Page 1 WORKSHOP MANUAL TRACTOR BX1800,BX2200 KiSC issued 07, 2006 A...
Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Tractors BX1800 and BX2200. It is divided into two parts, “Mechanism” and “Servicing” for each section. Mechanism Information on the construction and function are included.
Page 3 BX1800 · BX2200, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 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 4 BX1800 · BX2200, WSM SAFETY INSTRUCTIONS SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Do not alter or remove any part of machine safety system. • Before starting the engine, make sure that all shift levers are in neutral positions or in disengaged positions.
Page 5 BX1800 · BX2200, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 6: Safety Decals
BX1800 · BX2200, WSM SAFETY INSTRUCTIONS SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
Page 7 BX1800 · BX2200, WSM SAFETY INSTRUCTIONS KiSC issued 07, 2006 A...
Page 8: Specifications
BX1800 · BX2200, WSM SPECIFICATIONS SPECIFICATIONS Model BX1800 BX2200 PTO power 10.2 kW (13.7 HP)* 12.4 kW (16.7 HP)* Maker KUBOTA Model D722-E-BX D905-E-BX Type Indirect Injection. Vertical, water-cooled, 4-cycle diesel Number of cylinders 67 × 68 mm (2.64 × 2.68 in.) 72 ×...
Page 9 BX1800 · BX2200, WSM TRAVELLING SPEEDS TRAVELLING SPEEDS Model BX1800, BX2200 26 × 12.00 – 12 Tire size (Rear) Range gear shift km/h mile/h lever 0 to 5.9 0 to 3.7 Forward High 0 to 13.0 0 to 8.1 0 to 4.5 0 to 2.8...
Page 10 BX1800 · BX2200, WSM DIMENSIONS DIMENSIONS KiSC issued 07, 2006 A...
Page 11 GENERAL KiSC issued 07, 2006 A...
Page 12: Table Of Contents
GENERAL CONTENTS 1. TRACTOR IDENTIFICATION ................. G-1 2. GENERAL PRECAUTIONS ................G-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3 [1] WIRING...................... G-3 [2] BATTERY....................G-5 [3] FUSE......................G-5 [4] CONNECTOR .................... G-5 [5] HANDLING OF CIRCUIT TESTER............G-6 4.
Page 13: Tractor Identification
BX1800 · BX2200, WSM G GENERAL 1. TRACTOR IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number, tractor serial number and hour meter reading. (1) Tractor Identification Plate (3) Engine Serial Number (2) Tractor Serial Number (4) Hour Meter...
Page 14: General Precautions
BX1800 · BX2200, WSM G GENERAL 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. 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 15: Handling Precautions For Electrical Parts And Wiring
BX1800 · BX2200, WSM G GENERAL 3. HANDLING 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...
Page 16 BX1800 · BX2200, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W10114580 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 17: Battery
BX1800 · BX2200, WSM G 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.
Page 18: Handling Of Circuit Tester
BX1800 · BX2200, WSM G 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) Bend Terminal (4) Rust W10123460 • Make certain that there is no female connector being too open.
Page 19: Lubricants, Fuel And Coolant
BX1800 · BX2200, WSM G GENERAL 4. LUBRICANTS, FUEL AND COOLANT Capacity Place Lubricants, fuel and coolant BX1800 BX2200 21.0 L No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below −10 °C Fuel tank 5.5 U.S.gals. 4.6 Imp.gals.
Page 20: Tightening Torques
BX1800 · BX2200, WSM G 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...
Page 21: American Standard Screws, Bolts And Nuts With Unc Or Unf Threads
BX1800 · BX2200, WSM G GENERAL [3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS Grade SAE GR.5 SAE GR.8 Unit N·m kgf·m ft-lbs N·m kgf·m ft-lbs Nominal Diameter 5/16 23.1 to 27.8 2.35 to 2.84 17.0 to 20.5 32.5 to 39.3...
Page 22: Maintenance Check List
BX1800 · BX2200, WSM G GENERAL 6. MAINTENANCE CHECK LIST Period After Indication on hour meter Refer- purchase Impor- ence tant page 50 100 150 200 250 300 350400 450 500 550 600 650 700 750 80015003000 Item year years...
Page 23: Check And Maintenance
BX1800 · BX2200, WSM G GENERAL 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the tractor on a flat place with engine shut off, the parking brake on and chock the wheels. [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the tractor. Check the following items before starting.
Page 24: Check Points Of Initial 50 Hours
BX1800 · BX2200, WSM G GENERAL [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Be sure to stop the engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine.
Page 25 BX1800 · BX2200, WSM G GENERAL Replacing Transmission Oil Filter Cartridge CAUTION • Be sure to stop the engine before changing the oil filters. 1. Remove the oil filter cartridge by using a filter wrench. 2. Apply a slight coat of oil onto the cartridge gasket.
Page 26: Check Points Of Every 50 Hours
BX1800 · BX2200, WSM G GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System CAUTION • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test do not operate the tractor.
Page 27: Check Points Of Every 100 Hours
BX1800 · BX2200, WSM G GENERAL Checking Wheel Mounting Screws Tightening Torque CAUTION • Never operate tractor with a loose rim, wheel, or axle. • Any time screws are loosened, retighten to specified torque. • Check all screws frequently and keep them tight.
Page 28 BX1800 · BX2200, WSM G 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 29 BX1800 · BX2200, WSM G GENERAL Cleaning Air Cleaner Element 1. Remove the air cleaner cover (2) and element (1). 2. Clean the element if: - 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 30 BX1800 · BX2200, WSM G GENERAL Checking Fuel Lines and Fuel Filter 1. The fuel line is made of rubber and ages regardless of service period. 2. After inspection, if the fuel line and clamps are found damaged or deteriorated, replace them.
Page 31 BX1800 · BX2200, WSM G GENERAL Adjusting HST Neutral Spring (Speed Control Pedal) CAUTION • To avoid personal injury: Do not operate if tractor moves on level ground with foot off speed control pedal. −1 1. Start the engine and set at low idle (approx. 1500 min (rpm)).
Page 32: Check Points Of Every 200 Hours
BX1800 · BX2200, WSM G GENERAL [5] CHECK POINTS OF EVERY 200 HOURS Replacing Engine Oil Filter Cartridge 1. See page G-12. W1018516 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.
Page 33: Check Points Of Every 300 Hours
BX1800 · BX2200, WSM G GENERAL Checking Intake Air Line 1. Check to see that hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found to be worn or damaged, replace or repair them at once.
Page 34: Check Points Of Every 400 Hours
BX1800 · BX2200, WSM G GENERAL Cleaning Transmission Oil Strainer 1. Remove the strainer and clean with nonflammable solvent. NOTE • When reassembling be careful not to damage the parts. • Since the fine fillings in the oil can damage the precision...
Page 35: Check Points Of Every 500 Hours
BX1800 · BX2200, WSM G GENERAL [8] CHECK POINTS OF EVERY 500 HOURS Replacing Fuel Filter 1. Disconnect the fuel hoses and replace the fuel filter (2). 2. Disconnect the fuel hoses and loosen the filter band to replace the fuel filter (3).
Page 36: Check Points Of Every 2 Years
BX1800 · BX2200, WSM G GENERAL [13] CHECK POINTS OF EVERY 2 YEARS Replacing Radiator Hose (Water Pipes) 1. Replace the hoses and clamps. Refer to “Checking Radiator Hose and Hose Clamp”. (See page G-20.) W1020468 Replacing Power Steering Hose 1.
Page 37: Others
BX1800 · BX2200, WSM G GENERAL Flash Cooling System and Changing Coolant (Continued) Anti-Freeze If coolant freezes, it can damage the cylinders and radiator. It is necessary, if the ambient temperature falls below 0 °C (32 °F), to remove coolant after operating or to add anti-freeze to it.
Page 38 BX1800 · BX2200, WSM G 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 39: Special Tools
BX1800 · BX2200, WSM G 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. W1024050 Piston Ring Compressor Code No:...
Page 40 BX1800 · BX2200, WSM G 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 41 BX1800 · BX2200, WSM G GENERAL Plastigage Code No: 07909-30241 Application: Use to check the oil clearance between crankshaft and bearing, etc. Measuring: Green ..0.025 to 0.076 mm (0.001 to 0.003 in.) range Red ..0.051 to 0.152 mm (0.002 to 0.006 in.) Blue ..
Page 42 BX1800 · BX2200, WSM G GENERAL Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. D722-E-BX 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.) 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) 200 mm (7.87 in.)
Page 43 BX1800 · BX2200, WSM G GENERAL Bushing Replacing Tool Application: Use to press out and to press fit the bushing. D722-E-BX 1. For small end bushing 145 mm (5.71 in.) 20 mm (0.79 in.) 100 mm (3.94 in.) 19.90 to 19.95 mm (0.7835 to 0.7854 in.) 21.90 to 21.95 mm dia.
Page 44 BX1800 · BX2200, WSM G GENERAL Flywheel Stopper Application: Use to loosen and tighten the flywheel screw. 200 mm (7.87 in.) 20 mm (0.79 in.) 30 mm (1.18 in.) 8 mm (0.31 in.) 10 mm dia. (0.39 in. dia.) W1025948...
Page 45 BX1800 · BX2200, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. D722-E-BX [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 1.57 rad. (40 °) 10 mm (0.39 in.) 22 mm (0.87 in.)
Page 46: Special Tools For Tractor
