Kubota BX1860, BX2360, BX2660, LA203, LA243, RCK48-18BX Workshop Manual
Kubota RCK48-18BX is a rotary mower designed for use with BX1860, BX2360, and BX2660 tractors. It features a 48-inch cutting width and is ideal for mowing large areas of grass. The RCK48-18BX is equipped with a variety of features that make it easy to use and maintain, including a height-adjustable cutting deck, anti-scalping wheels, and a mulching kit. With its powerful engine and durable construction, the RCK48-18BX is a great choice for homeowners and professionals alike.
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WORKSHOP MANUAL
TRACTOR,ROTARY MOWER,
FRONT LOADER
BX1860,BX2360,BX2660,
RCK48-18BX,RCK54-23BX,
RCK60B-23BX,RCK48P-18BX,
RCK54P-23BX,LA203,LA243
KiSC issued 06, 2009 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Tractor BX1860,
BX2360, BX2660, KUBOTA Rotary Mower RCK48-18BX, RCK54-23BX, RCK60B-
23BX, RCK48P-18BX, RCK54P-23BX and KUBOTA Front Loader LA203, LA243. It is divided into three parts, “General”, “Mechanism” and “Servicing” for each section.
Q
General
Information on the tractor identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
Q
Mechanism
Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine / Tractor Mechanism Workshop Manual (Code No. 9Y021-
01875 / 9Y021-18201) for the one which has not been described to this workshop manual.
Q
Servicing
Information on the troubleshooting, servicing specification lists, tightening torque, checking and adjusting, disassembling and assembling and servicing which cover procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
August 2008
© KUBOTA Corporation 2008
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
Q
IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed.
Q
NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground, and set the parking brake.
• Lower the implement to the ground.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “
DO NOT OPERATE
” tag in operator station.
1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
• Never start the engine while standing on ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued.
• Wear close fitting clothing and safety equipment appropriate to the job.
• Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.
• When servicing is performed together by two or more persons, take care to perform all work safely.
• Do not work under the machine that is supported solely by a jack. Always support the machine by safety stands.
• Do not touch the rotating or hot parts while the engine is running.
• Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause serious injury. Do not disconnect or attempt repair fuel lines, sensors, or any other components between the high-pressure fuel pump and injectors on engines with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in the
ECU, and is applied to the injector.
Pay sufficient caution to electric shock when performing work activities.
2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
AVOID FIRES
• Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area.
• To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.
• Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery.
• Make sure that no fuel has been spilled on the engine.
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.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, clothing and cause blindness if splashed into eyes. Keep electrolyte away from eyes, hands and clothing. If you spill electrolyte on yourself, flush with water, and get medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, electrolyte and other harmful waste.
3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all times.
• Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone.
4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SPECIFICATIONS
SPECIFICATIONS
PTO power
Engine
Capacities
Maker
Model
Type
Number of cylinders
Bore and stroke
Total displacement
Engine gross power
Rated revolution
Maximum torque
Battery
Fuel
Model
Fuel tank
Engine crankcase (with filter)
Engine coolant
Dimensions
Recovery tank
Transmission case
Overall length (without 3P)
Overall length (with 3P)
Overall width (min. tread)
Overall height (with ROPS)
Overall height (Top of seat)
Wheel base
Minimum ground clearance
Tread
Front
Rear
Weight (with ROPS)
Clutch
Travelling system
Hydraulic system
PTO
Tires
Front
Rear
Steering
Transmission
Brake
Min. turning radius (without brake)
Hydraulic control system
Pump capacity
Three point hitch
Max. lift force
At lift points
24 in. behind lift points
PTO shaft
Rear PTO
Revolution
PTO shaft
Mid
Revolution
BX1860
10.2 kW (13.7 HP)*
BX2360
13.2 kW (17.7 HP)*
KUBOTA
BX2660
14.5 kW (19.5 HP)*
D722-E3-BX-2 D902-E3-BX-2 D1005-E3-BX
Indirect Injection, vertical, water-cooled, 4-cycle diesel
67
×
68 mm
(2.64
×
2.68 in.)
719 cm
3
(43.9 cu.in.)
13.4 kW (18.0 HP)
3
72
×
73.6 mm
(2.83
×
2.90 in.)
898 cm
3
(54.8 cu.in.)
17.1 kW (23.0 HP)
3200 min
-1
(rpm)
56.1 N·m (5.7kgf·m,
41.4lbf·ft)
76
×
73.6 mm
(2.99
×
2.90 in.)
1001 cm
3
(61.1 cu.in.)
19.0 kW (25.5 HP)
44.9N·m (4.6kgf·m, 33.1 lbf·ft)
2.5 L (2.6 U.S.qts., 2.2
Imp.qts.)
2.7 L (2.8 U.S.qts., 2.4
Imp.qts.)
