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L5240
Kubota L5240 Workshop Manual
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L3540,L4240,L5040,
L5240,L5740
WORKSHOP MANUAL
TRACTOR
KiSC issued 04, 2010 A
2
Table of Contents
General
22
Default Chapter
7
Safety Decals
7
Specifications
10
Table of Contents
22
1 Tractor Identification
23
Model Name and Serial Numbers
23
Engine Serial Number
24
Cylinder Number
25
Emission Control Information
25
2 General Precautions
26
3 Handling Precautions for Electrical Parts and Wiring
27
Wiring
27
Battery
29
Fuse
29
Connector
29
Handling of Circuit Tester
30
4 Lubricants, Fuel and Coolant
31
5 Tightening Torques
34
General Use Screws, Bolts and Nuts
34
Stud Bolts
34
Plugs
35
6 Maintenance
36
7 Check and Maintenance
39
Daily Check
39
Check Points of Initial 50 Hours
43
Adjusting Clutch Pedal Free Travel
44
Replacing Transmission Oil Filter
44
Replacing Hydraulic Oil Filter
45
Check Points of Every 50 Hours
46
Lubricating Grease Fitting
48
Check Points of Every 100 Hours
49
Check Points of Every 200 Hours
55
Check Points of Every 400 Hours
59
Check Point of Every 600 Hours
61
Check Point of Every 800 Hours
62
Check Point of Every 1500 Hours
62
Check Points of Every 3000 Hours
62
Check Points of Every 1 Year
62
Check Points of Every 2 Years
63
Others
66
8 Special Tools
70
Special Tools for Engine
70
Special Tools for Tractor
80
9 Tires
89
Tire Pressure
89
Treads Adjustment
90
Front Wheels
90
Rear Wheels
90
Tire Liquid Injection
92
Mechanism
96
1 Features
97
2 Egr (Exhaust Gas Recirculation) System (if Equipped)
98
Egr Valve
99
Egr Cooler
99
Servicing
100
1 Troubleshooting
101
2 Servicing Specifications
104
3 Tightening Torques
111
4 Checking and Adjusting
112
Engine Body
112
Lubricating System
114
Cooling System
115
Fuel System
117
Turbocharger (V2403-M-T)
121
5 Preparation
122
Coolant and Lubricants (Rops and Cabin Model)
122
Separating Engine and Clutch Housing
125
Engine Separating (ROPS Model)
125
Dismounting Cabin from Tractor (Cabin Model)
132
Engine Separating (Cabin Model)
132
Separating Engine from Tractor (Rops and Cabin Model)
134
6 Disassembling and Assembling
136
Outer Parts
136
Egr Valve and Egr Cooler (if Equipped)
137
Cylinder Head and Valves
138
Timing Gears, Camshaft and Fuel Camshaft
142
Piston and Connecting Rod
150
Crankshaft
153
7 Servicing
156
Cylinder Head and Valves
156
Timing Gears, Camshaft and Fuel Camshaft
162
Piston and Connecting Rod
167
Crankshaft
169
Cylinder
174
Oil Pump
175
Servicing
179
1 Troubleshooting
180
2 Servicing Specifications
181
3 Tightening Torques
182
4 Checking and Adjusting
183
5 Preparation
184
Coolant and Lubricants
184
Separating Engine and Clutch Housing
184
Dismounting Cabin from Tractor (Cabin Model)
184
Engine Separating (ROPS Model)
184
Engine Separating (Cabin Model)
185
6 Disassembling and Assembling
186
7 Servicing
187
Mechanism
190
1 Structure
191
Glide Shift Transmission (Gst) Model
192
Hydrostatic Transmission (Hst) Model
193
2 Manual Transmission Model
194
Shift Linkage Mechanism
197
Main Gear Shift Lever
197
Shuttle Lever
197
Creep Gear Shift Lever
198
Front Wheel Drive Lever (for Four Wheel Drive Model)
198
Range Gear Shift Lever
198
3 Glide Shift Transmission (Gst) Model
199
Characteristic and System Outline
199
Power Train
200
Electrical Control System
201
Construction and Function of Components
201
Electrical Control
201
Hydraulic Control System
202
Hydraulic Circuit and System Outline
202
Construction and Function of Components
204
Front Wheel Drive Section
211
Creep Gear Section
211
Shift Linkage Mechanism
211
4 Hydrostatic Transmission (Hst) Model
212
Power Train
212
Structure
212
Oil Flow
214
Function of Components
215
Operation
216
Front Wheel Drive Section
229
Range Gear Shift Section
229
Shift Linkage Mechanism
230
Range Gear Shift Lever
230
5 Pto System
231
Structure
231
Pto Clutch
233
Oil Flow
233
Shift Linkage
233
Operation
234
Two Stage Pto (Manual Transmission Model)
235
Power Train
235
Shift Linkage
235
Servicing
236
Default Chapter
240
Manual Transmission Model
240
Gst System
242