BX1800 · BX2200, WSM G GENERAL Governor Gear Holder Bushing Replacing Tool Application: Use to press out and to press fit the governor gear holder bushing. 188 mm (7.4 in.) 18 mm (0.7 in.) 150 mm (5.9 in.) C1 : Chamfer 1.0 mm (0.039 in.) 73.9 to 74.0 mm dia.
Page 47: Tires
BX1800 · BX2200, WSM G GENERAL 9. TIRES [1] TIRE PRESSURE CAUTION • Do not attempt mount a tire. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure as shown below.
Page 48: Tire Liquid Injection
BX1800 · BX2200, WSM G GENERAL [3] TIRE LIQUID INJECTION Auxiliary weights can be used to increase traction force for plowing in fields or clayey grounds. 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 49 BX1800 · BX2200, WSM G 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 50: Implement Limitations
BX1800 · BX2200, WSM G GENERAL 10. IMPLEMENT LIMITATIONS The KUBOTA Tractor has been thoroughly tested for proper performance with implements sold or approved by KUBOTA. Use with implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Tractor may result in malfunctions or failures of the tractor, damage to other property and injury to the operator or others.
Page 51 BX1800 · BX2200, WSM G GENERAL Implement Remarks BX1800 BX2200 Max. Cutting Width 1524 mm (60 in.) Mid-Mount Max.Weight 140 kg (309 lbs) Max. Cutting Width 1067 mm (42 in.) Rotary-Cutter (1 Blade) Max.Weight 140 kg (309 lbs) Mower Max. Cutting Width 1524 mm (60 in.)
Page 52 ENGINE KiSC issued 07, 2006 A...
Page 53 MECHANISM CONTENTS 1. ENGINE BODY ..................... 1-M1 [1] CYLINDER BLOCK................. 1-M1 [2] CYLINDER HEAD ................... 1-M2 [3] CRANKSHAFT..................1-M3 [4] PISTON AND PISTON RINGS ............. 1-M3 [5] CONNECTING ROD ................1-M4 [6] CAMSHAFT ..................... 1-M4 [7] FUEL CAMSHAFT .................. 1-M5 [8] ROCKER ARM..................
Page 54: Engine Body
BX1800 · BX2200, WSM ENGINE 1. ENGINE BODY [1] CYLINDER BLOCK The engine has a high durability tunnel-type cylinder block in which the crank bearing component is a constructed body. Furthermore, liner less type, allow effective cooling, less distortion, and greater wear-resistance.
Page 55: Cylinder Head
BX1800 · BX2200, WSM ENGINE [2] CYLINDER HEAD The cross-flow tape intake / exhaust ports in this engine have their openings at both sides of the cylinder head. Because overlaps of intake / exhaust ports are smaller than in ports of other types which have openings on one side, the suction air can be protected from being heated and expanded by heated exhaust air.
Page 56: Crankshaft
BX1800 · BX2200, WSM ENGINE [3] CRANKSHAFT The crankshaft with the connecting rod converts the reciprocating motion of the piston into the rotating motion. The crankshaft is made of tough special alloy steel, and the journals, pins and oil seal sliding portions are induction hardened to increase the hardness for higher wear resistance.
Page 57: Connecting Rod
BX1800 · BX2200, WSM ENGINE [5] CONNECTING ROD The connecting rod (2) is used to connect the piston with the crankshaft. The big end of the connecting rod has a crankpin bearing (3) (split type) and the small end has a small end bushing (1) (solid type).
Page 58: Fuel Camshaft
BX1800 · BX2200, WSM ENGINE [7] FUEL CAMSHAFT The fuel camshaft (2) controls the reciprocating movement of the injection pump. The fuel camshaft is made of carbon steel and the cam sections are quenched and tempered to provide greater wear resistance.
Page 59: Intake And Exhaust Valve
BX1800 · BX2200, WSM ENGINE [9] INTAKE AND EXHAUST VALVE The intake and exhaust valves (7), (8) and their guides (6) are different from each other. Other parts, such as valve springs (4), valve spring retainers (2), valve spring collets (3), valve stem seals (5) and valve caps (1) are the same for both the inlet and exhaust valves.
Page 60: Air Cleaner
BX1800 · BX2200, WSM ENGINE [12] AIR CLEANER The air cleaner is of a dry type with evacuator valve (2) for easy maintenance. The dust, while circulating in the air flow, is absorbed by the element (1) and thus prevented from entering the engine.
Page 61: Lubricating System
BX1800 · BX2200, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Governor Shaft Gear (D905 Only) (6) Idle Gear (7) Crankshaft (8) Oil Pump (9) Oil Strainer (10) Relief Valve...
Page 62: Oil Pump
BX1800 · BX2200, WSM ENGINE [1] OIL PUMP D722-E-BX The oil pump is a trochoid pump. Inside the pump body, the 4 lobe inner rotor (2) is eccentrically engaged with the 5 lobe outer rotor (1). The inner rotor is driven by the crankshaft, which in turn rotate the outer rotor.
Page 63: Relief Valve
BX1800 · BX2200, WSM ENGINE [2] RELIEF VALVE The relief valve prevents the damage of the lubricating system due to high oil pressure. This relief valve is a ball type direct acting relief valve, and is best suited for low pressures.
Page 64: Oil Pressure Switch
BX1800 · BX2200, WSM ENGINE [4] OIL PRESSURE SWITCH The oil pressure switch is mounted on the cylinder block, to warn the operator that the lubricating oil pressure is poor. If the oil pressure falls below the specified value, the oil warning lamp will light up, warning the operator.
Page 65: Cooling System
BX1800 · BX2200, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (2) Water Pump (3) Cooling Fan (4) Thermostat (5) Cylinder Head Water Jacket (6) Cylinder Block Water Jacket W1016367 The cooling system consists of a radiator (1), a centrifugal water pump (2), a cooling fan (3) and a thermostat (4).
Page 66: Thermostat
BX1800 · BX2200, WSM ENGINE [2] THERMOSTAT The thermostat maintains the coolant at correct temperature. KUBOTA’s engine uses a wax pellet type thermostat. Wax is enclosed in the pellet. The wax is solid at low temperatures, but turns liquid at high temperatures, expands and opens the valve.
Page 67: Radiator Cap
BX1800 · BX2200, WSM ENGINE [4] RADIATOR CAP The pressure type cap is installed on the radiator, which prevents the pressure difference between the inside and the outside of the radiator from deforming the radiator. (A) At high pressure (higher than 88 kPa, 0.9 kgf/cm...
Page 68: Fuel System
BX1800 · BX2200, WSM ENGINE 4. FUEL SYSTEM [1] FUEL LINE (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Tank 2 (5) Fuel Filter (6) Fuel Feed Pump (7) Fuel Filter (8) Injection Pump (9) Injection Pipe...
Page 69: Fuel Pump
BX1800 · BX2200, WSM ENGINE [3] FUEL PUMP An electro magnetic fuel pump uses a transistor that causes the pump to start pumping fuel when the main switch is turned to the “ON” position. Therefore, fuel is supplied to the injection pump regardless of engine speed.
Page 70 BX1800 · BX2200, WSM ENGINE Injection Control 1. No fuel delivery (Engine stop) At the engine stop position of the control rack (3), the lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). And the delivery chamber (4) is led to the feed hole during the entire stroke of the plunger.
Page 71 BX1800 · BX2200, WSM ENGINE Delivery Valve The delivery valve consists of the delivery valve (1) and delivery valve seat (2). The delivery valve performs the following functions. 1. Reverse flow preventing function If the fuel flow reverse from the injection nozzle side when the plunger lowers, the time lag between the next delivery start and the nozzle injection start increases.
Page 72: Injection Nozzle
BX1800 · BX2200, WSM ENGINE [5] INJECTION NOZZLE This nozzle is of a flat cut provided double throttle type. This type of nozzle is designed to control the injection quantity when the lift rate is low at start of the...
Page 73: Governor
BX1800 · BX2200, WSM ENGINE [6] GOVERNOR (1) D722-E-BX The governor controls the amount of the fuel to be fed in the entire speed range to prevent the engine from changing its speed according to the load. The fork lever 1 (3) is held where two forces on it are balanced.
Page 74: D905-E-Bx
BX1800 · BX2200, WSM ENGINE At maximum speed running with an overload When the engine is overloaded at the high speeds and the engine speed drops, the centrifugal force of the steel ball (6) decreases and the governor spring (2) pulls fork lever 1 (1) and 2 (3).
Page 75 BX1800 · BX2200, WSM ENGINE At Start As no centrifugal force is applied to flyweight (6), low tension of start spring (1) permits control rack to move to the starting position, supplying the amount of fuel required to start the engine.
Page 76 SERVICING CONTENTS 1. TROUBLESHOOTING ..................1-S1 2. SERVICING SPECIFICATIONS ..............1-S4 [1] D722-E-BX ....................1-S4 [2] D905-E-BX ....................1-S9 3. TIGHTENING TORQUES ................1-S15 4. CHECKING, DISASSEMBLING AND SERVICING........1-S17 [1] SEPARATING ENGINE .................1-S17 (1) Draining Coolant and Engine Oil............1-S17 [2] ENGINE BODY ..................1-S20 (1) Checking and Adjusting ..............1-S20 (2) Disassembling and Assembling ............1-S23 (3) Servicing ...................1-S37 [3] LUBRICATING SYSTEM ...............1-S62...
Page 77 BX1800 · BX2200, 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-25 • Water in the fuel system Change fuel and G-18...