0.4 L (0.4 U.S.qts., 0.4 Imp.qts.)
60.2 N·m (6.1 kgf·m, 44.4 lbf·ft)
12 V, RC : 62 min., CCA :
435 A
12 V, RC : 80 min., CCA : 535 A
Diesel fuel No. 1 [below
−
10 °C (14 °F)], Diesel fuel No. 2 [above
−
10 °C (14 °F)]
2.9 L (3.1 U.S.qts., 2.6
Imp.qts.)
25 L (6.6 U.S.gals, 5.5 Imp.gals.)
3.1 L (3.3 U.S.qts., 2.7
Imp.qts.)
3.5 L (3.7 U.S.qts., 3.1
Imp.qts.)
2.9 L (3.1 U.S.qts., 2.6
Imp.qts.)
2035 mm (80.1 in.)
2340 mm (92.1 in.)
1760 mm (69.3in.)
1230 mm (48.4 in.)
1340 mm (52.8 in.)
150 mm (5.9 in.)
880 mm (34.6 in.)
11.6 L (3.06 U.S.gals, 2.55 Imp.gals.)
2120 mm (83.5 in.)
2425 mm (95.5 in.)
1145 mm (45.1 in.)
1785 mm (70.3 in.)
1255 mm (49.4 in.) 1330 mm (52.4 in.)
1400 mm (55.1 in.)
175 mm (6.9 in.)
910 mm (35.8 in.)
820 mm (32.2 in.)
570 kg (1256.6 lbs)
16
×
7.50 – 8
24
×
12.00 – 12
585 kg (1289.7 lbs)
N / A
18
26
×
×
636 kg (1402.1 lbs)
8.50 – 10
12.00 – 12
Hydrostatic type power steering
Main: hydrostatic transmission, High-Low gear shift (2 forward and 2 reverse)
2.18 m (7.15 feet)
Wet disk type
2.3 m (7.5 feet)
Directional control, auto-return lever system
23.5 L/min. (6.2 U.S.gals./min., 5.2 Imp.gals./min.)
SAE Category I
5390 N (1210 lbs)**
3040 N (680 lbs)**
SAE 1-3/8, 6 splines
1 speed (540 min
-1
(rpm) at engine 3142 min
-1
(rpm))
USA No. 5 (KUBOTA 10-tooth) involute spline
1 speed (2500 min
-1
(rpm) at engine 3043 min
-1
(rpm))
NOTE: * Manufacture’s estimate The company reserves the right to change the specifications without notice.
** See and check “IMPLEMENT LIMITATIONS”.
W1028103
9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
TRAVELING SPEEDS
Model BX1860
Tire size (Rear)
Forward
Range gear shift lever
Low
High
24
×
12.00 – 12 km/h
0 to 5.5
0 to 12.0
mph
0 to 3.4
0 to 7.5
Reverse
Low
High
0 to 4.5
0 to 9.0
0 to 2.5
0 to 5.6
The company reserves the right to change the specifications without notice.
TRAVELING SPEEDS
(At rated engine rpm)
BX2360
BX2660
26
×
12.00 – 12 km/h mph
0 to 6.0
0 to 13.0
0 to 3.7
0 to 8.1
0 to 4.5
0 to 10.0
0 to 2.8
0 to 6.2
W1035065
10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, BCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
DIMENSIONS
DIMENSIONS
11
KiSC issued 06, 2009 A
G
GENERAL
KiSC issued 06, 2009 A
GENERAL
CONTENTS
1. TRACTOR IDENTIFICATION ......................................................................... G-1
[1] SERIAL NUMBER..................................................................................... G-1
[2] CYLINDER NUMBER ............................................................................... 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. LUBRICANTS, FUEL AND COOLANT ......................................................... G-7
5. TIGHTENING TORQUES ............................................................................... G-9
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................... G-9
[2] STUD BOLTS............................................................................................ G-9
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS ............................................................................... G-10
[4] PLUGS ..................................................................................................... G-10
6. MAINTENANCE CHECK LIST ..................................................................... G-11
7. CHECK AND MAINTENANCE ..................................................................... G-12
[1] DAILY CHECK ........................................................................................ G-12
[2] CHECK POINTS OF INITIAL 50 HOURS ........................................... G-13
[3] CHECK POINTS OF EVERY 50 HOURS ........................................... G-15
[4] CHECK POINTS OF EVERY 100 HOURS ......................................... G-17
[5] CHECK POINTS OF EVERY 200 HOURS ......................................... G-22
[6] CHECK POINTS OF EVERY 400 HOURS ......................................... G-24
[7] CHECK POINT OF EVERY 500 HOURS ........................................... G-25
[8] CHECK POINT OF EVERY 800 HOURS ........................................... G-25
[9] CHECK POINT OF EVERY 1500 HOURS ......................................... G-25
[10]CHECK POINT OF EVERY 3000 HOURS ......................................... G-25
[11]CHECK POINT OF EVERY 1 YEAR................................................... G-25
[12]CHECK POINTS OF EVERY 2 YEARS.............................................. G-26
[13]OTHERS .................................................................................................. G-30
8. SPECIAL TOOLS.......................................................................................... G-32
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-32
[2] SPECIAL TOOLS FOR TRACTOR....................................................... G-37
9. TIRES............................................................................................................. G-41
[1] TIRE PRESSURE ................................................................................... G-41
[2] WHEEL TREAD ...................................................................................... G-42
(1) Front Wheels...................................................................................... G-42
(2) Rear Wheels ...................................................................................... G-43
[3] BALLAST ................................................................................................. G-44
(1) Front Ballast....................................................................................... G-44
(2) Rear Ballast ....................................................................................... G-45
10. IMPLEMENT LIMITATIONS.......................................................................... G-46
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
1. TRACTOR IDENTIFICATION
[1] SERIAL NUMBER
When contacting your local KUBOTA distributor, always specify engine serial number, tractor serial number and hour meter reading.
