User Manuals: Kubota WSM BX2380 Tractor Mower Package

Manuals and User Guides for Kubota WSM BX2380 Tractor Mower Package. We have 1 Kubota WSM BX2380 Tractor Mower Package manual available for free PDF download: Workshop Manual

Kubota WSM BX2380 Workshop Manual

Kubota WSM BX2380 Workshop Manual (436 pages)

Brand: Kubota | Category: Lawn Mower | Size: 20.96 MB

Table of Contents

Table of Contents
5
Information

19
- Safety First
  20
  - Before You Start Service
    21
  - Start Safely
    21
  - Operate Safely
    21
  - Avoiding High Pressure Fluid
    22
  - Avoiding Hot Exhaust
    22
  - Cleaning Exhaust Filter
    22
  - Prevent a Fire
    23
  - Keep a Good Airflow in the Work Area
    23
  - Discard Fluids Correctly
    23
  - Prevent Acid Burns
    23
  - Preparing for Emergencies
    24
- Safety Label
  26
  - Safety Labels for BX Tractor
    26
  - Safety Labels for Mower
    31
    
    Care of Danger, Warning and Caution Labels
    33
- Specifications
  34
- Traveling Speeds
  38
- Dimensions
  40
General

42
- Identification
  43
  - Tractor Identification
    43
    
    Checking Serial Number and Hour Meter
    43
    
    Cylinder Number
    44
  - Checking Mower Identification
    44
- General Precautions
  45
- Handling Precautions for Electrical Parts and Wiring
  47
- Lubricants, Fuel and Coolant
  49
  - BX Tractor
    49
    
    Engine Oil
    50
    
    Fuel
    50
    
    Transmission Oil
    50
    
    Overview of Biodiesel Fuel (BDF)
    51
  - Mower
    53
    
    Lubricants
    53
- Tightening Torques
  55
- Maintenance Check List
  57
  - BX Tractor Service Intervals
    57
  - Mower Service Intervals
    59
- Check and Maintenance
  61
  - Periodic Service
    61
    
    Opening Bonnet
    61
- Daily Check
  61
- Check Points of Initial 50 Hours
  65
- Check Points of Every 50 Hours
  66
- Check Points of Every 100 Hours
  69
  - Checking Battery Condition
    69
  - Cleaning Air Cleaner Element
    70
  - Checking Fuel Filter
    71
  - Adjusting Fan Belt Tension
    72
  - Adjusting HST Neutral Spring
    72
  - Adjusting Brake Pedal
    73
- Check Point of Every 200 Hours
  73
  - Replacing Engine Oil Filter
    73
  - Changing Engine Oil
    74
  - Replacing Transmission Oil Filter
    75
  - Adjusting Toe-In
    75
- Check Points of Every 400 Hours
  75
- Check Points of Every 800 Hours
  78
  - Adjusting Engine Valve Clearance
    78
- Check Points of Every 1000 Hours or 1 Year
  78
  - Replacing Air Cleaner Element
    78
- Check Points of Every 1500 Hours
  78
  - Checking Injection Pressure of Fuel Injection Nozzle
    78
- Check Points of Every 2000 Hours or 2 Years
  78
  - Flushing Cooling System and Changing Coolant
    78
  - Antifreeze
    79
- Check Points of Every 3000 Hours
  80
  - Checking Injection Pump
    80
- Check Points of Every 1 Year
  80
  - Checking Intake Air Line
    80
  - Checking Radiator Hoses and Hose Clamps
    80
  - Checking Power Steering Line
    81
  - Checking Fuel Lines
    81
  - Checking Engine Breather Hose
    82
    