Page 78 BX1800 · BX2200, WSM ENGINE Reference Symptom Probable Cause Solution Page Either Black or Dark • Overload Loosen load – Gray Exhaust Gas Is • Low grade fuel used Use specified fuel Observed • Fuel filter clogged Replace G-18 • Air cleaner clogged...
Page 79 BX1800 · BX2200, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Overheated • Engine oil insufficient Replenish • Fan belt broken or tensioned improperly Replace or adjust G-18 • Coolant insufficient Replenish • Radiator net and radiator fin clogged with Clean –...
Page 80 BX1800 · BX2200, WSM ENGINE 2. SERVICING SPECIFICATIONS [1] D722-E-BX ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.50 to 0.70 mm – 0.0197 to 0.0276 in. Compression Pressure 2.84 to 3.24 MPa 2.26 MPa...
Page 81 BX1800 · BX2200, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm 1.232 to 1.252 in. 1.118 in. Setting Load 64.7 N 54.9 N 6.6 kgf 5.6 kgf 14.6 lbs 12.3 lbs...
Page 82 BX1800 · BX2200, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.043 to 0.124 mm 0.15 mm 0.00169 to 0.00488 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.047 to 0.123 mm 0.15 mm...
Page 83 BX1800 · BX2200, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.028 to 0.059 mm 0.20 mm 2 (Flywheel Side) 0.00110 to 0.00232 in. 0.0079 in. Crankshaft Journal O.D. 43.978 to 43.993 mm –...
Page 84 BX1800 · BX2200, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Thermostat Valve Opening 80.5 to 83.5 °C – Temperature 176.9 to 182.3 °F (At Beginning) Valve Opening 95 °C – Temperature 203 °F (Opened Completely) Radiator Water Leakage No leaks at –...
Page 85 BX1800 · BX2200, WSM ENGINE [2] D905-E-BX ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.55 to 0.70 mm – 0.0217 to 0.0276 in. Compression Pressure (When Cranking with Starting Motor) 2.84 to 3.24 MPa...
Page 86 BX1800 · BX2200, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Spring Free Length 37.0 to 37.5 mm 36.5 mm 1.457 to 1.476 in. 1.437 in. Setting Load 117.6 N 100.0 N 12.0 kgf 10.2 kgf 26.4 lbs 22.5 lbs...
Page 87 BX1800 · BX2200, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Crank Gear to Idle Gear Backlash 0.032 to 0.115 mm 0.15 mm 0.00126 to 0.00453 in. 0.0059 in. Idle Gear to Cam Gear Backlash 0.036 to 0.114 mm 0.15 mm...
Page 88 BX1800 · BX2200, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.034 to 0.114 mm 0.20 mm 0.00134 to 0.00449 in. 0.0079 in. Crankshaft Journal O.D. 47.934 to 47.950 mm –...
Page 89 BX1800 · BX2200, WSM ENGINE LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed More than 49 kPa – 0.5 kgf/cm 7 psi At Rated Speed 196 to 441 kPa 147 kPa 2.0 to 4.5 kgf/cm 1.5 kgf/cm...
Page 90 BX1800 · BX2200, WSM ENGINE FUEL SYSTEM Item Factory Specification Allowable Limit Injection Pump Injection Timing 0.35 to 0.38 rad. – 20 to 22 ° before T.D.C. Pump Element Fuel Tightness – 14.7 MPa 150 kgf/cm 2133 psi Delivery Valve...
Page 91 BX1800 · BX2200, 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-8.) Item N·m kgf·m ft-lbs Cushion mounting nut 48.1...
Page 92 BX1800 · BX2200, WSM ENGINE [D905-E-BX] Size × Pitch Item N·m kgf·m ft-lbs M10 × 1.25 Air cleaner stay nut 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2 M6 × 1.0 * Bearing case cover screw 9.8 to 11.3 1.00 to 1.15...
Page 93 BX1800 · BX2200, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] SEPARATING ENGINE (1) Draining Coolant and Engine Oil Draining Coolant CAUTION • Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator.
Page 94 BX1800 · BX2200, WSM ENGINE Battery CAUTION • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Remove the under panel (1). 2. Disconnect the negative cable (2) from the battery.
Page 95 BX1800 · BX2200, WSM ENGINE Bonnet Post, Support and Others 1. Disconnect the wire harness (4) and battery positive cable (3). 2. Disconnect the accelerator wire (5). 3. Remove the intake pipe (7). 4. Remove the supports (1), (6) and bonnet post (2).
Page 96 BX1800 · BX2200, WSM ENGINE [2] ENGINE BODY (1) Checking and Adjusting Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Disconnect the 2P connector from the fuel pump. 4. Remove the air cleaner, the muffler and all injection nozzles.
Page 97 BX1800 · BX2200, WSM ENGINE Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.) 2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
Page 98 BX1800 · BX2200, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs. 2. Align the “1TC” mark (1) on the flywheel and alignment mark (2) on the rear end plate so that the No.
Page 99 BX1800 · BX2200, WSM ENGINE (2) Disassembling and Assembling (A) Cylinder Head and Valves Alternator, Fan Belt and Muffler 1. Disconnect the radiator hoses and separate the radiator (9) with recovery tank (7) from engine assembly. 2. Remove the cooling fan (10) and fan pulley.
Page 100 BX1800 · BX2200, WSM ENGINE Injection Pipes 1. Loosen the screws on the pipe clamps. 2. Detach the injection pipes. (When reassembling) • Sent compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order.
Page 101 BX1800 · BX2200, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp, and remove the water return pipe. 2. Remove the cylinder head screw in the order of (n) to (a). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring (1).
Page 102 BX1800 · BX2200, WSM ENGINE (B) Timing Gears, Camshaft and Fuel Camshaft [D722-E-BX] Injection Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (3). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the spring (4).
Page 103 BX1800 · BX2200, WSM ENGINE Gear Case 1. Remove the screw (1) of inside the gear case and outside screws. 2. Disconnect the start spring (2) in the speed control plate mounting hole. 3. Remove the gear case (3). (When reassembling) •...
Page 104 BX1800 · BX2200, WSM ENGINE Fuel Camshaft 1. Remove the screws and draw out the camshaft with the gear on 2. Remove the retaining plate (1). 3. Remove the screws, then draw out the injection pump gear (2) and fuel camshaft (3) with the governor fork assembly.
Page 105 BX1800 · BX2200, WSM ENGINE Water Pump 1. Remove the water pump flange. (When reassembling) • Before installing the water pump flange gasket, apply liquid gasket (Three Bond 1215 or equivalent) to the both side. W1017530 Gear Case 1. Remove the gear case.
Page 106 BX1800 · BX2200, WSM ENGINE Injection Pump 1. Remove the injection pump mounting screws and nuts. 2. Align the control rack pin (2) with the notch (3) on the crankcase, then remove the injection pump (1). 3. Remove the injection pump timing shims.
Page 107 BX1800 · BX2200, WSM ENGINE Governor Shaft 1. Remove the pump cover. 2. Remove the external snap ring (1) from the governor shaft (2). 3. Pull out the governor shaft (2). (When reassembling) • Make sure assembling the external snap ring of the governor shaft.
Page 108 BX1800 · BX2200, WSM ENGINE Fork Lever 1. Remove the start spring (7). 2. Remove the fork lever shaft cover (1). 3. Pull out the fork lever shaft (4), and remove the spacer (2), bearing (3), fork levers 1 (6) and 2 (5).
Page 109 BX1800 · BX2200, WSM ENGINE (D) Piston and Connecting Rod Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws. 2. Remove the oil pan (4) by lightly tapping the rim of the pan with a wooden hammer.
Page 110 BX1800 · BX2200, WSM ENGINE Pistons 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer.
Page 111 BX1800 · BX2200, WSM ENGINE Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) •...
Page 112 BX1800 · BX2200, WSM ENGINE (E) Crankshaft Flywheel 1. Fit the stopper to the flywheel. 2. Remove all flywheel screws and then remove the flywheel. (When reassembling) • Fit the flywheel giving care to the position of the knock pin.
Page 113 BX1800 · BX2200, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1, and remove the main bearing case assembly, being careful with thrust bearing and crankshaft bearing 2. 2. Remove the main bearing case assembly 1 and 2 as above.
Page 114 BX1800 · BX2200, WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check (Code No. 07909-31371). 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the read permeative liquid (1).
Page 115 BX1800 · BX2200, WSM ENGINE Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.
Page 116 BX1800 · BX2200, WSM ENGINE Valve Seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows.
Page 117 BX1800 · BX2200, WSM ENGINE Valve Lapping 1. Apply compound evenly to the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.
Page 118 BX1800 · BX2200, WSM ENGINE Valve Spring Setting Load 1. Place the valve spring on a tester and compress it to the same length it is actually compressed in the engine. 2. Read the compression load on the gauge. 3. If the measurement is less than the allowable limit, replace it.
Page 119 BX1800 · BX2200, 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 120 BX1800 · BX2200, WSM ENGINE (B) Timing Gears, Camshaft and Fuel Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear.
Page 121 BX1800 · BX2200, 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 122 BX1800 · BX2200, WSM ENGINE Cam Height 1. Measure the height of the cam at its highest point with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. [D722] 26.88 mm Factory spec.
Page 123 BX1800 · BX2200, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.