(1) Tractor Identification Plate
(2) Tractor Serial Number
(3) Engine Serial Number
(4) Hour Meter
W1010590
[2] CYLINDER NUMBER
The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure.
The sequence of cylinder numbers is given as No.1, No.2 and
No.3 starting from the gear case side.
W1011077
G-1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be installed in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
• Before disassembling or servicing electrical wires, always disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
See the figure left side.
• When reassembling external snap rings or internal snap rings, they must be positioned so that sharp edge faces against the direction from which a force is applied. See the figure left side.
• When inserting spring pins, their splits must face the direction from which a force is applied. See the figure left side.
• To prevent damage to the hydraulic system, use only specified fluid or equivalent.
(1) Grease
(2) Force
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
(A) External Snap Ring
(B) Internal Snap Ring
W10109040
G-2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
Q
IMPORTANT
• Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check and at the same time recommend the dealer to perform periodic check for a fee.
• Do not attempt to modify or remodel any electrical parts and wiring.
• When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.
(1) Negative Terminal (2) Positive Terminal
W10111140
[1] WIRING
• Securely tighten wiring terminals.
(1) Correct
(Securely Tighten)
(2) Incorrect
(Loosening Leads to Faulty Contact)
W10112160
• Do not let wiring contact dangerous part.
(1) Dangerous Part
(2) Wiring (Incorrect)
(3) Wiring (Correct)
(4) Dangerous Part
W10113130
• Securely insert grommet.
(1) Grommet
(A) Correct
(B) Incorrect
W10113880
G-3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
• Securely clamp, being careful not to damage wiring.
(1) Clamp
• Wind Clamp Spirally
(2) Wire Harness
(3) Clamp
(4) Welding Dent
W10114580
• Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
(1) Wiring
(2) Clamp
(A) Correct
(B) Incorrect
W10115870
• In installing a part, take care not to get wiring caught by it.
(1) Wiring
(A) Incorrect
W10116700
• After installing wiring, check protection of terminals and clamped condition of wiring, only connect battery.
(1) Cover
• Securely Install Cover
W10117350
G-4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] BATTERY
G
GENERAL
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect positive cable first.
• Do not install any battery with capacity other than is specified
(Ah).
• After connecting cables to battery terminal posts, apply high temperature grease to them and securely install terminal covers on them.
• Do not allow dirt and dust to collect on battery.
CAUTION
• Take care not to let battery liquid spill on your skin and clothes. If contaminated, wash it off with water immediately.
• Before recharging the battery, remove it from the machine.
• Before recharging, remove cell caps.
• Do recharging in a well-ventilated place where there is no open flame nearby, as hydrogen gas and oxygen are formed.
W10118160
[3] FUSE
• Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
• Never use steel or copper wire in place of fuse.
• Do not install working light, radio set, etc. on machine which is not provided with reserve power supply.
• Do not install accessories if fuse capacity of reserve power supply is exceeded.
(1) Fuse (2) Slow Blow Fuse
W10120920
[4] CONNECTOR
• For connector with lock, push lock to separate.
(A) Push
W10122110
• In separating connectors, do not pull wire harnesses.
• Hold connector bodies to separate.
(A) Correct (B) Incorrect
W10122720
G-5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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
(2) Deformed Terminal
(3) Sandpaper
(4) Rust
W10123460
• Make certain that there is no female connector being too open.
(A) Correct (B) Incorrect
W10124300
• Make certain plastic cover is large enough to cover whole connector.
(1) Cover
(A) Correct
(B) Incorrect
W10125190
[5] HANDLING OF CIRCUIT TESTER
• Use tester correctly following manual provided with tester.
• Check for polarity and range.
W10126840
G-6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
4. LUBRICANTS, FUEL AND COOLANT
No.
