Page 1 WORKSHOP MANUAL TRACTOR L4100 KiSC issued 08, 2012 A...
Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the L4100. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing". Information This section contains information below. • Safety First • Safety Label •...
Page 3 INFORMATION KiSC issued 08, 2012 A...
Page 4: Table Of Contents
INFORMATION CONTENTS SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-4 3. SPECIFICATIONS.......................... I-6 4. TRAVELING SPEEDS........................I-7 5. DIMENSIONS ..........................I-8 KiSC issued 08, 2012 A...
Page 5: Safety First
L4100, 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 L4100, 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 L4100, 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
L4100, WSM INFORMATION 2. SAFETY DECALS The following safety decals (pictorial safety labels) are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
Page 9 L4100, WSM INFORMATION 9Y1210278INI0002US0 (EU) KiSC issued 08, 2012 A...
Page 10: Specifications
L4100, WSM INFORMATION 3. SPECIFICATIONS L4100 Rear mount type ROPS Mid mount type ROPS Model Manual Transmission Model V2203-M-E2A Type Indirect injection, Vertical, Water-Cooled 4 cylinder diesel Number of cylinder Total displacement 2.197 L (1.341 cu.in.) Bore and stroke 87 x 92.4 mm (3.4 x 3.64 in.)
Page 11: Traveling Speeds
L4100, WSM INFORMATION 4. TRAVELING SPEEDS Manual Transmission Type (At rated engine rpm) Model L4100 Tire size (Rear) 13.6 - 26 Shuttle shift Range gear Main gear shift km/h (mph) lever shift lever lever 1.4 (0.87) 1.9 (1.2) 3.1 (1.9) 6.0 (3.7)
Page 12: Dimensions
L4100, WSM INFORMATION 5. DIMENSIONS Rear mount type ROPS 9Y1210278INI0005US0 (EU) KiSC issued 08, 2012 A...
Page 13 L4100, WSM INFORMATION Mid mount type ROPS 9Y1210278INI0006US0 (EU) KiSC issued 08, 2012 A...
Page 14 GENERAL KiSC issued 08, 2012 A...
Page 15 GENERAL CONTENTS 1. TRACTOR IDENTIFICATION....................... G-1 [1] MODEL NAME AND SERIAL NUMBERS ................G-1 [2] CYLINDER NUMBER ......................G-2 2. GENERAL PRECAUTIONS......................G-3 3. HANDING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ........G-4 [1] WIRING ..........................G-4 [2] BATTERY ..........................G-6 [3] FUSE ............................
Page 16: Tractor Identification
L4100, 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 (5) ROPS Identification Plate (2) Tractor Serial Number (ROPS Serial No.)
Page 17: Cylinder Number
L4100, WSM GENERAL [2] CYLINDER NUMBER You can see the cylinder numbers of KUBOTA diesel engine in the figure. The sequence of cylinder numbers is No.1, No.2, No.3 and No.4 and it starts from the gear case side. WSM000001GEG0058US0 (EU)
Page 18: General Precautions
L4100, WSM GENERAL 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools.
Page 19: Handing Precautions For Electrical Parts And Wiring
L4100, WSM GENERAL 3. HANDING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
Page 20 L4100, WSM GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US1 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 21: Battery
L4100, WSM GENERAL [2] BATTERY • Take care not to confuse positive and negative terminal posts. • When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. • Do not install any battery with capacity other than is specified (Ah).
Page 22: Handling Of Circuit Tester
L4100, WSM GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust WSM000001GEG0075US1 • Make certain that there is no female connector being too open.
Page 23: Color Of Wiring
L4100, 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...
Page 24: Lubricants, Fuel And Coolant
L4100, WSM GENERAL 4. LUBRICANTS, FUEL AND COOLANT Place Capacity Lubricants, fuel and coolant 42.0 L • No. 2-D diesel fuel Fuel 11.1 U.S.gals • No. 1-D diesel fuel if temperature 9.24 Imp.gals is below –10 °C (14 °F) 6.5 L Coolant 6.9 U.S.qts...
Page 25 L4100, WSM GENERAL NOTE Engine Oil • Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above: • With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-sulfur fuel on on-road vehicle engines.
Page 26: Tightening Torques
L4100, WSM GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt...
Page 27: Metric Screws, Bolts And Nuts
L4100, WSM GENERAL [3] METRIC SCREWS, BOLTS AND NUTS Grade Property class 8.8 Property class 10.9 Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft 24 to 27 2.4 to 2.8 18 to 20 30 to 34 3.0 to 3.5 22 to 25 48 to 55 4.9 to 5.7...
Page 28: Maintenance
L4100, 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-18 50 hr every 2 Wheel bolt torque...
Page 29 L4100, WSM GENERAL Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page Fuel injection nozzle injection every Check G-29 pressure 1500 hr every 24 Injection pump Check...
Page 30: Check And Maintenance
L4100, WSM GENERAL 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the machine on a flat place with engine shut off, the parking brake on and chock the wheels. 9Y1210278GEG0010US0 [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the machine. Check the following items before starting.
Page 31 L4100, WSM GENERAL Changing Engine Oil CAUTION • Before changing oil, be sure to stop the engine. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely.
Page 32 L4100, WSM GENERAL Replacing Hydraulic Oil Filter CAUTION • Be sure to stop the engine before changing the oil filter. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Remove the drain plugs at the bottom of the transmission case and drain the oil completely into the oil pan.
Page 33: Check Points Of Every 50 Hours
L4100, WSM GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System CAUTION To avoid personal injury: • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test do not operate the tractor.
Page 34 L4100, WSM GENERAL Checking Engine Start System and OPC System (OPC Model) CAUTION To avoid personal injury: • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test do not operate the tractor.
Page 35 L4100, WSM GENERAL Greasing 1. Apply a grease to the following position as figures. NOTE • 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.
Page 36: Check Points Of Every 100 Hours
L4100, WSM GENERAL [4] CHECK POINTS OF EVERY 100 HOURS Checking Battery Condition CAUTION • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion.
Page 37 L4100, WSM GENERAL Battery Charging 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 38 L4100, WSM GENERAL Adjusting Fan Belt Tension CAUTION • Be sure to stop the engine before checking fan belt tension. 1. Stop the engine and remove the key. 2. Apply moderate thumb pressure to belt between pulleys. 3. If tension is incorrect, loosen the alternator mounting bolts (2),...
Page 39 L4100, WSM GENERAL Cleaning Air Cleaner Element 1. Remove the air cleaner cover (3) and primary element (2). 2. Clean the primary element: • When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm...
Page 40 L4100, WSM GENERAL Cleaning Fuel Filter This job should not be done in the field, but in a clean place. 1. Close the fuel cock (1). 2. Unscrew the screw ring (6), remove the filter bowl (5), and rinse the inside with kerosene.
Page 41: Check Points Of Every 200 Hours
L4100, WSM GENERAL [5] CHECK POINTS OF EVERY 200 HOURS Toe-in 1. Park the tractor on flat ground. 2. Inflate the tires to the specified pressure. 3. Turn steering wheel so front wheels are in the straight ahead position. 4. Lower the implement, lock the parking brake and stop the engine.
Page 42: Check Points Of Every 400 Hours
L4100, 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 (2) are loose or water leaks, tighten hose clamps (2) securely.
Page 43 L4100, WSM GENERAL Changing Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2). (When refilling) • Fill up new oil from the oil filling port (3) up to the upper line of the oil level gauge (4).
Page 44: Check Point Of Every 600 Hours
L4100, WSM GENERAL [7] CHECK POINT OF EVERY 600 HOURS Adjusting Front Axle Pivot 1. Loosen the lock nut (2), tighten the adjusting screw (1) all the way, and then loosen the adjusting screw (1) by 1/6 turn. 2. Retighten the lock nut (2).
Page 45 L4100, WSM GENERAL Flush Cooling System and Changing Coolant CAUTION • Do not remove the radiator cap when the engine is hot. Loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down.
Page 46 L4100, WSM GENERAL (Continued) Anti-Freeze CAUTION • When using antifreeze, put on some protection such as rubber gloves (Antifreeze contains poison.). • If should drink antifreeze, throw up at once and take medical attention. • When antifreeze comes in contact with the skin or clothing, wash it off immediately.
Page 47 L4100, WSM GENERAL (Continued) IMPORTANT • When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50 %. Freezing Point Boiling Point* Vol % Anti-freeze °C °F °C °F −24 −12 −37 −34 * At 1.013 x 1000000 Pa (760 mmHg) pressure (atmospheric).
Page 48: Others
L4100, WSM GENERAL [13] OTHERS Bleeding Fuel System Air must be removed: 1. When the fuel filter or lines are removed. 2. When tank is completely empty. 3. After the tractor has not been used for a long period of time.
Page 49 L4100, 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 50: Special Tools
L4100, WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No. • 07916-09032 Application • Use exclusively for pulling out bearing, gears and other parts with ease. WSM000001GEG0011US0 Piston Ring Compressor Code No. • 07909-32111 Application •...
Page 51 L4100, 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...
Page 52 L4100, WSM GENERAL Plastigauge Code No. • 07909-30241 Application • Use to check the oil clearance between crankshaft and bearing, etc.. Measuring range • Green: 0.03 to 0.07 mm (0.001 to 0.003 in.) • Red: 0.05 to 0.1 mm (0.002 to 0.006 in.) •...
Page 53 L4100, WSM GENERAL Valve Guide Replacing Tool Application • To press out and press fit the valve guide. 225 mm (8.86 in.) 70 mm (2.8 in.) 45 mm (1.8 in.) 20 mm dia. (0.79 in. dia.) 12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.) 7.50 to 7.60 mm dia.
Page 54: Special Tools For Tractor
L4100, WSM GENERAL Crankshaft Bearing 1 Replacing Tool Application • To press out and press fit the crankshaft bearing 1. [1] Extracting tool 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 20 mm (0.79 in.)
Page 55 L4100, WSM GENERAL Steering Wheel Puller Code No. • 07916-51090 Application • Use for removing the steering wheel without damaging the steering shaft. WSM000001GEG0030US0 Injector CH3 Code No. • 07916-52501 Application • Use to put calcium chloride solution into a rear wheel and to remove it.