Page 124 BX1800 · BX2200, WSM ENGINE (C) 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 125 BX1800 · BX2200, WSM ENGINE Replacing Small End Bushing (When removing) 1. Press out the used bushing using a small end bushing replacing tool. (When installing) 1. Clean a new small end bushing and bore, and apply engine oil to them.
Page 126 BX1800 · BX2200, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston ring compressor and piston. 2. Measure the ring gap with a feeler gauge.
Page 127 BX1800 · BX2200, WSM ENGINE Connecting Rod Alignment 1. Remove the crankpin bearing, and install the connecting rod cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661).
Page 128 BX1800 · BX2200, WSM ENGINE Crankshaft Side Clearance (Continued) • Oversize dimensions of crankshaft journal [D722] 0.2 mm 0.4 mm Oversize 0.008 in. 0.016 in. 23.40 to 23.45 mm 23.80 to 23.85 mm Dimension A 0.9134 to 0.9154 in. 0.9213 to 0.9232 in.
Page 129 BX1800 · BX2200, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) 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 130 BX1800 · BX2200, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing (Continued) (Reference) • Undersize crankpin bearing [D722] Undersize Bearing Code Number Marking 0.2 mm Crankpin bearing 02 15861-22970 020 US 0.008 in. 0.4 mm Crankpin bearing 04 15861-22980 040 US 0.016 in.
Page 131 BX1800 · BX2200, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
Page 132 BX1800 · BX2200, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 (Continued) (Reference) • Undersize crankshaft bearing 1 [D722] Undersize Bearing Code Number Marking 0.2 mm Crankshaft bearing 1 15861-23910 020 US 0.008 in. 0.4 mm Crankshaft bearing 1...
Page 133 BX1800 · BX2200, WSM ENGINE Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
Page 134 BX1800 · BX2200, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigage (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
Page 135 BX1800 · BX2200, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 (Continued) (Reference) • Undersize crankshaft bearing 2 and 3 [D722] Undersize Bearing Code Number Marking Crankshaft bearing 2 02 15694-23930 020 US 0.2 mm...
Page 136 BX1800 · BX2200, WSM ENGINE (E) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s.
Page 137 BX1800 · BX2200, WSM ENGINE Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. [D722] 67.250 to 67.269 mm Factory spec. 2.64764 to 2.64839 in. Oversized cylinder liner I.D.
Page 138 BX1800 · BX2200, WSM ENGINE [3] LUBRICATING SYSTEM (1) Checking Engine Oil Pressure 1. Remove the engine oil pressure switch, and set a oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 139 BX1800 · BX2200, WSM ENGINE Clearance between Rotor and Cover 1. Put a strip of plastigage (Code No. 07909-30241) onto the rotor face with grease. 2. Install the cover and tighten the screws. 3. Remove the cover carefully, and measure the amount of the flattening with the scale and get the clearance.
Page 140 BX1800 · BX2200, WSM ENGINE Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string.
Page 141 BX1800 · BX2200, WSM ENGINE (2) Disassembling and Assembling Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
Page 142 BX1800 · BX2200, WSM ENGINE [5] FUEL SYSTEM (1) Checking and Adjusting (A) Injection Pump Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder.
Page 143 BX1800 · BX2200, WSM ENGINE Fuel Tightness of Delivery Valve 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Set a pressure tester to the fuel injection pump. 4. Turn the flywheel and raise the pressure to approx. 14.7 MPa (150 kgf/cm , 2130 psi).
Page 144 BX1800 · BX2200, WSM ENGINE Fuel Injection Pressure 1. Set the injection nozzle to a nozzle tester (Code No. 07909- 31361). 2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.
Page 145 BX1800 · BX2200, WSM ENGINE (2) Disassembling and Assembling (A) Injection Nozzle Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil.
Page 146 TRANSAXLE KiSC issued 07, 2006 A...
Page 147 MECHANISM CONTENTS 1. STRUCTURE ....................2-M1 2. TRAVELLING SYSTEM ................2-M2 [1] HYDROSTATIC TRANSMISSION ............2-M2 (1) Structure .................... 2-M2 (2) Pump and Motor ................2-M3 (3) Charge Relief Valve ................2-M3 (4) Check and High Pressure Relief Valve ..........2-M4 (5) Oil Flow ....................
Page 148: Structure
BX1800 · BX2200, WSM TRANSAXLE 1. STRUCTURE (1) Hydrostatic Transmission (4) Brake Section (7) Front Wheel Drive Gear (8) Hydraulic Pump Drive Gear (2) Mid-PTO Section (5) Differential Gear Section Section Section (3) Rear PTO Section (6) Range Gear Shift Section...
Page 149: Travelling System
BX1800 · BX2200, WSM TRANSAXLE 2. TRAVELLING SYSTEM [1] HYDROSTATIC TRANSMISSION (1) Structure (1) Check and High Pressure (6) Thrust Roller Bearing (12) Needle Bearing (17) Needle Bearing Relief Valve (7) Swashplate (13) Thrust Ball Bearing (18) Motor Shaft (2) Trunnion Arm...
Page 150: Pump And Motor
BX1800 · BX2200, WSM TRANSAXLE (2) Pump and Motor (1) Swashplate (4) Oil (6) Piston (A) Pump (2) Piston (5) Cylinder (7) Swashplate (B) Motor (3) Cylinder Pump and motor cylinder, each containing pistons, are connected by lines. Cylinders and lines are filled with oil.
Page 151: Check And High Pressure Relief Valve
BX1800 · BX2200, WSM TRANSAXLE (4) Check and High Pressure Relief Valve The check and high pressure relief valves monitor the oil pressure in each line of the main oil circuit. In neutral, both check valves are open and charging oil enters into the main oil circuit through the valves.
Page 152: Oil Flow
BX1800 · BX2200, WSM TRANSAXLE (5) Oil Flow (1) Cylinder Block (Pump) (6) Check and High Pressure (11) Oil Strainer A : A Port (2) Swashplate Relief Valve (Forward) (12) Hydraulic Pump B : B Port (3) Piston (7) PTO Clutch Valve...
Page 153 BX1800 · BX2200, WSM TRANSAXLE Neutral (1) Cylinder Block (Pump) (6) Check and High Pressure (11) Oil Strainer A : A Port (2) Swashplate Relief Valve (Forward) (12) Hydraulic Pump B : B Port (3) Piston (7) PTO Clutch Valve...
Page 154 BX1800 · BX2200, WSM TRANSAXLE Forward (1) Cylinder Block (Pump) (6) Check and High Pressure (11) Oil Strainer A : A Port (2) Swashplate Relief Valve (Forward) (12) Hydraulic Pump B : B Port (3) Piston (7) PTO Clutch Valve...
Page 155 BX1800 · BX2200, WSM TRANSAXLE Reverse (1) Cylinder Block (Pump) (6) Check and High Pressure (11) Oil Strainer A : A Port (2) Swashplate Relief Valve (Forward) (12) Hydraulic Pump B : B Port (3) Piston (7) PTO Clutch Valve...
Page 156: Control Linkage
BX1800 · BX2200, WSM TRANSAXLE (6) Control Linkage (1) Neutral Plate (4) Neutral Spring (7) Collar (9) Speed Control Pedal (2) Neutral Adjust Lever (5) Adjust Rod (8) Speed Control Rod (10) Damper (3) Trunnion Arm (6) Neutral Arm The speed control pedal (9) and the trunnion shaft of variable swashplate are linked with the speed control rod (8) and the trunnion arm (3).
Page 157: Range Gear Shift Section
BX1800 · BX2200, WSM TRANSAXLE [2] RANGE GEAR SHIFT SECTION Two kinds of power flow are selected by operating the range gear shift lever to shift the 16T-24T shifter gear (4) on the spiral bevel gear shaft (3). Low Range 17T Gear Shaft (2) →...
Page 158: Differential Gear Section
BX1800 · BX2200, WSM TRANSAXLE [4] DIFFERENTIAL GEAR SECTION (1) Differential Gears (1) Differential Case (4) 10T Final Gear Shaft (6) Differential Pinion Shaft (8) Differential Pinion (2) Differential Pinion (5) Differential Side Gear (7) 66T Final Gear (9) Differential Side Gear (3) 37T Spiral Bevel Gear 1.
Page 159: Differential Lock
BX1800 · BX2200, WSM TRANSAXLE (2) Differential Lock (1) Rear Axle (2) Differential Lock Shifter (3) Differential Case (4) Differential Pinion (5) Rear Axle (6) Differential Lock Arm (7) Differential Lock Shaft (8) Differential Lock Shift Fork (9) Differential Side Gear...
Page 160: Brake Section
BX1800 · BX2200, WSM TRANSAXLE [5] BRAKE SECTION (1) Brake Cam Lever LH (5) Cam Plate LH (9) Axle Cover (13) Parking Brake Lock Pedal (2) Transmission Case (6) Friction Plate (10) Brake Cam Lever RH (14) Spring (3) Rear Axle LH...
Page 161: Pto System
BX1800 · BX2200, WSM TRANSAXLE 3. PTO SYSTEM [1] PTO CLUTCH AND VALVE (1) PTO Select Gear (5) Front Cover (9) Oil Filter Cartridge C : From Power Steering (2) PTO Clutch Pack (6) PTO Clutch Valve A : To Mid-PTO Shaft...
Page 162 BX1800 · BX2200, WSM TRANSAXLE PTO Relief Valve The PTO relief valve is provided to control the PTO operating pressure. When the oil pressure exceed the relief valve setting pressure, relief valve opens and the oil flows into PTO clutch and hydrostatic transmission.
Page 163: Mid And Rear Pto Section
BX1800 · BX2200, WSM TRANSAXLE [2] MID AND REAR PTO SECTION (1) Clutch Shaft (4) Rear Cover (7) PTO Select Gear (10) Idle Shaft (2) 12T Gear Clutch (5) Rear PTO Shaft (8) 26T Idle Gear (11) 22T Gear (3) PTO Clutch Pack...
Page 164: Others
BX1800 · BX2200, WSM TRANSAXLE 4. OTHERS [1] HYDRAULIC PUMP DRIVE GEAR SECTION The hydraulic pump (5) is mounted to front cover (3) of the transmission case and driven by 13T gear (4) on the clutch shaft (6). (1) 19T Gear Shaft...