2
Place
1 Fuel tank
Cooling system with recovery tank
BX1860
2.9 L
3.1 U.S.qts
2.6 Imp.qts
Capacity
BX2360
25.0 L
6.6 U.S.gals
5.5 Imp.gals
3.1 L
3.3 U.S.qts
2.7 Imp.qts
BX2660
3.3 L
3.5 U.S.qts
2.9 Imp.qts
Lubricants, fuel and coolant
No. 2-D diesel fuel
No. 1-D diesel fuel if temperature is below
−
10 °C (14 °F)
Fresh clean water with anti-freeze
3 Engine crankcase
2.9 L
3.1 U.S.qts
2.6 Imp.qts
3.1 L
3.3 U.S.qts
2.7 Imp.qts
3.5 L
3.7 U.S.qts
3.1 Imp.qts
Engine oil : API Service
Classification CF or better
Below 0 °C (32 °F) : SAE10W,
10W-30 or 15W-40
0 to 25 °C (32 to 77 °F): SAE20,
10W-30 or
15W-40
Above 25 °C (77 °F): SAE30, 10W-
30 or 15W-40
4 Transmission case
5 Front axle case
Place
2.3 L
2.4 U.S.qts
2.0 Imp.qts
11.6 L
3.1 U.S.gals
2.6 Imp.gals
4.7 L
5.0 U.S.qts
4.1 Imp.qts
Greasing
No. of greasing point
KUBOTA SUPER UDT fluid*
KUBOTA SUPER UDT fluid or
SAE80, SAE90 gear oil
6 Battery terminal
7
Speed control pedal
* KUBOTA original transmission hydraulic fluid.
2
1
Capacity
Moderate amount
Until grease overflows
Type of grease
Multipurpose type Grease
NLGI-2 or NLGI-
1 (GC-LG)
G-7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Q
NOTE
O
Engine Oil :
• Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE
Engine Oil according to the ambient temperature as shown above.
• With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a lowsulfur fuel on on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the “CF or better” lubricating oil with a high Total Base Number (TBN).
If the “CF-4 or CG-4, CH-4 or
CI-4” lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.
(approximately half)
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
O : Recommendable X : Not Recommendable
Lubricating oil class
Low-sulfur
Fuel
CF
CF-4
P
P,
High-sulfur
P
X
Remark
TBN
≥
10
CG-4
CH-4
P,
P,
X
X
CI-4
P
X
•
,
Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR (Exhaust Gas Re-circulation) type engines.
• The CJ-4 engine oil is intended for DPF (Diesel Particulate Filter) type engines, and cannot be used on this tractor.
O
Fuel :
• Cetane number of 45 minimum. Cetane number greater then 50 is preferred, especially for temperatures below
−
20 °C (
−
4 °F) or elevations above 1500 m (5000 ft).
• If diesel fuel with sulfur content greater than 0.5 % sulfur content is used, reduce the service interval for engine oil and filter by 50 %.
• Do not use diesel fuel with sulfur content greater then 1.0 %.
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No. 2-D is distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)
• Since this engine adopts EPA Tier 4 and Interim Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory in EPA regulated area (North America). Therefore, please use No. 2-D S500 or S15 diesel fuel as an alternative to No. 2-D, or use No. 1-D S500 or S15 diesel fuel as an alternative to No. 1-D if outside air temperature is below
−
10 °C (14 °F)
O
Transmission Oil :
• The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and to complete lubrication of the transmission, it is important that a multi-grade transmission fluid is used in this system. We recommend the use of
KUBOTA UDT or SUPER UDT fluid
for optimum protection and performance.
Do not mix different brands together.
• Indicated capacities of water and oil are manufacture’s estimate.