Page 56 L4100, WSM GENERAL Flow Meter Code No. • 07916-52791 (Flow Meter) • 07916-52651 (Hydraulic Test Hose) Application • This allows easy testing of hydraulic system. (1) Flow Meter (2) Hydraulic Test Hose WSM000001GEG0036US0 Adaptor Set for Flow Meter Code No.
Page 57 L4100, 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-41). 22 mm (0.872 in.) 10 mm dia.
Page 58 L4100, WSM GENERAL Rear Propeller Shaft Tool Application • For installing bearing, oil seals and sleeves on rear propeller shaft. 40.0 mm dia. (1.57 in. dia.) 26.0 mm dia. (1.02 in. dia.) 36.0 mm dia. (1.42 in. dia.) 200 mm (7.87 in.) 40.0 mm (1.57 in.)
Page 59 L4100, WSM GENERAL Hydraulic Arm Shaft Bushing Press-Fitting Tool Application • Use for replacing the hydraulic arm shaft bushings in the hydraulic cylinder body. Right Left 54.7 to 54.9 mm 49.7 to 49.9 mm (2.154 to 5.161 in.) (1.957 to 1.964 in.) 24.5 to 25.5 mm...
Page 60 L4100, WSM GENERAL Draft Control Test Bar Application • Use for checking the lift range and floating range of hydraulic draft control. NOTE • When checking and adjusting the draft control rod by using the draft control test bar, about 50 kg (490 N, 110 lbf) of weight is needed.
Page 61 L4100, WSM GENERAL Balancer Metal Replacing Tool (for Removing) Application • Use to remove the metal bearing. 25 mm dia. (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. (0.9826 to 0.9835 in. dia.) Chamfer 0.3 mm (0.01 in.)
Page 62 L4100, 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 dia. (0.130 to 0.146 in. dia.) Chamfer 0.3 mm (0.01 in.)
Page 63: Tires
L4100, WSM GENERAL 9. TIRES [1] TIRE 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. Recommended inflation pressure Maintain the pressure shown below.
Page 64: Rear Wheels
L4100, WSM GENERAL (2) Rear Wheels Models 13.6 – 26 1145 mm 1235 mm 1335 mm 1340 mm Farm (45.1 in.) (48.6 in.) (52.6 in.) (52.8 in.) Rear tread width can be adjusted as shown with the standard equipped tires.
Page 65: Tire Liquid Injection
L4100, WSM GENERAL [3] TIRE LIQUID INJECTION Auxiliary weights can be used to increase traction force for plowing in fields or clayey ground. Another way is to inject water or another liquid, such as a calcium chloride solution in the tires. Water must not be used in winter since it freezes at 0 °C (32 °F).
Page 66 L4100, 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 67 ENGINE KiSC issued 08, 2012 A...
Page 68 MECHANISM CONTENTS LUBRICATING SYSTEM......................1-M1 2. COOLING SYSTEM ........................1-M2 3. FUEL SYSTEM........................... 1-M3 KiSC issued 08, 2012 A...
Page 69: Lubricating System
L4100, WSM ENGINE 1. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Governor Shaft (6) Idle Gear (7) Crankshaft (8) Oil Pump (9) Oil Strainer (10) Relief Valve (11) Oil Filter Cartridge...
Page 70: Cooling System
L4100, WSM ENGINE 2. COOLING SYSTEM Bottom bypass system is introduced in 03-M Series for improving the cooling performance of the radiator. While the temperature of coolant in the engine is low, the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.
Page 71: Fuel System
L4100, WSM ENGINE 3. FUEL SYSTEM (1) Fuel Overflow Pipe (4) Fuel Tank (7) Fuel Filter Feed Fuel Flow (2) Injection Nozzle (5) Injection Pump Air Vent Pipe (8) Fuel Feed Pump Injected Fuel Flow (3) Injection Pipe (6) Injection Pump...
Page 72 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S8 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S9 [1] CHECKING AND ADJUSTING....................1-S9 (1) Compression Pressure ....................1-S9 (2) Valve Clearance ......................1-S10 (3) Top Clearance .......................1-S11 (4) Engine Oil Pressure.......................1-S12 (5) Fan Belt .........................1-S12 (6) Radiator .........................1-S13 (7) Fuel Injection Pump.......................1-S15 (8) Injection Nozzle ......................1-S16...
Page 73: Troubleshooting
L4100, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel Start Air in the fuel system Bleed G-33 Water in the fuel system Change fuel and – repair or replace fuel system...
Page 74 L4100, WSM ENGINE Reference Symptom Probable Cause Solution Page Either White or Blue Excessive engine oil Reduce to specified Exhaust Gas Is level Observed Piston ring and cylinder worn or stuck Repair or replace 1-S35, 1-S56 Incorrect injection timing Adjust...
Page 75 L4100, WSM ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish G-16 Oil filter clogged Clean G-16 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace – Excessive oil clearance of crankshaft bearing...
Page 76: Servicing Specifications
L4100, WSM ENGINE 2. SERVICING SPECIFICATIONS CYLINDER HEAD AND VALVES Item Factory Specification Allowable Limit Piston Top Clearance 0.55 to 0.70 mm – 0.0217 to 0.0276 in. Cylinder Head Surface Flatness – 0.05 mm / 500 mm 0.0020 in. / 19.69 in.
Page 77 L4100, WSM ENGINE TIMING GEARS, CAMSHAFT AND FUEL CAMSHAFT Item Factory Specification Allowable Limit Timing Gear • Idle Gear to Crank Gear Backlash 0.04150 to 0.1122 mm 0.15 mm 0.001634 to 0.004417 in. 0.0059 in. • Idle Gear to Cam Gear Backlash 0.04150 to 0.1154 mm...
Page 78 L4100, WSM ENGINE Item Factory Specification Allowable Limit Balancer Shaft Journal 2 to Balancer Shaft Clearance 0.051 to 0.132 mm 0.20 mm Bearing 2 0.00201 to 0.00520 in. 0.0079 in. • Balancer Shaft Journal 2 O.D. 41.934 to 41.950 mm –...
Page 79 L4100, WSM ENGINE CRANKSHAFT Item Factory Specification Allowable Limit Crankshaft Side Clearance 0.15 to 0.31 mm 0.5 mm 0.0059 to 0.012 in. 0.02 in. Alignment – 0.02 mm 0.0008 in. Crankpin to Crankpin Bearing Clearance 0.025 to 0.087 mm 0.20 mm 0.00099 to 0.0034 in.
Page 80: Tightening Torques
L4100, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: See page G-11.) 9Y1210278ENS0123US0 PREPARATION Item N·m kgf·m lbf·ft Oil pressure switch 14.7 to 19.6 1.50 to 2.00...
Page 81: Checking, Disassembling And Servicing
L4100, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Compression Pressure Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine and disconnect the 2P connector from the stop solenoid in order to inject fuel.
Page 82: Valve Clearance
L4100, WSM ENGINE (2) Valve Clearance 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. Align the "TC" mark line on the flywheel and center or timing window so that the No.1 piston comes to the compression or...
Page 83: Top Clearance
L4100, WSM ENGINE (3) Top Clearance Top Clearance 1. Remove the cylinder head. 2. Move the piston and place a trip of fuse on the piston head at three positions with grease. 3. Lower the piston, and install the cylinder head. (Use a new cylinder head gasket and tighten with a specified tightening torque.)
Page 84: Engine Oil Pressure
L4100, WSM ENGINE (4) Engine Oil Pressure Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No. 07916-32032). (Adaptor screw size: PT 1/8) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 85: Radiator
L4100, 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. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
Page 86 L4100, WSM ENGINE Radiator Water Leakage 1. Pour a specified amount of water into the radiator. 2. Set a radiator tester (Code No. 07909-31551) with an adaptor (BANZAI Code No. RCT-2S-30S) and raise the water pressure to the specified pressure.
Page 87: Fuel Injection Pump
L4100, WSM ENGINE (7) Fuel Injection Pump Injection Timing 1. Remove the stop solenoid. 2. Remove the injection pipes and nozzle. 3. Set the speed control lever to maximum fuel discharge position. (Reference) • Turn the flywheel with screwdriver. 4. Turn the flywheel counterclockwise (facing the flywheel) until the fuel fills up to the hole of the delivery valve holder for 1st cylinder.
Page 88: Injection Nozzle
L4100, WSM ENGINE (8) Injection Nozzle CAUTION • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction of the injected fuel. • If the injected fuel from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 89: Preparation
L4100, WSM ENGINE [2] PREPARATION (1) Separating Engine and Clutch Housing Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. Remove the drain plugs (1) to drain oil.
Page 90 L4100, WSM ENGINE Draining Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2). (When refilling) • Fill up new oil from the oil filling port (3) up to the upper line of the oil level gauge (4).
Page 91 L4100, WSM ENGINE Bonnet and Front Cover 1. Disconnect the battery negative cable (1). 2. Disconnect the connector to head light (3), horn (2) and the head light wiring. 3. Remove bonnet (4) and side covers (5) on both sides.
Page 92 L4100, WSM ENGINE Steering Wheel and Rear Bonnet 1. Remove the steering wheel (1) with steering puller. 2. Remove the throttle grip (4). 3. Disconnect the hourmeter cable from engine. 4. Remove the meter panel (2). 5. Disconnect 4P connector (7) to main switch.
Page 93 L4100, WSM ENGINE Wiring, Pipes and Rods 1. Disconnect 1P connector (1) to coolant temperature sensor. 2. Disconnect glow plug terminal (9). 3. Disconnect accelerator cable (7), 2P connector to engine stop solenoid (8) and then set aside the wiring harness.
Page 94 L4100, WSM ENGINE Wirings 1. Disconnect 1P battery connector (1) and remove slow blow fuse boxes (3). 2. Disconnect 2P connector (4) to alternator and wings (5). 3. Disconnect 1P connector (8) to starter motor and B terminal (7). 4. Disconnect 1P connector (6) to engine oil pressure switch, then set aside the wiring harness.
Page 95 L4100, WSM ENGINE Propeller Shaft 1. Slide propeller shaft front cover (1) and rear cover (2) after removing screws (3). 2. Tap out spring pins (4), (5), slide couplings (6), (7), and then remove propeller shaft together with propeller shaft covers.
Page 96: Separation Engine From Front Axle Frame
L4100, WSM ENGINE Clutch Assembly 1. Insert the clutch center tool. 2. Remove the clutch assembly together with the clutch center tool. (When reassembling) • Direct the shorter end of the clutch disc boss toward the flywheel. • Apply molybdenum disulphide (Three Bond 1901 or equivalent) to the splines of clutch disc boss.
Page 97: Disassembling And Assembling
L4100, WSM ENGINE Separating Engine from Front Axle Frame 1. Remove one of the two engine hooks (1) and mount it on the right rear side of the engine. 2. Hoist the engine by the chain at the engine hook (2), (3).
Page 98 L4100, WSM ENGINE Cylinder Head Cover 1. Remove the lead (1). 2. Remove the breather hose (2). 3. Remove the head cover screws (3). 4. Remove the cylinder head cover (4). (When reassembling) • Check to see if the cylinder head cover gasket is not defective.