Page 165 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 2. SERVICING SPECIFICATIONS ..............2-S5 3. TIGHTENING TORQUES ................2-S7 4. CHECKING AND ADJUSTING ..............2-S8 5. DISASSEMBLING AND ASSEMBLING ............2-S13 [1] SEPARATING TRANSAXLE..............2-S13 [2] HYDROSTATIC TRANSMISSION ............2-S18 [3] TRANSMISSION CASE .................2-S21 6. SERVICING ....................2-S29 [1] HYDROSTATIC TRANSMISSION ............2-S29 [2] TRANSMISSION CASE .................2-S30 KiSC issued 07, 2006 A...
Page 166: Troubleshooting
BX1800 · BX2200, WSM TRANSAXLE 1. TROUBLESHOOTING KiSC issued 07, 2006 A 2-S1...
Page 167 BX1800 · BX2200, WSM TRANSAXLE KiSC issued 07, 2006 A 2-S2...
Page 168 BX1800 · BX2200, WSM TRANSAXLE TRAVELLING GEAR SHIFT SECTION Reference Symptom Probable Cause Solution Page Noise from • Transmission oil insufficient Refill 2-S13 Transmission • Gear worn or broken Replace – • Bearings worn Replace – Gear Slip Out of •...
Page 169 BX1800 · BX2200, WSM TRANSAXLE PTO SECTION Reference Symptom Probable Cause Solution Page PTO Clutch Slip • Operating pressure is low Check 2-S11 • PTO clutch valve malfunctioning Repair or replace 2-S23 • Clutch disc or drive plate excessively worn...
Page 170: Servicing Specifications
BX1800 · BX2200, WSM TRANSAXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Charge Relief Valve Setting Pressure 294.2 to 490.4 kPa – 3.0 to 5.0 kgf/cm 42.7 to 71.1 psi Check and High Pressure Relief Valve Setting Pressure 13.73 MPa –...
Page 171 BX1800 · BX2200, WSM TRANSAXLE Item Factory Specification Allowable Limit PTO Clutch Disc Thickness 1.70 to 1.90 mm 1.55 mm 0.067 to 0.075 in. 0.061 in. Pressure Plate Thickness 1.95 to 2.05 mm 1.80 mm 0.077 to 0.081 in. 0.071 in.
Page 172: Tightening Torques
BX1800 · BX2200, WSM TRANSAXLE 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-8.) Item N·m kgf·m ft-lbs Charge relief valve checking plug 21.58 to 25.50...
Page 173: Checking And Adjusting
BX1800 · BX2200, WSM TRANSAXLE 4. CHECKING AND ADJUSTING Adjusting Maximum Speed Forward 1. Depress the speed control pedal (2) all the way and lengthen the stopper bolt (3) until it touches the bottom surface of the speed control pedal (2).
Page 174 BX1800 · BX2200, WSM TRANSAXLE Preparation before HST Adjustment CAUTION • Park the machine on a firm and level ground. 1. Place the wooden blocks (2) at F and R side of wheels not to move the tractor. 2. Measure the speed control pedal (6) control force with a push- pull gauge before starting the engine.
Page 175 BX1800 · BX2200, WSM TRANSAXLE Adjustment of HST Neutral Position 1. Start the engine. 2. Shift the range gear shift lever (1) to “Hi” position (2). 3. Loosen the locking screw (6). And push the neutral adjust lever (5) toward the tractor rear side as shown in the figure until the rear wheels (4) begin to rotate forward.
Page 176 BX1800 · BX2200, WSM TRANSAXLE Charge Relief Pressure CAUTION • When checking, park the tractor on flat ground, apply the parking brake. 1. Remove the plug (M14, Pitch 1.5 mm) (1) from the front cover, then install the adaptor, cable and pressure gauge.
Page 177 BX1800 · BX2200, WSM TRANSAXLE PTO Clutch Operating Pressure CAUTION • When checking, park the tractor on flat ground, apply the parking brake. 1. Lift the rear of the tractor and remove the left rear wheel. 2. Remove the plug (M14, Pitch 1.5 mm), then install the adaptor, cable and pressure gauge.
Page 178: Disassembling And Assembling
BX1800 · BX2200, WSM TRANSAXLE 5. DISASSEMBLING AND ASSEMBLING [1] SEPARATING TRANSAXLE Draining Transmission Fluid CAUTION • Be sure to stop the engine before checking and changing the transmission fluid. 1. Place oil pan under the tractor. 2. Remove the drain plugs (1) at the bottom of the transmission case.
Page 179 BX1800 · BX2200, WSM TRANSAXLE Seat 1. Remove the snap pin (2) to remove the seat (1). (1) Seat (2) Snap Pin W1014409 Roll-Over Protective Structures (ROPS) 1. Disconnect the lead wires from the hazard lights (2), (3). 2. Remove the ROPS mounting nuts and remove the ROPS (1).
Page 180 BX1800 · BX2200, WSM TRANSAXLE Fuel Tank 1. Drain the fuel. 2. Disconnect the lead wire from fuel level sensor and fuel hoses from the fuel tank (1). 3. Remove the fuel tank stays (2), (3) and cushions, then remove the fuel tank (1).
Page 181 BX1800 · BX2200, WSM TRANSAXLE PTO Cover, Fender Bracket, Hitch Plate and Others 1. Remove the PTO covers (1), (2) and (6). 2. Remove the hitch plate (4) and rear supports (3), (5). 3. Remove the fender brackets (7), (9), shim (10) and fender center stay (8).
Page 182 BX1800 · BX2200, WSM TRANSAXLE Transaxle Assembly 1. Disconnect the speed control rod (2), differential lock rod (4) and brake rod (6), (8). 2. Remove the rear coupling mounting bolt (11) and spring (9). 3. Remove the nuts from the lift link rear (7) and wire harness (12) clamps.
Page 183: Hydrostatic Transmission
BX1800 · BX2200, WSM TRANSAXLE Differential Lock Pedal 1. Unhook the spring (1) and remove the differential lock pedal (2). (1) Spring (2) Differential Lock Pedal W1016728 Brake Pedal, Speed Change Rod and HST Damper 1. Remove the cotter pin and clevis pin, then remove the brake arm (4).
Page 184 BX1800 · BX2200, WSM TRANSAXLE Neutral Plate and Neutral Switch Stay 1. Remove the trunnion arm mounting bolt and nut (3). 2. Remove the neutral plate mounting screws, then remove the neutral plate (2). 3. Remove the neutral switch stay (1).
Page 185 BX1800 · BX2200, WSM TRANSAXLE Charge Relief Valve 1. Remove the plug (3) and draw out the spring (2) and charge relief cone (1). (When reassembling) • Take care not to damage the O-ring on the plug. NOTE • If the shims are placed at the bottom of the relief valve plug bore, place them as they are.
Page 186: Transmission Case
BX1800 · BX2200, WSM TRANSAXLE Cradle Bearing, Slot Guide and Trunnion Arm 1. Remove the slot guide (2) and trunnion arm (3). 2. Remove the cradle bearing (1) from the HST housing. (When reassembling) • Apply clean transmission oil to the cradle bearing and trunnion arm.
Page 187 BX1800 · BX2200, WSM TRANSAXLE PTO Select Lever and Control Valve 1. Remove the delivery pipe (1) and PTO clutch rod (3). 2. Tap out the spring pin and remove the PTO select lever (2). 3. Remove the control valve (5) with PTO safety switch stay (4).
Page 188 BX1800 · BX2200, WSM TRANSAXLE Hydraulic Cylinder 1. Remove the hydraulic cylinder mounting screws and dismount the hydraulic cylinder (1). (When reassembling) • Apply liquid gasket (Three Bond 1208D or equivalent) to joint face of the transmission case to hydraulic cylinder.
Page 189 BX1800 · BX2200, WSM TRANSAXLE Front Wheel Drive Shaft and Shift Fork 1. Remove the plate (1), then draw out the spring (3) and steel ball (4). 2. Remove the oil seal (5) and internal snap ring (6). 3. Tap out the front wheel drive shaft (7) to the front.
Page 190 BX1800 · BX2200, WSM TRANSAXLE Rear Cover, Rear PTO Shaft and Rear PTO Drive Shaft 1. Remove the rear cover (1) and rear PTO shaft assembly (2). 2. Remove the PTO select bolt (3) and draw out the spring and steel ball.
Page 191 BX1800 · BX2200, WSM TRANSAXLE Disassembling PTO Clutch Assembly 1. Remove the collar (1), needle bearings (2) and 12T gear clutch (3). 2. Remove the external snap ring (9), then remove the shims (10), brake pressure plate (8) and brake disc (12).
Page 192 BX1800 · BX2200, WSM TRANSAXLE Final Gear Shaft and Differential Gear Assembly 1. Draw out the final gear shaft assembly (1), differential gear assembly (2) and differential lock shift fork (3). (When reassembling) • Take care not to damage the O-ring.
Page 193 BX1800 · BX2200, WSM TRANSAXLE Brake Disc and Friction Plate 1. Remove the internal snap ring (1). 2. Remove the bearing holder (6), brake discs (5), friction plates (2), actuator (3) and steel balls (4). 3. Remove the external snap ring (8), then remove the cam lever (7).
Page 194: Servicing
BX1800 · BX2200, WSM TRANSAXLE 6. SERVICING [1] HYDROSTATIC TRANSMISSION Center Section 1. Check the surface (1) of center section for scratches or wear. If deep scratch or excessive wear is found, replace the hydrostatic transmission assembly. (1) Surface W1027317 Charge Relief Valve 1.
Page 195: Transmission Case
BX1800 · BX2200, WSM TRANSAXLE Thrust Washer, Thrust Roller Bearing and Thrust Plate 1. Check the thrust roller bearing (2) for scratches and excessive wear. 2. If worn, replace. 3. Check the thrust plate (1) for scratches and excessive wear.
Page 196 BX1800 · BX2200, WSM TRANSAXLE Clearance between 13T-25T Gear and Front Wheel Drive Idle Shaft 1. Measure the 13T-25T gear I.D. with a cylinder gauge, and then front wheel drive idle shaft O.D. with an outside micrometer. 2. Measure the O.D. of two needles in the needle bearing with an outside micrometer.
Page 197 BX1800 · BX2200, WSM TRANSAXLE Clearance between 12T Gear Clutch and Clutch Shaft 1. Measure the 12T gear clutch I.D. with a cylinder gauge, and then clutch shaft O.D. with an outside micrometer. 2. Measure the O.D. of two needles in the needle bearing with an outside micrometer.
Page 198 BX1800 · BX2200, WSM TRANSAXLE Clutch Spring Free Length 1. Measure the free length of spring with vernier calipers. 2. If the measurement is less than the allowable limit, replace it. 37.3 to 37.7 mm Factory spec. 1.47 to 1.48 in.
