cover and Linkage 1. Remove the mats (1). 2. Remove the steering post covers 1 (3) and the steering post cover 2 (4). 3. Remove the panel cover (2). 4. Remove the brake rods (7) and clutch rod (5). 5.
  • Page 134 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Air Conditioner Parts and Cabin Assembly 1. Remove the radiator upper hose (1) and recovery tank hose (2). 2. Remove the intake hose (3). 3. Remove the battery (8). 4. Remove the radiator lower hose (11). 5.
  • Page 135 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Hydraulic Pipes and Radiator Hose 1. Remove the radiator hose (1). 2. Remove the front loader pipe bracket bolts (9). 3. Remove the oil cooler pipe (2). 4. Remove the suction pipe (3). 5.
  • Page 136 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Separating Engine and Clutch Housing 1. Place the disassembling stand under the engine and clutch housing. 2. Remove the engine and clutch housing mounting screws and nuts. 3. Separate the engine and clutch housing. (When reassembling) •...
  • Page 137 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Front Axle Frame [L3540-II, L4240-II] 1. Lift the engine by the chain at the engine hook. 2. Remove the dipstick stay mounting screw and front axle frame mounting screws. 3. Separate the front axle frame (2) from engine (1). (When reassembling) 78 to 90 N·m Front axle frame mounting...

  • Page 138: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 6. DISASSEMBLING AND ASSEMBLING [1] OUTER PARTS Outer Parts of Engine 1. Remove the cooling fan (1) and fan pulley (2). 2. Remove the turbo charger (3). 3. Remove the starter motor (4). 4.

  • Page 139: Egr Valve And Egr Cooler (If Equipped)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [2] EGR VALVE AND EGR COOLER (IF EQUIPPED) EGR Valve 1. Remove the air tube 1 (3) from the thermo valve (4) and EGR valve (1). 2. Remove the air tube 2 (5) from the thermo valve (4), inlet manifold (2).

  • Page 140: Cylinder Head And Valves

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [3] CYLINDER HEAD AND VALVES 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) •...
  • Page 141 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe assembly (6). 2. Remove the nozzle holder assemblies (2) using a 21 mm deep socket wrench. 3. Remove the copper gasket (3) and heat seal (4). 4.
  • Page 142 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Cylinder Head 1. Loosen the pipe clamp (2), and remove the water return pipe (1). 2. Remove the cylinder head screw in the order of (n or r) to (a). 3. Lift up the cylinder head (3) to remove. 4.
  • Page 143 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE (Continued) NOTE • When replacing piston, piston pin, small end bushing, connecting rod, or crankpin bearings, measure piston head's protrusion or recessing from the level of crankcase cylinder face (average of all pistons) after installing the pistons, and select the cylinder head gasket following the below table.
  • Page 144 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 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).

  • Page 145: Timing Gears, Camshaft And Fuel Camshaft

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [4] TIMING GEARS, CAMSHAFT AND FUEL CAMSHAFT Injection Pump 1. Remove the stop solenoid (4) and the hi-idling body (1). 2. Remove the engine stop lever (3) and the stop solenoid guide (6).
  • Page 146 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Governor Springs and Speed Control Plate NOTE • Governor spring hooking special tool (1): 1.2 mm diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent to hang governor springs. 1.
  • Page 147 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE (Continued) (When reassembling) • Using the governor spring hooking special tool (1), Hook the small spring (4) first and then the large governor spring (2) on the speed control plate (6). • Put the governor spring hooking special tool (1) from the injection pump side to catch the large governor spring (2).
  • Page 148 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Fan Drive Pulley 1. Lock the flywheel not to turn using the flywheel stopper. 2. Remove the fan drive pulley mounting nut (1) using 46 mm deep socket wrench (3). 3. Remove the fan drive pulley (2) with gear puller (4). 4.
  • Page 149 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Idle Gear (for D1803-M) 1. Remove the external snap ring. 2. Remove the idle gear collar. 3. Remove the idle gear (2). (When reassembling) • Check to see each gear is aligned with its aligning mark 1 Mark: Idle gear (2) and crank gear (4) 2 Marks: Idle gear (2) and cam gear (3) 3 Marks: Idle gear (2) and injection pump gear (1)
  • Page 150 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Camshaft and Balancer Shaft (for V2203-M and V2403-M) 1. Remove the camshaft set bolts and draw out the camshaft (1). 2. Remove the balancer shaft 1 (2) set bolts and draw out the balancer shaft 1 (2).

  • Page 151: Piston And Connecting Rod

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Crank Gear 1. Draw out the crank gear (2) with a puller (1). 2. Remove the feather key. (1) Crank Puller (2) Crank Gear 9Y1211167ENS0048US0 [5] PISTON AND CONNECTING ROD Oil Pan and Oil Strainer 1.
  • Page 152 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Pistons 1. Completely clean carbon (1) in the cylinders. 2. Remove the connecting rod cap (3). 3. Turn the flywheel and bring the piston to top dead center. 4. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
  • Page 153 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings (1), (2), (3) using a piston ring tool. 2. Remove the piston pin (9), and separate the connecting rod (7) from the piston (6). (When reassembling) •...

  • Page 154: Crankshaft

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [6] CRANKSHAFT Flywheel 1. Fit the stopper to the flywheel (1). 2. At first, remove two pieces of the flywheel screws (2). 3. Insert two pieces of the flywheel guide screws (3) in the holes. 4.
  • Page 155 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Crankshaft NOTE • Before disassembling, check the side clearance of crankshaft. Also check it during reassembling. [For D1803-M] 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crank pin of the third cylinder to the bottom dead center.
  • Page 156 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1, and remove the main bearing case assembly being careful with thrust bearing and crankshaft bearing. 2. Remove the main bearing case 1, 2 as above. (When reassembling) •...

  • Page 157: Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE 7. SERVICING [1] CYLINDER HEAD AND VALVES Top Clearance 1. Remove the cylinder head. 2. Move the piston up and stick a strip of fuse on the piston head at three position with grease. 3.
  • Page 158 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check (Code No. 07909-31371). 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the read permeative liquid (1).
  • Page 159 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
  • Page 160 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 161 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
  • Page 162 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.

  • Page 163: Timing Gears, Camshaft And Fuel Camshaft

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE [2] TIMING GEARS, CAMSHAFT AND FUEL CAMSHAFT Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3.
  • Page 164 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. Measure the side clearance by moving the cam gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
  • Page 165 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Oil Clearance of Balancer Shaft Journal (for V2203-M and V2403-M) 1. Measure the balancer shaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for balancer shaft with an inside micrometer or cylinder gauge.
  • Page 166 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Replacing Idle Gear Bushing (A) When removing 1. Using an idle gear bushing replacing tool, press out the used bushing. (B) When installing 1. Clean a new idle gear bushing and idle gear bore, and apply engine oil to them.

  • Page 167: Piston And Connecting Rod

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3.
  • Page 168 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Replacing Connecting Rod Small End Bushing (A) When removing 1. Push out the small end bushing with a connecting rod small end bushing replacing tool. (B) When installing 1. Clean a new small end bushing and bore, and apply engine oil to them.

  • Page 169: Crankshaft

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand. 1. Install the piston pin into the connecting rod. 2.
  • Page 170 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 171 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate oil clearance.
  • Page 172 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.

  • Page 173: Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve using a special-use puller set (Code No.: 07916-32091). 2. Set the sleeve guide (2) to the crankshaft. 3. Set the stopper (1) to the crankshaft as shown in figure. 4.

  • Page 174: Oil Pump

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ENGINE Correcting Cylinder (Oversize +0.25 mm, +0.0098 in.) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. D1703-M, Factory D1803-M, Oversize cylinder 87.250 to 87.272 mm specifica- V2203-M, I.D.
  • Page 175 CLUTCH KiSC issued 02, 2015 A...
  • Page 176 MECHANISM CONTENTS 1. FEATURE ........................... 2-M1 KiSC issued 02, 2015 A...
  • Page 177 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 1. FEATURE The dry single plate with diaphragm spring type clutch is adapted for all models. This clutch is operated with the hanging type pedal, and the pedal (5) and release fork (3) have been linked as shown in figure.
  • Page 178 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 2. SERVICING SPECIFICATIONS ....................2-S3 3. TIGHTENING TORQUES......................2-S4 4. CHECKING AND ADJUSTING....................2-S5 5. PREPARATION ...........................2-S6 [1] SEPARATING CLUTCH HOUSING AND ENGINE...............2-S6 6. DISASSEMBLING AND ASSEMBLING ..................2-S18 7. SERVICING ..........................2-S19 KiSC issued 02, 2015 A...

  • Page 179: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Clutch Drags 1. Clutch pedal free play Adjust 2-S5 excessive 2. Dust on clutch disc Remove dust or replace 2-S18 generated from clutch disc facing 3.
  • Page 180 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Probable Cause and Reference Symptom Solution Checking Procedure Page Vibration 1. Main shaft bent Replace 3-S53, 3-S72, 3-S99 2. Clutch disc rivet worn or Replace 2-S19 broken 3. Clutch parts broken Replace 2-S18 9Y1211167CLS0001US0 2-S2...

  • Page 181: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Clutch Pedal Free travel 20 to 30 mm – 0.78 to 1.18 in. Clutch Disc Boss to Gear Shaft Backlash – 2.0 mm (Displacement 0.079 in.

  • Page 182: Tightening Torques

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m...

  • Page 183: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 4. CHECKING AND ADJUSTING Clutch Pedal Free Travel CAUTION • When checking, park the tractor on flat ground, apply the parking brake, stop the engine and remove the key. 1. Slightly depress the clutch pedal and measure free travel "L" at top of clutch pedal.

  • Page 184: Preparation

    10.8 U.S.gals L5740-II 9.0 Imp.gals IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. (Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-10.) • Do not mix different brands of fluid together.
  • Page 185 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Draining Coolant WARNING • Do not remove the radiator cap when the engine is hot. 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.
  • Page 186 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Battery, Front Grill, Skirt and Bonnet 1. Open the bonnet and disconnect the battery negative cable (5). 2. Disconnect the head light connector (6) and remove the front grill (4). 3. Remove the left and right side skirts (3). 4.
  • Page 187 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Clutch Rod, Brake Pedal Rod and Electric Wiring 1. Disconnect the brake pedal rod (6) and clutch rod (4). 2. Disconnect the wiring connectors for alternator (1), coolant temperature sensor (9), oil pressure switch (2), fuel unit (3), starter motor (7) and battery (10).
  • Page 188 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Seat, Seat Bracket and Lever Grips 1. Remove the seat switch connector. 2. Remove the seat (1). 3. Remove the seat bracket (2). 4. Remove the front wheel drive lever (3). (HST Model) 5.
  • Page 189 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Steps and Wiring Harness 1. Remove the step LH (2) and step RH (6). 2. Disconnect the ground cable (3). (HST Model) 3. Remove the solenoid cover (1). 4. Remove the solenoid connector (4). 5.
  • Page 190 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Cables and Wiring Harness 1. Disconnect the PTO connector (1). 2. Disconnect the PTO speed change switch connector (7) (Manual Transmission Model only). 3. Disconnect the speed sensor connector (2). 4. Remove the stay (5) and disconnect the position control cable (4).
  • Page 191 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Differential Lock Rod and Lowering Speed Adjusting Knob 1. Remove the lowering speed adjusting lever (2). 2. Remove the differential lock rod (1) and range gear shift rod (4). 3. Disconnect the range gear shift sensor connector (3). (1) Differential Lock Rod (3) Range Gear Shift Sensor Connector (2) Lowering Speed Adjusting Lever...
  • Page 192 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Mats, Panel Cover and Linkage 1. Remove the mats (1). 2. Remove the steering post covers 1 (3) and the steering post cover 2 (4). 3. Remove the panel cover (2). 4. Remove the brake rods (7) and clutch rod (5). 5.
  • Page 193 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Air Conditioner Parts and Cabin Assembly 1. Remove the radiator upper hose (1) and recovery tank hose (2). 2. Remove the intake hose (3). 3. Remove the battery (8). 4. Remove the radiator lower hose (11). 5.
  • Page 194 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Hydraulic Pipes and Radiator Hose 1. Remove the radiator hose (1). 2. Remove the front loader pipe bracket bolts (9). 3. Remove the oil cooler pipe (2). 4. Remove the suction pipe (3). 5.
  • Page 195 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Separating Engine and Clutch Housing 1. Place the disassembling stand under the engine and clutch housing. 2. Remove the engine and clutch housing mounting screws and nuts. 3. Separate the engine and clutch housing. (When reassembling) •...

  • Page 196: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 6. DISASSEMBLING AND ASSEMBLING Clutch Assembly 1. Remove the clutch from the flywheel. (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.

  • Page 197: Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH 7. SERVICING Backlash between Clutch Disc Boss and Gear Shaft 1. Mount the clutch disc to the gear shaft. 2. Hold the gear shaft so that it may not turn. 3. Rotate disc lightly and measure the displacement around the disc edge.
  • Page 198 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CLUTCH Pressure Plate Flatness 1. Place a straight edge on the pressure plate and measure clearance with a feeler gauge at several points. 2. If the clearance exceeds the allowable limit, replace it. 3.
  • Page 199 TRANSMISSION KiSC issued 02, 2015 A...
  • Page 200 MECHANISM CONTENTS 1. STRUCTURE..........................3-M1 [1] MANUAL TRANSMISSION MODEL ..................3-M1 [2] GLIDE SHIFT TRANSMISSION (GST) MODEL ..............3-M2 [3] HYDROSTATIC TRANSMISSION (HST) MODEL ............... 3-M3 2. MANUAL TRANSMISSION MODEL................... 3-M4 [1] POWER TRAIN FOR TRAVELING GEAR ................3-M4 (1) Main Gear Shift Section....................3-M4 (2) Shuttle Shift Section .......................

  • Page 201: Structure

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 1. STRUCTURE [1] MANUAL TRANSMISSION MODEL (1) Main Gear Shift Section (2) PTO Clutch Section (3) Shuttle Shift Section (4) Range Gear / Creep Gear Shift Section (5) Front Wheel Drive Shift Section (6) PTO Gear Shift Section 3-M1 KiSC issued 02, 2015 A...
  • Page 202 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] GLIDE SHIFT TRANSMISSION (GST) MODEL (1) Main Gear Shift Section (2) Clutch Pack for GST (3) PTO Clutch Section (4) Hi-Lo Shift / Shuttle Shift Section (5) Range Gear Shift / Creep Gear Shift Section (6) Front Wheel Drive Shift Section 3-M2 KiSC issued 02, 2015 A...
  • Page 203 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] HYDROSTATIC TRANSMISSION (HST) MODEL (1) Hydrostatic Transmission Section (2) PTO Clutch Section (3) Range Gear Shift Section (4) Front Wheel Drive Shift Section 3-M3 KiSC issued 02, 2015 A...

  • Page 204: Manual Transmission Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 2. MANUAL TRANSMISSION MODEL [1] POWER TRAIN FOR TRAVELING GEAR The transmission consists of a series of gears and shafts as shown in previous page. The traveling system consists of main gear shift section, shuttle shift section, range gear shift section and front wheel drive section.
  • Page 205 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) Range Gear Shift Section The range gear shift section is located in the differential gear case, and it uses constant mesh. (1) Shuttle Gear Shaft Low Speed (2) Gear for Low High Speed (3) Shifter Neutral...
  • Page 206 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (5) Front Wheel Drive Section Front wheel drive shift section is located in the differential gear case. Two wheel drive or four wheel drive is selected by operating the front wheel drive lever to shift the shifter gear (4).
  • Page 207 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] SHIFT LINKAGE MECHANISM (1) Main Gear Shift Lever The links are connected from the shift lever (6) to the shift forks (1), (2) as shown in the figure. Each speed from the 1st to 4th can be changed by a single shift lever (6).
  • Page 208 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) Range Gear Shift Lever The links from the shift lever (1) to the shift fork (5) are connected as shown in the figure. When the shift lever (1) is moved to the "A" side, the shift fork (5) is moved to the "A"...

  • Page 209: Glide Shift Transmission (Gst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 3. GLIDE SHIFT TRANSMISSION (GST) MODEL [1] CHARACTERISTIC AND SYSTEM OUTLINE In addition to the former GST system that controls the gear shifting and clutch operation hydraulically, the GST system of L40 series tractor has the function to control these operations electrically.

  • Page 210: Power Train

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] POWER TRAIN (1) Main Shift Section (3) Sub-range Shift Section (4) Shuttle Shift Section (5) Main Range Shift Section (2) GST Clutch Pack The transmission consists of the fully synchronized gear shifting and the hydraulic clutch as shown above figure. And the double cone type synchromesh is adapted on L side of main range shift section (5).
  • Page 211 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] ELECTRICAL CONTROL SYSTEM (1) Electrical Control An electrical control of GST system is as follows. 1. Shift the GST lever and shuttle lever to desired position. 2. The output voltage of selected gear shift position is output to microcomputer of the ECU by lever sensor.

  • Page 212: Hydraulic Circuit And System Outline

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [4] HYDRAULIC CONTROL SYSTEM (1) Hydraulic Circuit and System Outline (1) Regulating Valve Assembly (11) Solenoid Valve 5 (19) 3-4 Shift Check Valve To Steering Controller (2) Hydraulic Pump (Sub-range Shift) (20) 1-2 Shift Check Valve From Steering Controller (3) Hydraulic Oil Filter (12) Shift Piston...
  • Page 213 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 1. Oil is supplied from the power steering hydraulic pump (2) while running the engine. 2. The oil entering the regulating valve assembly (1) flows through the pressure reducing valve (5) to the GST circuit. This oil pressure is kept at a fixed level by the pressure reducing valve (5).