Page 99 L4100, WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe assembly (5). 2. Remove the nozzle holder assemblies (2) using a 21 mm deep socket wrench. 3. Remove the copper gasket and heat seal (3). 4. Remove the glow plugs (1).
Page 100 L4100, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp, and remove the water return pipe (1). 2. Remove the cylinder head screw in the order of (18) to (1). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket.
Page 101: Timing Gears, Camshaft And Fuel Camshaft
L4100, WSM ENGINE (2) Timing Gears, Camshaft and Fuel Camshaft Injection Pump 1. Remove the stop solenoid (1) and hi-idling body (2). 2. Remove the engine stop lever (3) and stop solenoid guide (5). 3. Remove the fuel injection pump assembly (4).
Page 102 L4100, WSM ENGINE Governor Springs and Speed Control Plate NOTE • Specific tool (1): 1.2 mm (0.047 in.) diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent like the hook to hang governor springs.
Page 103 L4100, WSM ENGINE (Continued) (When reassembling) • Hook the small spring (4) first and then the large governor spring (2) on the speed control plate (6). • Put the specific tool (1) from the injection pump side to catch the large governor spring (2).
Page 104 L4100, WSM ENGINE Fan Drive Pulley 1. Remove the crankshaft nut. 2. Draw out the fan drive pulley (1) with a puller. (When reassembling) • Do not tighten the nut excessively, it may damage the oil slinger, causing oil leakage.
Page 105 L4100, WSM ENGINE Camshaft and Balancer Shaft 1. Remove the camshaft set screws and draw out the camshaft (1). 2. Remove the balancer shaft 1 (2) set bolts and draw out the balancer shaft 1 (2). 3. Remove the balancer shaft 2 (3) set bolts and draw out the balancer shaft 2 (3).
Page 106: Piston And Connecting Rod
L4100, WSM ENGINE (3) Piston and Connecting Rod Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws. 2. Remove the oil pan (1) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil pan gasket (2).
Page 107 L4100, WSM ENGINE Pistons 1. Completely clean carbon (1) from 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 108 L4100, WSM ENGINE (Continued) (When reassembling) • Before inserting piston into the cylinder, apply enough engine oil to the piston. • When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump. IMPORTANT •...
Page 109 L4100, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings (4), (5), (6) using a piston ring tool (Code No. 07909-32121). 2. Place the tip of a small edge screwdriver at the piston hollow (13), compress the piston pin snap ring (3) in the radial direction and then remove the piston snap ring.
Page 110: Crankshaft
L4100, WSM ENGINE (Continued) NOTE • Be sure not to position the gap of piston pin snap ring (3) facing the piston hollow (13). • Use new piston pin snap rings when reassembling. (2) Piston (A) Good (3) Piston Pin Snap Ring...
Page 111 L4100, WSM ENGINE Crankshaft NOTE • Before disassembling, check the side clearance of crankshaft. Also check it during reassembling. 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly, taking care not to damage the crankshaft bearing 1.
Page 112: Thermostat
L4100, WSM ENGINE (5) Thermostat CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. 9Y1210278ENS0057US0 Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1).
Page 113: Servicing
L4100, WSM ENGINE [4] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. Move the piston and place a trip of fuse on the piston head at three positions with grease. 3. Lower the piston, and install the cylinder head. (Use a new cylinder head gasket and tighten with a specified tightening torque.)
Page 114 L4100, WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
Page 115 L4100, WSM ENGINE Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page "SPECIAL TOOLS".) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
Page 116 L4100, 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 117 L4100, 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 118: Timing Gears, Camshaft And Fuel Camshaft
L4100, 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 119 L4100, WSM ENGINE Idle Gear Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the idle gear collar.
Page 120 L4100, WSM ENGINE Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
Page 121 L4100, WSM ENGINE Balancer Shaft Alignment 1. Support the balancer shaft with V blocks on the surface plate and set a dial indicator with its tip on the intermediate journal at high angle. 2. Rotate the balancer shaft on the V blocks and get the misalignment (half of the measurement).
Page 122: Piston And Connecting Rod
L4100, WSM ENGINE (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
Page 123 L4100, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the liner (the least worn out part) with the piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the ring.
Page 124: Crankshaft
L4100, WSM ENGINE (4) Crankshaft Side Clearance of Crankshaft 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
Page 125 L4100, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigauge 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 126 L4100, 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 127 L4100, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 1. Put a strip of plastigauge on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again.
Page 128: Cylinder
L4100, WSM ENGINE Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve (3). 2. Set the sleeve guide (2) to the crankshaft (5). 3. Set the stopper (1) to the crankshaft as shown in figure. 4. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft (5) as...
Page 129: Oil Pump
L4100, WSM ENGINE Correcting Cylinder (Oversize +0.25 mm) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 87.250 to 87.272 mm Oversize cylinder I.D. Factory specification 3.4351 to 3.4359 in. 87.420 mm...
Page 130 CLUTCH KiSC issued 08, 2012 A...
Page 131 MECHANISM CONTENTS STRUCTURE..........................2-M1 [1] TRAVELING CLUTCH......................2-M1 [2] HYDRAULIC PTO CLUTCH ....................2-M1 KiSC issued 08, 2012 A...
Page 132 L4100, WSM CLUTCH 1. STRUCTURE [1] TRAVELING CLUTCH This tractor is equipped with dry single plate type clutch. The clutch is located between the engine and the transmission and is operated by stepping on the clutch pedal (13). When the clutch pedal is depressed, the clutch is...
Page 133 L4100, WSM CLUTCH Shift Linkage The PTO Clutch control lever (1) and the PTO clutch valve (4) are connected by the shift cable (3) as shown in the left figure. When the shift lever is moved to the "B" side, the PTO clutch valve (4) is set at "ENGAGED"...
Page 134 L4100, WSM CLUTCH Operation The oil from the regulator valve flows into the clutch valve and opens the check valve (1). When the shift lever is set at the "ENGAGED" position, the spool (2) is turned to "A" position, then the oil flows through the spool (2) into the accumulator and the clutch pack.
Page 135 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 2. SERVICING SPECIFICATIONS ....................2-S3 3. TIGHTENING TORQUES......................2-S4 4. CHECKING, DISASSEMBLING AND SERVICING ..............2-S5 [1] CHECKING AND AJUSTING ....................2-S5 [2] PREPARATION ........................2-S6 (1) Travelling Clutch......................2-S6 (2) PTO Clutch ........................2-S12 (3) PTO Clutch Valve ......................2-S14 [3] DISASSEMBLING AND ASSEMBLING ................2-S15 (1) Traveling Clutch......................2-S15 (2) PTO Clutch ........................2-S17 (3) PTO Clutch Valve ......................2-S20...
Page 136: Troubleshooting
L4100, WSM CLUTCH 1. TROUBLESHOOTING TRAVELING CLUTCH Reference Symptom Probable Cause Solution Page Clutch Drags Too much free play in the clutch Adjust 2-S5 Dust on clutch disc generated from clutch disc Remove dust – facing Release fork broken Replace...
Page 137 L4100, WSM CLUTCH PTO CLUTCH Reference Symptom Probable Cause Solution Page PTO Clutch Slips Operating pressure is low Adjust 2-S5 PTO clutch valve malfunctioning Repair or replace 2-S15 Clutch disc or drive plate excessively worn Replace 2-S18 Deformation of piston or return plate...
Page 138: Servicing Specifications
L4100, WSM CLUTCH 2. SERVICING SPECIFICATIONS TRAVELING CLUTCH Item Factory Specification Allowable Limit Clutch Pedal Free Travel 20 to 30 mm – 0.8 to 1.2 in. Clutch Disc Boss to Gear Shaft Backlash – 2.0 mm (Displacement 0.079 in. Around Disc Edge)
Page 139: Tightening Torques
L4100, 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: See page G-11.) 9Y1210278CLS0037US0 PREPARATION Item N·m kgf·m lbf·ft Steering wheel mounting nut 48 to 55 4.9 to 5.7...
Page 140: Checking, Disassembling And Servicing
L4100, WSM CLUTCH 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND AJUSTING Adjusting Clutch Pedal Free Travel 1. Slightly depress the clutch pedal (4) and measure free travel on top of clutch pedal. 2. If the measurement is not within the factory specifications, loosen the lock nut (2), remove the cotter pin (3) and the clevis pin, then adjust the length of rod (1) within acceptable limits.
Page 141: Preparation
L4100, WSM CLUTCH PTO Shift Lever Stroke 1. Set the PTO shift lever (1) to OFF (Neutral) position. 2. Loosen the lock nut (2) of cable, and connect cable (3) to the PTO clutch valve lever (4), and then place the cable (3) to the hook.
Page 142 L4100, WSM CLUTCH Bonnet and Front Cover 1. Disconnect the battery negative cable (1). 2. Disconnect the connector to head light (3), horn (2) and the head light wiring. 3. Remove bonnet (4) and side covers (5) on both sides.
Page 143 L4100, WSM CLUTCH Steering Wheel and Rear Bonnet 1. Remove the steering wheel (1) with steering puller. 2. Remove the throttle grip (4). 3. Disconnect the hourmeter cable from engine. 4. Remove the meter panel (2). 5. Disconnect 4P connector (7) to main switch.
Page 144 L4100, WSM CLUTCH Wiring, Pipes and Rods 1. Disconnect 1P connector (1) to coolant temperature sensor. 2. Disconnect glow plug terminal (9). 3. Disconnect accelerator cable (7), 2P connector to engine stop solenoid (8) and then set aside the wiring harness.
Page 145 L4100, WSM CLUTCH Wirings 1. Disconnect 1P battery connector (1) and remove slow blow fuse boxes (3). 2. Disconnect 2P connector (4) to alternator and wings (5). 3. Disconnect 1P connector (8) to starter motor and B terminal (7). 4. Disconnect 1P connector (6) to engine oil pressure switch, then set aside the wiring harness.
Page 146 L4100, WSM CLUTCH Propeller Shaft 1. Slide propeller shaft front cover (1) and rear cover (2) after removing screws (3). 2. Tap out spring pins (4), (5), slide couplings (6), (7), and then remove propeller shaft together with propeller shaft covers.
Page 147: Pto Clutch