    Check Points of Every 4 Years
    82
    
    Replacing Engine Breather Hose
    82
    
    Replacing Fuel Hose
    82
    
    Replacing Intake Air Line
    82
    
    Replacing Power Steering Hose
    82
    
    Replacing Radiator Hose
    82
    
    Bleeding Fuel System
    83
    
    Replacing Fuse
    83
    
    Service as Required
    83
    
    Check Points of Daily or each Use
    84
    
    Checking Mower Blade
    84
    
    Mower
    84
    
    Replacing Light Bulb
    84
    
    Retightening Mower Blade Screw
    84
    
    Checking Gear Box Oil Level
    85
    
    Checking Mower Belt
    85
    
    Greasing Spindle Shafts, Belt Tension Pivot and Tension Pulley
    85
    
    Greasing Balance Shaft
    86
    
    Changing Gear Box Oil
    87
    
    Check Points of Initial 50 Hours
    87
    
    Greasing Front and Rear Anti-Scalp Rollers
    87
    
    Greasing Universal Joint
    87
    
    Changing Gear Box Oil
    88
    
    Check Point of Every 150 Hours
    88
    
    Check Point of Every 4 Years
    88
    
    Check Points of Every 1 Year
    88
    
    Checking Gear Box Oil Seal
    88
    
    Replacing Gear Box Oil Seal
    88
  - Tires, Wheels, and Ballast
    89
    
    Dual Tires
    89
    
    Inflation Pressure of Tires
    89
    
    Tires
    89
    
    Wheel Tread
    89
    
    Front Wheels
    90
    
    Rear Wheels
    90
    
    Ballast
    91
    
    Front Ballast
    91
    
    Rear Ballast
    91
  - Implement Limitations
    93
    
    Weight of Implements as Rear Ballast
    93
    
    Implement Limitation Tables
    94
  - Special Tools
    97
    
    Diesel Engine Compression Tester (for Injection Nozzle)
    97
    
    Injection Pump Pressure Tester
    97
    
    Nozzle Tester
    97
    
    Special Tools for Engine
    97
    
    Special Use Puller Set
    97
    
    Valve Guide Replacing Tool
    98
    
    Bushing Replacing Tool
    99
    
    Flywheel Stopper
    100
    
    Crankshaft Bearing 1 Replacing Tool
    101
    
    Governor Gear Holder Busing Replacing Tool
    101
    
    Independent PTO Clutch Spring Compression Tool
    102
    
    Special Tools for Tractor
    102
    
    Tie-Rod End Lifter
    102
    
    Disassembling and Assembling Stand (1/2)
    103
    
    Disassembling and Assembling Stand (2/2)
    105
    
    Check and High Pressure Relief Valve Assembly Tool
    107
    
    Quick Coupler Cartridge Socket
    109
Engine

111
- Mechanism
  112
  - Engine Body
    112
    
    Function of Closed Breather
    112
    
    Function of Cylinder Block
    112
    
    Function of Half-Floating Head Cover
    112
    
    Function of Connecting Rod
    113
    
    Function of Crankshaft
    113
    
    Function of Piston
    113
    
    Function of Piston Ring
    113
    
    Function of Camshaft
    114
    
    Function of Flywheel
    114
    
    Function of Rocker Arm
    114
    
    Function of Timing Gears
    115
  - Lubricating System
    116
    
    Overview of Lubricating System
    116
    
    Function of Oil Filter
    118
    
    Function of Oil Pump
    118
    
    Function of Oil Strainer
    118
    
    Function of Oil Pressure Switch
    119
    
    Function of Relief Valve
    119
  - Cooling System
    120
    
    Overview of Cooling System
    120
    
    Function of Radiator
    122
    
    Function of Radiator Cap
    122
    
    Function of Water Pump
    122
  - Fuel System
    123
    
    Function of Fuel Feed Pump
    123
    
    Function of Fuel Filter
    123
    
    Function of Injection Nozzle
    123
    
    Overview of Fuel System
    123
- Servicing
  126
  - Troubleshooting for Engine
    126
  - Servicing Specifications for Engine
    130
  - Tightening Torques for Engine
    139
  - Checking and Adjusting
    141
    