  • Page 214: Construction And Function Of Components

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Construction and Function of Components [A] Regulating Valve The oil from the hydraulic pump for the power steering system flows to the GST circuit to set the pressure of the circuit. Other oil flows to the power steering circuit.
  • Page 215 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [B] GST Valve GST Valve Assembly The GST valve assembly is installed at the left side of the transmission mid case. In the GST valve assembly, many parts comprising the system are installed, including the solenoid valves, shift pistons, shift check valves, low-pass valve, proportional reducing valve, clutch valve, check valves, sensor and switches.
  • Page 216 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shift Piston The shift pistons (1), (2), (3), (4) are actuated by the oil distributed by the each solenoid valve. At the tip of these shift pistons (1), (2), (3) are installed the shifters (5), which are connected to each shift rod and shift the gear.
  • Page 217 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shift Check Valve The shift check valves (2), (3), (4), (5), (6) are provided on each shift piston and the shuttle shift rod. From the start to the end of gear shifting, the shift check valves (2), (4), (5), (6) of the shift pistons are opened because the ball (9) of the check pin (18) is on the straight portion, the oil in the pilot circuit of the clutch...
  • Page 218 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Low-pass Valve After completion of the gear shifting, the low-pass valve (8) opens immediately to flow oil into the GST clutch (9), to promote the engagement of the clutch. When the gear shifting starts, the oil in the GST clutch (9) passes the clutch valve (7) to be drained into the tank.
  • Page 219 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Proportional Reducing Valve After the gear shifting is completed, this valve has function which gradually rises the pressure in the clutch (4) in order to make a clutch engaging for without shock and smoothly.
  • Page 220 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Clutch Valve The clutch valve (5) changes the flow of the oil flowing to the GST clutch to change "ENGAGE" / "DISENGAGED" of the clutch. Except for during gear shifting, the oil of the pilot circuit flows in from the A-port to push the spool to the right when the pilot circuit is pressurized.

  • Page 221: Front Wheel Drive Section

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [C] GST Clutch The GST clutch is hydraulic multiple plate type and is provided between the counter shaft (3) and the shuttle shaft (8), and it "engages" and "disengages" the power from the engine. This is controlled by the operation of clutch valve (2).

  • Page 222: Hydrostatic Transmission (Hst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 4. HYDROSTATIC TRANSMISSION (HST) MODEL [1] POWER TRAIN The transmission of this model consists of a series of gears and shafts as shown in previous page. The traveling system chiefly consists of hydrostatic transmission section, range gear shift section and front wheel drive section. 9Y1211167TRM0033US0 (1) Structure (1) Input Shaft...
  • Page 223 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (1) Input Shaft (10) Piston (Pump) (19) Check and High Pressure Sectional View X-X (2) Servo Piston (11) Piston (Hi) Relief Valve (Foward) Sectional View Y-Y (3) Feedback Rod (12) Cylinder Block (Motor) (20) Check and High Pressure Sectional View Z-Z (4) Proportional Valve...

  • Page 224: Oil Flow

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Oil Flow (1) HST Assembly (7) Charge Relief Valve (14) Filter To PTO Clutch Valve (2) Case Relief Valve (8) Motor Cylinder Block (15) Oil Cooler To Steering Controller (3) Pump Cylinder Block (9) Piston H (16) Hydraulic Pump From Steering Controller...

  • Page 225: Function Of Components

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) Function of Components [A] Servomechanism (1) Servo Piston (5) Piston Adjusting Screw To Reverse Side Pump Port (2) Feedback Rod (Connected to (6) Spring To Forward Side Tank Port Swashplate Position Sensor) (7) Proportional Valve (Forward) Slit for Connection of (3) Swashplate Position Sensor...

  • Page 226: Operation

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (4) Operation [A] Stage 1  When the HST pedal is in the neutral position [Tractor Condition] HST pedal: Neutral Position Hi-Lo select lever: Lo (1) Pump Swashplate (12) Piston H (24) PTO Valve A Port (2) Pump Piston (13) Piston L...
  • Page 227 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [B] Stage 2  When the pedal is pressed toward the forward side [Tractor Condition] HST pedal: Forward Position Hi-Lo select lever: Lo (1) Pump Swashplate (12) Piston H (24) PTO Valve A Port (2) Pump Piston (13) Piston L...
  • Page 228 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [C] Stage 3  When the pedal is pressed toward the reverse side [Tractor Condition] HST pedal: Reverse Position Hi-Lo select lever: Lo (1) Pump Swashplate (12) Piston H (24) PTO Valve A Port (2) Pump Piston (13) Piston L...
  • Page 229 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [D] Stage 4  When the pedal is located on the forward side and the Hi-Lo change lever is set to "Hi" (The lamp of the rabbit lights up and the turtle goes off) [Tractor Condition] HST pedal: Forward Position Hi-Lo select lever: Lo →...
  • Page 230 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (Continued) Signals are sent from the Hi-Lo change lever switch to the ECU. Then the signals are sent from the ECU to the Hi-Lo change valve. Then the Hi-Lo solenoid valve is opened. As a result, the position of the two-speed change spool is changed with charge oil to the position shown in the drawing.
  • Page 231 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [E] Stage 5  When the pedal is located on the forward side and the Hi-Lo change lever is changed from "Hi" to "Lo" (The lamp of the turtle lights up and the rabbit goes off) [Tractor Condition] HST pedal: Forward Position Hi-Lo select lever: Lo →...
  • Page 232 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (Continued) Signals are sent from the Hi-Lo change lever switch to the ECU. Then the signals are sent from the ECU to the Hi-Lo change valve. As a result, the Hi-Lo solenoid valve is closed and the two-speed change spool is changed by the force of the spring to the position shown in the drawing.
  • Page 233 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [F] Stage 6  When loads are applied with the pedal located on the forward side and the engine stall prevention function is activated (Stall Guard lamp lights up on the panel) [Tractor Condition] HST pedal: Forward Position Hi-Lo select lever: Lo...
  • Page 234 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (Continued) Since loads are applied on the motor shaft, the pressure between "A" and "C" is increased. With the pressure between "A" and "C" increased, the pump receives more resistance, thereby decreasing the engine speed. The engine stall prevention function is controlled by the engine speed sensor and accelerator opening sensor.
  • Page 235 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [G] Stage 7  When loads are applied and the engine stall prevention function is activated with the HST pedal located on the forward side, the Hi-Lo lever sets at "Hi" position, and the automatic gear shifting sets at "ON" (Stall Guard lamp and AUTO H-DS lamp light up on the panel) [Tractor Condition] HST pedal: Forward Position...
  • Page 236 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (Continued) With loads applied on the motor shaft, the pressure between "A" and "C" is increased. With the pressure between "A" and "C" increased, the pump receives more resistance, thereby decreasing the engine speed. Since the engine stall prevention function starts to operate first, the ECU controls the proportional control valve according to signals from the engine speed sensor and accelerator opening sensor so that the engine torque and loads on the HST should keep well-balanced relation.
  • Page 237 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [H] Stage 8  When loads are applied and the engine stall prevention function is activated with the HST pedal located on the forward side, the Hi-Lo lever sets at "Hi", and the automatic gear shifting sets at "ON" (Stall Guard lamp and AUTO H-DS lamp light up on the panel) [Tractor Condition] HST pedal: Forward Position...
  • Page 238 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (Continued) 1. The swashplate on the motor side is changed to the Lo side (The lamp of the turtle lights up and the rabbit lamp goes off). 2. At the same time, the swashplate on the pump side is inclined toward the speed increasing side (To achieve smooth shift transmission).

  • Page 239: Range Gear Shift Section

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (5) Range Gear Shift Section The range gar shift section is located in the differential gear case. It changes the speed to five positions ("L", "N", "M", "N" and "H") by shifting of shifter gear (3) in the straight line on bevel pinion shaft (7).

  • Page 240: Shift Linkage Mechanism

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] SHIFT LINKAGE MECHANISM The shift linkage mechanism of "Front Wheel Drive Lever", refer to page. 9Y1211167TRM0049US0 (1) Range Gear Shift Lever (1) Shift Fork (2) Shift Arm (3) Range Gear Shift Lever (4) Rod (5) Sub-arm The links are connected from the shift lever (3) to the shift fork (1) as shown in figure.

  • Page 241: Auto Throttle Advance (Ata)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] AUTO THROTTLE ADVANCE (ATA) (1) HST Accelerator Lever (2) HST Accelerator Cable (3) Auto Throttle Advance (ATA) Lever (4) Auto Throttle Advance (ATA) Cable (5) Auto Throttle Advance (ATA) Lever 1 (6) HST Neutral Holder Arm (7) HST Neutral Cam (8) HST Pedal...

  • Page 242: Pto System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 5. PTO SYSTEM [1] STRUCTURE (1) PTO Gear Shaft 1 (4) PTO Counter Shaft (7) Output Shaft (Motor Shaft) [A] Manual Transmission and (2) PTO Gear Shaft 2 (5) PTO Drive Shaft (8) PTO Gear Shaft 1 GST Model (3) PTO Clutch Pack...
  • Page 243 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Hydraulic Circuit The oil from the regulator valve (4) flows into the PTO clutch solenoid valve (6). When PTO switch is at "OFF" position, the oil flows is stopped by PTO solenoid valve (6). When PTO switch is at "ON"...

  • Page 244: Two Stage Pto (Manual Transmission Model)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] TWO STAGE PTO (MANUAL TRANSMISSION MODEL) (1) Power Train The two stage PTO gear section is located in the mid case, and it uses constant mesh. (1) Gear for High Lo-speed Shift (2) Gear for Low Neutral Position (3) PTO Drive Shaft...
  • Page 245 SERVICING CONTENTS 1. TROUBLESHOOTING.........................3-S1 [1] GENERAL ..........................3-S1 [2] MANUAL TRANSMISSION MODEL ..................3-S3 [3] GST SYSTEM ........................3-S5 [4] HST SYSTEM........................3-S11 [5] PTO SYSTEM ........................3-S18 2. SERVICING SPECIFICATIONS ....................3-S19 [1] ALL MODEL ........................3-S19 [2] GLIDE SHIFT TRANSMISSION (GST) MODEL ..............3-S20 [3] HST MODEL........................3-S21 [4] PTO CLUTCH........................3-S21 3.
  • Page 246 (4) Differential Gears......................3-S120 (5) GST Clutch ........................3-S120 [3] HYDROSTATIC TRANSMISSION (HST) MODEL ............3-S122 (1) Bearing, Gear and Shaft ....................3-S122 (2) PTO Clutch ........................3-S122 (3) Differential Gears......................3-S122 (4) HST..........................3-S122 KiSC issued 02, 2015 A...

  • Page 247: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 1. TROUBLESHOOTING [1] GENERAL Probable Cause and Reference Symptom Solution Checking Procedure Page Excessive 1. Transmission fluid Fill G-37 Transmission Noise insufficient 2. Bearing worn or broken Replace 3-S112 3. Snap rings on the shaft Repair or replace –...
  • Page 248 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Probable Cause and Reference Symptom Solution Checking Procedure Page Gears Clash When 1. Clutch does not release Adjust or repair 2-S5, Shifting 2-S18 2. Synchronizer unit Replace 3-S113 damaged 3. Gears worn or damaged Replace –...

  • Page 249: Manual Transmission Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] MANUAL TRANSMISSION MODEL Electrical Diagnosis by Electrical Instrument Panel (Intelipanel) 9Y1211167TRS0002US0 3-S3 KiSC issued 02, 2015 A...
  • Page 250 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Error Display for Manual Transmission Model Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Electronic • Electronic instrument Replace the electronic 9-S36 instrument panel panel memory device instrument panel memory device failure has failed...

  • Page 251: Gst System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] GST SYSTEM Electrical Diagnosis by Electronic Instrument Panel (Intellipanel) 9Y1211167TRS0004US0 3-S5 KiSC issued 02, 2015 A...
  • Page 252 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Error Display for GST Model Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Electronic • Electronic instrument Replace the electronic 9-S36 instrument panel panel memory device instrument panel memory device failure has failed Communication...
  • Page 253 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Proportional • Output voltage of Check the connector of – reducing valve proportional reducing proportional reducing failure valve terminal or return valve current is out of Check the proportional...
  • Page 254 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Solenoid 1 • Solenoid output Able to travel at speeds – failure terminal's voltage is out other than 1, 7 and 8 (At forward or of specification (Forward) or 1 and 5...
  • Page 255 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Solenoid 4 • Solenoid output Able to travel at speeds – failure terminal's voltage is out other than 5, 6 and 12 (At forward or of specification (Forward) or 4 and 8...
  • Page 256 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Error Message Does not Indicate on LCD Probable Cause and Reference Symptom Solution Checking Procedure Page The Tractor Does Not 1. Oil level is low Check oil level or fill oil to proper level G-37 Move While Shifted 2.

  • Page 257: Hst System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [4] HST SYSTEM Electrical Diagnosis by Electronic Instrument Panel (Intellipanel) 9Y1211167TRS0007US0 3-S11 KiSC issued 02, 2015 A...
  • Page 258 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Error Display for HST Model Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Electronic • Electronic instrument Replace the electronic 9-S39 instrument panel panel memory device instrument panel memory device failure has failed Communication...
  • Page 259 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Display on LCD Reference Trouble Item Probable Cause Solution Screen Page HST pedal • Sensor output terminal The running that uses – sensor failed is out of adjustment the pedal is impossible, •...
  • Page 260 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Throttle sensor • Sensor output terminal Travel motion is – failed is out of adjustment possible. • Sensor output wire The HST electronic terminal broken or control function is in short-circuited...
  • Page 261 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Display on LCD Reference Trouble Item Probable Cause Solution Screen Page • Output voltage of Travel motion is – proportional proportional valve possible on the valve, forward terminal or return backward side only failed current is out of Check the connector of...
  • Page 262 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Error Message Does not Indicate on LCD Probable Cause and Reference Symptom Solution Checking Procedure Page System Will Not 1. Oil level is low Check oil level or fill oil to proper level G-37 Operate in Either 2.
  • Page 263 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Probable Cause and Reference Symptom Solution Checking Procedure Page Transmission Oil 1. Low transmission oil level Fill transmission oil level up to proper G-37 Over Heats level 2. Radiator net clogged Clean radiator net G-20 3.

  • Page 264: Pto System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [5] PTO SYSTEM PTO CLUTCH Reference Symptom Probable Cause Solution Page PTO Clutch Slip 1. Operating pressure is low Adjust 3-S25 2. PTO clutch valve malfunctioning Repair or replace 3-S56, 3-S76, 3-S103 3.

  • Page 265: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 2. SERVICING SPECIFICATIONS [1] ALL MODEL Item Factory Specification Allowable Limit Gear to Spline Clearance 0.030 to 0.078 mm 0.2 mm 0.0012 to 0.0030 in. 0.008 in. Shift Fork to Shifter Gear Groove Clearance 0.20 to 0.40 mm 0.8 mm...

  • Page 266: Glide Shift Transmission (Gst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] GLIDE SHIFT TRANSMISSION (GST) MODEL Item Factory Specification Allowable Limit GST System Pressure Setting Pressure 2.30 to 2.50 MPa – Condition 23.5 to 25.4 kgf/cm • Engine Speed 334 to 362 psi Idling •...

  • Page 267: Hst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] HST MODEL Item Factory Specification Allowable Limit Check and High Pressure Relief Valve Setting Pressure 33.3 to 36.3 MPa – Condition 340 to 370 kgf/cm • Engine Speed 4830 to 5260 psi Rated Speed •...

  • Page 268: Tightening Torques

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) [CABIN] Item N·m...
  • Page 269 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [ALL MODEL] Item N·m kgf·m lbf·ft Alternator B terminal 5.9 to 9.8 0.6 to 1.0 4.4 to 7.2 Starter B terminal 7.4 to 9.8 0.75 to 1.0 5.5 to 7.2 Seat bracket mounting bolts and nuts 23.5 to 27.5 2.4 to 2.8 18 to 20...
  • Page 270 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [MANUAL TRANSMISSION MODEL] Item N·m kgf·m lbf·ft Main shift base mounting screw 24 to 27 2.4 to 2.8 18 to 20 Main shift arm mounting screw 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31 [GLIDE SHIFT TRANSMISSION MODEL] Item...

  • Page 271: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 4. CHECKING AND ADJUSTING [1] PTO CLUTCH PTO Clutch Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the main shift lever, shuttle lever and HST pedal in Neutral position.

  • Page 272: Glide Shift Transmission (Gst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] GLIDE SHIFT TRANSMISSION (GST) MODEL (1) Electrical Adjusting [GST Fine-adjustment with Electronic Instrument Panel (Intellipanel)] NOTE • Before executing the following fine-adjustment, refer to "Testing, Setting and Adjusting by Electronic Instrument Panel" at "Electrical System" section. The fine-adjustment function is a function to update the data of the memory device in the ECU when a sensor, a valve, and an electronic instrument panel which relates to the GST system are repaired or are re-installed.
  • Page 273 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION GST Valve Fine-adjustment (Setting the function of proportional reducing valve) NOTE • When the ECU or GST valve is replaced, this adjustment is required. 1. Push down both the display mode switch and the travel speed switch at once, continue holding switches, and then start the engine.
  • Page 274 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION GST Shift Shock Fine-adjustment Mode (Adjusting the clutch engaging interval) NOTE • When the sense of shifting shock is not suitable, shifting shock can be changed by this adjustment. 1. Push down both the display mode switch and the travel speed switch at once, continue holding switches, and then start the engine.

  • Page 275: Hydraulic Checking

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Hydraulic Checking Checking GST System Pressure 1. Start the engine and warm up the transmission fluid, and then stop the engine. 2. Remove the GST system pressure checking port (1) plug (PT 1/8) on the GST valve (2).
  • Page 276 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Checking Regulating Valve Setting Pressure 1. Start the engine and warm up the transmission fluid, and then stop the engine. 2. Remove the pressure checking port (5) plug (PT 1/8). 3. Install the adaptor "7" to checking port (5) and then install the adaptor "D", the threaded joint, cable and pressure gauge.
  • Page 277 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Checking Clutch Pack Pressure 1. Start the engine and warm up the transmission fluid, and then stop the engine. 2. Remove the clutch pack pressure checking port plug (PT 1/8) on the GST valve (2). 3.