L4100, WSM CLUTCH (2) PTO Clutch [A] Separating Engine from Clutch Housing • Refer to "[2] PREPARATION FOR TRAVELING CLUTCH" in this section. 9Y1210278CLS0009US0 [B] Separating Clutch Housing Mid Case Outer Components 1. Disconnect foot accelerator rod (3). 2. Remove brake rod R.H. (2) and L.H. (10).
Page 148 L4100, WSM CLUTCH Main Gear Shift Lever 1. Shift main gear shift lever (1) to neutral position. 2. Unscrew mounting screws and remove main gear shift base (2). (When reassembling) • Apply grease to the O-rings (3) and take care not to damage it.
Page 149: Pto Clutch Valve
L4100, WSM CLUTCH (3) PTO Clutch Valve [A] Removing PTO Clutch Valve Draining Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2).
Page 150: Disassembling And Assembling
L4100, WSM CLUTCH PTO Clutch Valve 1. Disconnect the PTO shift cable (1) from the PTO clutch valve (2). 2. Remove the PTO clutch valve assembly (2). (When reassembling) • Replace the hydraulic pipe (3) with new ones and apply oil to them.
Page 151 L4100, WSM CLUTCH Release Fork and Clutch Lever 1. Draw out the clutch release hub (4) and the release bearing (5) as a unit. 2. Remove the release fork setting screws (2). 3. Draw out the clutch lever (3) to remove the release fork (1).
Page 152: Pto Clutch
L4100, WSM CLUTCH (2) PTO Clutch PTO Clutch Valve, PTO Clutch Holder 1. Remove PTO clutch valve (1). 2. Remove PTO clutch holder (6) together with PTO clutch pack (5). 3. Tap out 18T gear shaft (7). 4. Tap out 23T gear shaft (8).
Page 153 L4100, WSM CLUTCH Clutch Hub and Clutch Discs 1. Remove the internal snap ring (8), and then take out the clutch discs (5), the back plate (7), the steel plates (6), (9), (10), (11) and (12), the hub (3) and the bearings (2).
Page 154 L4100, WSM CLUTCH Modulating Valve 1. Remove the internal snap ring (1). 2. Remove the spring seat (2). 3. Draw out the spring (3) and piston (4). (1) Internal Snap Ring (3) Spring (2) Spring Seat (4) Piston 9Y1210278CLS0021US0 Clutch Case 1.
Page 155: Pto Clutch Valve
L4100, WSM CLUTCH Clutch Case 1. Press the washer (6) lightly by the hand press, using the hand made jig. (Refer to the figure.) 2. Draw out the piston (4). (When reassembling) • Apply enough transmission fluid to seal rings (3) and (8).
Page 156: Servicing
L4100, WSM CLUTCH Clutch Valve Spool 1. Remove the oil seal and the external snap ring (5). 2. Draw out the spool (6). 3. Make a marks on the spool (6) and the lever (4). 4. Remove the spring (3) and tap out the spring pin (7), and then remove the lever (4).
Page 157 L4100, WSM CLUTCH Release Bearing 1. Check for abnormal wear on contact surface. 2. Rotate the release bearing outer race, while applying pressure to it. 3. If the bearing rotation is rough or noisy, replace the release bearing. NOTE • Do not depress the release bearing outer race, when replacing the release bearing.
Page 158: Pto Clutch
L4100, WSM CLUTCH Pressure Plate Flatness 1. Place a straightedge 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. When the pressure plate is worn around its outside and its inside surface only is in contact with the straightedge, replace even if the clearance is within allowable limit.
Page 159 L4100, WSM CLUTCH 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 160 TRANSMISSION KiSC issued 08, 2012 A...
Page 161 MECHANISM CONTENTS 1. STRUCTURE..........................3-M1 KiSC issued 08, 2012 A...
Page 162 L4100, WSM TRANSMISSION 1. STRUCTURE (1) Main Gear Shift Section (2) PTO Clutch Pack (3) Front Wheel Drive Section (4) Lo-Reverse, Hi Shift Section 3-M1 (EU) KiSC issued 08, 2012 A...
Page 163 SERVICING CONTENTS 1. TROUBLESHOOTING.........................3-S1 2. SERVICING SPECIFICATIONS ....................3-S3 3. TIGHTENING TORQUES......................3-S5 4. CHECKING, DISASSEMBLING AND SERVICING ..............3-S7 [1] CHECKING AND ADJUSTING....................3-S7 (1) Range Gear Shift Lever....................3-S7 [2] PREPARATION ........................3-S9 (1) Separating Engine and Clutch Housing................3-S9 (2) Separating Clutch Housing from Mid Case ..............3-S15 (3) Separating Transmission....................3-S17 [3] DISASSEMBLING AND ASSEMBLING ................3-S22 (1) Clutch Housing ......................3-S22...
Page 164: Troubleshooting
L4100, WSM TRANSMISSION 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive Transmission fluid insufficient Replenish 3-S9 Transmission Noise Gear worn or backlash improper Replace 3-S32 Bearing worn or broken Replace 3-S32 Shift fork worn Replace 3-S32 Spline worn Replace...
Page 165 L4100, WSM TRANSMISSION Reference Symptom Probable Cause Solution Page Noise While Turning Differential pinions or differential side gears worn Replace 3-S37 or damaged Differential lock binding (does not disengage) Replace – Bearing worn Replace 3-S33 9Y1210278TRS0003US0 3-S2 (EU) KiSC issued 08, 2012 A...
Page 166: Servicing Specifications
L4100, WSM TRANSMISSION 2. SERVICING SPECIFICATIONS CLUTCH HOUSING AND MID CASE Item Factory Specification Allowable Limit Gear Backlash 0.10 to 0.30 mm 0.40 mm 0.0040 to 0.011 in. 0.016 in. Gear to Spline Clearance 0.030 to 0.078 mm 0.20 mm 0.0012 to 0.0030 in.
Page 167 L4100, WSM TRANSMISSION Item Factory Specification Allowable Limit Differential Pinion Shaft to Differential Clearance 0.0900 to 0.132 mm 0.25 mm Pinion 0.00354 to 0.00520 in. 0.0098 in. • Differential Pinion Shaft O.D. 19.950 to 19.971 mm – 0.78543 to 0.78626 in.
Page 168: Tightening Torques
L4100, 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: See page G-11.) 9Y1210278TRS0053US0 RANGE GEAR SHIFT LEVER Item N·m kgf·m lbf·ft Turnbuckle lock screw range gear shift lever 40 to 45 4.0 to 4.6...
Page 169 L4100, WSM TRANSMISSION SEPARATING TRANSMISSION Item N·m kgf·m lbf·ft ROPS mounting screw (M14) 167 to 196 17.0 to 20.0 123 to 144 ROPS mounting screw (M12) 78 to 90 7.9 to 9.2 58 to 66 ROPS fulcrum screw 118 to 137 12.0 to 14.0...
Page 170: Checking, Disassembling And Servicing
L4100, WSM TRANSMISSION 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Range Gear Shift Lever CAUTION • Park the tractor on a firm and level ground and set the parking brake. • Lower the loader and other implement to the ground.
Page 171 L4100, WSM TRANSMISSION Range Gear Shift Lever Position 1. Adjust (shorten) the turnbuckle H (3) so that the overlapping length becomes 1 to 5 mm (0.04 to 0.2 in.). Length of the rod 194.2 mm Reference value "A" 7.646 in.
Page 172: Preparation
L4100, WSM TRANSMISSION [2] PREPARATION (1) Separating Engine and Clutch Housing Draining Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2).
Page 173 L4100, WSM TRANSMISSION Bonnet and Front Cover 1. Disconnect the battery negative cable (1). 2. Disconnect the connector to head light (3), horn (2) and the head light wiring. 3. Remove bonnet (4) and side covers (5) on both sides.
Page 174 L4100, WSM TRANSMISSION Steering Wheel and Rear Bonnet 1. Remove the steering wheel (1) with steering puller. 2. Remove the throttle grip (4). 3. Disconnect the hourmeter cable from engine. 4. Remove the meter panel (2). 5. Disconnect 4P connector (7) to main switch.
Page 175 L4100, WSM TRANSMISSION Wiring, Pipes and Rods 1. Disconnect 1P connector (1) to coolant temperature sensor. 2. Disconnect glow plug terminal (9). 3. Disconnect accelerator cable (7), 2P connector to engine stop solenoid (8) and then set aside the wiring harness.
Page 176 L4100, WSM TRANSMISSION Wirings 1. Disconnect 1P battery connector (1) and remove slow blow fuse boxes (3). 2. Disconnect 2P connector (4) to alternator and wings (5). 3. Disconnect 1P connector (8) to starter motor and B terminal (7). 4. Disconnect 1P connector (6) to engine oil pressure switch, then set aside the wiring harness.
Page 177 L4100, WSM TRANSMISSION Propeller Shaft 1. Slide propeller shaft front cover (1) and rear cover (2) after removing screws (3). 2. Tap out spring pins (4), (5), slide couplings (6), (7), and then remove propeller shaft together with propeller shaft covers.
Page 178: Separating Clutch Housing From Mid Case
L4100, WSM TRANSMISSION (2) Separating Clutch Housing from Mid Case Outer Components 1. Disconnect foot accelerator rod (3). 2. Remove brake rod R.H. (2) and L.H. (10). 3. Remove mounting bolts and steering support (1). 4. Remove clutch rod (4).
Page 179 L4100, WSM TRANSMISSION Main Gear Shift Lever 1. Shift main gear shift lever (1) to neutral position. 2. Unscrew mounting screws and remove main gear shift base (2). (When reassembling) • Apply grease to the O-rings (3) and take care not to damage it.
Page 180: Separating Transmission
L4100, WSM TRANSMISSION (3) Separating Transmission Draining Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2). (When refilling) • Fill up new oil from the oil filling port (3) up to the upper line of the oil level gauge (4).
Page 181 L4100, WSM TRANSMISSION Three Point Linkage and ROPS 1. Upper ROPS (1) with safety strap (2). 2. Remove check chains (8), top link (5), lift rods (6) and lower links (7). 3. Remove the lower ROPS (4). (When reassembling) 167 to 196 N·m M14 screw 17.0 to 20.0 kgf·m...
Page 182 L4100, WSM TRANSMISSION Suction Pipe and Hydraulic Block 1. Remove suction pipe (1), (4). 2. Remove oil filter bracket (3) together with oil filter (8). 3. Remove hydraulic block (7) together with return pipe (6). 4. Remove 3P delivery pipe (2), I-PTO delivery pipe (5).
Page 183 L4100, WSM TRANSMISSION Fender, Wiring Harness 1. Disconnect rear combination lamp connector RH (1) and LH, PTO switch connector (4), and then clear wiring harness (7) from the hydraulic cylinder. 2. Remove the 3P delivery pipe (8), the fenders (6), the fender stay (10), seat stay (5) and lever stay (6).
Page 184 L4100, WSM TRANSMISSION Rear Axle Case 1. Place the support stand under the rear axle case. 2. Loosen and remove the rear axle case mounting screws and nuts. 3. Support the rear axle case with nylon lift strap and hoist.
Page 185: Disassembling And Assembling
L4100, WSM TRANSMISSION [3] DISASSEMBLING AND ASSEMBLING (1) Clutch Housing Clutch Lever, Release Fork and Release Bearing 1. Remove the release fork mounting screws (2). 2. Draw out the clutch lever (3) to remove the release fork (1). 3. Remove the release bearing (4) together with release holder.
Page 186 L4100, WSM TRANSMISSION 24T Gear Shaft and 27T Gear 1. Remove the 24T gear shaft (1). 2. Remove the external snap ring (2) and 27T gear (3). (1) 24T Gear Shaft (3) 27T Gear (2) External Snap Ring 9Y1210278TRS0019US0 Clutch Housing Bearing Holder 1.
Page 187 L4100, WSM TRANSMISSION Gear Shaft Assemblies 1. Remove shift fork assembly (1), (2) together with counter gear shaft assembly (3). 2. Remove main gear shaft assembly (4), I-PTO counter gear shaft assembly (5), I-PTO gear shaft assembly (6), and then PTO gear shaft (7).