Hst System
248
Pto System
256
2 Servicing Specifications
257
All Model
257
Glide Shift Transmission (Gst) Model
258
Hst
259
Pto Clutch
259
3 Tightening Torques
260
4 Checking and Adjusting
263
Pto Clutch Valve
263
Glide Shift Transmission (Gst) Model
264
Electrical Adjusting [GST Fine-Adjustment with Electronic Instrument Panel (Intellipanel)]
264
Hydraulic Checking
267
Hydrostatic Transmission (Hst) Model
270
Electrical Adjusting [Adjustment with Electronic Instrument Panel (Intellipanel)]
270
Hydraulic Checking and Adjusting
274
5 Preparation
278
Coolant and Lubricants
278
Rops Model
278
Dismounting the Step and Floor Seat
278
Cabin Model
287
Dismounting Cabin from Tractor
287
6 Disassembling and Assembling
288
Manual Transmission Model
288
Clutch Housing
288
MID Case
293
Transmission Case
298
Glide Shift Transmission Model
306
Clutch Housing
306
MID Case
313
Transmission Case
318
Regulating Valve
325
GST Valve Assembly
327
Hydrostatic Transmission Model
333
Clutch Housing
333
MID Case
341
Transmission Case
344
Regulating Valve
350
7 Servicing
352
Manual Transmission Model
352
Bearing, Gear and Shaft
352
Synchronized Gear
353
PTO Clutch
354
Servicing
378
2 Servicing Specifications
380
4 Checking and Adjusting
382
Brake Pedal
382
5 Disassembling and Assembling
383
Brake Pedal
383
Brake Case
385
6 Servicing
389
Servicing
394
2 Servicing Specifications
396
4 Checking and Adjusting
400
5 Disassembling and Assembling
402
Separating Front Axle Assembly
402
Disassembling Front Axle
404
6 Servicing
411
Mechanism
418
Structure
419
Hydraulic Circuit
420
Hydraulic Pump
421
Steering Controller
422
Steering Cylinder
424
Servicing
425
2 Servicing Specifications
427
4 Checking and Adjusting
429
Steering Controller
429
5 Disassembling and Assembling
430
Steering Controller
430
Steering Cylinder
431
Servicing
432
Steering Linkage
433
Mechanism
435
1 Structure
436
Manual Transmission and Glide Shift Transmission
436
Hydrostatic Transmission
437
2 Hydraulic Circuit
438
Manual Transmission
438
Glide Shift Transmission (Gst)
439
3 Hydraulic Pump
439
4 Three Point Hitch Hydraulic System
442
Three Point Hitch Hydraulic Circuit
442
Rear Hydraulic Block
443
Position Control Valve
444
Position Control Linkage
446
Lowering Speed Adjusting Valve
447
Hydraulic Cylinder
448
Position Control Operation
450
Draft Control Operation
451
Mixed Control
452
6 Front Hydraulic Block
453
7 Auxiliary Control Valve
454
Double Acting Type 1
454
Double Acting Type 2 (Floating with Detent)
455
Single Acting Type
457
Servicing
459
2 Servicing Specifications
461
4 Checking and Adjusting
464
Hyraulic Pump (for Power Steering)
464
Pump Test Using Flow-Meter
464
Hydraulic Pump (for Three Point Hitch)
467
Pump Test Using Flow-Meter
467
Relief Valve
470
Position Control Rod
472
Draft Control Rod (if Equipped)
473
5 Disassembling and Assembling
475
Hydraulic Pump
475
Removing Hydraulic Pump Assembly
475
Disassembling Hydraulic Pump
477
Three Point Hitch Hydraulic Block Assembly
478
Separating Hydraulic Block Assembly
478
Disassembling Hydraulic Assembly
479
Position Control Valve
480
Separating Control Valve
480
Lift Arm Support and Hydraulic Cylinder
481
Separating Hydraulic Cylinder
481
Disassembling Hydraulic Cylinder
482
Separating Lift Arm Support
482
Disassembling Lift Arm Shaft
483
Safety Valve
484
6 Servicing
485
Lift Arm
485
Hydraulic Cylinder
486
Hydraulic Pump
487
Mechanism
489
1 Wiring Diagram
490
Rops Type
490
Manual Transmission Model
490
HST Model
491
Cabin Type
492
Main Harness for HST Model
493
Main Harness for GST Model
494
Cabin Harness for All Model
495
Color of Wiring
496
2 Electronic Control Panel
497
System Outline and Electrical Circuit
497
System Outline
497
Control Items
498
Construction and Function of Components
499
Basic Control System
510
Attention Display (at Engine Starting)
511
Service Interval Alert
514
Warning Display or Warning Information
514
Lamp Control
516
Assistant Control System
517
Fail-Safe Function
517
Self-Diagnosis Function
517
Testing, Setting and Adjusting Function
519
Glow Control
520