  • Page 278: Hydrostatic Transmission (Hst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] HYDROSTATIC TRANSMISSION (HST) MODEL (1) Electrical Adjusting [Adjustment with Electronic Instrument Panel (Intellipanel)] NOTE • Before executing the following fine-adjustment, refer to "Testing, Setting and Adjusting by Electronic Instrument Panel" of an Electrical System section. 9Y1211167TRS0025US0 Adjustment of Transmission Model Input Mode NOTE...
  • Page 279 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Adjustment of HST Sensor (HST Pedal, Range Shift Lever, Cruise Lever, HST Response Dial, Fine-adjustment Mode) NOTE • When any of ECU, HST pedal sensor, cruise control lever position sensor, swashplate position sensor, range gear shift sensor, HST response dial or proportional valve connector (Forward, Reverse) is replaced, this adjustment is required.
  • Page 280 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (Continued) 6. "STEP-01" is displayed (d): Follow the procedures as follows. • Cruise control lever: Set the "Maximum forward position". • HST response dial: Set the "Maximum fast position". • HST pedal: Keep the "Maximum forward position". 7.
  • Page 281 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Adjustment of Throttle Sensor NOTE • When the ECU or throttle sensor is replaced, this adjustment is required. • Tractor Condition Parking brake: Set the Apply the Parking Brake Cruise Control Lever: Set the Neutral Position HST Pedal: Set the Neutral Position Range Gear Shift Lever: Set the Neutral Position HST Response Dial: Set the Center Detente Position...

  • Page 282: Hydraulic Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Hydraulic Checking and Adjusting Checking High Pressure Relief Valve Pressure CAUTION • When checking, park the machine on flat ground and be sure anyone is NOT standing near the machine. 1. Remove the hex. socket head plug (GPF 3/8) from P1 or P2 port.
  • Page 283 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Checking Charge Relief Pressure CAUTION • When checking, park the machine on flat ground, apply the parking brake. NOTE • Use a new transmission oil filter. 1. Remove the hex. socket head plug (GPF 3/8) from charge pressure check port (1).
  • Page 284 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Checking and Adjusting HST Neutral Position CAUTION • Park the tractor on a flat place and keep all the levers at neutral position. • Jack up the tractor and bring it in the 2WD mode. 1.
  • Page 285 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Cruise Lever Operating Force 1. Push the cruise control lever (1) into maximum tied position. After that pull it 50 mm (2.0 in.) back. 2. Measure the force needed to move the cruise control lever back into the maximum position at the top of the lever grip (2).

  • Page 286: Preparation

    10.8 U.S.gals L5740-II 9.0 Imp.gals IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. (Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-10.) • Do not mix different brands of fluid together.
  • Page 287 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Draining Coolant WARNING • Do not remove the radiator cap when the engine is hot. 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.
  • Page 288 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Battery, Front Grill, Skirt and Bonnet 1. Open the bonnet and disconnect the battery negative cable (5). 2. Disconnect the head light connector (6) and remove the front grill (4). 3. Remove the left and right side skirts (3). 4.
  • Page 289 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Clutch Rod, Brake Pedal Rod and Electric Wiring 1. Disconnect the brake pedal rod (6) and clutch rod (4). 2. Disconnect the wiring connectors for alternator (1), coolant temperature sensor (9), oil pressure switch (2), fuel unit (3), starter motor (7) and battery (10).
  • Page 290 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Seat, Seat Bracket and Lever Grips 1. Remove the seat switch connector. 2. Remove the seat (1). 3. Remove the seat bracket (2). 4. Remove the front wheel drive lever (3). (HST Model) 5.
  • Page 291 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Steps and Wiring Harness 1. Remove the step LH (2) and step RH (6). 2. Disconnect the ground cable (3). (HST Model) 3. Remove the solenoid cover (1). 4. Remove the solenoid connector (4). 5.
  • Page 292 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Cables and Wiring Harness 1. Disconnect the PTO connector (1). 2. Disconnect the PTO speed change switch connector (7) (Manual Transmission Model only). 3. Disconnect the speed sensor connector (2). 4. Remove the stay (5) and disconnect the position control cable (4).
  • Page 293 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Lock Rod and Lowering Speed Adjusting Knob 1. Remove the lowering speed adjusting lever (2). 2. Remove the differential lock rod (1) and range gear shift rod (4). 3. Disconnect the range gear shift sensor connector (3). (1) Differential Lock Rod (3) Range Gear Shift Sensor Connector (2) Lowering Speed Adjusting Lever...
  • Page 294 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Mats, Panel Cover and Linkage 1. Remove the mats (1). 2. Remove the steering post covers 1 (3) and the steering post cover 2 (4). 3. Remove the panel cover (2). 4. Remove the brake rods (7) and clutch rod (5). 5.
  • Page 295 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Air Conditioner Parts and Cabin Assembly 1. Remove the radiator upper hose (1) and recovery tank hose (2). 2. Remove the intake hose (3). 3. Remove the battery (8). 4. Remove the radiator lower hose (11). 5.

  • Page 296: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 6. DISASSEMBLING AND ASSEMBLING [1] MANUAL TRANSMISSION MODEL (1) Clutch Housing Hydraulic Pipe 1. Remove the main delivery pipe (4). 2. Remove the front loader pipes (1). 3. Remove the suction pipe (2) and PTO delivery pipe (3). (When reassembling) 118 to 137 N·m Joint bolt for delivery pipe...
  • Page 297 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Release Hub and Clutch Lever 1. Draw out the clutch release hub (7) and the release bearing (5) as a unit. 2. Remove the release fork setting screws (4) and fork keys (2). 3.
  • Page 298 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Separating Clutch Housing and Mid Case 1. Remove the clutch housing and mid case mounting screws and nuts. 2. Separate the clutch housing and mid case. (When reassembling) • Apply liquid gasket (Three Bond 1208C or equivalent) to joint face of the clutch housing and mid case.
  • Page 299 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 23T (24T) Gear Shaft, 27T (26T) Gear and Front Axle Drive Shaft 1. Remove the 23T (24T) gear shaft (3). 2. Remove the external snap ring (1) and 27T (26T) gear (2). 3.
  • Page 300 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shaft Assemblies 1. Remove the external snap ring (1) and collar (2). 2. Draw out the shaft assemblies (3), (5), (6), (7), (8). (1) External Snap Ring (5) 18T Gear Shaft Assembly (2) Collar (6) Idle Shaft Assembly (3) Counter Shaft Assembly...

  • Page 301: Mid Case

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Mid Case Hydraulic Pipe 1. Remove the suction pipe (1). 2. Remove the PTO delivery pipe (2) and main delivery pipe (3). (When reassembling) 35 to 39 N·m Joint bolt for PTO delivery 3.5 to 4.0 kgf·m pipe 26 to 28 lbf·ft...
  • Page 302 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Separating Mid Case 1. Lift up the shuttle shift arm (1). 2. Separate the mid case from the clutch housing after removing their mounting screws. (When reassembling) • Apply liquid gasket (Three Bond 1208C or equivalent) to joint face of clutch housing and mid case.
  • Page 303 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Mid Case Bearing Holder 1. Remove the PTO drive shaft (3). 2. Remove the mid case bearing holder mounting screws, and then remove the bearing holder (2) with PTO clutch (1) as a unit. NOTE •...
  • Page 304 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Clutch Discs and Hub of PTO Clutch 1. Remove the internal snap ring (3). 2. Remove the back plate (4), clutch discs (5), clutch plates (6), hub (1) and bearing (2). (When reassembling) •...
  • Page 305 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Clutch Case 1. Remove the external snap ring (5). 2. Remove the clutch case (1). (When reassembling) • Apply small amount of the grease to the seal rings (2). (1) Clutch Case (4) Bearing (2) Seal Ring (5) External Snap Ring...

  • Page 306: Transmission Case

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) Transmission Case Hydraulic Pipe 1. Remove the main delivery pipe (1). (1) Main Delivery Pipe 9Y1211167TRS0057US0 Rear Wheel 1. Place disassembling stand under the transmission case, and support it with a jack. 2.
  • Page 307 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Hydraulic Cylinders and Front Loader Control Valve 1. Disconnect the hydraulic cylinder hoses (2) and return hoses (3) at the rear hydraulic block (1). 2. Remove the two pins, and remove the hydraulic cylinders (4). 3.
  • Page 308 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Brake Case 1. Remove the range gear shift lever fulcrum screw. 2. Remove the brake case mounting screws and nuts. 3. Separate the brake case, tapping the brake case lever lightly. (When reassembling) •...
  • Page 309 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Transmission Bearing Holder 1. Remove the transmission bearing holder mounting screws. 2. Tap out the spring pin (8) on the shift fork rod (3). 3. Jack up the bearing holder (1) by using the two jack bolts (5) until the taper roller bearing (7) can be removed.
  • Page 310 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Disassembling Shaft Assemblies 1. Disassembling the each shaft referring to the figure. (1) 20T-49T Gear (9) PTO Drive Shaft (2) Range Gear Shaft (10) 27T Gear (L3240, L3940) (3) 17T Gear (11) Front Wheel Drive Shaft (4) Needle Bearing (12) 24T Shifter Gear (5) 34T Gear (L3240, L4240)
  • Page 311 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION PTO Shaft 1. Remove the PTO shaft cover. 2. Remove the bearing case mounting screws, and draw out the PTO shaft (1) with bearing case (2). 3. Remove the internal snap ring (3). 4.
  • Page 312 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Case Cover and Differential Side Gear 1. Remove the differential case cover (3). 2. Remove the differential side gear (1) and differential side gear washer (2). (When reassembling) • Apply molybdenum disulfide (Three Bond 1901 or equivalent) to the inner circumferential surface of the differential side gear boss.
  • Page 313 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Side Gear 1. Remove the differential side gear (2) and differential side gear washer (1). (When reassembling) • Check the thrust and bearing surface of both differential side gears (2). If they are worn or damaged, bores in the differential case may also be damaged.

  • Page 314: Glide Shift Transmission Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] GLIDE SHIFT TRANSMISSION MODEL (1) Clutch Housing Hydraulic Pipes 1. Remove the main delivery pipe (4). 2. Remove the front loader pipes (1). 3. Remove the suction pipe (2) and PTO delivery pipe (3). (When reassembling) 118 to 137 N·m Joint bolt for delivery pipe...
  • Page 315 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Release Hub and Clutch Lever 1. Draw out the clutch release hub (7) and the release bearing (5) as a unit. 2. Remove the release fork setting screws (4) and fork keys (2). 3.
  • Page 316 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shuttle Shift Arm and GST Valve Assembly 1. Disconnect the return pipe (1). 2. Disconnect the brake rods (2), (4). 3. Remove the shuttle shift arm stopper screw, and then pull the shuttle shift shaft (3) with shuttle shift arm (6) up.
  • Page 317 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shaft Case 1. Remove the shaft case mounting screws. 2. Screw down the two M6 jack bolts (1) into the shaft case (2) and pull it out. 3. Remove the shaft case (2). (When reassembling) •...
  • Page 318 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 23T (24T) Gear Shaft and 27T (26T) Gear 1. Remove the 23T (24T) gear shaft (1). 2. Remove the external snap ring (3) and 27T (26T) gear (2). (When reassembling) • Install the oil seal (4) on the 18T gear shaft (6), noting the direction of the oil seal (4) as shown in the figure.
  • Page 319 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shaft Assemblies 1. Remove the external snap ring (1) and thrust collar (2). 2. Draw out the shaft assemblies (4), (5), (6), (7), (9) and shift forks (10) and rods. 3. Pull out the front axle drive shaft (8) to the rear side. (When reassembling) •...
  • Page 320 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Counter Shaft (1) Internal Snap Ring (2) Bearing (3) Needle Bearing (4) 24T Gear (4th) (5) External Snap Ring (6) Synchronizer Ring (7) Synchronizer Spring (8) Hub (9) Synchronizer Key (10) Shifter (11) 29T Gear (3rd) (12) Counter Shaft (13) 34T Gear (2nd)

  • Page 321: Mid Case

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Mid Case Hydraulic Pipes 1. Remove the suction pipe (1). 2. Remove the PTO delivery pipe (2). (When reassembling) 35 to 39 N·m Joint bolt for PTO delivery Tightening torque 3.5 to 4.0 kgf·m pipe 26 to 28 lbf·ft (1) Suction Pipe...
  • Page 322 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Separating Mid Case 1. Lift up the shuttle shift arm (1). 2. Separate the mid case from the clutch housing after removing their mounting screws. (When reassembling) • Apply liquid gasket (Three Bond 1208C or equivalent) to joint face of clutch housing and mid case.
  • Page 323 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Mid Case Bearing Holder 1. Remove the internal snap ring (9) and remove the disc spring (8) and clutch input hub (7). 2. Remove the external snap ring (6) and remove the GST clutch case (5).
  • Page 324 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION GST Clutch Discs 1. Remove the clutch hub (2), clutch disc (3) and steel plate (5), (6) from clutch case (1). (When reassembling) • Assemble the two (L3240, L3540) or three (L3940, L4240, L4740, L5040) steel plates (6) with plug rubbers (4) to the front side, one steel plate (5) without plug rubber to the piston side.
  • Page 325 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shuttle Shift Gears (1) External Snap Ring (2) Thrust Collar (3) Bearing (4) Thrust Collar (5) External Snap Ring (6) Thrust Collar (7) External Snap Ring (8) Hub (9) Needle Bearing (10) 20T Gear (11) 22T Gear (12) Needle Bearing (13) Thrust Collar...

  • Page 326: Transmission Case

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) Transmission Case Hydraulic Pipes and Brake Rods 1. Remove the main delivery pipe (4). 2. Remove the front loader pipes (1). 3. Remove the suction pipe (2) and PTO delivery pipe (3). 4.
  • Page 327 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Hydraulic Cylinders and Front Loader Control Valve 1. Disconnect the hydraulic cylinder hoses (2) and return hoses (3) at the rear hydraulic block (1). 2. Remove the two pins, and remove the hydraulic cylinders (4). 3.
  • Page 328 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Brake Case 1. Remove the brake case mounting screws and nuts. 2. Separate the brake case, tapping the brake case lever lightly. (When reassembling) • Apply grease to the steel ball seats. (Do not grease excessively.) •...
  • Page 329 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Pinion Bearing Cover 1. Remove the stake of lock nut (5). 2. Lock the turning of spiral bevel pinion and remove the lock nut (5). 3. Remove the pinion bearing case mounting screws. 4.
  • Page 330 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shaft Assemblies 1. Remove the traveling speed sensor (1). 2. Remove the spiral bevel pinion shaft assembly (4), range gear shaft assembly (5) with shift fork (6) and PTO drive shaft assembly (3). 3.
  • Page 331 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Lock Shift Fork 1. Tap out the left side spring pin (4). 2. Remove the cotter pin and remove the clevis pin (3). 3. Draw out the differential lock fork shaft (1) and remove the differential lock shift fork (2).

  • Page 332: Regulating Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Gear Assembly 1. Remove the differential support, noting the number of left shims. 2. Remove the differential gear assembly, noting the number of right shims. (When reassembling) • Check the spiral bevel gear for wear or damage. If it is no longer serviceable, replace it.
  • Page 333 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Disassembling Regulating Valve NOTE • The regulating valve has been precisely machined and assembled. It is advisable not to disassemble it as long as there is no necessary. 1. Remove the plate (8) and remove reducing spool (11), spring retainer (5) and spring (10).

  • Page 334: Gst Valve Assembly

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (5) GST Valve Assembly NOTE • The GST valve has been precisely machined and assembled. It is advisable not to disassemble it. If unavoidably necessary to do it, take the following precautions. 1.
  • Page 335 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Solenoid Valve 1. Remove the cover (7). 2. Disconnect the connector (8) and remove the solenoid valves. (When reassembling) • Be sure to install the each solenoid valve to their original positions as shown in the photo and table below. Solenoid Name Color of wiring Shift Solenoid 1 (1st shift)
  • Page 336 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shift Check Valve 1. Remove the lower body mounting hex. socket head cap screws (1). 2. Separate the upper body (2) and lower body (4). 3. Remove the 1-2, 3-4 shift check pin (10), (11), sub-range shift check pin (7), main range shift check pin (6), shuttle shift check pin (8), balls (5) and pin (9) from lower body (4).
  • Page 337 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shift Piston 1. Separate the upper body, and lower body. (See page 3-S90.) 2. Tap out the spring pins (6), and remove the shifters (5). (For 1-2, 3-4 and sub-range shift piston) 3.
  • Page 338 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Low-pass Valve IMPORTANT • Do not adjust or remove the adjustor (2), otherwise the GST clutch engagement feeling will be changed. If this valve is disassembled, be sure to check and adjust the low-pass pressure.
  • Page 339 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Proportional Reducing Valve and Filter 1. Remove the valve mounting hex. socket head cap screws. 2. Remove the proportional reducing valve (2). 3. Remove the cover (6). 4. Remove the plug (3) and orifice support (4) with filter (5). (When reassembling) •...

  • Page 340: Hydrostatic Transmission Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] HYDROSTATIC TRANSMISSION MODEL (1) Clutch Housing Hydraulic Pipe 1. Disconnect the suction pipe (1) from hydraulic pump. 2. Remove the main delivery pipe 1 (4) and main delivery pipe 2 (5). 3.
  • Page 341 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Clutch Lever, Release Fork and Release Bearing 1. Remove the release fork mounting screws (4). 2. Draw out the clutch lever (3) to remove the release fork (1). 3. Remove the release bearing and release hub together. 4.
  • Page 342 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Separating Clutch Housing and Mid Case 1. Remove the clutch housing and mid case mounting screws and nuts. 2. Separate the clutch housing and mid case. (When reassembling) • Be sure to install the gasket. 103 to 117 N·m Clutch housing and mid 10.5 to 12.0 kgf·m...
  • Page 343 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Regulating Valve Assembly and Charge Pump 1. Remove the regulating valve assembly (1). 2. Remove the charge pump (2). (When reassembling) NOTE • Replace the O-ring with a new one. • Alignment mark should be front side. Regulating valve assembly 48 to 56 N·m Tightening torque...
  • Page 344 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Swashplate, Pump Shaft and Motor Shaft 1. Remove the swashplate (1). 2. Remove the cradle bearing bracket mounting hex. socket head screws (6). 3. Tap the pump shaft (3) with a plastic hammer slightly to slide out it with cradle bearing bracket (5) to the rear side.
  • Page 345 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shaft Case, Input Shaft, Motor Shaft and Gear 1. Remove the shaft case mounting screws. 2. Screw down the M6 jack bolt (3) into the shaft case (1) and pull it out. 3.
  • Page 346 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Hi-Lo Valve 1. Remove the Hi-Lo solenoid valve assembly (1). 2. Remove the external snap ring (2). 3. Remove the Hi-Lo solenoid (5) with connector. 4. Remove the hex. socket head screw (7) and remove the spring (8) and Hi-Lo spool (9).
  • Page 347 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Charge Relief Valve 1. Remove the hex. socket head plug (5). 2. Remove the spring guide (3), shim (4), spring (2) and valve poppet (1). (When reassembling) NOTE • Install valve component, noting the number of shims (4) in the charge relief valve.