    Checking Compression Pressure
    141
    
    Checking Valve Clearance
    141
    
    Engine Body
    141
    
    Checking Engine Oil Pressure
    142
    
    Lubricating System
    142
    
    Checking Fan Belt Damage and Wear
    143
    
    Checking Fan Belt Tension
    143
    
    Checking Radiator Cap Air Leakage
    143
    
    Cooling System
    143
    
    Checking Radiator Water Leakage
    144
    
    Checking Thermostat Valve Opening Temperature
    144
    
    Checking Injection Timing
    145
    
    Fuel System
    145
    
    Checking Fuel Tightness of Delivery Valve
    146
    
    Checking Fuel Tightness of Pump Element
    146
    
    Checking Fuel Injection Pressure
    147
    
    Checking Nozzle Spraying Condition
    147
    
    Checking Nozzle Holder
    148
    
    Checking Valve Seat Tightness
    148
  - Disassembling and Assembling
    149
    
    Draining Engine Oil
    149
    
    Removing Battery
    149
    
    Separating Engine
    149
    
    Removing Bonnet
    150
    
    Disconnecting Fuel Hoses
    151
    
    Disconnecting Wiring Harness and Ground Cables
    151
    
    Disconnecting Accelerator Wire
    152
    
    Disconnecting Propeller Shaft Assembly
    152
    
    Separating Engine
    152
    
    Draining Coolant and Removing Outer Engine Parts
    153
    
    Cylinder Head and Valve
    154
    
    Disassembling Engine
    154
    
    Gear Case and Timing Gears
    158
    
    Piston and Connecting Rod
    162
    
    Flywheel and Crankshaft
    164
  - Servicing
    166
    
    Checking Cylinder Head Surface Flatness
    166
    
    Checking Top Clearance
    166
    
    Cylinder Head and Valve
    166
    
    Checking Cylinder Head Flaw
    167
    
    Checking Clearance between Valve Stem and Valve Guide
    168
    
    Checking Valve Recessing
    168
    
    Checking Valve Seating
    169
    
    Replacing Valve Guide
    169
    
    Correcting Valve
    170
    
    Correcting Valve Seat
    170
    
    Checking Free Length and Tilt of Valve Spring
    171
    
    Checking Valve Spring Setting Load
    171
    
    Lapping Valve
    171
    
    Checking Oil Clearance between Rocker Arm and Rocker Arm Shaft
    172
    
    Checking Push Rod Alignment
    172
    
    Checking Oil Clearance between Tappet and Tappet Guide Bore
    173
    
    Checking Timing Gear Backlash
    173
    
    Timing Gears, Camshaft and Governor Gear
    173
    
    Checking Camshaft Side Clearance
    174
    
    Checking Idle Gear 1 Side Clearance
    174
    
    Checking Cam Height
    175
    
    Checking Camshaft Alignment
    175
    
    Checking Oil Clearance of Camshaft Journal
    175
    
    Checking Oil Clearance between Idle Gear 1 Shaft and Idle Gear Bushing
    176
    
    Checking Oil Clearance between Piston Pin and Small End Bushing
    177
    
    Checking Piston Pin Bore I.D
    177
    
    Piston and Connecting Rod
    177
    
    Replacing Idle Gear Bushing
    177
    
    Checking Connecting Rod Alignment
    178
    
    Replacing Small End Bushing
    178
    
    Checking Clearance between Piston Ring and Piston Ring Groove
    179
    
    Checking Piston Ring Gap
    179
    
    Checking Crankshaft Side Clearance
    180
    
    Crankshaft
    180
    
    Checking Crankshaft Alignment
    181
    
    Checking Oil Clearance between Crankpin and Crankpin Bearing
    181
    
    Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1
    183
    
    Replacing Crankshaft Bearing 1
    184
    
    Checking Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3
    185
    
    Checking Cylinder Wear
    187
    
    Correcting Cylinder (Oversize)
    187
    
    Cylinder
    187
    
    Checking Clearance between Outer Rotor and Pump Body
    188
    
    Checking Rotor Lobe Clearance
    188
    
    Oil Pump
    188
    
    Checking Clearance between Rotor and Cover
    189
    
    Checking Relief Valve
    189
    
    Relief Valve Spring
    189
Transaxle

190
- Mechanism
  191
  - Structure of Transaxle
    191
  - Traveling System
    192
    
    Hydrostatic Transmission
    192
    
    Structure of Hydrostatic Transmission
    192
    
    Oil Flow of Hydrostatic Transmission
    193
    
    Structure of HST Control Linkage
    198
    
    Speed Set Linkage
    199
    
    Range Gear Shift Section
    202
    
    Structure of Range Gear Shift
    202
    
    Front Wheel Drive Section
    203
    
    Structure of Front Wheel Drive
    203
    
    Differential Gear Section
    204
    
    Structure of Differential Gears
    204
    
    Structure of Differential Lock
    206
    
    Brake Section
    207
    
    Structure of Brake System
    207
  - PTO System
    209
    
    Structure of PTO System
    209
    
    Disengaged Function of PTO Clutch
    210
    
    Engaged Function of PTO Clutch
    210
    
    Function of PTO Clutch Relief Valve
    210
    
    Structure of MID and Rear PTO
    211
  - Others
    212
    
    Hydraulic Pump Drive Gear Section
    212
    
    Structure of Hydraulic Pump Drive Gear
    212
- Servicing
  213
Front Axle

255
- Mechanism
  256
  - Structure of Front Axle
    256
  - Front Wheel Alignment
    257
    