G-8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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 bolt
No-grade or 4T 7T 9T
Material of bolt SS400, S20C S43C, S48C
SCr435,
SCM435
Material of opponent part
Unit
Diameter
Ordinariness Aluminum Ordinariness Aluminum Ordinariness
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
167 to
191
246 to
284
63 to
72
108 to
125
334 to
392
7.9
to
9.3
18 to
20
40 to
45
17.0
to
19.5
25.0
to
29.0
6.4
to
7.4
11.0
to
12.8
34.0
to
40.0
0.80
to
0.95
1.8
to
2.1
4.0
to
4.6
123 to
141
181 to
209
47 to
53
79.6
to
92.5
246 to
289
5.8
to
6.8
13 to
15
29 to
33
7.9
to
8.8
17 to
19
32 to
34
–
–
–
–
–
0.80
to
0.90
1.7
to
2.0
3.2
to
3.5
–
–
–
–
–
5.8
to
6.5
13 to
14
24 to
25
–
–
–
–
–
197 to
225
275 to
318
78 to
90
124 to
147
368 to
431
9.81
to
11.2
24 to
27
48 to
55
20.0
to
23.0
28.0
to
32.5
7.9
to
9.2
12.6
to
15.0
37.5
to
44.0
1.00
to
1.15
2.4
to
2.8
4.9
to
5.7
145 to
166
203 to
235
58 to
66
91.2
to
108
272 to
318
7.24
to
8.31
18 to
20
36 to
41
7.9
to
8.8
18 to
20
40 to
44
63 to
72
–
–
–
–
0.80
to
0.90
1.8
to
2.1
4.0
to
4.5
6.4
to
7.4
–
–
–
–
5.8
to
6.5
13 to
15
29 to
32
47 to
53
–
–
–
–
260 to
304
344 to
402
103 to
117
167 to
196
491 to
568
12.3
to
14.2
30 to
34
61 to
70
26.5
to
31.0
35.0
to
41.0
10.5
to
12.0
17.0
to
20.0
50.0
to
58.0
1.25
to
1.45
3.0
to
3.5
6.2
to
7.2
W1034542
192 to
224
254 to
296
76.0
to
86.7
123 to
144
362 to
419
9.05
to
10.4
22 to
25
45 to
52
[2] STUD BOLTS
Material of opponent part
Unit
Diameter
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
Ordinariness Aluminum
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
12 to
15
25 to
31
29.5
to
49.0
1.2
to
1.6
2.5
to
3.2
3.0
to
5.0
8.7
to
11
18 to
23
21.7
to
36.1
8.9
to
11
20 to
25
31.4
0.90
to
1.2
2.0
to
2.6
3.2
6.5
to
8.6
15 to
18
23.1
W1048139
G-9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR
UNF THREADS
SAE GR.5
SAE GR.8
Grade
Unit
Nominal
Diameter
5/16
3/ 8
1/ 2
9/16
5/ 8
N·m
23.1 to 27.7
48 to 56
109 to 130
149.2 to 178.9
203.4 to 244
kgf·m
2.35 to 2.83
4.9 to 5.8
11.1 to 13.2
15.21 to 18.24
20.74 to 24.88
lbf·ft
17.0 to 20.5
35.0 to 42.0
80.0 to 96.0
110.0 to 132.0
150.0 to 180.0
N·m
32.6 to 39.3
61.1 to 73.2
149.2 to 178.9
217.0 to 260.3
298.3 to 357.9
kgf·m
3.32 to 4.00
6.23 to 7.46
15.21 to 18.24
22.12 to 26.54
30.42 to 36.49
lbf·ft
24.0 to 29.0
45.0 to 54.0
110.0 to 132.0
160.0 to 192.0
220.0 to 264.0
W1022485
[4] PLUGS
Material of opponent part
Shape
Tapered screw
Size
R1/8
N·m
13 to 21
Ordinariness kgf·m
1.3 to 2.2
lbf·ft
9.4 to 15
N·m
13 to 21
Aluminum kgf·m
1.3 to 2.0
lbf·ft
9.4 to 15
R1/4
25 to 44 2.5 to 4.5
18 to 32 25 to 34 2.5 to 3.5
18 to 25
Straight screw
G1/4
G3/8
G1/2
25 to 34
62 to 82
49 to 88
2.5 to 3.5
6.3 to 8.4
5.0 to 9.0
18 to 25
46 to 60
37 to 65
–
–
–
–
–
–
–
–
–
0000001666E
G-10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
6. MAINTENANCE CHECK LIST
Period
No.
Item
1 Engine oil
2 Engine oil filter
3 Transmission oil filter
4 Transmission fluid
5 Transmission strainer
6 Front axle case oil
7 Front axle pivot
8 Engine start system
9 Greasing
10 Wheel bolt torque
11 Battery condition
12
13
14
15
16
17
18
19
20
Air cleaner element
Fuel filter element
Fan belt
HST neutral spring
Brake
Radiator hose and clamp
Power steering oil line
Fuel line
Intake air line
Service Interval
50 100 150 200 250 300 350 400 450 500 550 600 650 700
Since then
Important
Adjust
Adjust
Check
Replace
Check
Replace
Check
Replace
Check
Replace
Adjust
Adjust
–
Check
Check
Clean
Replace
Check
Replace
Adjust
Change
+
Replace
+
Replace
+
Change
Clean
Change
Adjust
Check
,
,
,
,
,
,
,
,
,
, every 200 Hr every 200 Hr every 200 Hr every 400 Hr
+ ,
, every 400 Hr every 400 Hr
, every 400 Hr
, , , , , , , , , , , , , , every 50 Hr
, , , , , , , , , , , , , , every 50 Hr
, , , , , , , , , , , , , , every 50 Hr
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
, every 100 Hr *4
, every 100 Hr *1 every 1 year *2
, every 100 Hr every 500 Hr
, every 100 Hr
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
, every 100 Hr every 100 Hr every 200 Hr every 2 years every 200 Hr every 2 years every 100 Hr every 2 years every 200 Hr every 2 years *3 every 200 Hr every 800 Hr
@
@
@
@
21 Toe-in
22 Engine valve clearance
23
Fuel injection nozzle injection pressure
24 Injection pump
25 Cooling system
26 Coolant
27 Fuel system
28 Fuse
29 Light bulb
Check
Check
Flush
Change
Bleed
Replace
Replace every 1500 Hr every 3000 Hr every 2 years every 2 years
Service as required
@
@
Reference page
1-S24
1-S23
G-27
G-27
G-30
G-30
G-31
G-21
G-22
G-22
G-26
G-23
G-26
G-20
G-26
G-23
G-26
G-23
1-S12
G-16
G-16
G-17
G-19
G-25
G-20
G-25
G-20
G-13
G-13
G-14
G-24
G-14
G-24
G-24
G-15
Q
IMPORTANT
• The jobs indicated by
+
must be done after the first 50 hours of operation.