  • Page 348: Mid Case

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Mid Case Hydraulic Pipes 1. Remove the suction pipe (2). 2. Remove the delivery pipe 2 (1). 3. Remove the brake rods (3). 4. Remove the PTO delivery pipe (4). (When reassembling) 118 to 137 N·m Joint bolt for delivery pipe 2 12.0 to 14.0 kgf·m...
  • Page 349 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Separating Mid Case 1. Separate the mid case from the clutch housing after removing their mounting screws. (When reassembling) • Be sure to install the gasket with a new one. 78 to 90 N·m Clutch housing and mid 7.9 to 9.2 kgf·m case mounting screw...

  • Page 350: Transmission Case

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) Transmission Case Rear Wheel 1. Place disassembling stand under the transmission case, and support it with a jack. 2. Remove the rear wheels. 3. After removing the rear wheels, support it at both sides of rear axle by stands.
  • Page 351 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Hydraulic Cylinders and Front Loader Control Valve 1. Disconnect the hydraulic cylinder hoses (2) and return hoses (3) at the rear hydraulic block (1). 2. Remove the two pins, and remove the hydraulic cylinders (4). 3.
  • Page 352 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Separating Mid Case and Transmission Case 1. Separate the mid case and transmission case after removing their mounting screws and nut. (When reassembling) • Make sure to insert the PTO shaft to PTO clutch firmly, turning the PTO shaft.
  • Page 353 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Transmission Bearing Holder 1. Remove the transmission bearing holder mounting screws. 2. Tap out the spring pin (8) on the shift fork rod (3). 3. Jack up the bearing holder (1) by using the two jack screws (5) until the taper roller bearing (7) can be removed.
  • Page 354 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Shaft Assemblies 1. Remove the traveling speed sensor (1). 2. Remove the spiral bevel pinion shaft assembly (4) with shift fork (6), range gear shaft assembly (5) and PTO drive shaft assembly (3). 3.
  • Page 355 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Lock Shift Fork 1. Tap out the left side spring pin (4). 2. Remove the cotter pin and remove the clevis pin (3). 3. Draw out the differential lock fork shaft (1) and remove the differential lock shift fork (2).

  • Page 356: Regulating Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Differential Gear Assembly 1. Remove the differential support, noting the number of left shims. 2. Remove the differential gear assembly, noting the number of right shims. (When reassembling) • Check the spiral bevel gear for wear or damage. If it is no longer serviceable, replace it.
  • Page 357 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Disassembling Regulating Valve NOTE • The regulating valve has been precisely machined and assembled. It is advisable not to disassemble it as long as there is no necessary. 1. Remove the cap nuts (1), (27) and lock nuts (3), (25). 2.

  • Page 358: Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION 7. SERVICING [1] MANUAL TRANSMISSION MODEL (1) Bearing, Gear and Shaft Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2.

  • Page 359: Synchronized Gear

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (2) Synchronized Gear Clearance between Shift Fork and Shifter Groove 1. Measure the width of shift fork. 2. Measure the shifter groove width, and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them. Shuttle 0.20 to 0.45 mm Factory...

  • Page 360: Pto Clutch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION (3) PTO Clutch PTO Clutch Disc Wear 1. Measure the thickness of PTO clutch disc with vernier calipers. 2. If the thickness is less than the allowable limit, replace it. 1.70 to 1.90 mm Factory specification 0.0670 to 0.0748 in.

  • Page 361: Differential Gears

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Thickness of Seal Ring 1. Measure the thickness of seal rings (1) with an outside micrometer. 2. If the measurement is less than the allowable limit, replace it. 2.45 to 2.50 mm Factory specification 0.0965 to 0.0984 in.
  • Page 362 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Backlash and Tooth Contact between Spiral Bevel Gear and Spiral Bevel Pinion Shaft 1. Set the dial indicator (lever type) with its finger on the tooth surface. 2. Measure the backlash by fixing the spiral bevel pinion shaft (3) and moving the spiral bevel gear (4) by hand.
  • Page 363 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION More than 35 % contact area on the gear tooth surface. The center of tooth contact at 1/3 of the entire width from the small end. (A) Proper Contact 9Y1211167TRS0158US0 Replace the adjusting shim (2) with thicker one to move the spiral bevel pinion shaft backward.
  • Page 364 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Clearance between Differential Case Bore (Differential Case Cover Bore) and Differential Side Gear Boss 1. Measure the bore I.D. of the differential case and differential case cover. 2. Measure the differential side gear boss O.D. and calculate the clearance.
  • Page 365 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Backlash between Differential Pinion and Differential Side Gear 1. Set a dial indicator (lever type) on the tooth of the differential pinion. 2. Hold the differential side gear and move the differential pinion to measure the backlash.

  • Page 366: Glide Shift Transmission (Gst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [2] GLIDE SHIFT TRANSMISSION (GST) MODEL (1) Bearing, Gear and Shaft Refer to "[1] MANUAL TRANSMISSION MODEL" of "7. SERVICING" in this section. 9Y1211167TRS0164US0 (2) Synchronizer Gear Refer to "[1] MANUAL TRANSMISSION MODEL" of "7. SERVICING" in this section. 9Y1211167TRS0165US0 (3) PTO Clutch Refer to "[1] MANUAL TRANSMISSION MODEL"...
  • Page 367 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Piston Return Spring Free Length 1. Measure the free length of spring with vernier calipers. 2. If the measurement is less than the allowable limit, replace it. 19.9 to 20.1 mm Factory specification 0.784 to 0.791 in.

  • Page 368: Hydrostatic Transmission (Hst) Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION [3] HYDROSTATIC TRANSMISSION (HST) MODEL (1) Bearing, Gear and Shaft Refer to "[1] MANUAL TRANSMISSION MODEL" of "7. SERVICING" in this section. 9Y1211167TRS0173US0 (2) PTO Clutch Refer to "[1] MANUAL TRANSMISSION MODEL" of "7. SERVICING" in this section. 9Y1211167TRS0174US0 (3) Differential Gears Refer to "[1] MANUAL TRANSMISSION MODEL"...
  • Page 369 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Cylinder Block Face 1. Check the polished face (1) of cylinder block for scoring. 2. If scored, replace cylinder block assembly. 3. Check the spring (2) for breakage. 4. If broken, replace cylinder block assembly. (1) Polished Face (2) Spring 9Y1211167TRS0180US0...
  • Page 370 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM TRANSMISSION Check and High Pressure Relief Valve 1. Check the valve plug (1) and valve for scratches and damage. 2. Check the valve seat in the port block for damage. 3. Check the spring (3) for breakage and wear. 4.

  • Page 371: Rear Axle

    REAR AXLE KiSC issued 02, 2015 A...
  • Page 372 MECHANISM CONTENTS 1. STRUCTURE..........................4-M1 KiSC issued 02, 2015 A...
  • Page 373 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE 1. STRUCTURE [L3540-II, L4240-II] (1) Ball Bearing (4) Differential Gear Shaft (7) Differential Pinion (10) Differential Lock Shifter (2) Rear Axle (5) Brake Case (8) Ring Gear (11) Differential Case (3) Rear Axle Case (6) Brake Disc (9) Final Gear (12) Differential Side Gear...
  • Page 374 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE [L5040-II, L5240-II and L5740-II] (1) Rear Axle Cover (5) Differential Gear Shaft (8) Differential Pinion (11) Differential Lock Shifter (2) Ball Bearing (6) Brake Case (9) Ring Gear (12) Differential Case (3) Rear Axle (7) Brake Disc (10) Final Gear...
  • Page 375 SERVICING CONTENTS 1. TROUBLESHOOTING.........................4-S1 2. TIGHTENING TORQUES......................4-S2 3. PREPARATION ...........................4-S3 4. DISASSEMBLING AND ASSEMBLING ..................4-S6 KiSC issued 02, 2015 A...
  • Page 376 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Excessive or Unusual 1. Insufficient or improper Fill or change G-37 Noise at All Time type of transmission fluid used 2.
  • Page 377 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE 2. TIGHTENING TORQUES Tightening torques of screws and nuts on the table below are especially specified. (For general use screws and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m lbf·ft...
  • Page 378 10.8 U.S.gals L5740-II 9.0 Imp.gals IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. (Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-10.) • Do not mix different brands of fluid together.
  • Page 379 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE Rear Wheel and Cabin Mount Screw (Cabin Model) 1. Place the disassembling stand under the transmission case. 2. Remove the rear wheel mounting screws and nuts. 3. Remove the rear wheels (1). 4.
  • Page 380 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE Rear Axle Case 1. Disconnect the brake rod. 2. Place the disassembling stand under the rear axle case. 3. Remove the rear axle mounting screws and nuts. 4. Separate the rear axle case from brake case. (When reassembling) •...
  • Page 381 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM REAR AXLE 4. DISASSEMBLING AND ASSEMBLING Rear Axle (1) Rear Axle (2) Oil Seal (3) Internal Snap Ring (4) Ball Bearing (5) Spacer (6) Rear Axle Case (7) Gear (8) Lock Nut (9) Ball Bearing (10) Ball Bearing (11) Rear Axle Cover (12) O-ring...
  • Page 382 BRAKES KiSC issued 02, 2015 A...
  • Page 383 MECHANISM CONTENTS 1. STRUCTURE..........................5-M1 2. OPERATION..........................5-M2 KiSC issued 02, 2015 A...
  • Page 384 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 1. STRUCTURE (1) Brake Pedal Turnbuckle Rod (4) Brake Cam Lever (7) Brake Plate (9) Parking Brake Cable (2) Brake Pedal (5) Parking Brake Rod (8) Cam Plate (10) Parking Brake Lever (3) Brake Rod (6) Brake Disc This is used hanging type brake pedals to have wider space of the platform.
  • Page 385 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 2. OPERATION (1) Brake Case (3) Cam Plate (5) Brake Cam Lever (7) Brake Cam (2) Brake Disc (4) Steel Ball (6) Plate (8) Brake Shaft The brakes are provided on the power transmitting shafts (brake shafts (8)) through which power is transmitted to the final reduction system.
  • Page 386 SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICING SPECIFICATIONS ....................5-S2 3. TIGHTENING TORQUES......................5-S3 4. CHECKING AND ADJUSTING....................5-S4 [1] BRAKE PEDAL........................5-S4 [2] PARKING BRAKE LEVER ....................5-S4 5. DISASSEMBLING AND ASSEMBLING ..................5-S5 [1] BRAKE PEDAL........................5-S5 [2] BRAKE CASE........................5-S7 6. SERVICING ..........................5-S11 KiSC issued 02, 2015 A...

  • Page 387: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Uneven Braking 1. Brake pedal play unevenly Adjust 5-S4 Force adjusted 2. Brake disc worn Replace 5-S11 3. Cam plate warped Replace 5-S11 Brake Drags...

  • Page 388: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 15 to 20 mm – 0.59 to 0.78 in. Cam Plate Flatness – 0.30 mm 0.012 in. Cam Plate and Ball Height 20.9 to 21.1 mm 20.5 mm...
  • Page 389 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 3. TIGHTENING TORQUES Tightening torques of screws and nuts in the table below are especially specified. (For general use screws and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m lbf·ft Rear wheel mounting screw and nut...

  • Page 390: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 4. CHECKING AND ADJUSTING [1] BRAKE PEDAL Checking Brake Pedal Free Travel CAUTION • Stop the engine and chock the wheels before checking brake pedal. 1. Release the parking brake. 2. Slightly depress the brake pedals and measure free travel "L" at top of pedal stroke.

  • Page 391: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 5. DISASSEMBLING AND ASSEMBLING [1] BRAKE PEDAL Panel Cover 1. Remove the panel cover (1). (1) Panel Cover 9Y1211167BRS0006US0 Meter Panel (Electronic Instrument Panel) 1. Disconnect the hazard switch connector (4), main switch connector (5) and mode switch connector (6).
  • Page 392 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES Brake Pedal and Brake Rod (1) Parking Brake Lever (2) External Snap Ring (3) Oil Seal (4) Needle Bearing (5) Brake Pedal RH (6) Spring (7) Spring Pin (8) Brake Pedal LH (9) Clutch Pedal (10) Brake Pedal Shaft (11) Brake Pedal Rod RH...

  • Page 393: Brake Case

    10.8 U.S.gals L5740-II 9.0 Imp.gals IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oils may damage the transmission or hydraulic system. (Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-10.) • Do not mix different brands of fluid together.
  • Page 394 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES Rear Wheel and Cabin Mount Screw (Cabin Model) 1. Place the disassembling stand under the transmission case. 2. Remove the rear wheel mounting screws and nuts. 3. Remove the rear wheels (1). 4.
  • Page 395 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES Rear Axle Case 1. Disconnect the brake rod. 2. Place the disassembling stand under the rear axle case. 3. Remove the rear axle mounting screws and nuts. 4. Separate the rear axle case from brake case. (When reassembling) •...
  • Page 396 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES Brake Cam and Brake Cam Lever 1. Remove the brake cam mounting nut and remove the brake cam (2) and brake cam lever (4). (When reassembling) • Apply grease to the O-ring (3) and be careful not damage the O-ring.
  • Page 397 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM BRAKES 6. SERVICING Brake Cam Lever Movement 1. Assemble the brake cam (1) and brake cam lever (2). 2. Move the brake cam lever by hand to check the movement. 3. If the movement is heavy, refine the brake cam lever or brake case with sandpaper.

  • Page 398: Front Axle

    FRONT AXLE KiSC issued 02, 2015 A...
  • Page 399 MECHANISM CONTENTS 1. STRUCTURE..........................6-M1 [1] 4WD TYPE ........................... 6-M1 KiSC issued 02, 2015 A...
  • Page 400 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 1. STRUCTURE [1] 4WD TYPE for L3540-II (1) Axle (7) Bevel Gear (13) Spiral Bevel Gear (19) Differential Yoke Shaft (2) Collar (8) Differential Side Gear (14) Spiral Bevel Pinion Shaft (20) Front Axle Case (3) Axle Flange (9) Differential Pinion...
  • Page 401 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE for L4240-II, L5040-II, L5240-II and L5740-II (1) Axle (8) Bevel Gear Case (14) Spiral Bevel Gear (20) Differential Yoke Shaft (2) Collar (9) Differential Side Gear (15) Spiral Bevel Pinion Shaft (21) Front Axle Case (3) Axle Flange (10) Differential Pinion...

  • Page 402: Servicing

    SERVICING CONTENTS 1. TROUBLESHOOTING.........................6-S1 2. SERVICING SPECIFICATIONS ....................6-S2 3. TIGHTENING TORQUES......................6-S4 4. CHECKING AND ADJUSTING....................6-S5 5. DISASSEMBLING AND ASSEMBLING ..................6-S7 [1] SEPARATING FRONT AXLE ASSEMBLY ................6-S7 [2] DISASSEMBLING 4WD TYPE FRONT AXLE ..............6-S9 6. SERVICING ..........................6-S16 [1] 4WD TYPE ..........................6-S16 KiSC issued 02, 2015 A...

  • Page 403: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Front Wheels Wander 1. Tire pressure uneven Adjust G-68 to Right or Left 2. Improper toe-in Adjust G-34 adjustment (improper alignment) 3.

  • Page 404: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 2 to 8 mm – 0.08 to 0.3 in. Front Wheel Axial Sway Less than – 5.0 mm 0.196 in. (for L4240-II, L5040-II, L5240-II and L5740-II) Clearance...
  • Page 405 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Item Factory Specification Allowable Limit (for L4240-II, L5040-II, L5240-II and L5740-II) Backlash 0.20 to 0.30 mm – Spiral Bevel Pinion Shaft to Spiral Bevel 0.0079 to 0.011 in. Gear (for L3540-II) Bevel Gear to Bevel Gear Backlash 0.15 to 0.35 mm...
  • Page 406 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m...

  • Page 407: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 4. CHECKING AND ADJUSTING Toe-in 1. Park the tractor on the flat place. 2. Inflate the tires to the specified pressure. 3. Turn steering wheel so front wheels are in the straight ahead position.
  • Page 408 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Adjust Front Axle Pivot 1. Loosen the lock nut (2), tighten the adjusting screw (1) with specified torque. 2. Retighten the lock nut (2). NOTE • If the axle pivot pin adjustment is not correct, front wheel vibration can occur causing vibration in the steering wheel.

  • Page 409: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 5. DISASSEMBLING AND ASSEMBLING [1] SEPARATING FRONT AXLE ASSEMBLY Propeller Shaft 1. Slide the propeller shaft cover (4) and (8) after removing the screws (7). 2. Tap out the spring pins (2), (6) and slide the couplings (1), (5) and then remove the propeller shaft with covers (4), (8).
  • Page 410 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Front Wheel and Front Axle Assembly 1. Check the front axle and flywheel housing are securely mounted on the disassembly stand. 2. Loosen the front wheel mounting nuts. 3. Lift the front axle and remove the front wheels. 4.