    Camber of Front Axle
    257
    
    Caster of Front Axle
    257
    
    Kingpin Angle of Front Axle
    257
    
    Toe-In of Front Axle
    257
- Servicing
  260
Steering

274
- Mechanism
  275
  - Structure of Steering System
    275
  - Hydraulic Circuit of Steering
    276
  - Steering Controller
    277
    
    Control Valve
    277
    
    Metering Device
    277
    
    Structure of Steering Controller
    277
    
    Relief Valve
    278
  - Steering Cylinder
    279
    
    Structure of Steering Cylinder
    279
- Servicing
  281
  - Troubleshooting for Steering
    281
  - Servicing Specifications for Steering
    283
  - Checking and Adjusting
    285
    
    Checking Relief Valve Operating Pressure
    285
  - Disassembling and Assembling
    285
    
    Power Steering Cylinder
    285
    
    Removing Adapter and Tie-Rod
    285
    
    Disassembling Steering Cylinder
    286
    
    Removing Battery
    286
    
    Separating Power Steering Controller
    286
    
    Removing Steering Controller
    287
    
    Removing Steering Wheel
    287
    
    Removing Upper Panel
    287
    
    Removing Bonnet
    288
    
    Separating Power Steering Cylinder
    288
    
    Removing Front Axle Assembly
    289
    
    Removing Power Steering Cylinder
    289
  - Servicing
    290
    
    Checking Clearance between Rod and Guide
    290
    
    Checking Steering Cylinder I.D
    290
Hydraulic System

291
- Mechanism
  292
  - Structure of Hydraulic System
    292
  - Hydraulic Circuit
    293
  - Hydraulic Pump
    295
    
    Outline of Hydraulic Pump
    295
    
    Specification of Hydraulic Pump
    295
    
    Structure of Hydraulic Pump
    295
  - Control Valve
    295
    
    Outline of Control Valve
    295
    
    Control Valve in Neutral Position
    296
    
    Function of Control Valve
    296
    
    Control Valve in Lift Position
    297
    
    Control Valve in down Position
    298
  - Flow Priority Valve
    299
    
    Outline of Flow Priority Valve
    299
    
    Structure of Flow Priority Valve
    300
    
    Specification of Flow Priority Valve
    301
  - Relief Valve
    301
    
    Outline of Relief Valve
    301
    
    Structure of Relief Valve
    302
    
    Function of Relief Valve
    303
    
    Specification of Relief Valve
    304
  - Hydraulic Cylinder
    305
    
    Structure of Hydraulic Cylinder
    305
  - Hydraulic Block Type Outlet
    306
    
    Structure of Hydraulic Block Type Outlet
    306
  - Mower Linkage
    307
    
    Structure of Mower Linkage
    307
  - Front Loader Valve
    308
    
    Structure
    308
    
    Structure of Front Loader Valve and Pipe
    308
    
    Structure of Front Loader Control Valve
    309
    
    Front Loader Hydraulic Circuit
    310
    
    Function of Loader Control Valve
    311
    
    Loader Control Lever in Neutral Position
    311
    
    Loader Control Lever in up Position
    312
    
    Loader Control Lever in down Position
    314
    
    Loader Control Lever in Floating Position
    316
    
    Loader Control Lever in Roll-Back Position
    318
    
    Loader Control Lever in Dump Position
    320
- Servicing
  322
  - Troubleshooting for Hydraulic System
    322
  - Servicing Specifications for Hydraulic System
    323
  - Tightening Torques for Hydraulic System
    324
  - Checking and Adjusting
    325
    