• *1 : Air cleaner should be cleaned more often in dusty conditions than in normal conditions.
• *2 : Every year or every 6 times of cleaning.
• *3 : Replace only if necessary.
• *4 : When the battery is used for less than 100 hours per year, check the fluid level annually.
• The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.
Please see the Warranty Statement in detail.
W1035769
G-11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
7. CHECK AND MAINTENANCE
G
GENERAL
CAUTION
• Be sure to check and service the tractor on a level surface with the engine shut off and the parking brake
“ON” and implement lowered to the ground.
[1] DAILY CHECK
To prevent trouble from occurring, it is important to know the condition of the tractor. Check the following items before starting.
Q
Walk Around Inspection
Look around the under the tractor for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts.
Checking
1. Checking and refueling.
2. Check the engine oil level.
3. Check the transmission fluid level.
4. Check the coolant level.
5. Clean panel and radiator screen.
6. Check the brake pedal.
7. Check the gauge, the meters and easy checkers.
8. Check the head light, the hazard light etc..
9. Check and clean the electrical wiring and the battery cables.
10.Check the seat belt and ROPS.
G-12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[2] CHECK POINTS OF INITIAL 50 HOURS
Changing Engine Oil
CAUTION
To avoid personal injury :
• Be sure to stop the engine and remove the key before changing the oil.
• Allow engine to cool down sufficiently, oil can be hot and can burn.
1. To drain the used oil, remove the drain plug at the bottom of the engine and drain the oil completely into the oil pan.
All the used oil can be drained out easily when the engine is still warm.
2. After draining reinstall the drain plug.
3. Fill with the new oil up to the upper notch on the dipstick.
4. Properly dispose of used oil.
Engine oil Capacity
BX1860
BX2360
BX2660
2.9 L
3.1 U.S.qts
2.6 Imp.qts
3.1 L
3.3 U.S.qts
2.7 Imp.qts
3.5 L
3.7 U.S.qts
2.9 Imp.qts
(1) Drain Plug
(2) Oil Inlet
(3) Dipstick
(A) Oil level is acceptable within this range.
W1014065
Replacing Engine Oil Filter
CAUTION
• Be sure to stop the engine before changing oil filter cartridge.
1. Remove the oil filter.
2. Put a film of clean engine oil on the rubber seal of the new filter.
3. Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
4. After the new filter has been replaced, the engine oil normally decrease a little. Make sure that the engine oil does not leak through the seal and be sure to check the oil level on the dipstick.
Then, replenish the engine oil up to the specified level.
5. Properly dispose of used oil.
Q
IMPORTANT
• To prevent serious damage to the engine, use only a
KUBOTA genuine filter.
(1) Engine Oil Filter Cartridge
W1014316
G-13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Replacing Transmission Oil Filter
CAUTION
• Allow engine to cool down sufficiently, oil can be hot and can burn.
1. Remove the oil filter.
2. Put a film of clean transmission oil on the rubber seal of the new filter.
3. Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
4. After the new filter has been replaced, the transmission fluid level will decrease a little. Make sure that the transmission fluid does not leak through the seal, and check the fluid level. Top off if necessary.
5. Properly dispose of used oil.
Q
IMPORTANT
• To prevent serious damage to the hydraulic system, use only a KUBOTA genuine filter.
(1) Transmission Oil Filter
W1014458
Cleaning Transmission Oil Strainer
1. When changing the transmission fluid, disassemble and rinse the strainer with nonflammable solvent to completely clean off fillings.
2. When reassembling, be careful not to damage the parts.
Q
NOTE
• Since the fine fillings in the oil can damage the precision component parts of the hydraulic system, the end of the suction line is provided with an oil strainer.
(1) Strainer (2) Filter Plate
W1019390
G-14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
Q
Preparation before testing.
1. Sit on the operator’s seat.
2. Set the parking brake and stop the engine.
3. Shift the range gear shift lever (1) to
“NEUTRAL”
position.
4. Check the speed control pedal
“NEUTRAL”
position
5. Shift the PTO clutch control lever (2) to
“OFF”
position.
Q
Test 1 : Switch for the speed control pedal
1. Shift the range gear shift lever (1) to
“NEUTRAL”
position.
2. Depress the speed control pedal (3).
3. Turn the key to
“START”
position.