  • Page 411: Disassembling 4Wd Type Front Axle

    6.0 L L5240-II, 6.3 U.S.qts L5740-II 5.3 lmp.qts IMPORTANT • Use KUBOTA SUPER UDT fluid or SAE80, 90 gear oil. Refer to "4. LUBRICANTS, FUEL AND COOLANT" on page G-10. (1) Check Plug (3) Drain Plug (2) Filling Plug 9Y1211167FAS0012US0 Propeller Shaft 1.
  • Page 412 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Tie-rods 1. Pull out the cotter pin and remove the tie-rod end slotted nuts. 2. Remove the tie-rod with a tie-rod end lifter (Code No. 07909-39051). (When reassembling) • After tightening the tie-rod end nut to the specified torques, install a cotter pin as shown in the figure left.
  • Page 413 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Axle Flange and Front Gear Case 1. Remove the axle flange mounting screws. 2. Remove the axle flange (1). (When reassembling) • Apply grease to the O-ring (2) of axle flange. •...
  • Page 414 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Axle 1. Remove the bearing with a special use puller set (Code No. 07916-09032). 2. Remove the bevel gear (2). 3. Remove the collar (1). 4. Tap out the axle (3). (When reassembling) •...
  • Page 415 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Steering Cylinder 1. Support the engine and front axle case by disassembling stand. 2. Remove the bracket mounting screw and nut, and remove the front axle case. 3. Remove the tie-rod joint (1) (right side). 4.
  • Page 416 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Spiral Bevel Pinion Shaft and Differential Gear Assembly 1. Remove the differential yoke shaft (9), (10) both sides. 2. Remove the oil seal (6) and internal snap ring (5). 3. Remove the collar (4). 4.
  • Page 417 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Differential Gear 1. Remove the differential case cover mounting screws (9) and then remove the differential case cover (5), ball bearing (6) and spiral bevel gear (7) as a unit. 2. Remove the external snap ring (8), and then remove the ball bearing (6) and spiral bevel gear (7) as a unit with a puller.
  • Page 418 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE 6. SERVICING [1] 4WD TYPE Clearance between Differential Case (Differential Case Cover) and Differential Side Gear 1. Measure the differential side gear O.D.. 2. Measure the differential case bore I.D. and calculate the clearance.
  • Page 419 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Backlash between Differential Pinion and Differential Side Gear 1. Set a dial gauge (lever type) on a tooth of the differential pinion. 2. Fix the differential side gear and move the differential pinion to measure the backlash.
  • Page 420 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Backlash between Spiral Bevel Pinion Shaft and Spiral Bevel Gear 1. Set a dial gauge (lever type) with its finger on the spline of spiral bevel pinion shaft. 2. Measure the backlash by moving the spiral bevel pinion shaft by hand lightly.
  • Page 421 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Backlash between Bevel Gear and Bevel Gear 1. Stick a strip of plastigauge to three spots on the bevel gear (1) with grease. 2. Fix the axle flange and front gear case. 3.
  • Page 422 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Clearance between Front Axle Case Bosses and Bracket Bushings 1. Measure the front axle case bosses O.D. with an outside micrometer. 2. Measure the bracket bushing I.D. and calculate the clearance. 3.
  • Page 423 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM FRONT AXLE Clearance between Bevel Gear Case Boss and Front Axle Support Bushing (for L4240-II, L5040-II, L5240-II and L5740-II) 1. Measure the bevel gear case boss O.D. with an outside micrometer. 2. Measure the support bushing I.D. and calculate the clearance. 3.
  • Page 424 STEERING KiSC issued 02, 2015 A...
  • Page 425 MECHANISM CONTENTS 1. STRUCTURE..........................7-M1 2. HYDRAULIC CIRCUIT ....................... 7-M2 3. HYDRAULIC PUMP........................7-M3 4. STEERING CONTROLLER......................7-M4 5. STEERING CYLINDER ......................7-M6 KiSC issued 02, 2015 A...

  • Page 426: Structure

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 1. STRUCTURE (1) Steering Wheel (3) Hydraulic Pump (5) Steering Controller (7) Steering Joint Shaft 2 (2) Steering Joint Shaft 1 (4) Steering Cylinder (6) Steering Joint Shaft 3 (8) Steering Shaft The full hydrostatic type power steering is used on these tractors.

  • Page 427: Hydraulic Circuit

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 2. HYDRAULIC CIRCUIT When the engine starts, the hydraulic pump (8) pressure-feeds the oil, drawn from the transmission case (7) through the oil filter (6), to the steering controller (3). The oil which has entered steering controller (3) is directed to control valve (10).
  • Page 428 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 3. HYDRAULIC PUMP The gear type hydraulic pump is adopted for these tractor. This pump is tandem type and it consists of two pair of gears, side plates, bushings and other components as shown in the figure. The hydraulic pump pressure-fed the oil drawn from the transmission case through oil filter to power steering circuit and main hydraulic circuit.

  • Page 429: Steering Controller

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 4. STEERING CONTROLLER Neutral Position When the steering wheel (1) is not being turned, valve plate (2) is held in the neutral position by centering spring. Under this condition, an oil passage is formed between P port (from pump) and T port (to transmission case) in the control valve, and all oil from the hydraulic pump flows to T port.
  • Page 430 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING Left Turn The steering system operates in the same way at a left-turn as well, except that oil flows into and out of steering cylinder in the directions opposite to those at a right-turn.

  • Page 431: Steering Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 5. STEERING CYLINDER (1) Tie-rod (3) Head Cover (5) Head Cover (7) Internal Snap Ring (2) Piston Rod (4) Cylinder Tube (6) Front Axle Case The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.

  • Page 432: Servicing

    SERVICING CONTENTS 1. TROUBLESHOOTING.........................7-S1 2. SERVICING SPECIFICATIONS ....................7-S3 3. TIGHTENING TORQUES......................7-S4 4. CHECKING AND ADJUSTING....................7-S5 [1] STEERING CONTROLLER....................7-S5 5. DISASSEMBLING AND ASSEMBLING ..................7-S6 [1] STEERING CONTROLLER....................7-S6 [2] STEERING CYLINDER ......................7-S7 [3] STEERING LINKAGE......................7-S8 6. SERVICING ..........................7-S9 [1] STEERING CYLINDER ......................7-S9 KiSC issued 02, 2015 A...

  • Page 433: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 1. TROUBLESHOOTING Probable Cause and Reference Symptom Solution Checking Procedure Page Tractor Can Not Be 1. Steering linkage broken Replace 7-S8 Steered 2. Pipe broken Replace – 3. Steering controller broken Replace 7-S6 Front Wheels Vibrate 1.
  • Page 434 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING Probable Cause and Reference Symptom Solution Checking Procedure Page Front Wheels Wander 1. Tire pressure uneven Inflate G-68 to Right or Left 2. Insufficient bleeding Bleed 7-S6 3. Improper toe-in Adjust G-34 adjustment 4.

  • Page 435: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 2. SERVICING SPECIFICATIONS STEERING CONTROLLER Item Factory Specification Allowable Limit Relief Valve Setting Pressure Condition L3540-II, L4240-II 10.7 to 11.7 MPa – • Engine Speed: 110 to 119 kgf/cm Maximum 1560 to 1690 psi •...
  • Page 436 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m...

  • Page 437: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 4. CHECKING AND ADJUSTING [1] STEERING CONTROLLER Relief Valve Setting Pressure Test 1. Disconnect the power steering hose LH. 2. Install the power steering tee fitting adaptor to the steering cylinder and connect the power steering hose LH. 3.

  • Page 438: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 5. DISASSEMBLING AND ASSEMBLING [1] STEERING CONTROLLER IMPORTANT • Use only the transmission fluid (Refer to "7. CHACK AND MAINTENANCE" at "G. GENERAL" section.), in no case use mixture of oils of different brands. •...

  • Page 439: Steering Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING [2] STEERING CYLINDER Front Wheel, Cylinder Cover and Tie-rod 1. Place a disassembly stand under the engine and support it with a jack. 2. Remove the front wheel and cylinder cover (2). 3.

  • Page 440: Steering Linkage

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING [3] STEERING LINKAGE Steering Wheel and Steering Post Covers 1. Remove the steering wheel (1). 2. Remove the steering post covers (2), (3). (When reassembling) 48.1 to 55.9 N·m Steering wheel mounting Tightening torque 4.9 to 5.7 kgf·m 35.4 to 41.2 lbf·ft...

  • Page 441: Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM STEERING 6. SERVICING [1] STEERING CYLINDER Steering Cylinder I.D. 1. Measure the steering cylinder I.D. with a cylinder gauge. 2. If the cylinder I.D. exceed the allowable limit, replace the cylinder tube. 55.000 to 55.074 mm Factory specification 2.1654 to 2.1682 in.

  • Page 442: Hydraulic System

    HYDRAULIC SYSTEM KiSC issued 02, 2015 A...
  • Page 443 MECHANISM CONTENTS 1. STRUCTURE..........................8-M1 [1] MANUAL TRANSMISSION AND GLIDE SHIFT TRANSMISSION ........8-M1 [2] HYDROSTATIC TRANSMISSION ..................8-M2 2. HYDRAULIC CIRCUIT ....................... 8-M3 [1] MANUAL TRANSMISSION ....................8-M3 [2] GLIDE SHIFT TRANSMISSION (GST) ................8-M4 [3] HYDROSTATIC TRANSMISSION (HST) ................8-M5 3.

  • Page 444: Structure

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 1. STRUCTURE [1] MANUAL TRANSMISSION AND GLIDE SHIFT TRANSMISSION (1) Power Steering Controller (4) Hydraulic Pump (7) Hydraulic Cylinder [A]: Manual Transmission Model (2) Power Steering Cylinder (5) PTO Solenoid Valve (8) Hydraulic Block (3) Regulating Valve (6) Front Loader Control Valve...

  • Page 445: Hydrostatic Transmission

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] HYDROSTATIC TRANSMISSION (1) Power Steering Controller (4) Regulating Valve (7) Hydraulic Cylinder (9) HST Unit (2) Power Steering Cylinder (5) PTO Solenoid Valve (8) Hydraulic Block (10) Oil Cooler (3) Hydraulic Pump (6) Front Loader Control Valve The hydraulic system of machine consists of a hydraulic pump (3), front loader control valve (6), hydraulic cylinder (7) and other components.

  • Page 446: Hydraulic Circuit

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 2. HYDRAULIC CIRCUIT [1] MANUAL TRANSMISSION (1) Position Control Valve (5) Auxiliary Control Valve (8) Regulating Valve (11) Front Loader Control Valve (2) Hydraulic Cylinder (6) Power Steering Controller (Refer to TRANSMISSION (12) Hydraulic Pump 1 (3) Cylinder Safety Valve (Refer to STEERING Section)

  • Page 447: Glide Shift Transmission (Gst)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] GLIDE SHIFT TRANSMISSION (GST) (1) Position Control Valve (5) Auxiliary Control Valve (9) Regulating Valve (13) Hydraulic Pump 1 (2) Hydraulic Cylinder (6) Power Steering Controller (10) Hydraulic Pump 2 (14) Relief Valve (3) Cylinder Safety Valve (7) PTO Clutch Valve...

  • Page 448: Rear Hydraulic Block

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [3] HYDROSTATIC TRANSMISSION (HST) (1) Position Control Valve (5) Auxiliary Control Valve (9) Hydrostatic Transmission (13) Oil Filter (2) Hydraulic Cylinder (6) Power Steering Controller (HST) (14) Front Loader Control Valve (3) Cylinder Safety Valve (7) Oil Filter (10) Hydraulic Pump 2...
  • Page 449 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 3. HYDRAULIC PUMP The gear type hydraulic pump is adopted for these tractor. This pump is tandem type and it consisits of two pair of gears, side plates, bushings and other components as shown in the figure.
  • Page 450 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 4. THREE POINT HITCH HYDRAULIC SYSTEM [1] THREE POINT HITCH HYDRAULIC CIRCUIT (1) Position Control Valve (2) Hydraulic Cylinder (3) Cylinder Safety Valve (4) Lowering Speed Adjusting Valve (5) Auxiliary Control Valve (6) Rear Hydraulic Block (7) Front Loader Control Valve (8) Hydraulic Pump 1...
  • Page 451 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] REAR HYDRAULIC BLOCK (1) Cylinder Safety Valve (3) Position Control Valve (5) Check Valve From Hydraulic Pump (2) Lowering Speed Adjusting (4) Cover To or From Hydraulic Valve (Rear Hydraulic Outlet Port) Cylinder To or From Hydraulic Cylinder...
  • Page 452 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Lifting When the control lever is moved to "LIFT" position, spool (1) is pushed by the spool operating lever, forming a circuit with the P port and chamber A. The pressurized oil thus flows into the chamber A and closes unload poppet 1 (2).

  • Page 453: Position Control Linkage

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [4] POSITION CONTROL LINKAGE Position control is a mechanism to raise or lower the implement attached to the tractor in proportion to the movement of the control lever. The implement can be set at any height by moving the position control lever.

  • Page 454: Lowering Speed Adjusting Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [5] LOWERING SPEED ADJUSTING VALVE Turning the rotor shaft (2) clockwise decreases the lowering speed, counterclockwise increases lowering speed of the three points linkage. When the rotor shaft (2) is completely closed, the three point linkage is held at its position since oil in the hydraulic cylinder is sealed between the hydraulic cylinder and rotor (4).

  • Page 455: Hydraulic Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [6] HYDRAULIC CYLINDER The external type hydraulic cylinders are used for three point linkage system. This hydraulic cylinder is single acting type, and it is installed directly between hydraulic lift arm and lower link. The main components of the hydraulic cylinder are shown in the figure.

  • Page 456: Front Loader Control Valve Assembly

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 5. FRONT LOADER CONTROL VALVE ASSEMBLY [1] STRUCTURE (1) Inlet and Outlet Section Pump Port A1: A1 Port B1: B1 Port (2) Boom Control Valve Tank Port A2: A2 Port B2: B2 Port (3) Bucket Control Valve PB: Power Beyond Port (4) Power Beyond...

  • Page 457: Front Loader Hydraulic Circuit

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] FRONT LOADER HYDRAULIC CIRCUIT (1) Relief Valve Pump Port A1: A1 Port To Hydraulic Block (2) Boom Control Valve Tank Port A2: A2 Port (3) Bucket Control Valve B1: B1 Port (4) Front Loader Control Valve B2: B2 Port PB: Power Beyond Port...

  • Page 458: Operation

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [3] OPERATION Neutral (1) Boom Control Section (5) PB Passage 1 Pump Port B1: B1 Port (2) Bucket Control Section (6) PB Passage 2 Tank Port B2: B2 Port (3) Spool for Bucket Control (7) Load Check Valve A1: A1 Port PB: Power Beyond Port...
  • Page 459 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (1) Boom Control Section (7) Load Check Valve Pump Port B1: B1 Port (2) Bucket Control Section (8) Relief Valve Tank Port B2: B2 Port (3) Spool for Bucket Control (9) Passage 1 A1: A1 Port PB: Power Beyond Port (4) Spool for Boom Control...
  • Page 460 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Down (1) Boom Control Section (7) Load Check Valve Pump Port B1: B1 Port (2) Bucket Control Section (8) Relief Valve Tank Port B2: B2 Port (3) Spool for Bucket Control (9) Passage 1 A1: A1 Port PB: Power Beyond Port...
  • Page 461 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Floating (1) Boom Control Section (7) Load Check Valve Pump Port B1: B1 Port (2) Bucket Control Section (8) Relief Valve Tank Port B2: B2 Port (3) Spool for Bucket Control (9) Passage 1 A1: A1 Port PB: Power Beyond Port...
  • Page 462 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Roll-back (1) Boom Control Section (7) Load Check Valve Pump Port B1: B1 Port (2) Bucket Control Section (8) Relief Valve Tank Port B2: B2 Port (3) Spool for Bucket Control (9) Passage 2 A1: A1 Port PB: Power Beyond Port...
  • Page 463 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Dump (1) Boom Control Section (7) Load Check Valve Pump Port B1: B1 Port (2) Bucket Control Section (8) Relief Valve Tank Port B2: B2 Port (3) Spool for Bucket Control (9) Passage 2 A1: A1 Port PB: Power Beyond Port...

  • Page 464: Auxiliary Control Valve (If Equipped)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 6. AUXILIARY CONTROL VALVE (IF EQUIPPED) [1] DOUBLE ACTING TYPE Neutral Pressure-fed oil from the hydraulic pump is delivered into the P port, and flows to the position control valve via N port.

  • Page 465: Other

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 7. OTHER [1] SAFETY VALVE 1. Operation of safety valve, refer to "8. HYDRAULIC SYSTEM" section in the workshop manual of tractor mechanism (Code No. 9Y021-18200). 9Y1211167HYM0028US0 8-M22 KiSC issued 02, 2015 A...
  • Page 466 SERVICING CONTENTS 1. TROUBLESHOOTING.........................8-S1 2. SERVICING SPECIFICATIONS ....................8-S2 3. TIGHTENING TORQUES......................8-S4 4. CHECKING AND ADJUSTING....................8-S5 [1] HYDRAULIC PUMP (FOR POWER STEERING) ..............8-S5 (1) Pump Test Using Flow-meter ..................8-S5 [2] HYDRAULIC PUMP (FOR THREE POINT HITCH) ..............8-S8 (1) Pump Test Using Flow-meter ..................8-S8 [3] RELIEF VALVE AND SAFETY VALVE ................8-S11 [4] POSITION CONTROL ROD ....................8-S13 5.

  • Page 467: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not 1. Control linkage improperly adjusted Adjust 8-S19 Rise (Not Noise) 2. Control linkage improperly assembled or Repair or replace – damaged 3.

  • Page 468: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS HYDRAULIC PUMP Item Factory Specification Allowable Limit Hydraulic Pump for Power Steering Delivery at No Above Condition Pressure 17.9 L/min. – • Engine Speed L3540-II 4.73 U.S.gals/min. Approx. 2700 min (rpm) 3.94 Imp.gals/min.
  • Page 469 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM RELIEF VALVE Item Factory Specification Allowable Limit Relief Valve Setting Pressure 17.1 to 18.1 MPa – Condition L3540-II 175 to 184 kgf/cm • Engine Speed 2480 to 2620 psi Maximum • Oil Temperature L4240-II, L5040-II, 18.1 to 19.1 MPa –...
  • Page 470 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m...

  • Page 471: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 4. CHECKING AND ADJUSTING [1] HYDRAULIC PUMP (FOR POWER STEERING) (1) Pump Test Using Flow-meter Preparation 1. Open the bonnet. 2. Remove the side skirt RH. 3. Remove the fuel tank frame support (1), cover (4) and steering joint shaft (2).
  • Page 472 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Hydraulic Flow Test (for Power Steering) IMPORTANT • When using a flowmeter other than KUBOTA specified flowmeter, be sure to use the instructions with that flowmeter. • Do not close the flowmeter loading valve completely, before testing, because it has no relief valve.
  • Page 473 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (Continued) [L3540-II] Above Hydraulic pump delivery 17.9 L/min. Factory specification at no pressure 4.73 U.S.gals/min. 3.94 lmp.gals/min. Above 17.5 L/min. Factory specification 4.62 U.S.gals/min. Hydraulic pump delivery 3.85 lmp.gals/min. at rated pressure 15.6 L/min.