    Checking Hydraulic Pump Oil Flow
    325
    
    Checking Relief Valve Setting Pressure
    325
    
    Pump and Priority Valve
    325
    
    Relief Valve
    325
    
    Checking Power Steering Oil Flow
    326
    
    Adjusting Mower Lift Linkage
    327
    
    Mower Lift Linkage
    327
  - Disassembling and Assembling
    328
    
    Hydraulic Pump
    328
    
    Removing Battery
    328
    
    Removing Lift Rod and Lower Link
    328
    
    Removing Fender
    329
    
    Removing ROPS
    329
    
    Removing Seat
    329
    
    Removing Step
    329
    
    Removing Fender Center Stay
    330
    
    Removing Fuel Tank
    330
    
    Removing Hydraulic Pump
    330
    
    Hydraulic Cylinder Block
    331
    
    Removing Battery
    331
    
    Removing Lift Rod and Lower Link
    332
    
    Removing ROPS
    332
    
    Removing Seat
    332
    
    Removing Step
    332
    
    Removing Fender
    333
    
    Removing Fuel Tank
    333
    
    Removing Fender Center Stay
    334
    
    Removing Hydraulic Cylinder Block
    334
    
    Removing Mower Linkage and Wire Harness
    334
    
    Hydraulic Cylinder and Control Valve
    335
    
    Removing Control Valve
    335
    
    Removing Control Valve Lever
    335
    
    Removing Hydraulic Piston
    336
    
    Removing Lift Arm, Hydraulic Arm Shaft and Hydraulic Arm
    336
    
    Removing Lowering Speed Adjusting Valve
    336
    
    Disassembling Mower Linkage
    337
    
    Mower Lift Linkage
    337
    
    Control Valve (Front Loader)
    338
    
    Removing Battery
    338
    
    Removing ROPS
    338
    
    Removing Seat
    338
    
    Removing Step
    338
    
    Removing Control Valve
    339
    
    Removing Fender
    339
    
    Disassembling Control Valve
    340
    
    Quick Coupler
    341
    
    Removing Quick Coupler (Tractor Side)
    341
  - Servicing
    341
    
    Checking Clearance between Tip of Gear Tooth and Casing
    341
    
    Hydraulic Pump
    341
    
    Checking Clearance between Bushing and Shaft
    342
    
    Checking Hydraulic Cylinder Bore
    342
    
    Checking Side Plate Thickness
    342
    
    Hydraulic Cylinder
    342
    
    Checking Hydraulic Arm Shaft Bushing
    343
Electrical System

344
- Mechanism
  345
  - Wiring Diagram of BX Tractor
    345
  - Electrical Connector Chart
    346
  - Reading Electrical Circuit Diagrams
    347
    
    Electrical Wiring Chart Symbols
    347
    
    Layout of Connector Diagrams
    350
    
    Precautions on Handling Electrical Connectors
    351
  - Starting System
    352
    
    Electrical Circuit of Starting System
    352
    
    Function of Relay
    353
    
    Function of Starter
    353
    
    Function of Fuel Pump
    354
    
    Function of Glow Plug
    354
    
    Function of Safety Switch
    354
  - Operator Presence Control (OPC) System
    355
    
    Electrical Circuit of OPC Timer
    355
  - Charging System
    356
    
    Electrical Circuit for Charging System
    356
    
    Function of IC Regulator (3P Connector Type)
    357
  - Lighting System
    358
    
    Electrical Circuit for Lighting System
    358
  - Gauges
    359
    
    Electrical Circuit of Gauge System
    359
    
    Function of Coolant Temperature Gauge
    360
    
    Function of Fuel Gauge
    360
    
    Function of Hour Meter
    360
    
    Function of Tachometer
    360
    
    Meter Panel
    360
    
    Function of Coolant Temperature Sensor
    361
    
    Function of Fuel Level Sensor
    361
    
    Function of Oil Pressure Switch
    362
  - Others
    363
    
    Electrical Circuit for Accessory
    363
    
    Function of DC Outlet
    364
- Servicing
  365
  - Troubleshooting for Electrical System
    365
  - Service Specifications for Electrical System
    371
  - Tightening Torques for Electrical System
    372
  - Checking and Adjusting
    373
    