Page 199 BX1800 · BX2200, WSM TRANSAXLE Backlash between Differential Pinion and Differential Side Gear 1. Secure the differential case with a vise. 2. Set the dial indicator (lever type) with its finger on the tooth of the differential side gear. 3. Press differential pinion and side gear against the differential case.
Page 200 BX1800 · BX2200, WSM TRANSAXLE Backlash between Spiral Bevel Pinion Shaft and Spiral Bevel Gear 1. Temporary assemble the spiral bevel pinion shaft, and properly adjust the side clearance. 2. Place fuses between spiral bevel pinion shaft and spiral bevel gear (2).
Page 201 BX1800 · BX2200, WSM TRANSAXLE Brake Disc and Friction Plate Wear 1. Measure the brake disc thickness and the friction plate thickness with an outside micrometer. 2. If the thickness is less than the allowable limit, replace it. 3.3 to 3.5 mm Factory spec.
Page 202: Front Axle
FRONT AXLE KiSC issued 07, 2006 A...
Page 203 MECHANISM CONTENTS 1. STRUCTURE ....................3-M1 2. FRONT WHEEL ALIGNMENT ..............3-M2 KiSC issued 07, 2006 A...
Page 204 BX1800 · BX2200, WSM FRONT AXLE 1. STRUCTURE (1) Axle (6) Bevel Gear (11) Differential Pinion Shaft (16) Bevel Gear Shaft (2) Axle Flange (7) Differential Yoke Shaft, RH (12) Differential Pinion Gear (17) Front Gear Case (3) Bevel Gear...
Page 205: Front Wheel Alignment
BX1800 · BX2200, 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 206 BX1800 · BX2200, 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 front wheels.
Page 207 SERVICING CONTENTS 1. TROUBLESHOOTING ..................3-S1 2. SERVICING SPECIFICATIONS ..............3-S2 3. TIGHTENING TORQUES ................3-S3 4. CHECKING, DISASSEMBLING AND SERVICING........3-S4 [1] CHECKING AND ADJUSTING ...............3-S4 [2] DISASSEMBLING AND ASSEMBLING..........3-S5 (1) Separating Front Axle Assembly............3-S5 (2) Disassembling Front Axle Assembly...........3-S8 [3] SERVICING ....................3-S12 KiSC issued 07, 2006 A...
Page 208: Troubleshooting
BX1800 · BX2200, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels • Tire pressure uneven Adjust G-35 Wander to Right or • Improper toe-in adjustment (improper Adjust G-21, 3-S4 Left alignment) • Clearance between center pin and shaft...
Page 209: Servicing Specifications
BX1800 · BX2200, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 1 to 10 mm – 0.04 to 0.39 in. Front Axle Rocking Force 49.0 to 117.7 N – 5.0 to 12.0 kgf 11.0 to 26.5 lbs...
Page 210: Tightening Torques
BX1800 · BX2200, WSM FRONT AXLE 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : See page G-8.) Item N·m kgf·m ft-lbs Under cover mounting bolt and nut 7.8 to 8.8...
Page 211: Checking, Disassembling And Servicing
BX1800 · BX2200, WSM FRONT AXLE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Toe-in 1. Inflate the tires to the specified pressure. 2. Turn the front wheels straight ahead. 3. Measure the toe-in (B-A). 4. If the measurement is not within the factory specifications, adjust the tie-rod length.
Page 212: Disassembling And Assembling
BX1800 · BX2200, WSM FRONT AXLE Front Wheel Steering Angle 1. Inflate the tires to the specified pressure. 2. Loosen the lock nut and shorten the length of stopper bolt LH (1). 3. Steer the wheels to the extreme left.
Page 213 BX1800 · BX2200, WSM FRONT AXLE Under Cover 1. Remove the under cover mounting bolts (1), loosen the mounting nuts (2) and pull forward to remove the under cover (3). (When reassembling) 7.8 to 8.8 N·m Under cover mounting bolt Tightening torque 0.8 to 0.9 kgf·m...
Page 214 BX1800 · BX2200, WSM FRONT AXLE Front Wheel and Propeller Shaft Cover 1. Lift up the front side of tractor and place the disassembling stand under the front axle frame. 2. Remove the front wheels. 3. Remove the propeller shaft cover mounting bolt and slide the propeller shaft cover (1).
Page 215: Disassembling Front Axle Assembly
BX1800 · BX2200, WSM FRONT AXLE (2) Disassembling Front Axle Assembly Power Steering Cylinder 1. Remove the cotter pin and remove the slotted nut for tie-rod (1). 2. Remove the power steering cylinder mounting screws and remove the power steering cylinder (2) with tie-rod.
Page 216 BX1800 · BX2200, WSM FRONT AXLE 36T Bevel Gear and Front Axle Shaft 1. Remove the bearing (5). 2. Take out the 36T bevel gear (4). 3. Take out the collar (3). 4. Tap out the axle shaft (2). (When reassembling) •...
Page 217 BX1800 · BX2200, WSM FRONT AXLE Front Gear Case and Bevel Gear Case 1. Remove the internal snap ring (1). 2. Remove the 12T bevel gear (8) with ball bearing (3) and shim (2). 3. Remove the 15T bevel gear (7) and ball bearing (4).
Page 218 BX1800 · BX2200, WSM FRONT AXLE Bevel Pinion Shaft and Differential Gear Assembly 1. Take out the differential yoke shaft (4), (7). 2. Remove the oil seal (11). 3. Remove the internal snap ring (1). 4. Pull out the bevel pinion shaft (3).
Page 219 BX1800 · BX2200, WSM FRONT AXLE [3] SERVICING Clearance between Differential Case and Differential Side Gear 1. Measure the differential side gear boss O.D.. 2. Measure the differential case bore I.D., and calculate the clearance. 3. Measure the differential case cover bore I.D., and calculate the clearance.
Page 220 BX1800 · BX2200, WSM FRONT AXLE Turning Torque of Bevel Pinion Shaft 1. Cramp the spiral bevel pinion shaft assembly to the vise and tighten the staking nut. 2. Measure the turning torque of bevel pinion shaft. 3. If the turning torque is not within the factory specifications, adjust with the lock nut.
Page 221 BX1800 · BX2200, WSM FRONT AXLE Backlash between 12T Bevel Gear and 15T Bevel Gear 1. Stick a strip of fuse to three spots on the 15T bevel gear (1) with grease. 2. Fix the front axle case, bevel gear case and front gear case.
Page 222 STEERING KiSC issued 07, 2006 A...
Page 223 MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT .................. 4-M1 2. STEERING CONTROLLER ................4-M2 3. STEERING CYLINDER................. 4-M3 KiSC issued 07, 2006 A...
Page 224 BX1800 · BX2200, WSM STEERING 1. HYDRAULIC CIRCUIT (1) Steering Controller (2) Steering Cylinder (3) Flow Priority Valve (4) Hydraulic Control Valve Assembly (5) Hydraulic Pump (6) Oil Strainer A : To PTO Clutch Valve B : To HST C : To Hydraulic Cylinder...
Page 225 BX1800 · BX2200, WSM STEERING 2. STEERING CONTROLLER The steering controller consists of a control valve (4) and a metering device (3). Control Valve The control valve is a rotating spool type. When the steering wheel is not turned, the position of the spool (7) and sleeve (9) is kept neutral by the centering spring (8).
Page 226: Steering Cylinder
BX1800 · BX2200, WSM STEERING 3. STEERING CYLINDER (1) Rod (4) Guide (7) Center Piston (10) Cylinder Tube (2) Wiper Ring (5) O-ring (8) Piston O-ring (11) Rod O-ring (3) Internal Snap Ring (6) Seal Ring (9) External Snap Ring The steering cylinder is single piston both rod double-acting type.
Page 227: Servicing
SERVICING CONTENTS 1. TROUBLESHOOTING ..................4-S1 2. SERVICING SPECIFICATIONS ..............4-S2 3. TIGHTENING TORQUES ................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING........4-S4 [1] CHECKING ....................4-S4 (1) Relief Valve..................4-S4 [2] DISASSEMBLING AND ASSEMBLING..........4-S4 (1) Separating Power Steering Controller ..........4-S4 (2) Separating Power Steering Cylinder ...........4-S6 (3) Disassembling Power Steering Cylinder ..........4-S7 [3] SERVICING ....................4-S8 KiSC issued 07, 2006 A...
Page 228: Troubleshooting
BX1800 · BX2200, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Cannot Be Steered • Steering controller malfunctioning Replace 4-S5 • Pipe broken Replace 4-S5 Hard Steering • Power steering oil improper Change with G-20 specified oil • Hydraulic pump malfunctioning...
Page 229: Servicing Specifications
BX1800 · BX2200, WSM STEERING 2. SERVICING SPECIFICATIONS POWER STEERING BODY Item Factory Specification Allowable Limit Relief Valve Operating 9.30 to 9.79 MPa – Pressure 94.8 to 99.8 kgf/cm 1348 to 1419 psi W1013874 STEERING CYLINDER Steering Cylinder I.D. 40.000 to 40.062 mm 40.100 mm...
Page 230: Tightening Torques
BX1800 · BX2200, 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-8.) Item N·m kgf·m ft-lbs Steering wheel mounting nut 20 to 25 2.0 to 2.6...
Page 231: Checking, Disassembling And Servicing
BX1800 · BX2200, WSM STEERING 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING (1) Relief Valve Relief Valve Operating Pressure 1. Disconnect the power steering hose L (or R) from steering controller, and set a pressure gauge and cable. (Reference) • Hose and adaptor size : 9/16-18UNF, 37 ° flare 2.
Page 232 Meter Panel 1. Remove the hand accelerator lever grip (2). 2. Disconnect the connector for main switch (4), timer relay (2) (BX1800 only) and flasher unit (1). 3. Remove the panel mounting screws and dismount the meter panel (5). 4. Disconnect the all connectors from panel and remove the meter panel (5).
Page 233: Separating Power Steering Cylinder
BX1800 · BX2200, WSM STEERING (2) Separating Power Steering Cylinder Under Cover 1. Remove the under cover mounting boles (1), loosen the mounting nuts (2) and pull forward to remove the under cover (3). (When reassembling) 7.8 to 8.8 N·m...
Page 234: Disassembling Power Steering Cylinder