  • Page 474: Hydraulic Pump (For Three Point Hitch)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] HYDRAULIC PUMP (FOR THREE POINT HITCH) (1) Pump Test Using Flow-meter Preparation 1. Open the bonnet. 2. Remove the side skirt RH. 3. Remove the delivery pipe 1 (1). (When reassembling) •...
  • Page 475 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Hydraulic Flow Test IMPORTANT • When using a flowmeter other than KUBOTA specified flowmeter, be sure to use the instructions with that flowmeter. • Do not close the flowmeter loading valve completely, before testing, because it has no relief valve.
  • Page 476 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (Continued) [L3540-II] Above Hydraulic pump delivery 31.5 L/min. Factory specification at no pressure 8.32 U.S.gals/min. 6.93 Imp.gals/min. Above 30.9 L/min. Factory specification 8.16 U.S.gals/min. Hydraulic pump delivery 6.80 Imp.gals/min. at rated pressure 27.6 L/min.

  • Page 477: Relief Valve And Safety Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [3] RELIEF VALVE AND SAFETY VALVE Relief Valve Setting Pressure Test Using Pressure Tester (Coupler) 1. Install the relief valve set pressure adaptor to the quick coupler and then install a pressure gauge (Code No. 07916-50322), cable (Code No.
  • Page 478 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Safety Valve Setting Pressure Test Using Injection Nozzle Tester 1. Remove the safety valve assembly (1). 2. Attach the safety valve to an injection nozzle tester with a safety valve setting adaptor (Refer to "8. SPECIAL TOOLS" at "G. GENERAL"...

  • Page 479: Position Control Rod

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [4] POSITION CONTROL ROD Adjusting Uppermost Position of Lift Arm 1. Set the position control lever (1) to the lowest position. 2. Start the engine, and after warming-up, set the engine speed at the idling.

  • Page 480: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 5. DISASSEMBLING AND ASSEMBLING [1] HYDRAULIC PUMP IMPORTANT • The hydraulic pump is precision machined and assembled: if disassemble once, it may be unable to keep its original performance. Therefore, when the hydraulic pump fails, replacement should be carried out with the hydraulic pump assembled except when emergency repair is unavoidable.
  • Page 481 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Power Steering Delivery Pipe and Oil Cooler Return Pipe (HST Models) 1. Disconnect the power steering delivery pipe (2) and oil cooler return pipe (1). (When reassembling) • Install the copper washers firmly. •...

  • Page 482: Disassembling Hydraulic Pump

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (2) Disassembling Hydraulic Pump Hydraulic Pump Assembly 1. Remove the pump cover mounting screws (7). 2. Remove the drive gear (6), driven gear (2) and side plate (3) from the casing. (When reassembling) •...

  • Page 483: Three Point Hitch Hydraulic Block Assembly

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY (1) Separating Hydraulic Block Assembly Seat, Seat Bracket and Cover 1. Remove the seat switch connector. 2. Remover the seat (1). 3. Remove the seat bracket (2). (1) Seat (2) Seat Bracket 9Y1211167HYS0018US0...

  • Page 484: Disassembling Hydraulic Assembly

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (2) Disassembling Hydraulic Assembly Lowering Speed Adjusting Valve 1. Draw out the spring pin (4). 2. Remove the holder (5). 3. Draw out the lowering speed adjusting shaft (3), dowel pin (6) and rotor (2).

  • Page 485: Position Control Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [3] POSITION CONTROL VALVE (1) Separating Control Valve Separating Hydraulic Block Assembly Refer to "4. DISASSEMBLING AND ASSEMBLING" in this section. 9Y1211167HYS0024US0 Disassembling Position Control Valve (1) Nut (2) External Snap Ring (3) Unload Plug (4) Spring (5) Unload Poppet...

  • Page 486: Lift Arm Support And Hydraulic Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [4] LIFT ARM SUPPORT AND HYDRAULIC CYLINDER (1) Separating Hydraulic Cylinder Top Link, Lift Rod and PTO Cover 1. Remove the top link (1) and PTO cover (3). 2. Disconnect the lift rods (2), (4) from lift arm. (When reassembling) 78 to 90 N·m Lift arm pin mounting nut...

  • Page 487: Disassembling Hydraulic Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (2) Disassembling Hydraulic Cylinder Hydraulic Cylinder 1. Remove the cylinder cover (1). 2. Remove the liquid gasket from top of head (5). 3. Slightly tap-in the head (5) to inside, and remove the internal snap ring (4) by using the small screwdriver.

  • Page 488: Disassembling Lift Arm Shaft

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (4) Disassembling Lift Arm Shaft Lift Arm and Lift Arm Shaft 1. Remove the external snap ring (5). 2. Remove the lift arm RH (6). 3. Draw out the lift arm shaft (1) and lift arm LH (7) as a unit. 4.

  • Page 489: Front Loader Control Valve And Relief Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [5] FRONT LOADER CONTROL VALVE AND RELIEF VALVE (1) Removing Front Loader Control Valve Assembly Position Control Cable and Front Loader Control Cable 1. Place the disassembling stand under the transmission case. 2.
  • Page 490 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM Front Loader Control Valve Assembly 1. Remove the delivery pipe 1 (2) and delivery pipe 2 (1). 2. Remove the front loader pipes (3). 3. Remove the front loader control valve assembly (4). (When reassembling) 118 to 137 N·m Joint bolt for delivery pipe 1...

  • Page 491: Disassembling Front Loader Control Valve And Relief Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM (2) Disassembling Front Loader Control Valve and Relief Valve (1) Plug (2) O-ring (3) Washer (4) Shim (5) Spring (6) Poppet 2 (7) Poppet 1 (8) Plug (9) O-ring (10) Spring (11) Check Valve (12) Dust Seal (13) O-ring...

  • Page 492: Safety Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [6] SAFETY VALVE Disassembling Safety Valve 1. Remove the safety valve assembly (1). 2. Secure the safety valve assembly in a vise. 3. Loosen the lock nut (3), and remove the adjust screw (2). 4.

  • Page 493: Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM 6. SERVICING [1] LIFT ARM Lift Arm Support Bushing 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy portion "A", replace (Reference) 0.57 mm Lift arm support bushing...

  • Page 494: Hydraulic Cylinder

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [2] HYDRAULIC CYLINDER Hydraulic Cylinder Rod Bushing 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy portion "A", replace (Reference) Hydraulic cylinder rod 0.57 mm...

  • Page 495: Hydraulic Pump

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM HYDRAULIC SYSTEM [3] HYDRAULIC PUMP Clearance between Bushing and Gear Shaft 1. Measure the gear shaft O.D. with an outside micrometer. 2. Measure the bushing I.D. with an inside micrometer or cylinder gauge, and calculate the clearance. 3.
  • Page 496 ELECTRICAL SYSTEM KiSC issued 02, 2015 A...
  • Page 497 MECHANISM CONTENTS 1. WIRING DIAGRAM........................9-M1 [1] MANUAL TRANSMISSION MODEL (MAIN HARNESS)............9-M1 [2] GST MODEL (MAIN HARNESS)..................9-M2 [3] HST MODEL (MAIN HARNESS) ..................9-M3 [4] CABIN HARNESS ........................ 9-M4 2. ELECTRONIC CONTROL PANEL ..................... 9-M5 [1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT ............... 9-M5 (1) System Outline .......................

  • Page 498: Wiring Diagram

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] MANUAL TRANSMISSION MODEL (MAIN HARNESS) 9-M1 KiSC issued 02, 2015 A...

  • Page 499: Gst Model (Main Harness)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [2] GST MODEL (MAIN HARNESS) 9-M2 KiSC issued 02, 2015 A...

  • Page 500: Hst Model (Main Harness)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [3] HST MODEL (MAIN HARNESS) 9-M3 KiSC issued 02, 2015 A...

  • Page 501: Cabin Harness

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [4] CABIN HARNESS 9-M4 KiSC issued 02, 2015 A...

  • Page 502: Electronic Control Panel

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 2. ELECTRONIC CONTROL PANEL [1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT (1) System Outline (1) Liquid Crystal Display (LCD) (2) Electronic Instrument Panel (Intellipanel) The Electronic Instrument Panel (Intellipanel) adopted in the L40 series tractors consists of an 8-bit CPU sensors and input devices, memory devices such as RAM and ROM, and others.

  • Page 503: Control Items

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Control Items For manual transmission model, the electronic instrument panel (Intellipanel) functions to receive data from sensors and switches, and displays them on the meter. For GST and HST models, the electronic instrument panel also receives data also from the control ECU (Electric Control Unit) through multiplex communication, and displays them on the panel.

  • Page 504: Construction And Function Of Components

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [2] CONSTRUCTION AND FUNCTION OF COMPONENTS (1) Parking Brake Switch (9) Throttle Sensor (20) Oil Temperature Sensor (32) PTO Switch (2) Multi Function Combination (10) Swashplate Position Sensor (21) Oil Pressure Switch (33) Shuttle Switch (GST and Lever (Turn Signal and Head (11) HST Pedal Sensor...
  • Page 505 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Electronic Instrument Panel (Intellipanel) An 8 bit CPU is incorporated into the electronic instrument panel, and outputs the status of the tractor to the liquid crystal display, monitor lamp, tachometer, and buzzer.
  • Page 506 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display Mode Switch and Travel Speed Switch These switches are located at the right of the electronic instrument panel and both are of tact type. Usually, the display mode switch (1) is used at the switching of display indication, and the traveling speed switch (2) is used to switching to the traveling speed display as well as at data input and fine adjustment.
  • Page 507 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Coolant Temperature Sensor This sensor (1) is designed to detect the temperature of coolant. It employs a thermistor, and detects the variation in resistance due to a change in temperature to indicate the temperature on the LCD.
  • Page 508 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Traveling Speed Sensor This sensor (1) is mounted at the right bottom of the transmission case, and generates pulses proportional to the rotating speed and the number of teeth of the front-wheel drive gear on the PTO drive shaft.
  • Page 509 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Shuttle Switch: for Manual Transmission and GST Model This switch (1) is mounted at the bottom of the shuttle lever shaft (2) and is turned on when the position of F, N, or R is detected through the movement of the sensor lever, thereby outputting a 12 V signal to the electronic instrument panel and ECU.
  • Page 510 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Range Gear Shift Lever Sensor: for HST Model This sensor (1) is designed to detect the position at which the HST range gear shift lever changes the speed, and is mounted at the bottom of the lever. It has the variable resistor of revolution angle type, and the maximum resistance value is approximately 5.4 kΩ.
  • Page 511 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Emergency Connector: for GST Model This is a device which compulsorily operates the shift solenoid when the tractor does not move due to the trouble of the GST system and moves the tractor. (Situation for necessity of emergency connector) •...
  • Page 512 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Mode Select Switch The HST mode select switch is used to change HST functions. There are three HST modes. The first one is the same as for the existing HST on which the lamp does not light up on the panel.
  • Page 513 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Swashplate Position Sensor The swashplate position sensor is located above the regulating valve. The sensor is linked with the servo piston. If the servo piston moves (if swashplate is inclined), the sensor detects its position and signals are sent to the ECU.

  • Page 514: Basic Control System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [3] BASIC CONTROL SYSTEM (1) Normal Display The normal display is a message indicated in the liquid crystal display (LCD) while the main switch is turned "ON" or the engine is starting. The fuel gauge and coolant temperature gauge are always displayed on a right edge of LCD, and the position of gear shifting is displayed on a left edge for...

  • Page 515: Attention Display (At Engine Starting)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Attention Display (At Engine Starting) If neither of the levers or pedals are in neutral positions when the main switch is turned to the "START" position, the engine cannot be started. The electronic instrument panel displays a message for the operator to correct the situation by placing the appropriate lever or pedal in the neutral position.
  • Page 516 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM  HST Model The safety switch for engine starting is adapted for HST pedal, PTO shift lever and clutch pedal in this model. When the HST pedal is not set at a Neutral position Release the HST pedal to set the Neutral position.
  • Page 517 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM When the HST pedal is not set at a Neutral position and the clutch pedal is not depressed Release the HST pedal to set Neutral position and depress the clutch pedal. 9Y1211167ELM0053US0 When the PTO shift lever is not set a Neutral position and the clutch pedal is not depressed...

  • Page 518: Service Interval Alert

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Service Interval Alert The electronic instrument panel display will alert the operator when the scheduled service is required. IMPORTANT • This display, SERVICE INSPECT, informs the operator that periodic maintenance service is due.
  • Page 519 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Overheating Warning The electronic instrument panel perceive the rise of coolant temperature, and has the function to display the overheat warning on the LCD. When the coolant temperature becomes 125 °C (257 °F) or more, "OVERHEAT"...

  • Page 520: Lamp Control

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (5) Lamp Control In this electronic instrument panel, the control of various monitor lamps shown in figure are equipped in addition to warning lamps. (1) Rear PTO Lamp If the PTO switch is "ON" position, PTO switch is turned on, and monitor lamp will come on.

  • Page 521: Assistant Control System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [4] ASSISTANT CONTROL SYSTEM (1) Fail-safe Function If a sensor or solenoid valve of the system gets in trouble during operation, an error message appears in the LCD screen of the electronic instrument panel. The entire system adjusts itself on the safer side and keeps itself from getting into another trouble.
  • Page 522 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (Error Messages)  For All Models • ERROR-00: Electronic meter in trouble  For GST and HST Models • ERROR-20: Communication from ECU in trouble • ERROR-30: ECU in trouble • ERROR-40: Power supply of sensor from ECU in trouble •...

  • Page 523: Testing, Setting And Adjusting Function

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Testing, Setting and adjusting Function It can do various settings, adjustments and testing by using the electronic instrument panel. When the main switch is turned to "ON" or "START" position while pushing both the display mode switch (2) and the travel speed switch (3), the mode selection display as shown in figure is indicated.

  • Page 524: Glow Control

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (4) Glow Control The electronic meter incorporates the glow control which was external single parts so for, and controls it with CPU. When the main switch is turned "ON", the temperature of the coolant is detected with the coolant temperature sensor, and the time to supply current to the glow plug and the glow indicator lamp is controlled by CPU according to the detected temperature.

  • Page 525: Engine Starting System And Stopping System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 3. ENGINE STARTING SYSTEM AND STOPPING SYSTEM [1] MANUAL TRANSMISSION MODEL (1) Main Switch (4) PTO Switch (7) Meter panel (10) Engine Stop Solenoid (2) Shuttle Switch (5) Seat Switch (8) Starter (11) Battery (3) Parking Brake Switch (6) OPC Controller...

  • Page 526: Gst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [2] GST MODEL (1) Main Switch (4) Seat Switch (7) Meter panel (10) Engine Stop Solenoid Relay (2) Shuttle Switch (5) Parking Brake Switch (8) Starter Relay (11) Engine Stop Solenoid (3) PTO Switch (6) ECU (9) Starter...

  • Page 527: Hst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [3] HST MODEL (1) Main Switch (5) Clutch Pedal Switch (9) Starter Relay (12) Engine Stop Solenoid (2) Seat Switch (6) Mid-PTO Switch (Option) (10) Starter (13) Battery (3) Parking Brake Switch (7) ECU (11) Engine Stop Solenoid Relay (14) HST Pedal Sensor...

  • Page 528: Related Switches

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (1) Related Switches Seat Switch and Seat Tilt Switch These switches are located under the seat. When sitting on the seat, the seat switch (1) is pushed in and electrical circuit is closed. When the seat is vacant, this switch is not pushed and electric circuit is opened.
  • Page 529 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Pedal Sensor: for HST Model The HST pedal sensor is located on the right of the HST pedal. When the HST pedal is operated, signals are sent to the ECU. (1) HST Pedal Sensor 9Y1211167ELM0073US0 ECU (Electrical Control Unit) for GST and HST Model...

  • Page 530: Engine Starting Conditions

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Engine Starting Conditions When the following conditions become complete, electric voltage reaches starter AC terminal through OPC controller or ECU from main switch ST terminal, and the engine can be started. (1) Shuttle Shift Lever [A] Manual Transmission and (2) PTO Clutch Switch...

  • Page 531: Automatic Engine Stop

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Automatic Engine Stop Engine can be shut off under the following conditions since these conditions cause ECU or OPC controller to operate and it controls engine stop solenoid. (1) Shuttle Shift Lever [A] Manual Transmission and (2) PTO Clutch Switch GST Model...
  • Page 532 SERVICING CONTENTS 1. TROUBLESHOOTING.........................9-S1 2. SERVICING SPECIFICATIONS ....................9-S14 3. TIGHTENING TORQUES......................9-S15 4. CHECKING AND ADJUSTING....................9-S16 [1] BATTERY ..........................9-S16 (1) Checking........................9-S16 [2] ECU AND ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL)........9-S18 (1) ECU ..........................9-S18 (2) Electronic Instrument Panel...................9-S19 [3] TESTING, SETTING AND ADJUSTING BY ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL) .........................9-S20 (1) Mode Selection......................9-S20 (2) Mode "A"...
  • Page 533 (4) Glow Control System .....................9-S58 (5) Engine Stop Solenoid ....................9-S60 (6) OPC Controller (Manual Transmission Model) ..............9-S61 [7] CHARGING SYSTEM......................9-S62 [8] LIGHTING SYSTEM ......................9-S63 (1) Multi Function Combination Lever (Combination Switch) ..........9-S63 (2) Hazard Switch........................9-S64 (3) Flasher Unit ........................9-S64 (4) Beacon Switch .......................9-S65 (5) Lamp Relay........................9-S65 (6) Brake Lamp Switch......................9-S66 (7) Head Light ........................9-S67...