3 Engine Starting System and Stopping System
521
Manual Transmission Model
521
Gst Model
522
Hst Model
523
Related Switches
524
Engine Starting Conditions
526
Servicing
527
Default Chapter
536
Error Display for HST Model
536
2 Servicing Specifications
540
4 Checking and Adjusting
542
Battery
543
Ecu and Electronic Instrument Panel (Intellipanel) .9-S17
545
Ecu
545
Electronic Instrument Panel
546
Testing, Setting and Adjusting by Electronic Instrument Panel (Intellipanel)
547
Mode Selection
547
Mode "A" (Test Mode)
549
Mode "B" (Traveling Speed Coefficient Input Mode) Input the 4 Digit Tire Code for Correct Travel Speed to the Electronic Instrument Panel Memory Panel
551
Mode "D" (Error Information Reset Mode) Delete the Error Information from the Electronic Instrument Panel
552
Mode "E" (GST Lever Sensor Fine-Adjustment Mode) Setting the GST Lever's Neutral Position with Its Sensor
553
Mode "F" (GST Valve Fine-Adjustment Mode) Setting the Function of Proportional Reducing Valve
554
Mode "G" (GST Shift Shock Fine-Adjustment Mode) Adjusting the Clutch Engaging Interval
555
Mode "H" (Error Information Display Mode) Confirming or Reviewing the Error Information
555
Mode "I" (Transmission Model Input Mode) Input the Transmission Model into Electronic Instrument Panel
556
Mode "J" (Speed Unit Selection Mode) Input the Traveling Speed Unit to the Electronic Instrument Panel
556
Mode "K
557
Mode "L" (Throttle Sensor Fine-Adjustment Mode)
559
Mode "M" (Mode for Factory)
559
Mode "N" (Tractor Model Select Mode)
560
Electric Control System
561
Check the Fuse and Connector
562
Checking by Electronic Instrument Panel Connector
564
Unit Checking
566
Ecu Control System (Gst Model and Hst Model)
567
Checking Fuse and Connector
567
Checking by Electric Control Unit (ECU)
568
Checking Sensor and Switch for GST Model
571
Checking Sensor and Switch for HST Model
572
Starting System
580
Main Switch (ROPS Type)
580
Main Switch (CABIN Type)
581
Safety Switch
582
Starter and Starter Relay
583
Glow Control System
584
Engine Stop Solenoid
585
Charging System
586
Lighting System
587
Multi Function Combination Lever (Combination Switch)
587
Warning Lamps
590
Checking
590
Monitor Lamp
592
Gauges
593
Checking
593
Coolant Temperature Sensor
593
Others
594
5 Disassembling and Assembling
596
Starter
596
Alternator
597
6 Servicing
599
Starter
599
Alternator
602
Air Conditioner System
606
Outline of Air Conditioning System
606
System Control
608
Electrical Circuit
609
Electrical System
609
Air Conditioner Relay, Blower Relays and Compressor Relay
610
Servicing
611
2 Servicing Specifications
616
3 Tightening Torques
617
4 Precautions at Repairing Refrigerant Cycle
618
Handling of Service Tools
620
Manifold Gauge Set
620
Refrigerant Charging Hose
621
Can Tap Valve
622
Electric Gas Leak Tester
622
Vacuum Pump Adaptor
622
R134A Refrigerant Recovery and Recycling Machine
623
T-Joint
623
5 Checking and Charging Refrigerant Cycle
624
Checking with Manifold Gauge
624
Discharging, Evacuating and Charging
628
Discharging the Refrigerant
628
Evacuating the System
629
Charging the Refrigerant
630
Checking Charge Refrigerant Amount
632
6 Checking, Disassembling and Servicing
633
Checking and Adjusting
633
Compressor
633
Control Panel (Blower Switch, A/C Switch, Mode Control Dial and Temperature Control Dial)
634
Blower Resistor
636
Blower Motor
637
Temperature Motor
637
Air Conditioner Relay and Blower Relay
638
Mode Motor
638
Pressure Switch
639
Front Wiper Switch
640
Front Wiper Motor
641
Rear Windshield Wiper (if Equipped)
641
Disassembling and Assembling
643
Separating Cabin from Tractor
643
Removing Compressor Assembly
653
Removing Air Conditioner Unit
655
Removing Air Conditioner Pipes
658
Removing Heater Hoses
660
Cabin Windshields
662
Wiper Motor
665
Servicing
665
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Kubota L5240 Specifications
General
Engine Type
Diesel
Fuel
Diesel
Drive
4WD
Number of Gears
3 ranges
Hydraulic System
Open Center
3-Point Hitch
Category I
Transmission
Hydrostatic
Displacement
148.5 ci
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