Page 188: Mid Case
L4100, WSM TRANSMISSION (2) Mid Case NOTE • Refer to section 2. CLUTCH (See page 2-S12) for hydraulic PTO clutch. 9Y1210278TRS0023US0 PTO Clutch Valve, PTO Clutch Holder 1. Remove PTO clutch valve (1). 2. Remove PTO clutch holder (6) together with PTO clutch pack (5).
Page 189: Transmission Case
L4100, WSM TRANSMISSION (3) Transmission Case Pinion Bearing Cover 1. Remove the stake of lock nut (5). 2. Fix the 37T - 22T gear by pinion locking tool (Code No. 07916-52311) and remove the lock nut (5). 3. Remove the pinion bearing case mounting screws.
Page 190 L4100, WSM TRANSMISSION Transmission Bearing Holder 1. Remove spring pin (2) holding Hi-shift fork rod (3) to transmission bearing holder (1). 2. Remove transmission bearing holder by using 2 jack screws M8 (4). (1) Transmission Bearing Holder (3) Hi-Shift Fork Rod...
Page 191 L4100, WSM TRANSMISSION Shaft Assemblies 1. Remove front wheel drive gear shaft assembly (7). 2. Remove pinion gear shaft assembly (2) and Hi-shift fork (1). 3. Remove PTO gear shaft assembly (6). (1) Hi-shift Fork Rod (5) Front Wheel Drive Shift Lever...
Page 192 L4100, WSM TRANSMISSION (Continued) 4. Remove Lo-reverse gear shaft assembly (4). 5. Remove Lo-reverse fork rod (3), front wheel drive shift lever (5). (1) Hi-shift Fork Rod (5) Front Wheel Drive Shift Lever (2) Pinion Gear Shaft Assembly (6) PTO Gear Shaft Assembly...
Page 193 L4100, 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. Tap out the PTO shaft (1) to the front.
Page 194 L4100, 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 195: Servicing
L4100, WSM TRANSMISSION [4] SERVICING (1) Clutch Housing and Mid Case Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 196: Transmission Case
L4100, WSM TRANSMISSION Free Length of the Shift Fork Spring 1. Measure free length of spring with vernier caliper. 2. If the free length is less than the allowable limit, replace. 22.0 mm Factory specification 0.866 in. Free length of the shift fork spring 20.0 mm...
Page 197 L4100, WSM TRANSMISSION Free Length of the Lo-Reverse Shift Fork Spring and Hi-Shift Fork Spring 1. Measure free length of lo-reverse shift fork spring (2) and hi-shift fork spring (3) with vernier caliper. 2. If the free length is less than the allowable limit-replace it.
Page 198 L4100, 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 199 L4100, WSM TRANSMISSION More than 35 % red lead 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 Replace the adjusting shim (2) with thicker one to move the spiral bevel pinion shaft backward.
Page 200 L4100, WSM TRANSMISSION Clearance between Differential Pinion Shaft and Differential Pinion 1. Measure the differential pinion shaft O.D. 2. Measure the differential pinion I.D. and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them. 0.0900 to 0.132 mm...
Page 201: Rear Axle
REAR AXLE KiSC issued 08, 2012 A...
Page 202 MECHANISM CONTENTS 1. STRUCTURE..........................4-M1 KiSC issued 08, 2012 A...
Page 203 L4100, WSM REAR AXLE 1. STRUCTURE (1) Ball Bearing (4) Differential Gear Shaft (7) Ring Gear (10) Differential Lock Shifter (2) Rear Axle (5) Brake Case (8) Differential Pinion (11) Differential Case (3) Rear Axle Case (6) Brake Disc (9) Final Gear (12) Differential Side Gear The final gear (9) are final reduction mechanism which further reduces the speed of rotation.
Page 204 SERVICING CONTENTS 1. TROUBLESHOOTING.........................4-S1 2. TIGHTENING TORQUES......................4-S2 3. DISASSEMBLING AND SERVICING ..................4-S3 [1] PREPARATION ........................4-S3 [2] DISASSEMBLING AND ASSEMBLING ................4-S5 (1) Rear Axle Assembly ......................4-S5 [3] SERVICING ...........................4-S5 KiSC issued 08, 2012 A...
Page 205: Troubleshooting
L4100, WSM REAR AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive or Unusual Improper back lash between differential gear Replace 4-S5 Noise at All Time shaft and final gear Bearing worn Replace 4-S5 Insufficient or improper type of transmission fluid...
Page 206 L4100, WSM REAR AXLE 2. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, and nuts: See page G-11.) Item N·m kgf·m lbf·ft ROPS mounting M14, grade 9 screw 167 to 196 17.0 to 20.0...
Page 207: Tightening Torques
L4100, WSM REAR AXLE 3. DISASSEMBLING AND SERVICING [1] PREPARATION Draining Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2).
Page 208 L4100, WSM REAR AXLE Wiring Harness • Disconnect rear combination lamp connector (R.H.) (1) and L.H., PTO switch connectors (2), PTO shift cable (3), and then clear wiring harness from fender. (1) Rear Combination Lamp Connector (2) PTO Switch Connector (R.H.)
Page 209: Disassembling And Assembling
L4100, WSM REAR AXLE [2] DISASSEMBLING AND ASSEMBLING (1) Rear Axle Assembly Rear Axle 1. Remove the ball bearing (1) with a puller. 2. Remove the stake of lock nut (2). 3. Secure the rear axle (4) in a vise and remove the lock nut (2).
Page 210 BRAKES KiSC issued 08, 2012 A...
Page 211 MECHANISM CONTENTS 1. STRUCTURE..........................5-M1 2. OPERATION..........................5-M2 KiSC issued 08, 2012 A...
Page 212 L4100, WSM BRAKES 1. STRUCTURE (1) Brake Pedal Turnbuckle Rod (4) Brake Cam Lever (7) Brake Plate (9) Parking Brake Lever (2) Brake Pedal (5) Parking Brake Rod (8) Cam Plate (10) Parking Brake Cable (3) Brake Rod (6) Brake Disc This is used hanging type brake pedals to have wider space of the platform.
Page 213 L4100, WSM BRAKES 2. OPERATION (1) Cam Plate (4) Brake Case (6) Brake Shaft (Differential Gear (7) Brake Cam (2) Steel Plate (5) Steel Ball Shaft) (8) Brake Cam Lever (3) Brake Disc The brake body is incorporated in the brake case (4) filled with transmission oil and is designed to brake when the brake disc (3) splined with the differential gear shaft (6) is pressed against the cam plate (1) by means of the cam mechanism incorporating steel balls (5).
Page 214 SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICING SPECIFICATIONS ....................5-S2 3. TIGHTENING TORQUES......................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............5-S4 [1] CHECKING AND ADJUSTING....................5-S4 [2] PREPARATION ........................5-S5 (1) Separating Rear Axle Case from Transmission Case .............5-S5 [3] DISASSEMBLING AND ASSEMBLING ................5-S7 [4] SERVICING ...........................5-S8 KiSC issued 08, 2012 A...
Page 215 L4100, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Uneven Braking Brake pedal free travel unevenly adjusted Adjust 5-S4 Force Brake disc worn Replace 5-S8 Cam plate warped Replace 5-S8 Brake Drags Too little free travel in the brakes...
Page 216: Servicing Specifications
L4100, 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 217 L4100, WSM BRAKES 3. TIGHTENING TORQUES Tightening torques of screws, and nuts on the table below are especially specified. (For general use screws, bolts and nuts: See page G-11.) Item N·m kgf·m lbf·ft ROPS mounting M14, grade 9 screw 167 to 196 17.0 to 20.0...
Page 218: Checking, Disassembling And Servicing
L4100, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjusting Brake Pedal Free Travel CAUTION • Stop the engine and remove the key, then chock the wheel before checking brake pedals. 1. Release the parking brake. 2. Slightly depress the brake pedals and measure free travel "A"...
Page 219: Preparation
L4100, WSM BRAKES [2] PREPARATION (1) Separating Rear Axle Case from Transmission Case Draining Transmission Fluid 1. Place an oil pan underneath the transmission case. 2. Remove the drain plugs (1), (2). 3. Drain the transmission fluid. 4. Reinstall the drain plugs (1), (2).
Page 220 L4100, WSM BRAKES Wiring Harness • Disconnect rear combination lamp connector (R.H.) (1) and L.H., PTO switch connectors (2), PTO shift cable (3), and then clear wiring harness from fender. (1) Rear Combination Lamp Connector (2) PTO Switch Connector (R.H.)
Page 221: Disassembling And Assembling
L4100, WSM BRAKES 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 brake ball seats. (Do not grease excessively.) • Apply liquid gasket (Three Bond 1206C or equivalent) to joint face of the brake case and transmission case, around hole "A"...
Page 222: Servicing
L4100, 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 take care not damage the O-ring.
Page 223 L4100, WSM BRAKES Brake Plate Wear 1. Measure the brake plate thickness with vernier calipers. 2. If the measurement is less than the allowable limit, replace it. 2.54 to 2.66 mm Factory specification 0.100 to 0.104 in. Brake plate thickness 2.10 mm...
Page 224 FRONT AXLE KiSC issued 08, 2012 A...
Page 225 MECHANISM CONTENTS 1. STRUCTURE..........................6-M1 2. FRONT WHEEL ALIGNMENT....................6-M2 KiSC issued 08, 2012 A...
Page 226 L4100, WSM FRONT AXLE 1. STRUCTURE (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) Differential Case (3) Axle Flange (9) Differential Pinion (15) Bevel Gear...
Page 227: Front Wheel Alignment
L4100, WSM FRONT AXLE 2. FRONT WHEEL ALIGNMENT To assure smooth mobility or maneuverability and enhance stable and straight running, the front wheels are mounted at an angle to the right, left and forward directions. This arrangement is referred to as the Front Wheel Alignment.
Page 228 L4100, WSM FRONT AXLE Toe-in Viewing the front wheels from above reveals that the distance between the toes of the front wheels is smaller than that between the heels. It is called toe-in. The front wheels tend to roll outward due to the camber, but toe-in offsets it and ensures parallel rolling of the wheels.
Page 229 SERVICING CONTENTS 1. TROUBLESHOOTING.........................6-S1 2. SERVICING SPECIFICATIONS ....................6-S2 3. TIGHTENING TORQUES......................6-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............6-S4 [1] CHECKING AND ADJUSTING....................6-S4 [2] PREPARATION ........................6-S5 (1) Separating Front Axle Case From Front Axle Frame ............6-S5 [3] DISASSEMBLING AND ASSEMBLING ................6-S7 (1) Front Axle ........................6-S7 [4] SERVICING .........................6-S11 KiSC issued 08, 2012 A...
Page 230 L4100, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Wander Tire pressure uneven Adjust G-48 to Right or Left Improper toe-in adjustment (improper alignment) Adjust 6-S4 Clearance between front axle case boss and Replace 6-S15...
Page 231: Servicing Specifications
L4100, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 2 to 8 mm – 0.08 to 0.32 in. Front Wheel Axial Sway Less than – 5.0 mm 0.20 in. Spiral Bevel Pinion Shaft Turning Torque 0.98 to 1.1 N·m...