  • Page 534: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical 1. Battery discharged or damaged Recharge or replace 9-S16 Equipment Do Not 2. Battery negative cable disconnected or Repair or replace 9-S16 Operate improperly connected...
  • Page 535 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page Starter Motor Does 1. Battery discharged or damaged Recharge or replace 9-S16 Not Operate 2. Slow blow fuse blown Replace 9-S35 3. Safety switch improperly adjusted or damaged Repair or replace 9-M28 4.
  • Page 536 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not 1. Fuse blown Replace 9-S35 Light 2. Wiring harness disconnected or improperly Repair or replace – connected (between main switch terminal and multi-function combination lever B1 terminal, between combination switch 1 terminal and head light, between multi-function...
  • Page 537 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL) Reference Symptom Probable Cause Solution Page Nothing is Displayed 1. Battery discharged or damaged (Battery Recharge or replace 9-S16 in LCD voltage is below 7 V) 2. Slow blow fuse blown Replace 9-S35 3.
  • Page 538 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Error Display for GST Model Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Electronic • Electronic instrument Replace the electronic 9-S39 instrument panel panel memory device instrument panel memory device failure has failed...
  • Page 539 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Proportional • Output voltage of Check the connector of – reducing valve proportional reducing proportional reducing failure valve terminal or return valve current is out of Check the proportional...
  • Page 540 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Solenoid 1 • Solenoid output Able to travel at speeds – failure terminal's voltage is out other than 1, 7 and 8 (At forward or of specification (Forward) or 1 and 5...
  • Page 541 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Solenoid 4 • Solenoid output Able to travel at speeds – failure terminal's voltage is out other than 5, 6 and 12 (At forward or of specification (Forward) or 4 and 8...
  • Page 542 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Engine stop • Engine stop solenoid Engine is stopped – solenoid starter relay output terminals Engine does not start – relay voltage is out of Check the engine stop...
  • Page 543 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Error Display for HST Model Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Electronic • Electronic instrument Replace the electronic 9-S39 instrument panel panel memory device instrument panel memory device failure has failed...
  • Page 544 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page HST pedal • Sensor output terminal The running that uses – sensor failed is out of adjustment the pedal is impossible, •...
  • Page 545 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page Throttle sensor • Sensor output terminal Travel motion is – failed is out of adjustment possible. • Sensor output wire The HST electronic terminal broken or control function is in...
  • Page 546 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Display on LCD Reference Trouble Item Probable Cause Solution Screen Page • Output voltage of Travel motion is – proportional proportional valve possible on the valve, forward terminal or return backward side only failed current is out of Check the connector of...

  • Page 547: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit GST Proportional Reducing Valve Resistance Approx. 8 to 9 Ω – Shift Solenoid Valve Resistance Approx. 11 to 15 Ω – Glow Plug Resistance Approx.
  • Page 548 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m...

  • Page 549: Checking And Adjusting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 4. CHECKING AND ADJUSTING CAUTION • To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. •...
  • Page 550 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Recharging CAUTION • 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.

  • Page 551: Ecu And Electronic Instrument Panel (Intellipanel)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [2] ECU AND ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL) (1) ECU ECU Connector 1. Remove the seat switch connector. 2. Remover the seat (1). 3. Remove the seat bracket (2). 4. Disconnect the ECU connector (3). NOTE •...

  • Page 552: Electronic Instrument Panel

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Electronic Instrument Panel Disconnecting Electronic Instrument Panel Connector 1. Remove the panel cover (1). 2. Disconnect the panel connectors (4), (5). 3. Remove the electronic instrument panel (3) from panel frame (2).

  • Page 553: Mode Selection

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [3] TESTING, SETTING AND ADJUSTING BY ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL) The following settings, adjustments and testing can be done by using the electronic instrument panel. • Testing: Check a voltage of various sensor or rotation of engine. •...
  • Page 554 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (Continued) Manual Transmission Model Mode Details of Mode Necessary Situation • When the checking of sensor voltage or engine Test Mode revolution is required. • When the Intellipanel is replaced or changed. Traveling Speed Coefficient Input Mode •...

  • Page 555: Mode "A" (Test Mode)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Mode "A" (Test Mode) 1. While holding down the both switches at once, turn the main switch to "ON" or "START" position. 2. Select the mode "A". 3. "T1" is displayed (b). 4.
  • Page 556 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Availability* Symbol Contents Condition Value (unit) Engine revolution Idling to Max. 700 to Max. (n/min.)    Coolant temperature sensor −20 → 60 → 100 °C 4.76 to 4.81 → 2.80 to 3.00 → ...

  • Page 557: Mode "B" (Traveling Speed Coefficient Input Mode) Input The 4 Digit Tire Code For Correct Travel Speed To The Electronic Instrument Panel Memory Panel

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Mode "B" (Traveling Speed Coefficient Input Mode) Input the 4 Digit Tire Code for Correct Travel Speed to the Electronic Instrument Panel Memory Panel NOTE • When the tire size is changed or electronic instrument panel is replaced, this operation is required.

  • Page 558: Mode "C" (Pto Coefficient Number Input Mode) Input The Numeric Code Number For Pto Speed Into The Electronic Instrument Panel

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (4) Mode "C" (PTO Coefficient Number Input Mode) Input the Numeric Code Number for PTO Speed into the Electronic Instrument Panel NOTE • When the electronic instrument panel is replaced, this operation is required.

  • Page 559: Mode "E" (Gst Lever Sensor Fine-Adjustment Mode) Setting The Gst Lever's Neutral Position With Its Sensor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (6) Mode "E" (GST Lever Sensor Fine-adjustment Mode) Setting the GST Lever's Neutral Position with its Sensor IMPORTANT • As for this fine-adjustment, be sure to set it correctly because the set state becomes the standard of the control thereafter.

  • Page 560: Mode "F" (Gst Valve Fine-Adjustment Mode) Setting The Function Of Proportional Reducing Valve

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (7) Mode "F" (GST Valve FIne-adjustment Mode) Setting the Function of Proportional Reducing Valve NOTE • When the ECU or GST valve is replaced, this adjustment is required. 1. While holding down the both switches at once, start the engine. 2.

  • Page 561: Mode "G" (Gst Shift Shock Fine-Adjustment Mode) Adjusting The Clutch Engaging Interval

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (8) Mode "G" (GST Shift Shock Fine-adjustment Mode) Adjusting the Clutch Engaging Interval NOTE • When the sense of shifting shock is not suitable, shifting shock can be changed by this adjustment. 1.

  • Page 562: Mode "I" (Transmission Model Input Mode) Input The Transmission Model Into Electronic Instrument Panel

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (10) Mode "I" (Transmission Model Input Mode) Input the Transmission Model into Electronic Instrument Panel NOTE • When the electronic instrument panel is replaced, this operation is required. • On the HST models, the range gear shift lever sensor must be adjusted at the same time.

  • Page 563: Mode "K

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (12) Mode "K" (HST Pedal, Range Shift Lever, Cruise Control Lever, HST Response Dial, Fine-adjustment Mode) NOTE • When any of ECU, HST pedal sensor, cruise control lever position sensor, swashplate position sensor, range gear shift sensor, HST response dial or proportional valve (Forward, Reverse) is replaced, this adjustment is required.
  • Page 564 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (Continued) 6. "STEP-01" is displayed (d): Follow the procedures as follows. • Cruise control lever: Set the "Maximum forward position". • HST response dial: Set the "Maximum fast position". • HST pedal: Keep the "Maximum forward position". 7.

  • Page 565: Mode "L" (Throttle Sensor Fine-Adjustment Mode)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (13) Mode "L" (Throttle Sensor Fine-adjustment Mode) NOTE • When the ECU or throttle sensor is replaced, this adjustment is required. • Tractor Condition Parking brake: Set the Apply the Parking Brake Cruise Control Lever: Set the Neutral Position HST Pedal: Set the Neutral Position Range Gear Shift Lever: Set the Neutral Position...

  • Page 566: Mode "M" (Mode For Factory)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (14) Mode "M" (Mode for Factory) NOTE • This mode is used in factory only. 9Y1211167ELS0029US0 9-S33 KiSC issued 02, 2015 A...

  • Page 567: Mode "N" (Tractor Model Select Mode)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (15) Mode "N" (Tractor Model Select Mode) NOTE • When the ECU is replaced, this adjustment is required. 1. While holding down the both switches at once, turn on main switch. 2.

  • Page 568: Electric Control System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [4] ELECTRIC CONTROL SYSTEM CAUTION • For checking of electric circuit, use the circuit tester and test function of electronic instrument panel (Refer to "[2] TESTING, SETTING AND ADJUSTING BY ELECTRONIC INSTRUMENT PANEL (INTELLIPANEL) of "4.
  • Page 569 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Checking Ground Cable 1. Check the whether the ground cable (1) is connected securely to the tractor chassis. 2. If the ground cable is broken or disconnected, replace it. (1) Ground Cable (A) Located at Left Side of Front Axle Frame (B) Located at Left Side of...

  • Page 570: Checking By Electronic Instrument Panel Connector

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Checking by Electronic Instrument Panel Connector (A) Connector A (20P Connector) of Wire Harness Side Color of wiring Terminal Name – Green / White Mid PTO (HST) Black / Yellow Shuttle switch (Manual transmission, GST) Orange / Black Clutch pedal switch (HST)
  • Page 571 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (B) Connector B (16P Connector) of Wire Harness Side Color of wiring Terminal Name Yellow / Blue Fuel unit White Coolant temperature – Brown Communication line – Brown / White Communication line + Black / Yellow GND (for sensor) Black...
  • Page 572 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Disconnecting Electronic Instrument Panel Connector 1. Remove the panel cover (1). 2. Disconnect the panel connectors (4), (5). 3. Remove the electronic instrument panel (3) from panel frame (2). (1) Panel Cover (4) Connector A (20P) (2) Panel Frame (5) Connector B (16P)

  • Page 573: Checking Sensor And Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Checking Sensor and Switch Display Mode Switch and Travel Speed Switch 1. Check the resistance between terminal a (3) and c (5) while pushing the display made switch (1). 2. It is OK if 0 ohm is indicated. 3.
  • Page 574 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Engine Tachometer Sensor 1. Check the voltage of the sensor in mode "A". 2. Measure the voltage and resistance of the wire harness connector. 3. If measured values are normal, the switch is damaged. Terminal 1 of the Main switch at Voltage...

  • Page 575: Ecu Control System (Gst Model And Hst Model)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [5] ECU CONTROL SYSTEM (GST MODEL AND HST MODEL) (1) Checking Connector Checking ECU Connector 1. Disconnect the connector (1), and check their terminals for contamination and deformation. 2. Check to see that cable does not broken or terminals are not shelled off.

  • Page 576: Checking By Electric Control Unit (Ecu)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Checking by Electric Control Unit (ECU) GST Model Color of wiring Terminal Name Color of wiring Terminal Name +12 V (power source from main Brown / Black Output terminal for 1st shift solenoid Red / Yellow switch) Brown / White...
  • Page 577 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Model Color of wiring Terminal Name Color of wiring Terminal Name +12 V Red / Black Output terminal for Hi-Lo solenoid Red / Yellow (power source from main switch) Pink / Blue PTO solenoid Output terminal for proportional Blue / Red...
  • Page 578 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Connector Voltage (Main Circuit) 1. Turn on the main switch. (Do not start engine.) 2. Measure the voltage between terminal 23 (+) and terminal 29 (–). 3. Measure the voltage between terminal 6 (+) and terminal 29 (–). (Sensor Voltage) 1.

  • Page 579: Checking Sensor And Switch For Gst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Checking Sensor and Switch for GST Model GST Lever Sensor Resistance 1. Measure the resistance between terminal a (1) and c (3). 2. Then, check resistance between terminal a (1) and b (2) while slowly turning the sensor shaft.

  • Page 580: Checking Sensor And Switch For Hst Model

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Proportional Reducing Valve Resistance 1. Measure the resistance between the valve terminals. 2. It is OK if the resistance comes to have shown in the table below. NOTE • When replacing the proportional reducing valve be sure to adjust the mode "F".
  • Page 581 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Range Gear Shift Lever Sensor Resistance 1. Measure the resistance between terminal a (2) and b (3) while shifting the range gear shift lever. 2. It is OK if the resistance is smoothly changing. NOTE •...
  • Page 582 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Pedal Sensor, Cruise Lever Sensor and Swashplate Position Sensor 1. Measure the resistance between terminal B (7) and GND (8). 2. Measure the resistance between terminal GND (8) and a while slowly turning the sensor shaft.
  • Page 583 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Cruise Control Release Switch 1. Disconnect the cruise control release switch connector (2). 2. Measure the resistance between connector terminal as shown in the table below. 3. If the switch is damaged, replace it. NOTE •...
  • Page 584 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Response Control Dial and HST Mode Select Switch  HST Response Control Dial 1. Measure the resistance between terminal 1 and 3, referring to the table below. 2. Turning the HST response control dial (2) and the measure the resistance between terminal 1 and 2, referring to the table below.
  • Page 585 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM HST Proportional Valve (Forward and Reverse) 1. Remove the cover. 2. Disconnect the 2P connector of the proportional valve (1), (2). IMPORTANT • In installing the connector of the proportional valve, pay attention to the color of the connector to ensure correct installation.

  • Page 586: Starting System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [6] STARTING SYSTEM (1) Main Switch Remove the Main Switch 1. Remove the panel cover. 2. Disconnect the main switch connector (2). 3. Perform the following checking. (1) Main Switch (2) Main Switch Connector 9Y1211167ELS0059US0 Connector Voltage 1.

  • Page 587: Safety Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Safety Switch PTO Switch 1) Connector Voltage 1. Remove the PTO switch connector. 2. Turn the main switch "ON" position. 3. Measure the voltage across terminal 2 (Harness) and chassis. 4.
  • Page 588 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Seat Switch 1. Disconnect the seat switch connector (2). 2. Check the continuity with an ohmmeter across the switch terminals. 3. If it does not conduct or any value is indicated when the switch is pushed ("ON"...

  • Page 589: Starter And Starter Relay

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (3) Starter and Starter Relay Starter Motor B Terminal Voltage 1. Measure the voltage across the B terminal and chassis. 2. If the voltage differs from the battery voltage, check the battery's cable.
  • Page 590 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Checking Starter Relay (HST and GST Model) 1. Remove the panel cover and meter panel. 2. Remove the starter relay (1). 3. Apply battery voltage across terminals 3 and 4, and check for continuity across terminals 1 and 2.

  • Page 591: Glow Control System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (4) Glow Control System Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off. 2. Turn the main switch key to the "ON" position, and measure the voltage between the lead terminal and the chassis.
  • Page 592 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Glow Relay 1) Connector Voltage 1. Turn the main switch off. 2. Disconnect the glow relay (1). 3. Measure the voltage across the terminal 1 (Positive) and chassis (Negative). 4. If the voltage differs from the battery voltage, the wiring harness is faulty.

  • Page 593: Engine Stop Solenoid

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (5) Engine Stop Solenoid Connector Voltage 1. Disconnect the 2P connector from engine stop solenoid. 2. Turn the main switch key to the "ON" position. 3. Measure the voltage between the terminal 1, terminal 2 and body.

  • Page 594: Opc Controller (Manual Transmission Model)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (6) OPC Controller (Manual Transmission Model) OPC Controller 1. Check the "Engine Starting Conditions" and "Automatic Engine Stop Conditions". (Refer to "3. ENGINE STARTING SYSTEM AND STOPPING SYSTEM" of "MECHANISM" in this section.) 2.

  • Page 595: Charging System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [7] CHARGING SYSTEM Alternator 1. Disconnect the 2P connector (3) from alternator after turning the main switch "OFF". 2. Perform the following checkings. (1) B Terminal (3) 2P Connector (2) Alternator 9Y1211167ELS0076US0 Connector Voltage 1.

  • Page 596: Lighting System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [8] LIGHTING SYSTEM (1) Multi Function Combination Lever (Combination Switch) Multi Function Combination Lever Switch 1. Remove the steering post cover 1. 2. Disconnect the multi function combination lever switch connector (2). 3.

  • Page 597: Hazard Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (2) Hazard Switch Hazard Switch 1. Remove the meter panel and disconnect the 4P connector from hazard switch (1) after disconnect the battery negative code. 2. Remove the hazard switch (1). 3.

  • Page 598: Beacon Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (4) Beacon Switch Beacon Switch 1. Disconnect the connector for beacon switch (1). 2. Check the resistance across the terminals. 3. If the measured value is different from the table below, the switch is damaged.

  • Page 599: Brake Lamp Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (6) Brake Lamp Switch Brake Lamp Switch 1. Disconnect the connector for brake lamp switch (1). 2. Check the resistance across the terminals. 3. If the measured value is different from the table below, the switch is damaged.

  • Page 600: Head Light

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM (7) Head Light Adjustment of Optical Axis 1. To adjust the optical axis of head light (1), refer the table below. 1) Adjustment of Vertical direction For Right For Left Clockwise Downward Counterclockwise Upward...

  • Page 601: Monitor Lamp

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Charging Circuit (Panel Board and Wiring Harness) 1. Disconnect the 2P connector (2) from the alternator after turning the main switch "OFF". 2. Turn the main switch "ON" and connect a jumper lead from the wiring harness connector terminal (WR) to the chassis.

  • Page 602: Gauges

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [11] GAUGES (1) Fuel Level Sensor Fuel Level Sensor 1) Sensor Continuity 1. Remove the fuel level sensor from the fuel tank. 2. Measure the resistance across the sensor terminal and its body. 3.

  • Page 603: Others

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [12] OTHERS (1) PTO Speed Change Switch (Manual Transmission Model) PTO Speed Change Switch 1. Measure the resistance across the sensor terminals. 2. If the reference value is not indicated, the sensor is damaged. When the switch is Resistance Infinity...

  • Page 604: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 5. DISASSEMBLING AND ASSEMBLING [1] STARTER Disassembling Motor 1. Disconnect the connecting lead (9) from the magnet switch (8). 2. Remove the screws (6), and then separate the end frame (4), yoke (2) and armature (1).
  • Page 605 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Rear End Cover 1. Remove the three rear end cover screws and the B terminal nut, and remove the rear end cover. WSM000001ELS0024US0 Brush Holder 1. Remove the two screws holding the brush holder, and remove the brush holder (1).
  • Page 606 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Rotor 1. Press out the rotor (1) from drive end frame (3). IMPORTANT • Be very careful not to drop the rotor and damage the slip ring or fan, etc.. (1) Rotor (3) Drive End Frame (2) Block WSM000001ELS0029US0...

  • Page 607: Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM 6. SERVICING [1] STARTER Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any problem, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
  • Page 608 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. Brush holder – Resistance Infinity Holder support WSM000001ELS0036US0 Armature Coil 1.

  • Page 609: Alternator

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM [2] ALTERNATOR Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. WSM000001ELS0039US0 Stator 1. Measure the resistance across each lead of the stator coil with an ohmmeter.
  • Page 610 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM ELECTRICAL SYSTEM Rectifier 1. Check the continuity across each diode of rectifier with an analog ohmmeter. Conduct the test in the (R x 1) setting. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
  • Page 611 CABIN KiSC issued 02, 2015 A...
  • Page 612 MECHANISM CONTENTS 1. AIR CONDITIONER SYSTEM....................10-M1 [1] OUTLINE OF AIR CONDITIONING SYSTEM..............10-M1 [2] SYSTEM CONTROL ......................10-M3 [3] ELECTRICAL SYSTEM...................... 10-M4 (1) Electrical Circuit......................10-M4 (2) Air Conditioner Relay, Blower Relays and Compressor Relay........10-M5 KiSC issued 02, 2015 A...