4. The engine must not crank.
Q
Test 2 : Switch for the PTO clutch lever
1. Shift the range gear shift lever (1) to
“NEUTRAL”
position.
2. Check the speed control pedal (3)
“NEUTRAL”
position.
3. Shift the PTO clutch control lever (2) to
“ON”
position.
4. Turn the key to
“START”
position.
5. The engine must not crank.
Q
Test 3 : Switches for the operator’s seat and the speed control pedal
1. Sit on the operator’s seat (4).
2. Shift the range gear shift lever (1) to
“NEUTRAL”
position.
3. Start the engine.
4. Depress the speed control pedal (3).
5. Stand up. (Do not get off the machine.)
6. The engine must shut off after approximately 1 second.
Q
Test 4 : Switches for the operator’s seat and the PTO clutch lever
1. Sit on the operator’s seat.
2. Start the engine.
3. Engage the PTO clutch control lever (2).
4. Stand up. (Do not get off the machine.)
5. The engine must shut off after approximately 1 second.
(1) Range Gear Shift Lever
(2) PTO Clutch Control Lever
(3) Speed Control Level
(4) Operator’s Seat
W1014904
G-15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Greasing
1. Apply a small amount of multipurpose grease to the following points.
(1) Battery Terminal (2) Speed Control Pedal
W1015242
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.
1. Check wheel screws regularly especially when new. If there are loosened, tighten as follows.
Tightening torque
Front wheel mounting screws
Rear wheel mounting screws
149.2 to 179.0 N·m
15.2 to 18.3 kgf·m
110 to 132 lbf·ft
108.5 to 130.2 N·m
11.1 to 13.3 kgf·m
80 to 96 lbf·ft
(1) Front Wheel Mounting Screw
(2) Rear Wheel Mounting Screw
[A] Front
[B] Rear
W1015311
G-16
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[4] CHECK POINTS OF EVERY 100 HOURS
Checking Battery Condition
DANGER
To avoid the possibility of battery explosion:
For the refillable type battery, follow the instructions below.
• Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery’s service life or cause an explosion. Check the fluid level regularly and add distilled water as required so that the fluid level is between the UPPER and LOWER levels.
CAUTION
• Never remove the vent plugs while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention.
• Wear eye protection and rubber gloves when working around battery.
1. Mishandling the battery shortens the service life and adds to maintenance costs.
2. The original battery is maintenance free type battery, but need some servicing.
If the battery is weak, the engine is difficult to start and the lights become dim. It is important to check the battery periodically.
(1) Battery
W1015551
G-17
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Checking Battery Condition (Continued)
Q
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.
• When charging battery, remove battery vent caps are securely in place (if equipped).
• When disconnecting the cable from the battery, start with the negative terminal first.
When connecting the cable to the battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across the posts.
Use a voltmeter or hydrometer. (For accessible maintainable type batteries with removable vent caps.)
1. Make sure each electrolyte level is to the bottom of vent wells, if necessary add distilled water in a well-ventilated area.
2. The water in the electrolyte evaporates during recharging. Liquid shortage damages the battery. Excessive liquid spills over and damages the tractor body.
3. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the normal manner.
4. A boost charge is only for emergencies. It will partially charges the battery at a high rate and in a short time.
When using a boost-charged battery, it is necessary to recharge the battery as early as possible.
Failure to do this will shorten the battery’s service life.
5. When the specific gravity of electrolyte become between 1.27
and 1.29 charge has completed.
6. When exchanging an old battery for a new one, use battery of equal specification shown in table 1.
Table 1
Battery Type
526RA
Volts (V)
12
Reserve
Capacity (min.)
80
Cold Cranking
Amps
535
(1) Lowest Level
(2) Highest Level
(3) Electrolyte
(4) Vent Well
(5) Separator
W1019057
G-18
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Checking Battery Condition (Continued)
Q
Battery for storage
1. When storing the tractor for a long period, remove the battery from tractor, adjust the electrolyte to the proper level and store in a dry place out of direct sunlight.
2. The battery self-discharges while it is stored.
Recharge it once every three months in hot seasons and once every six months in cold seasons.
3. (For non-accessible maintenance-free type batteries.)
Maintenance-free, non-accessible batteries are designed to eliminate the need to add water. Yet the volume of electrolyte above plates may eventually become depleted due to abnormal conditions such as high heat or improper regulator setting. Use a voltmeter to check the state of change. (See reference chart below to determine if charging is necessary.)
Battery voltage
12.6
12.4
12.2
12.0
11.8
Reference state of charge
100 % (Full charge)
75 %
50 %
25 %
0 %
W1033625
Cleaning Air Cleaner Element
CAUTION
• Be sure to stop the engine and remove the key before cleaning air cleaner element.
1. Remove the air cleaner cover (2) and the element (1).
- Undo the hook.
- Turn the cover clockwise and detach it.