Page 232 L4100, WSM FRONT AXLE 3. TIGHTENING TORQUES Tightening torques of screws, and nuts on the table below are especially specified. (For general use screws, bolts and nuts: See page G-11.) Item N·m kgf·m lbf·ft Tie-rod joint lock nut 167 to 196 17.0 to 20.0...
Page 233: Checking, Disassembling And Servicing
L4100, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Park the tractor on flat ground. 2. Inflate the tires to the specified pressure. 3. Turn steering wheel so front wheels are in the straight ahead position.
Page 234: Preparation
L4100, WSM FRONT AXLE Adjusting Front Axle Pivot 1. Jack up the tractor body, then loosen the lock nut (2). 2. Measure the adjusting screw tightening torque. 3. If the measurement is not within the factory specifications, adjust the adjusting screw (1).
Page 235 L4100, WSM FRONT AXLE Propeller Shaft 1. Slide propeller shaft front cover (1) and rear cover (2) after removing screws (3). 2. Tap out spring pins (4), (5), slide couplings (6), (7), and then remove propeller shaft together with propeller shaft covers.
Page 236: Disassembling And Assembling
L4100, WSM FRONT AXLE Front Wheel and Front Axle Assembly 1. Check the front axle and engine are securely mounted on the disassembly stand. 2. Loosen the front wheel mounting nuts. 3. Lift the front axle and remove the front wheels.
Page 237 L4100, WSM FRONT AXLE Bevel Gear Case and Front Gear Case 1. Remove the bevel gear case mounting screws. 2. Remove the bevel gear case (3) and front gear case (4) as a unit from the front axle case (1).
Page 238 L4100, WSM FRONT AXLE Axle 1. Remove the bearing with a special use puller set. (Code No. 07916-09032) 2. Take out the bevel gear (2). 3. Take out the collar (1). 4. Take out the axle (3). (When reassembling) • Install the oil seal (5) of axle flange (4), nothing its direction as shown in the figure below.
Page 239 L4100, WSM FRONT AXLE Spiral Bevel Pinion Shaft and Differential Gear Assembly 1. Take out 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. Remove the spiral bevel pinion shaft (3) by the pinion shaft remover (14).
Page 240: Servicing
L4100, WSM FRONT AXLE Differential Gear 1. Remove the differential case cover mounting screws (9) and then take out 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 unit with a puller.
Page 241 L4100, WSM FRONT AXLE Clearance between Pinion Shaft and Differential Pinion 1. Measure the pinion O.D.. 2. Measure the differential pinion I.D. and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace the bushing. 0.0640 to 0.100 mm...
Page 242 L4100, WSM FRONT AXLE Backlash between Spiral Bevel Pinion Shaft and Spiral Bevel Gear 1. Set a 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 243 L4100, WSM FRONT AXLE Backlash between 11T Bevel Gear and 42T Bevel Gear 1. Place a strip of fuse to three spots on the 42T bevel gear (1) with grease. 2. Fix the axle flange and front gear case. 3. Turn the axle.
Page 244 L4100, 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. If the clearance exceeds the allowable limit, replace the bracket bushing.
Page 245 STEERING KiSC issued 08, 2012 A...
Page 246 MECHANISM CONTENTS 1. STRUCTURE..........................7-M1 [1] LINKAGE ..........................7-M1 [2] HYDRAULIC CIRCUIT ......................7-M2 [3] STEERING CONTROLLER....................7-M3 (1) Control Valve ........................7-M4 (2) Metering Device (Gerotor) ....................7-M4 (3) Relief Valve (with Check Valve) ..................7-M5 (4) Oil Flow........................... 7-M6 [4] STEERING CYLINDER ......................
Page 247: Structure
L4100, WSM STEERING 1. STRUCTURE [1] LINKAGE (1) Steering Wheel (3) Steering Shaft 2 (5) Steering Controller (7) Steering Cylinder (2) Steering Shaft 1 (4) Joint Shaft 2 (6) Hydraulic Pump Full hydrostatic type power steering is used on this tractor. The steering system is composed of steering wheel, steering controller, steering cylinder and other components shown in the figure.
Page 248: Hydraulic Circuit
L4100, WSM STEERING [2] HYDRAULIC CIRCUIT When the engine starts, the hydraulic pump (8) pressure-feeds the oil, drawn from the transmission case (7) thorough the oil fitter (6), to the steering controller (3). The oil which has entered steering controller (3) is directed to control valve (10).
Page 249: Steering Controller
L4100, WSM STEERING [3] STEERING CONTROLLER (1) Port Cover (4) Drive Plate (6) Valve Plate (8) Stator (2) Hex. Drive Assembly (5) Relief Valve (7) Drive Link (9) Upper Cover (3) Rotor The steering controller mainly consists of a control valve, a metering device and a relief valve with check valve.
Page 250: Control Valve
L4100, WSM STEERING (1) Control Valve The control valve is rotary plate type valve. WHen the steering wheel is not turned, the position od the valve plate (5) and the manifolds (1), (3) is kept neutral by the centering springs (2). This causes the forming of a "Neutral"...
Page 251: Relief Valve (With Check Valve)
L4100, WSM STEERING (3) Relief Valve (with Check Valve) If the pressure in the hydraulic circuit rises above the set pressure of the relief valve, the relief valve will actuate to prevent the pressure from rising further and protect the hydraulic system. Also, if no oil is supplied...
Page 252: Oil Flow
L4100, WSM STEERING (4) Oil Flow 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"...
Page 253 L4100, 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. (1) Steering Wheel...
Page 254: Steering Cylinder
L4100, WSM STEERING [4] 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 a single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.
Page 255 SERVICING CONTENTS 1. TROUBLESHOOTING.........................7-S1 2. SERVICING SPECIFICATIONS ....................7-S2 3. TIGHTENING TORQUES......................7-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............7-S4 [1] CHECKING..........................7-S4 (1) Relief Valve (Power Steering) ..................7-S4 [2] DISASSEMBLING AND ASSEMBLING ................7-S4 (1) Steering Post and Steering Controller ................7-S4 (2) Steering Cylinder ......................7-S7 [3] SERVICING ...........................7-S8 (1) Steering Cylinder ......................7-S8 KiSC issued 08, 2012 A...
Page 256 L4100, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Tractor Can Not Be Steering controller broken Replace 7-S6 Steered Hose broken Replace 7-S6 Front Wheels Improper toe-in adjustment Adjust 6-S4 Vibration Air in the hydraulic system Bleed 7-S4...
Page 257: Servicing Specifications
L4100, WSM STEERING 2. SERVICING SPECIFICATIONS STEERING CONTROLLER Item Factory Specification Allowable Limit Relief Valve Setting Pressure 10.7 to 11.6 MPa – Condition 109 to 119 kgf/cm • Engine Speed 1550 to 1690 psi Maximum • Oil Temperature 40 to 60 °C (104 to 140 °F)
Page 258 L4100, 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: See page G-11.) Item N·m kgf·m lbf·ft Power steering delivery hose joint bolt 49 to 58 5.0 to 6.0...
Page 259: Checking, Disassembling And Servicing
L4100, WSM STEERING 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING (1) Relief Valve (Power Steering) Relief Valve Setting Pressure 1. Disconnect the power steering delivery pipe joint bolt. 2. Install the adaptor E and adaptor 58 of relief valve setting pressure tester to the regulator valve, and then set a thread joint, cable and pressure gauge.
Page 260 L4100, WSM STEERING Steering Wheel and Rear Bonnet 1. Remove the steering wheel (1) with steering puller. 2. Remove the throttle grip (4). 3. Disconnect the hourmeter cable from engine. 4. Remove the meter panel (2). 5. Disconnect 4P connector (7) to main switch.
Page 261 L4100, WSM STEERING Steering Post Assembly Remove steering post assembly mounting screws (2) and then remove steering post assembly. (1) Steering Post Assembly (3) Steering Controller (2) Steering Post Assembly Mounting Screw 9Y1210278STS0007US0 Hydraulic Hoses 1. Disconnect the right delivery hose (3) and the left delivery hose (4).
Page 262: Steering Cylinder
L4100, 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. Pull out the cotter pin and remove the tie-rod and slotted nut.
Page 263: Servicing
L4100, WSM STEERING [3] 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. 55.012 to 55.062 mm Factory specification 2.1658 to 2.1678 in.
Page 264 HYDRAULIC SYSTEM KiSC issued 08, 2012 A...
Page 265 MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT ....................... 8-M1 2. HYDRAULIC PUMP........................8-M2 3. POSITION CONTROL VALVE ....................8-M3 4. HYDRAULIC CIRCUIT FOR THREE POINT HYDRAULIC SYSTEM ........8-M4 [1] HYDRAULIC OIL FLOW....................... 8-M4 5. HYDRAULIC CYLINDER......................8-M5 6. LINKAGE MECHANISM ......................8-M6 [1] POSITION CONTROL ......................
Page 266: Hydraulic Circuit
L4100, WSM HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT (1) Front Hydraulic Block (4) Auxiliary Control Valve (6) Power Steering COntroller (8) Oil Filter (2) Hydraulic Cylinder Block (Option) (Refer to STEERING Section) (9) Cylinder Safety Valve (3) Position Control Valve (5) Regulator Valve...
Page 267: Hydraulic Pump
L4100, WSM HYDRAULIC SYSTEM 2. HYDRAULIC PUMP The gear type hydraulic pump is adopted for this tractor. This pump is tandem type and it is composed two pair of gears, side plates, bushings and other components as shown in the figure.
Page 268: Position Control Valve
L4100, WSM HYDRAULIC SYSTEM 3. POSITION CONTROL VALVE (1) Three Point System Hydraulic (4) Position Control Valve (7) Quick Coupler (If Equipped) Delivery Lines Pump (5) Hydraulic Cylinder (8) Oil Tank (Transmission Case) Suction or Drain Lines (2) Front Hydraulic Block...
Page 269: Hydraulic Circuit For Three Point Hydraulic System
L4100, WSM HYDRAULIC SYSTEM 4. HYDRAULIC CIRCUIT FOR THREE POINT HYDRAULIC SYSTEM [1] HYDRAULIC OIL FLOW (1) Oil Tank (Transmission Case) (2) Hydraulic Oil Filter Cartridge (3) Engine (4) Three Point System Hydraulic Pump (5) Relief Valve (6) Front Hydraulic Block...
Page 270: Hydraulic Cylinder
L4100, WSM HYDRAULIC SYSTEM 5. HYDRAULIC CYLINDER (1) Lowering Speed Adjusting (4) Hydraulic Cylinder (8) Hydraulic Rod (12) Position Control Arm Knob (5) O-ring (9) Hydraulic Arm (13) Spool Drive Lever (2) Lowering Speed Adjusting (6) Back-up Ring (10) Hydraulic Arm Shaft...
Page 271: Linkage Mechanism
L4100, WSM HYDRAULIC SYSTEM 6. LINKAGE MECHANISM [1] POSITION CONTROL (1) Oil Position Control Lever (2) Control Arm (3) Spool Drive Lever (4) Spool Joint 1 (5) Spool Head (6) Valve Body (7) Feedback Lever Shaft (8) Feedback Lever (9) Feedback Rod...