  • Page 613: Air Conditioner System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 1. AIR CONDITIONER SYSTEM [1] OUTLINE OF AIR CONDITIONING SYSTEM (1) Heater Hose (Out Side) (5) Outside Air Filter (9) Front Air Outlet (13) Condenser (2) Heater Hose (In Side) (6) Inner Roof (10) High Pressure Pipe (14) Pressure Switch (3) Water Valve...
  • Page 614 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN The machine is equipped with a thin large-capacity air conditioner with outside air intake. Through the inside air filter (7) as well as the outside air filter (5), the inner roof (6) and reaches the air conditioner unit (13). The air is then cooled and dehumidified by this unit.

  • Page 615: System Control

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN [2] SYSTEM CONTROL (1) Temperature Control Dial (7) Recirculated Air (12) Air Outlet Door D3 (A) Control Plate (2) Mode Switch (8) Blower (Mode Door) (B) Air Selection Lever (3) Blow Switch (9) Evaporator (13) DEFOGGER (C) Block Diagram of Air Flow...

  • Page 616: Electrical System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN [3] ELECTRICAL SYSTEM (1) Electrical Circuit (1) Battery (5) Blower Motor (9) Compressor (12) Mode Motor (2) Slow Blow Fuse (6) Blower Resistor (10) Pressure Switch (13) Temperature Motor (3) Main Switch (7) Blower Switch (11) Thermostat (14) Control Panel...

  • Page 617: Air Conditioner Relay, Blower Relays And Compressor Relay

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (2) Air Conditioner Relay, Blower Relays and Compressor Relay Remove the outer roof and the relays are visible at the ceiling rear of the cabin: blower relay (1) and compressor relay (2). When the blower fan is adjusted for the air flow rate, the blower relay (1) is activated by a signal from the fan switch on the control panel.
  • Page 618 SERVICING CONTENTS 1. TROUBLESHOOTING.......................10-S1 2. SERVICING SPECIFICATIONS ....................10-S5 3. TIGHTENING TORQUES......................10-S6 4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE............10-S7 [1] HANDLING OF SERVICE TOOLS ..................10-S9 (1) Manifold Gauge Set.......................10-S9 (2) Refrigerant Charging Hose..................10-S10 (3) Vacuum Pump Adaptor ....................10-S11 (4) Electric Gas Leak Tester .....................10-S11 (5) Can Tap Valve......................10-S11 (6) T-joint...........................10-S12 (7) R134a Refrigerant Recovery and Recycling Machine..........10-S12...

  • Page 619: Troubleshooting

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 1. TROUBLESHOOTING COMPRESSOR Probable Cause and Reference Symptom Solution Checking Procedure Page Noisy 1. Belt slipping Adjust or replace G-35 (Compressor ON) 2. Compressor bracket Tighten – mounting screws loosen 3. Bearing of compressor Replace 10-S41 worn or damaged...
  • Page 620 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Probable Cause and Reference Symptom Solution Checking Procedure Page Insufficient Cooling 1. Too much refrigerant Check with manifold gauge 10-S21 (No Bubbles in Sight Glass) Insufficient Cooling 1. Belt slipping Adjust or replace G-35 (Compressor Does 2.
  • Page 621 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Probable Cause and Reference Symptom Solution Checking Procedure Page Insufficient Cooling 1. Refrigerant overcharged Check with manifold gauge 10-S21 (Hi-pressure Level is 2. Air mixed Check with manifold gauge 10-S21 Too High) 3.
  • Page 622 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Probable Cause and Reference Symptom Solution Checking Procedure Page Temperature Cannot 1. Heater hose caught Repair 10-S49 be Controlled 2. Heater hose twisted or Repair or replace 10-S49 (Heater Hoses Laid is bent Bad) WINDSHIELD WIPER...

  • Page 623: Servicing Specifications

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Refrigerating Cycle Pressure 0.15 to 0.20 MPa – (Refrigerating Cycle is Normal Operating) (LO Pressure Side) 1.5 to 2.0 kgf/cm 21 to 28 psi Pressure 1.27 to 1.66 MPa –...
  • Page 624 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-13.) Item N·m kgf·m...

  • Page 625: Precautions At Repairing Refrigerant Cycle

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE When checking or repairing the air conditioning system, the following precautions and rules must be observed. And it is of first importance that no other personnel than a well-trained serviceman should be allow to handle the refrigerant.
  • Page 626 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (Refrigerant) Factory R134a specifica- L3540-II 770 to 870 g tion 1.70 to 1.91 lbs Kinds of refrigerant L4240-II, (Charge amount) Factory R134a L5040-II, specifica- 800 to 900 g L5240-II, tion 1.77 to 1.98 lbs L5740-II (Compressor Oil) Quantity (Total)
  • Page 627 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN [1] HANDLING OF SERVICE TOOLS (1) Manifold Gauge Set The hand valves on the manifold gauge set are used to open and close the valve. The hand valve inscribed LO is for the low pressure side valve (5) and HI is for the high pressure side valve (3).

  • Page 628: Refrigerant Charging Hose

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (2) Refrigerant Charging Hose The charging hoses are classified into three colors. Each charging hose must be handled as follows: • The air conditioner manufacture recommends that the blue hose (6) is used for the LO pressure side (suction side), the green hose (5) for refrigeration side (center connecting port) and the red hose (3) for HI pressure side (discharged side).

  • Page 629: Vacuum Pump Adaptor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (3) Vacuum Pump Adaptor Objective of the Vacuum Pump Adaptor 1. After vacuum has been created in the air conditioning cycle, when the vacuum pump is stopped, since there is vacuum in hoses within the gauge manifold, the vacuum pump oil flows back into the charging hose.

  • Page 630: T-Joint

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (6) T-joint T-joint (2) is used to increase efficiency of gas charging using two refrigerant containers (4) at a time. 1. Install two refrigerant container service valves to T-joint (2) sides and connect the charging hose (1) to it. (1) Charging Hose (Green) (3) Can Tap Valve (2) T-joint...

  • Page 631: Checking And Charging Refrigerant Cycle

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 5. CHECKING AND CHARGING REFRIGERANT CYCLE [1] CHECKING WITH MANIFOLD GAUGE IMPORTANT • The gauge indications described in the following testing are those taken under the same condition, so it should be noted that the gauge readings will differs somewhat with the ambient conditions. Condition •...
  • Page 632 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Insufficient Refrigerant 1. Symptoms seen in refrigerating cycle • Both LO and HI pressure side (1), (2) pressures too low. LO pressure side (1) 0.05 to 0.10 MPa (0.5 to 1.0 kgf/cm , 7.1 to 14.2 psi) HI pressure side (2) 0.69 to 0.98 MPa (7 to 10 kgf/cm...
  • Page 633 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Air Entered in the Cycle 1. Symptoms seen in refrigerating cycle • Both LO and HI pressure side (1), (2) pressures too high. LO pressure side (1) 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm , 28.4 to 49.8 psi) HI pressure side (2) 1.96 to 2.45 MPa (20 to 25 kgf/cm...
  • Page 634 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Refrigerant Fails to Circulate 1. Symptoms seen in refrigerating cycle • LO pressure side (1) pressure is vacuum and, HI pressure side (2) is low pressure. LO pressure side (1) Vacuum HI pressure side (2) 0.49 to 0.59 MPa (5 to 6 kgf/cm , 71.2 to 85.3 psi) 2.

  • Page 635: Discharging, Evacuating And Charging

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Faulty Compression of Compressor 1. Symptoms seen in refrigerating cycle • LO pressure side (1) 0.39 to 0.59 MPa (4 to 6 kgf/cm , 56.9 to 85.3 psi) • HI pressure side (2) 0.69 to 0.98 MPa (7 to 10 kgf/cm , 99.6 to 142.2 psi) 2.

  • Page 636: Evacuating The System

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (2) Evacuating the System Evacuating the System 1. Discharge refrigerant from the system by R134a refrigerant recovery and recycling machine. (Refer to "(1) Discharging the Refrigerant" in this section.) 2. Connect the charging hose (red) (2) to the HI pressure side charging valve and connect the charging hose (blue) (1) to the LO pressure side charging valve.

  • Page 637: Charging The Refrigerant

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (3) Charging the Refrigerant Charging an Empty System (Liquid) This procedure is for charging an empty system through the HI pressure side with the refrigerant in the liquid state. CAUTION • Never run the engine when charging the system through the HI pressure side.
  • Page 638 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Charging an Empty or Partially Charged System (Vapor) This procedure is to charge the system through the LO pressure side with refrigerant in the vapor state. When the refrigerant container is set right side up, refrigerant will enter the system as a vapor.

  • Page 639: Checking Charge Refrigerant Amount

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (4) Checking Charge Refrigerant Amount After charging the refrigerant, check for amount of charging refrigerant as follows. NOTE • The pressure on the following checking are the gauge indications at ambient temperature 30 °C (86 °F), so it should be noted that the pressure will differ some what with the ambient temperature.

  • Page 640: Checking, Disassembling And Servicing

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN 6. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Compressor Operation of Magnetic Clutch 1. Turn off the A/C switch after starting the engine. 2. Check whether abrasion or abnormal noise is heard when only the magnetic clutch pulley is running.

  • Page 641: Control Panel (Blower Switch, A/C Switch, Mode Control Dial And Temperature Control Dial)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (2) Control Panel (Blower Switch, A/C Switch, Mode Control Dial and Temperature Control Dial) Blower Switch Connector Voltage 1. Disconnect the 6P connector (2) from blower switch. 2. Turn the main switch to "ON" position. 3.
  • Page 642 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Connector Voltage 1. Disconnect the 16P connector (2) from control panel switch. 2. Turn the main switch to "ON" position. 3. Measure the voltage with a voltmeter across the terminal o and terminal a.

  • Page 643: Blower Resistor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Temperature Control Dial Checking 1. Turn the temperature control dial counterclockwise till it stops (at "COOL" position). 2. Measure the voltage with a voltmeter across the terminal b and terminal d. Make the following measurement with the terminals connected.

  • Page 644: Blower Motor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (4) Blower Motor Blower Motor Test 1. Turn the blower motor (1) by hand and check whether it turns smoothly. 2. Disconnect the 2P connector (2) of blower motor (1). 3. Connect a jumper lead from battery (3) positive terminal to connector terminal b.

  • Page 645: Mode Motor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (6) Mode Motor Mode Motor Checking 1. Check whether the mode switch (2) is damaged. (Refer to "(4) Control Panel" in this section.) 2. Turn the main switch to "ON" position. 3. Turn the blower switch at 1 position. 4.

  • Page 646: Pressure Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (8) Pressure Switch Pressure Switch 1) HI Pressure Side 1. Connect the manifold gauge (5) to compressor as following procedure. Close the HI and LO pressure valves (3), (4) of manifold gauge tightly, and connect the charging hoses (2), (1) (red and blue) to the respective compressor service valves.

  • Page 647: Wiper Switch

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (9) Wiper Switch Front Wiper Switch 1. Remove the front wiper switch (1) and disconnect the connector. 2. Perform the following checkings 1) and 2). (1) Front Wiper Switch 9Y1211167CAS0049US0 1) Connector Voltage 1.
  • Page 648 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (10) Front Wiper Motor Front Wiper Motor 1. Raise up the front wiper arm (2). 2. Turn the main switch to "ON" position. 3. Push the front wiper switch to "ON" position. 4.

  • Page 649: Defogger (If Equipped)

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (11) Defogger (if equipped) Defogger Switch 1. Remove the defogger switch (1) and disconnect the connector. 1) Connector Voltage 1. Turn the main switch "ON". 2. Measure the voltage with a voltmeter across the connector IL terminal (2) and chassis.

  • Page 650: Disassembling And Assembling

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN [2] DISASSEMBLING AND ASSEMBLING (1) Separating Cabin from Tractor NOTE • There is no need to release refrigerant from air conditioner system. 9Y1211167CAS0052US0 Draining Coolant WARNING • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
  • Page 651 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Battery, Front Grill, Skirt and Bonnet 1. Open the bonnet and disconnect the battery negative cable (5). 2. Disconnect the head light connector (6) and remove the front grill (4). 3. Remove the left and right side skirts (3). 4.
  • Page 652 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Clutch Rod, Brake Pedal Rod and Electric Wiring 1. Disconnect the brake pedal rod (6) and clutch rod (4). 2. Disconnect the wiring connectors for alternator (1), coolant temperature sensor (9), oil pressure switch (2), fuel unit (3), starter motor (7) and battery (10).
  • Page 653 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Seat, Seat Bracket and Lever Grips 1. Remove the seat switch connector. 2. Remove the seat (1). 3. Remove the seat bracket (2). 4. Remove the front wheel drive lever (3). (HST Model) 5.
  • Page 654 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Steps and Wiring Harness 1. Remove the step LH (2) and step RH (6). 2. Disconnect the ground cable (3). (HST Model) 3. Remove the solenoid cover (1). 4. Remove the solenoid connector (4). 5.
  • Page 655 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Cables and Wiring Harness 1. Disconnect the PTO connector (1). 2. Disconnect the PTO speed change switch connector (7) (Manual Transmission Model only). 3. Disconnect the speed sensor connector (2). 4. Remove the stay (5) and disconnect the position control cable (4).
  • Page 656 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Differential Lock Rod and Lowering Speed Adjusting Knob 1. Remove the lowering speed adjusting lever (2). 2. Remove the differential lock rod (1) and range gear shift rod (4). 3. Disconnect the range gear shift sensor connector (3). (1) Differential Lock Rod (3) Range Gear Shift Sensor Connector (2) Lowering Speed Adjusting Lever...
  • Page 657 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Mats, Panel Cover and Linkage 1. Remove the mats (1). 2. Remove the steering post covers 1 (3) and the steering post cover 2 (4). 3. Remove the panel cover (2). 4. Remove the brake rods (7) and clutch rod (5). 5.
  • Page 658 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Air Conditioner Parts and Cabin Assembly 1. Remove the radiator upper hose (1) and recovery tank hose (2). 2. Remove the intake hose (3). 3. Remove the battery (8). 4. Remove the radiator lower hose (11). 5.

  • Page 659: Removing Compressor Assembly

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (2) Removing Compressor Assembly Compressor Assembly 1. Discharge the refrigerant from the system. (Refer to "(1) Discharging the Refrigerant" in this section.) 2. Disconnect the low pressure pipe (suction) (1) and high pressure pipe (discharge) (5) from the compressor, then cap the open fitting immediately to keep moisture out of the system.
  • Page 660 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Hub Plate 1. Three stopper bolts (1) are set in stopper magnet clutch (2) at the position corresponding to the shape of compressor. (Refer to "8. SPECIAL TOOLS at "G. GENERAL" section.) 2.

  • Page 661: Removing Air Conditioner Unit

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Stator 1. Remove the lead wire from compressor body. 2. Remove the external circlip (1). 3. Remove the stator (2). (When reassembling) • Do not use the circlip again. • Assemble the circlip for the tapered side to become outside of front housing.
  • Page 662 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Outer Roof and Stay 1. Remove the outer roof (1). 2. Disconnect the ground cable (2). 3. Remove the stay (3). (1) Outer Roof (3) Stay (2) Ground Cable 9Y1211167CAS0059US0 Wiring Harness 1.
  • Page 663 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Water Cable, Temperature Motor and Mode Motor 1. Disconnect the water cable (1). 2. Remove the motor screws (2). (1) Water Cable 6 mm (0.2 in.) (2) Motor Screw 9Y1211167CAS0061US0 Air Conditioning Unit 1.

  • Page 664: Removing Air Conditioner Pipes

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (4) Removing Air Conditioner Pipes Discharging Refrigerant Gas Refer to "(1) Discharging the Refrigerant" in this section. 9Y1211167CAS0063US0 Battery, Front Grill, Skirt and Bonnet 1. Open the bonnet and disconnect the battery negative cable (5). 2.
  • Page 665 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Hose Clamp 1. Remove the hose clamp (4). 2. Disconnect the pressure switch (6) connector. 3. Disconnect the high pressure pipe 2 (5) from the receiver (1) and low pressure pipe (3) from the compressor, then cap the open fittings immediately to keep moisture out of the system.

  • Page 666: Removing Heater Hoses

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (5) Removing Heater Hoses Battery, Front Grill, Skirt and Bonnet Refer to "[2] DISASSEMBLING AND ASSEMBLING" in this section. 9Y1211167CAS0067US0 Draining Coolant Refer to "[2] DISASSEMBLING AND ASSEMBLING" in this section. 9Y1211167CAS0068US0 Battery, Front Grill, Skirt and Bonnet 1.
  • Page 667 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Heater Hoses 1. Remove the outer roof. NOTE • Before disconnecting the heater hoses (2), put the parting marks on the hoses for marking proper reconnecting. 2. Disconnect the heater hoses (2) from the hose pipes (1). 3.

  • Page 668: Cabin Windshields

    • Sika product are made by Sika Corporation. • Shin Etsu silicon KE420 is made by Shin Etsu Polymer Corporation. • These materials can't be provided by Kubota Corporation. • Therefore, please find the local made equivalent materials in your country and use them when you need.
  • Page 669 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Before Replacing Windshields (3) 1. Check that the glasses are not damaged and cracked. 2. Turn over the glass and clean this surface of the glass by Sika-Activator. 3. The cleaning area of the rear surface is indicated "A" in the figure left.
  • Page 670 L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN Front Windshield NOTE • Apply the Sika Tack-Ultrafast (or equivalent) with the jig having the specified tip shape as shown in the figure left. • Apply it with a uniform speed to minimize unevenness. •...

  • Page 671: Wiper Motor

    L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM CABIN (7) Wiper Motor Front Wiper Motor 1. Remove the steering post covers (2) and steering post under cover. 2. Remove the meter panel (1). 3. Disconnect the front wiper motor 4P connector. 4.
  • Page 672 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2015. 02, S, EI, EI, engusa Code No.9Y111-11670...

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Wsm l5040-iiWsm l5240-iiWsm l4240-iiWsm l5740-ii

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