BX1800 · BX2200, WSM STEERING (3) Disassembling Power Steering Cylinder Adaptor and Tie-rod 1. Remove the cylinder hose adaptors (4), (6). 2. Remove the tie-rods (2), (8) from piston rod (7). 3. Remove the cylinder holder (1) and internal snap ring (3).
Page 235: Servicing
BX1800 · BX2200, WSM STEERING [3] SERVICING 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 barrel. 40.000 to 40.062 mm Factory spec. 1.57480 to 1.57724 in.
Page 236: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 07, 2006 A...
Page 237 MECHANISM CONTENTS 1. HYDRAULIC CIRCUIT .................. 5-M1 2. HYDRAULIC PUMP ..................5-M2 3. HYDRAULIC CONTROL VALVE ..............5-M3 4. FLOW PRIORITY VALVE ................5-M4 5. RELIEF VALVE ..................... 5-M5 6. HYDRAULIC CYLINDER ................5-M6 7. HYDRAULIC BLOCK TYPE OUTLET............5-M7 8.
Page 238: Hydraulic Circuit
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 1. HYDRAULIC CIRCUIT (1) Hydraulic Cylinder (4) Relief Valve (8) Oil Strainer (12) PTO Clutch Valve (2) Hydraulic Control Valve (5) Flow Priority Valve (9) PTO Relief Valve (13) PTO Clutch Assembly (6) Hydraulic Block Type Outlet...
Page 239: Hydraulic Pump
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 2. HYDRAULIC PUMP The hydraulic pump is composed of the casing (1), cover (3), side plate (5), and two spur gears (drive gear (4) and driven gear (2)) that are in mesh. Hydraulic pump is driven by the pump drive shaft in the transmission case.
Page 240: Hydraulic Control Valve
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 3. HYDRAULIC CONTROL VALVE Hydraulic control valve assembly is composed of control valve, flow priority valve (4) and relief valve (3). Oil from hydraulic pump is divided by flow priority valve (4) and forced into the control valve through passage (5) of hydraulic block type outlet.
Page 241: Flow Priority Valve
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 4. FLOW PRIORITY VALVE The flow priority valve is a flow divider that divides the flow from single hydraulic source (hydraulic pump) to actuates two circuits simultaneously. This valve feeds fixedly controlled flow (7 L/min., 1.8 U.S.gals./min., 1.5 Imp.gals./min.) to the PF port with...
Page 242: Relief Valve
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 5. RELIEF VALVE The implement control system circuit has a relief valve to restrict the maximum pressure in the circuit. The relief valve is located in the hydraulic control valve assembly. The relief valve is of the guide piston type with damping effect.
Page 243: Hydraulic Cylinder
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 6. HYDRAULIC CYLINDER (1) Lowering Speed Adjusting (3) Back-up Ring (6) Lift Arm (9) Ball Shaft (4) Piston (7) Hydraulic Arm (10) Cylinder Port (Connected to (2) O-ring (5) Hydraulic Cylinder (8) Hydraulic Rod Control Valve) The main components of the hydraulic cylinder are shown in the figure above.
Page 244: Hydraulic Block Type Outlet
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 7. HYDRAULIC BLOCK TYPE OUTLET The hydraulic block type outlet is located on the control valve assembly. This hydraulic block type outlet is provided to take power out from the tractor to operate the hydraulic cylinders on the implement, such as front end loader, front blade and so on.
Page 245: Mower Linkage
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 8. MOWER LINKAGE (1) Mower Rear Link RH (4) Link Adjusting Nut (7) Lift Link Shaft (10) Lift Link Rear LH (2) Lift Link RH (5) Lift Arm RH (8) Cutting Height Adjusting Dial...
Page 246 SERVICING CONTENTS 1. TROUBLESHOOTING ..................5-S1 2. SERVICING SPECIFICATIONS ..............5-S2 3. TIGHTENING TORQUES ................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING........5-S4 [1] HYDRAULIC CONTROL VALVE, PUMP AND CYLINDER ....5-S4 (1) Checking and Adjusting ..............5-S4 (2) Disassembling and Assembling ............5-S5 (3) Servicing ...................5-S12 [2] MOWER LIFT LINKAGE ...............5-S15 KiSC issued 07, 2006 A...
Page 247: Troubleshooting
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not • Control valve broken Replace 5-S10 Rise (No Noise) • Control valve improperly assembled Repair 5-S10 • Relief valve spring damaged Replace 5-S10 •...
Page 248: Servicing Specifications
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit [Hydraulic Pump] Gear to Casing Clearance – 0.15 mm 0.0059 in. Gear Shaft to Bushing Clearance 0.020 to 0.091 mm 0.12 mm 0.0008 to 0.0036 in.
Page 249: Tightening Torques
BX1800 · BX2200, 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-8.) Item N·m kgf·m ft-lbs ROPS mounting nut 124 to 147 12.6 to 15.0...
Page 250: Checking, Disassembling And Servicing
BX1800 · BX2200, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] HYDRAULIC CONTROL VALVE, PUMP AND CYLINDER (1) Checking and Adjusting Relief Valve Setting Pressure 1. Remove the plug (1) (G1/4) from rear of hydraulic cylinder body. 2. Install the adaptor, cable and pressure gauge.
Page 251: Disassembling And Assembling
BX1800 · BX2200, WSM HYDRAULIC SYSTEM Lift Arm Free Play 1. Set the hydraulic control lever to the lowest position. 2. Start the engine, and set at the idling speed. 3. Move the hydraulic control lever to Lift position until the lift arm (1) moves to the uppermost position.
Page 252 BX1800 · BX2200, WSM HYDRAULIC SYSTEM Battery CAUTION • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Remove the under panel (1). 2. Disconnect the negative cable (2) from the battery.
Page 253 BX1800 · BX2200, WSM HYDRAULIC SYSTEM Rear Wheel 1. Remove the rear wheels (1) and (2). (When reassembling) 108.5 to 130.2 N·m Rear wheel mounting Tightening torque 11.1 to 13.2 kgf·m screw 80 to 96 ft-lbs (1) Rear Wheel LH...
Page 254 BX1800 · BX2200, WSM HYDRAULIC SYSTEM PTO Cover, Fender Bracket, Hitch Plate and Others 1. Remove the PTO covers (1), (2) and (6). 2. Remove the hitch plate (4) and rear supports (3), (5). 3. Remove the fender brackets (7), (9), shim (10) and fender center stay (8).
Page 255 BX1800 · BX2200, WSM HYDRAULIC SYSTEM Hydraulic Control Valve 1. Tap out the spring pin and remove the PTO select lever (6). 2. Disconnect the PTO clutch lever rod (1). 3. Remove the delivery pipe (4). 4. Disconnect the power steering delivery hose (7).
Page 256 BX1800 · BX2200, WSM HYDRAULIC SYSTEM (B) Disassembling Control Valve Assembly PTO Clutch Lever and PTO Clutch Cam 1. Remove the external snap ring (1) and remove the PTO clutch lever (2). 2. Remove the PTO clutch cam (3). (When reassembling) •...
Page 257 BX1800 · BX2200, WSM HYDRAULIC SYSTEM (C) Disassembling Hydraulic Pump Pump Cover 1. Secure the hydraulic pump with a vise, and remove the pump cover (1). (When reassembling) • Take care not to damage the O-ring. • Align the holes of the pump cover and casing.
Page 258: Servicing
BX1800 · BX2200, WSM HYDRAULIC SYSTEM Hydraulic Piston 1. Inject the compressed air into the hydraulic cylinder, and take out the hydraulic piston (1). (When reassembling) • Take care not to damage the O-ring (3) and backup ring (2). • Apply transmission fluid to the O-ring.
Page 259 BX1800 · BX2200, WSM HYDRAULIC SYSTEM Clearance between Bushing and Shaft 1. Measure the gear shaft O.D. with an outside micrometer. 2. Measure the bushing I.D. with a cylinder gauge. 3. If the clearance exceeds the allowable limit, replace it.
Page 260 BX1800 · BX2200, WSM HYDRAULIC SYSTEM Hydraulic Arm Shaft Bushing 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy thickness (A), replace...
Page 261: Mower Lift Linkage
BX1800 · BX2200, WSM HYDRAULIC SYSTEM [2] MOWER LIFT LINKAGE Disassembling Mower Linkage (1) Mower Rear Link RH (2) Lift Link RH (3) Lift Link Rear RH (4) Mower Lift Arm (5) Link Adjusting Nut (6) Lift Arm RH (7) Bush...
Page 262 BX1800 · BX2200, WSM HYDRAULIC SYSTEM Adjusting Mower Lift Linkage After reassembling, be sure to adjust the mower lift linkages as follows. 1. Adjust the lift arm free play. (See page 5-S5.) 2. Loosen the adjusting nut (1), (2) and start the engine.
Page 263: Electrical System
ELECTRICAL SYSTEM KiSC issued 07, 2006 A...
Page 264 MECHANISM CONTENTS 1. WIRING DIAGRAM ..................6-M1 2. STARTING SYSTEM ..................6-M4 [1] STARTER ....................6-M5 [2] GLOW PLUG ..................6-M6 [3] SAFETY SWITCH ................... 6-M6 [4] FUEL PUMP.................... 6-M7 [5] ENGINE STOP SOLENOID ..............6-M7 3. CHARGING SYSTEM ................... 6-M8 [1] AC DYNAMO ..................
Page 265: Wiring Diagram
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM Color of Wiring W ..White WR ... White / Red BW ..Black / White R ... Red WY ... White / Yellow BR ..Black / Red L ... Blue RB ....
Page 266 BX1800 · BX2200, WSM ELECTRICAL SYSTEM KiSC issued 07, 2006 A 6-M2...
Page 267 BX1800 · BX2200, WSM ELECTRICAL SYSTEM KiSC issued 07, 2006 A 6-M3...
Page 268: Starting System
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM When the main switch is turned to the PREHEAT position, the terminal 30 is connected to the terminals 19 and AC. The glow plugs become red-hot, and the preheat indicator lamp also lights on while preheating.
Page 269: Starter