Page 272 L4100, WSM HYDRAULIC SYSTEM Lifting 1. When the position control lever is moved to the LIFT position, the control arm (2) rotates to the arrow. Therefore, the spool drive lever (1) moves around the fulcrum P and pull the spool (3) opening the LIFT circuit.
Page 273 L4100, WSM HYDRAULIC SYSTEM Lowering 1. When the position control lever is moved to the Lowering position, the control arm (2) rotates to the arrow. Therefore, the spool drive lever (1) moves around the fulcrum P and push the spool (3) and poppet 2 (4) opening the Lowering circuit.
Page 274: Position Control With Draft Operation (If Equipped)
L4100, WSM HYDRAULIC SYSTEM [2] POSITION CONTROL WITH DRAFT OPERATION (IF EQUIPPED) Draft control is a system which maintains a constant traction load, and is suited for the work which needs heavy traction load such as plowing. The implement is automatically raised when its traction load is increased, and lowers when the traction load is decreased.
Page 275 L4100, WSM HYDRAULIC SYSTEM (1) Lift Arm (2) Hydraulic Arm Shaft (3) Feedback Rod Stay (4) Feedback Rod (5) Draft Cam (6) Draft Control Lever Shaft (7) Position Control Link (8) Position Control Lever (9) Draft Control Lever (10) Arm 2...
Page 276: Front Hydraulic Block
L4100, WSM HYDRAULIC SYSTEM 7. FRONT HYDRAULIC BLOCK (1) Cap To Implement Control Valve To Position Control Valve T1: To Transmission Case (2) Front Hydraulic Block From Implement Control From Hydraulic Valve T2: From Implement Control (3) Relief Valve Valve...
Page 277: Relief Valve
L4100, WSM HYDRAULIC SYSTEM 8. RELIEF VALVE The 3-point hydraulic circuit has a relief valve to restrict the maximum pressure in its circuit. This is a guide piston relief valve with damper, a direct acting relief valve suitable for relatively high...
Page 278 SERVICING CONTENTS 1. TROUBLESHOOTING.........................8-S1 2. SERVICING SPECIFICATIONS ....................8-S3 3. TIGHTENING TORQUES......................8-S5 4. CHECKING, DISASSEMBLING AND SERVICING ..............8-S6 [1] CHECKING AND ADJUSTING....................8-S6 (1) Hydraulic Pump Test Using Flow-meter (Power Steering) ..........8-S6 (2) Hydraulic Pump Test Using Flow-meter (Three Point Hydraulic System) .......8-S8 (3) Relief Valve (Three Point Hydraulic System) ..............8-S10 (4) Position Control Lever and Draft Control Lever.............8-S11 [2] DISASSEMBLING AND ASSEMBLING ................8-S13...
Page 279 L4100, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not Control linkage improperly adjusted Adjust 8-S11 Rise (Without Noise) Control linkage improperly assembled or Repair or replace 8-S21 damaged Position control valve malfunctioning Repair or replace...
Page 280 L4100, WSM HYDRAULIC SYSTEM Reference Symptom Probable Cause Solution Page Oil Temperature Relief valve operating Adjust 8-S10 Increases Rapidly Hydraulic pump leak or damaged Repair or replace 8-S13 Oil leaks from control valves Repair or replace 8-S18 Gear or bearing damaged in the transmission Replace –...
Page 281: Servicing Specifications
L4100, 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: 4.73 U.S.gals/min. Approx. 2600 min (rpm) 3.94 Imp.gals/min. • Rated Pressure: 10.7 to 11.6 MPa...
Page 282 L4100, WSM HYDRAULIC SYSTEM CONTROL LINKAGE Item Factory Specification Allowable Limit Position Control Lever Operating Force 20 to 34 N – (without draft control lever) 2.0 to 3.5 kgf 4.4 to 7.7 lbf 40 to 58 N – 4.0 to 6.0 kgf 8.9 to 13 lbf...
Page 283 L4100, 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: See page G-11.) Item N·m kgf·m lbf·ft Delivery pipe joint bolt 49 to 58 5.0 to 6.0...
Page 284: Checking, Disassembling And Servicing
L4100, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Hydraulic Pump Test Using Flow-meter (Power Steering) Preparation 1. Remove side cover RH (1). 2. Remove the power steering main delivery hose (2). (When reassembling) 49 to 58 N·m...
Page 285 L4100, WSM HYDRAULIC SYSTEM Hydraulic Flow Test (Power Steering) IMPORTANT • When using a flowmeter which is not specified by KUBOTA, be sure to follow the instructions for that flowmeter. • Since the flowmeter has no relief valve, do not close the flowmeter loading valve completely before testing.
Page 286: Hydraulic Pump Test Using Flow-Meter (Three Point Hydraulic System)
L4100, WSM HYDRAULIC SYSTEM (2) Hydraulic Pump Test Using Flow-meter (Three Point Hydraulic System) Preparation Remove 3P delivery pipe 2 (1) between hydraulic pump (2) and front hydraulic block (3). (When reassembling) • Apply grease to the O-ring and take care not to damage it.
Page 287 L4100, WSM HYDRAULIC SYSTEM Hydraulic Flow Test (3P Hydraulic System) IMPORTANT • When using a flowmeter which is not specified by KUBOTA, be sure to flow the instructions for that flowmeter. • Since the flowmeter has no relief valve, do not close the flowmeter loading valve completely before testing.
Page 288: Relief Valve (Three Point Hydraulic System)
L4100, WSM HYDRAULIC SYSTEM (3) Relief Valve (Three Point Hydraulic System) Relief Valve Setting Pressure 1. Remove the delivery pipe joint bolt from front hydraulic block. 2. Install the adaptor E. Then connect the hose and pressure gauge to adaptor E.
Page 289: Position Control Lever And Draft Control Lever
L4100, WSM HYDRAULIC SYSTEM (4) Position Control Lever and Draft Control Lever Position Control Lever and Draft Control Lever Operating Force 1. Apply grease to the position "A" shown in the figure and apply gear oil to the disc springs (3).
Page 290 L4100, WSM HYDRAULIC SYSTEM Adjusting Draft Control Rod <Adjustment at Scale "1"> 1. Before draft control rod adjustment, adjust the position control feedback rod. 2. Set the test bar (6) to the top link bracket holder (4). 3. Set the about 50 kg (500 N, 110 lbs) to the lower links connecting bar.
Page 291: Disassembling And Assembling
L4100, WSM HYDRAULIC SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Hydraulic Pump (Power Steering, Three Point Hydraulic System) Preparation 1. Remove the side cover RH (11). 2. Disconnect the independent PTO delivery pipe (5), power steering delivery hose (4) and power steering return hose (3) from the regulator valve (2).
Page 292 L4100, WSM HYDRAULIC SYSTEM 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) • Take care no to damage the gasket.
Page 293: Hydraulic Cylinder
L4100, WSM HYDRAULIC SYSTEM (2) Hydraulic Cylinder Preparation 1. Remove lift-rods (1), top link (2). 2. Remove seat (3). 3. Remove step cover (5). 4. Remove upper part of position control lever (10). 5. Remove the seat stay (6). 6. Clear wiring harness (11) from the hydraulic cylinder.
Page 294 L4100, WSM HYDRAULIC SYSTEM Hydraulic Cylinder 1. Loosen and remove the hydraulic cylinder assembly mounting screws and nuts. 2. Support the hydraulic cylinder assembly with nylon lift strap and hoist, and then take out it. (When reassembling) • Apply liquid gasket (Three Bond 1206C or equivalent) to joint face of the hydraulic cylinder assembly and transmission case after eliminate the water, oil and stuck liquid gasket.
Page 295 L4100, WSM HYDRAULIC SYSTEM Hydraulic Rod and Hydraulic Piston 1. Tap out the spring pin. 2. Remove the hydraulic rod. 3. Remove the plug (screw head size: 17 mm) from front of hydraulic cylinder. 4. Inject the compressed air through the plug hole, and take out the hydraulic piston.
Page 296: Position Control Valve
L4100, WSM HYDRAULIC SYSTEM Bushings 1. Remove the bushings (3) and (4). (When reassembling) • When press-fitting new bushings (3), (4) with a press-fitting tool (See page G-44) observe the dimensions described in the figure. • Apply transmission fluid to the hydraulic cylinder boss and bushing.
Page 297 L4100, WSM HYDRAULIC SYSTEM (1) Nut 1 (2) Set Screw (3) Plate 1 (4) Washer (5) Spring (6) Spring (7) Poppet 1 (8) Valve Seat (9) Valve Body (10) Sleeve (11) Backup Ring (12) Poppet 2 (13) Plug 1 (14) Screw...
Page 298: Relief Valve
L4100, WSM HYDRAULIC SYSTEM (4) Relief Valve Relief Valve 1. Remove the plug (9), and draw out the spring (5) and the poppet (4). 2. Take out the valve seat (3). (When reassembling) • Take care not to damage the O-rings.
Page 299: Position Control And Draft Control (If Equipped)
L4100, WSM HYDRAULIC SYSTEM (6) Position Control and Draft Control (If Equipped) Position Control and Draft Control Linkage (1) Feedback Rod stay (2) Feedback Rod (3) Draft Cam (4) Draft Control Lever Shaft (5) Position Control Link (6) Position Control Lever...
Page 300: Servicing
L4100, WSM HYDRAULIC SYSTEM [3] SERVICING (1) Hydraulic Pump (Power steering, Three Point System) Housing Bore (Depth of Scratch) 1. Check for the scratch on the interior surface of the housing caused by the gear. 2. If the scratch reaches more then half the area of the interior surface of the housing, replace at pump assembly.
Page 301: Cylinder Safety Valve
L4100, WSM HYDRAULIC SYSTEM Clearance between Hydraulic Arm Shaft and Bushing 1. Measure the hydraulic arm shaft O.D. with an outside micrometer. 2. Measurement the bushing I.D. with an inside micrometer, and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace the bushing.
Page 302: Electrical System
ELECTRICAL SYSTEM KiSC issued 08, 2012 A...
Page 303 MECHANISM CONTENTS 1. WIRING DIAGRAM........................9-M1 [1] TRACTOR WITHOUT OPC....................9-M1 [2] TRACTOR WITH OPC ......................9-M2 2. ELECTRICAL CIRCUIT ......................9-M3 [1] TRACTOR WITHOUT OPC....................9-M3 [2] TRACTOR WITH OPC ......................9-M4 3. ENGINE STARTING SYSTEM ....................9-M5 [1] TRACTOR WITHOUT OPC....................9-M5 (1) Electrical Circuit......................
Page 304: Wiring Diagram
L4100, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] TRACTOR WITHOUT OPC Tractor serial number is below 51174. 9-M1 (EU) KiSC issued 08, 2012 A...
Page 305: Tractor With Opc
L4100, WSM ELECTRICAL SYSTEM [2] TRACTOR WITH OPC Tractor serial number is above 51175. 9-M2 (EU) KiSC issued 08, 2012 A...
Page 306: Electrical Circuit
L4100, WSM ELECTRICAL SYSTEM 2. ELECTRICAL CIRCUIT [1] TRACTOR WITHOUT OPC Tractor serial number is below 51174. 9-M3 (EU) KiSC issued 08, 2012 A...
Page 307: Tractor With Opc
L4100, WSM ELECTRICAL SYSTEM [2] TRACTOR WITH OPC Tractor serial number is above 51175. 9-M4 (EU) KiSC issued 08, 2012 A...
Page 308: Engine Starting System
L4100, WSM ELECTRICAL SYSTEM 3. ENGINE STARTING SYSTEM [1] TRACTOR WITHOUT OPC (1) Electrical Circuit Tractor serial number is below 51174. (1) Battery (5) Starter Relay (8) Range Gear Shift Lever (10) Meter Panel (2) Slow Blow Fuse (6) Starter Motor...
Page 309: Tractor With Opc