    Battery
    373
    
    Checking Battery Specific Gravity
    373
    
    Checking Battery Terminal Connection
    373
    
    Checking Battery Voltage
    373
    
    Checking Main Switch Connector Voltage
    374
    
    Checking Main Switch Continuity at off Position
    374
    
    Main Switch
    374
    
    Checking Main Switch Continuity at on Position
    375
    
    Checking Main Switch Continuity at Preheat Position
    375
    
    Checking Main Switch Continuity at Start Position
    375
    
    Starter
    376
  - Checking Motor
    376
  - Testing Starter Magnet Switch (Pull-In, Holding Coils)
    376
- Glow Plug
  376
  - Checking Glow Plug Lead Terminal Voltage
    376
  - Checking Glow Plug Continuity
    377
- Safety Switch
  377
- Fuel Pump
  380
  - Checking Fuel Pump Connector Voltage
    380
  - Checking Fuel Pump Continuity
    381
- Engine Stop Solenoid
  381
  - Testing Engine Stop Solenoid
    381
- Timer Relay
  381
  - Checking Timer Relay Connector Voltage
    381
  - Testing Timer Relay
    381
- Charging System
  382
  - Checking Battery Charging Current
    382
- Combination Switch
  382
- Gauge
  387
- Accessory
  390
  - Checking DC Outlet Connector Voltage
    390
  - Checking DC Outlet Continuity
    390
- Meter Panel
  391
  - Checking Connector Voltage, Sensor Resistance and Switch
    391
- Disassembling and Assembling
  391
  - Starter
    391
    
    Disassembling Starter Motor
    391
    
    Removing Magnet Switch
    392
    
    Removing Plunger
    392
  - Alternator
    392
    
    Removing Pulley
    392
    
    Removing Brush Holder
    393
    
    Removing IC Regulator
    393
    
    Removing Rear End Cover
    393
    
    Removing Rear End Frame
    393
    
    Removing Rectifier
    393
    
    Checking Overrunning Clutch
    394
    
    Removing Bearing at Slip Ring Side
    394
    
    Removing Bearing on Drive End Side
    394
    
    Removing Retainer Plate
    394
    
    Servicing
    394
    
    Starter
    394
    
    Checking Brush Wear
    395
    
    Checking Commutator and Mica
    395
    
    Checking Armature Coil
    396
    
    Checking Brush Holder
    396
    
    Checking Field Coil
    396
    
    Alternator
    397
    
    Checking Bearing
    397
    
    Checking Rotor
    397
    
    Checking Slip Ring
    397
    
    Checking Stator
    397
    
    Checking Brush Wear
    398
    
    Checking Rectifier
    398
Mower

399
- Mechanism
  400
- Servicing
  404
  - Troubleshooting for Mower
    404
  - Servicing Specifications for Mower
    405
  - Tightening Torques for Mower
    406
  - Setting up Mower [RCK48-18BX, RCK54-23BX, and RCK60B-23BX]
    407
    
    Assembling Mower
    407
    
    Setting Mower
    407
    
    Installing Universal Joint
    408
    
    Mounting Front Link
    408
    
    Mounting Rear Link
    408
  - Setting up Mower [RCK54D-26BX and RCK60D-26BX]
    410
    
    Assembling Mower
    410
    
    Mounting Front Link
    410
    
    Setting Mower
    410
    
    Mounting Frame Link
    411
    
    Mounting Mower
    412
    
    Setting Tractor
    412
  - Checking and Adjusting
    413
    
    Adjusting Mower Link
    413
    
    Mower Adjustment
    413
    
    Adjusting Front and Rear Cutting Height
    414
    
    Adjusting Left and Right Cutting Height
    415
    
    Adjusting Self-Balance Suspended Linkage
    416
    
    Adjusting Cutting Height
    417
    
    Checking Mower Belt
    418
    
    Checking Mower Blade
    418
    
    Checking Mower Blade and Belt
    418
  - Disassembling and Assembling
    419
    
    Removing Mower Blades
    419
    
    Removing Ramps and Belt Covers
    419
    
    Removing Universal Joint and Belt Cover
    419
- Removing Blade Boss
  420
- Removing Gear Box and Mower Belt
  420
- Disassembling Gear Box
  421
- Removing Center Pulley Holder
  421
- Removing Outer Pulley and Blade Shaft
  422
- Removing Balancer
  423
- Servicing
  424
  - Adjusting Turning Torque of Pinion Shaft
    424
  - Adjusting Backlash between Bevel Gears
    424

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