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [1] STARTER (1) Armature (2) Yoke (3) Brush Holder (4) End Frame (5) Gear (6) Drive End Frame (7) Pinion (8) Roller Clutch (9) Ball (10) Spring (11) Magnet Switch W1013045 The starter motor is a reduction type. The speed of the pinion gear is reduced to approximately one third of motor one.
Page 270: Glow Plug
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [2] GLOW PLUG This plug is a two-material type QGS (Quick Glow System) for quick temperature rise, and has self- controlling function as well as excellent durability. The heater (4) connected in series to the heater (3), which also functions as the resistor, is incorporated in the sheath tube (1) of the super glow plug.
Page 271: Fuel Pump
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [4] FUEL PUMP An electro magnetic fuel pump uses a transistor that causes the pump to start pumping fuel when the main switch is turned to the “ON” position. Therefore, fuel is supplied to the fuel injection pump regardless of engine speed.
Page 272: Charging System
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 3. CHARGING SYSTEM The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs. It consists of a AC dynamo and a regulator. KiSC issued 07, 2006 A...
Page 273: Ac Dynamo
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [1] AC DYNAMO The dynamo is an 8-8 pole rotating magnet type generator. It is simple in construction, consisting of a stator and rotor. The rotor is made up of eight permanent magnet pole pieces assembled on a shaft and rotates on...
Page 274: Lighting System
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 4. LIGHTING SYSTEM The lighting system consists of main switch, head light switch, blinker switch, hazard switch, head lights, blinker lights, tail lights, etc. KiSC issued 07, 2006 A 6-M10...
Page 275: Head Light
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [1] HEAD LIGHT The head light switch has two positions; OFF and ON. Current passes through the light circuit as shown in the figure above. [2] TURN SIGNAL LIGHT The blinker switch has three positions; OFF, L and R. When using blinker switch, blinks only one side light and other one stays on.
Page 276: Hazard Light
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [3] HAZARD LIGHT Hazard switch has two positions; ON and OFF. Blinking the hazard lights and indicator lamps as shown in the figure above. [4] EASY CHECKER To check the conditions of tractor easily before and during operation, easy checker combination of lamps on the easy checker board is provided.
Page 277: Gauges
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 5. GAUGES The fuel quantity and coolant temperature are indicated by the ammeters. The ammeters indicate each amperage flowing through the fuel level sensor for the fuel quantity detection and through the coolant temperature sensor for the coolant temperature detection.
Page 278: Coolant Temperature
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [2] COOLANT TEMPERATURE Coolant Temperature Sensor The coolant temperature sensor is installed to the cylinder head of engine, and its tip is in touch with the coolant. It contains a thermistor (4) whose electrical resistance decreases as the temperature increases.
Page 279 SERVICING CONTENTS 1. TROUBLESHOOTING ..................6-S1 2. SERVICING SPECIFICATIONS ..............6-S4 3. TIGHTENING TORQUES ................6-S5 4. CHECKING, DISASSEMBLING AND SERVICING........6-S6 [1] BATTERY....................6-S6 (1) Checking .....................6-S6 [2] STARTING SYSTEM ................6-S7 (1) Checking .....................6-S7 (2) Disassembling and Assembling ............6-S13 (3) Servicing ...................6-S13 [3] CHARGING SYSTEM ................6-S16 (1) Checking ...................6-S16 (2) Disassembling and Assembling ............6-S16 (3) Servicing ...................6-S17...
Page 280: Troubleshooting
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical • Battery discharged or defective Recharge or replace G-16, Equipments Do Not 2-S13 Operate • Battery positive cable disconnected or Repair or replace –...
Page 281 BX1800 · BX2200, WSM ELECTRICAL SYSTEM CHARGING SYSTEM Reference Symptom Probable Cause Solution Page Charging Lamp Does • Fuse blown (15 A) Replace G-26 Not Light when Main • Wiring harness disconnected or improperly Repair or Replace – Switch is Turned ON...
Page 282 BX1800 · BX2200, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM (Continued) Reference Symptom Probable Cause Solution Page Turn Signal Light • Fuse blown (15 A) Replace G-26 Does Not Light • Bulb blown Replace G-26 • Wiring harness disconnected or improperly Repair or Replace –...
Page 283: Servicing Specifications
BX1800 · BX2200, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More than 12 V – Potential Less than 0.1 V – Difference Approx. 0.9 Ω Glow Plug Resistance – Safety Switch Distance 3 to 5 mm –...
Page 284 BX1800 · BX2200, 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-8.) Item N·m kgf·m ft-lbs Starter B terminal nut 5.9 to 11.8...
Page 285: Checking, Disassembling And Servicing
BX1800 · BX2200, 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 286: Starting System
BX1800 · BX2200, 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 287 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Connector Voltage 1. Measure the voltage with a voltmeter across the connector 30 (red) terminal and chassis. 2. If the voltage differs from the battery voltage (11 to 14 V), the wiring harness is faulty.
Page 288 BX1800 · BX2200, WSM ELECTRICAL SYSTEM (B) Starter Motor Test CAUTION • Secure the starter to prevent if from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter.
Page 289 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Glow Plug Continuity 1. Disconnect the lead from the glow plugs. 2. Measure the resistance with an ohmmeter 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 290 BX1800 · BX2200, WSM ELECTRICAL SYSTEM (E) Fuel Pump Connector Voltage 1. Disconnect the 2P connector from the fuel pump. 2. Turn the main switch key to the “ON” position, and measure the voltage with a voltmeter between the connector terminals.
Page 291 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Engine Stop Solenoid Test (D905) 1. Disconnect the 3P connector from the engine stop solenoid. 2. Remove the engine stop solenoid from the engine. 3. Connect the jumper leads from the battery positive terminal to the terminal 1 (White), and from the battery negative terminal to the terminal 2 (Black).
Page 292: Disassembling And Assembling
BX1800 · BX2200, WSM ELECTRICAL SYSTEM (2) Disassembling and Assembling 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 293 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
Page 294 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
Page 295: Charging System
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [3] CHARGING SYSTEM (1) Checking Battery Charging Current 1. After starting the engine, disconnect the battery positive cord (+), and connect an ammeter and voltmeter. Then switch on all electrical loads (such as head lights) and measure the charging current.
Page 296: Servicing
BX1800 · BX2200, WSM ELECTRICAL SYSTEM Rotor 1. Tap out the shaft (1) from the rotor (3). (When reassembling) • Take care the direction of the collar (4), the flat side should face to the pulley (2) side. (1) Shaft...
Page 297 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Hazard Light Switch Continuity 1. Remove the under panel. 2. Disconnect the wiring leads from hazard light switch and remove 3. Measure the resistance with an ohmmeter across the hazard light switch terminals in each position.
Page 298 BX1800 · BX2200, WSM ELECTRICAL SYSTEM Charge Lamp (Charging Circuit) 1. Remove the under panel. 2. Disconnect the 6P connector from the regulator after turning the main switch OFF. 3. Turn the main switch ON and connect a jumper lead from the wiring harness connector terminal (Black) to the chassis.
Page 299: Gauges
BX1800 · BX2200, WSM ELECTRICAL SYSTEM [5] GAUGES (1) Checking Fuel Level Sensor 1) Sensor Continuity 1. Remove the fuel level sensor from the fuel tank. 2. Measure the resistance with an ohmmeter across the sensor terminal and its body.
Page 300 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 2005. 03, S, EI, EI, e Code No.9Y011-12463 KUBOTA Corporation 2000.

This manual is also suitable for:

Bx2200

wsm BX1800 Workshop Manual

General

1 Tractor Identification

2 General Precautions

3 Handling Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Maintenance Check List

7 Check and Maintenance

8 Special Tools

9 Tires

10 Implement Limitations

Mechanism

1 Engine Body

2 Lubricating System

3 Cooling System

4 Fuel System

Mechanism

1 Structure

2 Travelling System

3 Pto System

4 Others

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

5 Disassembling and Assembling

6 Servicing

Servicing

Servicing

Mechanism

Servicing

Mechanism

1 Wiring Diagram

2 Starting System

3 Charging System

4 Lighting System

5 Gauges

Servicing

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Quick Links

Chapters

Troubleshooting

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Summary of Contents for wsm BX1800