L4100, WSM ELECTRICAL SYSTEM [2] TRACTOR WITH OPC (1) Electrical Circuit Tractor serial number is above 51175. (1) Battery (5) Starter Relay (8) Range Gear Shift Lever (10) Meter Panel (2) Slow Blow Fuse (6) Starter Motor (Shuttle Lever) Neutral Switch...
Page 310 L4100, WSM ELECTRICAL SYSTEM (2) Safety Switch [A] PTO Lever Neutral Switch The PTO neutral switch (2) is mounted to the portion of the PTO lever. It serves as a safety switch of engine starting and OPC system. It consists of 2 electric switches (3), (4).
Page 311: Electrical Circuit
L4100, WSM ELECTRICAL SYSTEM 4. OPC SYSTEM [1] ELECTRICAL CIRCUIT Tractor serial number is above 51175. (1) Battery (5) Key Stop Solenoid Relay (9) OPC Timer (13) Range Gear Shift Lever (2) Slow Blow Fuse (6) Slow Blow Fuse (10) Seat Switch...
Page 312 L4100, WSM ELECTRICAL SYSTEM OPC electrical circuit consists of the parts shown in the electrical circuit. The operator presence control (OPC) system which automatically stops the engine when operator stands up from the seat while shifting the PTO shift lever or range gear shift lever (shuttle shift lever).
Page 313: Opc Timer
L4100, WSM ELECTRICAL SYSTEM [2] OPC TIMER OPC timer (2) is located electrically at between the seat switch and the solenoid relay. When the current supply from the seat switch is cut, the OPC timer (2) adopted for the OPC system maintains the state of "ON"...
Page 314: Range Gear Shift Lever (Shuttle Lever) Neutral Switch
L4100, WSM ELECTRICAL SYSTEM (2) Range Gear Shift Lever (Shuttle Lever) Neutral Switch The range gear shift lever (shuttle lever) neutral switch (2) is mounted on the range gear shift lever (shuttle lever). It serves as a safety switch of engine starting and OPC system.
Page 315: Parking Brake Switch
L4100, WSM ELECTRICAL SYSTEM (4) Parking Brake Switch The parking brake switch (2) detects the position of the parking brake. The type of the switch is normal close type. It serves as a safety switch of OPC system. It consists of one electric switch.
Page 316: Trailer Socket
L4100, WSM ELECTRICAL SYSTEM 5. TRAILER SOCKET The trailer socket is provided to take out the electrical power from tractor to tailer or implement. Terminal Function Color of wire harness Turn signal light (L.H.) Green / White — — Ground Black Turn signal light (R.H.)
Page 317 SERVICING CONTENTS 1. TROUBLESHOOTING.........................9-S1 2. SERVICING SPECIFICATIONS ....................9-S4 3. TIGHTENING TORQUES......................9-S5 4. CHECKING, DISASSEMBLING AND SERVICING ..............9-S6 [1] CHECKING AND ADJUSTING....................9-S6 (1) Battery ..........................9-S6 (2) Main Switch ........................9-S7 (3) Safety Switch........................9-S9 (4) OPC Timer (OPC Model)....................9-S12 (5) Starter and Starter Relay....................9-S12 (6) Glow Control System.....................9-S13 (7) Engine Stop Solenoid ....................9-S14 (8) Charging System ......................9-S16...
Page 318 L4100, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Recharge or replace 9-S6 Equipments Do Not Battery positive cable disconnected or improperly Repair or replace 9-S6 Operate connected Battery negative cable disconnected or...
Page 319 L4100, WSM ELECTRICAL SYSTEM CHARGING SYSTEM Reference Symptom Probable Cause Solution Page Charging Lamp Does Fuse blown (10 A) Replace G-34 Not Light When Main Wiring harness disconnected or improperly Repair or replace – Switch is Turned ON connected (between main switch AC terminal...
Page 320 L4100, WSM ELECTRICAL SYSTEM EASY CHECKER Reference Symptom Probable Cause Solution Page Engine Oil Pressure Engine oil pressure too low Repair engine 1-S12 Lamp Lights Up Engine oil insufficient Replenish G-16 When Engine is Engine oil pressure switch defective Replace –...
Page 321: Servicing Specifications
L4100, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS GLOW PLUG Item Factory Specification Allowable Limit Glow Plug Resistance Approx. 0.9 Ω – STARTER MOTOR Item Factory Specification Allowable Limit Commutator O.D. 30.0 mm 29.0 mm 1.18 in. 1.14 in. Mica Undercut 0.50 to 0.80 mm...
Page 322 L4100, 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: See page G-11.) Item N·m kgf·m lbf·ft Alternator pulley nut 58.4 to 78.9 5.95 to 8.05...
Page 323: Checking, Disassembling And Servicing
L4100, WSM ELECTRICAL SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING 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. • Never remove the battery cap while the engine is running.
Page 324: Main Switch
L4100, WSM ELECTRICAL SYSTEM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
Page 325 L4100, WSM ELECTRICAL SYSTEM Main Switch Key at OFF Position 1. Turn the main switch off. 2. Measure the resistance with an ohmmeter across the B terminal and the AC terminal, B terminal and ST terminal, and B terminal and G terminal.
Page 326: Safety Switch
L4100, WSM ELECTRICAL SYSTEM (3) Safety Switch PTO Clutch Lever Switch 1. Disconnect PTO lever safety switch connectors (1), (5). 2. Connect the circuit tester to each connectors (1), (5) as shown in the pictures. 3. Measure the resistance between connectors (1), (5).
Page 327 L4100, WSM ELECTRICAL SYSTEM Range Gear Shift Lever (Shuttle Lever) Switch 1. Disconnect the 2P connector 1 (1) and the 2P connector 2 (5). 2. Connect the leads of the circuit tester to the 2P connector 1 (1) and the connector 2 (5).
Page 328 L4100, WSM ELECTRICAL SYSTEM Parking Brake Lever Switch 1. Disconnect the 2P connector (2). 2. Connect the leads of the circuit tester to the 2P connector (2). 3. Set the parking brake lever (1) to "FREE" and "LOCK" position as shown in the pictures.
Page 329: Opc Timer (Opc Model)
L4100, WSM ELECTRICAL SYSTEM (4) OPC Timer (OPC Model) OPC Timer (OPC Model) 1. Remove the OPC timer (1). (OPC timer is located behind the panel.) 2. Connect jumper leads across the battery positive terminal and the timer 3 terminal, and across the battery positive terminal and the timer 4 terminal referring to the figure.
Page 330: Glow Control System
L4100, WSM ELECTRICAL SYSTEM Magnet Switch Test 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter M terminal. 3. Remove the starter from the engine. 4. Disconnect the connecting lead (1) from the starter C terminal (2).
Page 331: Engine Stop Solenoid
L4100, WSM ELECTRICAL SYSTEM Glow Plug Continuity 1. Disconnect the lead from the glow plugs. 2. Measure the resistance between the glow plug terminal and the chassis. 3. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.
Page 332 L4100, WSM ELECTRICAL SYSTEM Stop Solenoid Coil (Hold Coil and Pull Coil) Hold Coil 1. Connect the lead to the terminal 1 of the engine stop solenoid (1). 2. Connect the lead to the body of the engine stop solenoid (1).
Page 333: Charging System
L4100, WSM ELECTRICAL SYSTEM (8) 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 9Y1210278ELS0012US0 Connector Voltage 1. Turn the main switch OFF. Measure the voltage between the B terminal (1) and the chassis.
Page 334: Combination Switch
L4100, WSM ELECTRICAL SYSTEM (9) Combination Switch 1. Turn off the main switch (1). 2. Remove the panel board (2). 3. Perform the following checkings. (1) Main Switch (2) Panel Board 9Y1210278ELS0014US0 Connector Voltage (Wire Harness Side) 1. Disconnect the 8P connector (1) from the combination switch.
Page 335 L4100, WSM ELECTRICAL SYSTEM Head Light Switch Continuity when Setting Switch at ON1 Position 1. Measure the resistance with an ohmmeter across the B1 terminal to the T terminal and the B1 terminal to the 1 terminal. 2. If 0 ohm is not indicated, renew the head light switch.
Page 336: Hazard Switch And Beacon Switch
L4100, WSM ELECTRICAL SYSTEM (10) Hazard Switch and Beacon Switch Hazard and Beacon Switch Continuity 1. Measure the resistance with ohmmeter between the a terminal and c terminal, between the d terminal and e terminal. 2. If the measurement is not the same as below, the hazard (1) or beacon switch (8) or the bulb is faulty.
Page 337 L4100, WSM ELECTRICAL SYSTEM Flasher Unit 1. Disconnect the connector from the flasher unit. 2. Turn the main switch at ON position. 3. Measure the voltage between the 12, 13 terminal and chassis. 4. If the voltage differ from the battery voltage, the wiring harness is faulty 12 terminal –...
Page 338: Fuel Lever Sensor
L4100, WSM ELECTRICAL SYSTEM (12) Fuel Lever Sensor Fuel Level Sensor 1. Remove the fuel level sensor from the fuel tank. 2. Measure the resistance across the sensor terminal and its body. 3. If resistance does not meet reference value, the sensor is faulty.
Page 339: Disassembling And Assembling
L4100, WSM ELECTRICAL SYSTEM [2] 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 340 L4100, WSM ELECTRICAL SYSTEM Rear End Cover 1. Unscrew the three rear end cover screws and the B terminal nut, and remove the rear end cover. WSM000001ELS0024US0 Brush Holder 1. Unscrew the two screws holding the brush holder, and remove the brush holder (1).
Page 341 L4100, WSM ELECTRICAL SYSTEM Rotor 1. Press out the rotor (1) from drive end frame (3). IMPORTANT • Take special care not to drop the rotor and damage the slip ring or fan, etc.. (1) Rotor (3) Drive End Frame...
Page 342: Servicing
L4100, WSM ELECTRICAL SYSTEM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any defect, 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 343 L4100, 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. Check the continuity across the commutator and armature coil core with an ohmmeter.
Page 344: Alternator
L4100, 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. 2. If the measurement is not within factory specification, replace it.
Page 345 L4100, 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 346 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 : ksos-pub@kubota.co.jp Printed in Japan 2012. 08, S, EI, EI, engusa Code No.9Y111-02781 2009.

wsm Kubota L4100 Workshop Manual

Information

General

1 Tractor Identification

2 General Precautions

3 Handing Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Maintenance

7 Check and Maintenance

8 Special Tools

9 Tires

Servicing

Servicing

Servicing

Servicing

1 Troubleshooting

2 Tightening Torques

3 Disassembling and Servicing

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Mechanism

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Mechanism

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Mechanism

1 Wiring Diagram

2 Electrical Circuit

3 Engine Starting System

4 Opc System

5 Trailer Socket

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Quick Links

Chapters

Troubleshooting

Related Manuals for wsm Kubota L4100

Summary of Contents for wsm Kubota L4100