2. Clean the element:
- When dry dust adheres to the element, blow compressed air from the inside, turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm
2
, 30 psi).
- When carbon or oil adheres to the element, soak the element in detergent for 15 minutes then wash it several times in water, rinse with clean water and dry it naturally. After element is fully dried, inspect inside of the element with a light and check if it is damaged or not. (referring to the instructions on the label attached to the case.)
3. Replace air cleaner element:
Once yearly or after every sixth cleaning, whichever comes first.
Q
NOTE
• Check to see if the evacuator valve is blocked with dust.
Q
IMPORTANT
• The air cleaner uses a dry element, never apply oil.
• Do not run the engine with filter element removed.
• Align the arrow marks when reinstalling the cover. If the cover is improperly fitted, dust passes by the baffle and directly adheres to the element.
Q
Evacuator Valve
Open the evacuator valve once a week under ordinary conditions or daily when used in a dusty place to get rid of large particles of dust and dirt.
(1) Element
(2) Cover
(3) Evacuator Valve
W1017166
G-19
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Checking Fuel Lines and Fuel Filter
CAUTION
• Stop the engine and remove the key before checking fuel lines and fuel filter.
• Check the fuel lines periodically. The fuel lines are subject to wear and aging. Fuel may leak out onto the running engine, causing a fire.
The fuel line connections should be checked annually or every
100 service hours, whichever occurs first.
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.
3. Check fuel filter, if it is clogged by debris or contaminated by water, replace it.
Q
IMPORTANT
• When the fuel line is disconnected for maintenance or repair, plug both ends of the fuel line with a clean plug of suitable size to prevent dust and dirt from entering.
Particular care must be taken not to admit dust and dirt into the fuel system. Entrance of dust and dirt causes malfunction of the fuel pump.
Q
NOTE
• If the fuel line is removed, be sure to properly bleed the fuel system (see “Bleeding Fuel System” in service as required).
(1) Pipe Clamps
(2) Fuel Line
(3) Fuel Filter
(4) Fuel Pump
(5) Fuel Filter
W1017546
Checking Fan Belt Tension
CAUTION
• Be sure to stop engine and remove the key before checking belt tension.
1. Stop the engine and remove the key.
2. Apply moderate thumb pressure to belt between pulleys.
3. If tension is incorrect, loosen the alternator mounting bolts and using a lever placed between the alternator and the engine block, pull the alternator out until the deflection of the belt falls within acceptable limits.
4. Replace fan belt if it is damaged.
Fan belt tension Factory spec.
A deflection of between 7 to 9 mm (0.28 to 0.34 in.) when the belt is pressed in the middle of the span.
(1) Mounting Bolt
(A) Check the belt tension
W1017708
G-20
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Adjusting HST Neutral Spring (for Dynamic Braking)
WARNING
• Do not operate if tractor move on level ground with foot off speed control pedal.
• If tractor moves on level ground with foot off the pedal, or, if the pedal is too slow in returning to “NEUTRAL” position when removing the foot from the pedal, adjust the HST neutral spring.
The HST neutral spring located under the front right side of the fender can adjust returning speed of speed control pedal.
Since the HST neutral spring tension is weakened, the HST tension should be checked and adjusted every 100 hours.
1. Checking the HST neutral spring tension : Dynamic braking
- Start the engine and hold the maximum engine speeds.
- Operate the machine on the concrete level ground.
- Shift the range gear shift lever to “
High
” position.
- Depress the speed control pedal to “
Forward
”.
- Release the foot from the speed control pedal.
- Check the distance between the foot releasing point and the machine stopping point.
- If the distance is more than approximately 3 m (9.8 feet), strengthen the HST neutral spring tension so that the machine will stop in approximately 3 m (9.8 feet) after releasing the foot from the speed control pedal.
(Reference)
Distance (
L
) between the foot releasing point and the machine stopping point
Reference
Approximately 3 m (9.8 feet)
2. Remove the step from the machine.
- Loosen the lock nut (2).
- Turn the adjusting nut (3) half turn to pull the HST neutral spring
(1).
- Tighten and lock the lock nut (2).
- Start the engine and check dynamic brake as mentioned former.
- If the machine will not stop with dynamic brake in approximately
3 m (9.8 feet), adjust the neutral spring again.
(Reference)
Length (
M
) of adjusting rod at shipping the machine from the factory
Reference
10 mm
0.39 in.
(1) HST Neutral Spring
(2) Lock Nut
(3) Adjusting Nut
(4) Adjusting Rod
(A) Foot Releasing Point
(B) Machine Stopping Point
L : Distance between Foot Releasing
Point and the Machine Stopping
Point
M : Length of Adjusting Rod from
Stay
W1079634
G-21
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Adjusting Brake Pedal Free Travel
CAUTION
• Stop the engine, remove the key, lower the implement to the ground, and chock the wheels before checking brake pedal.
• Even if the brake pedal free travel is within the limitation, adjust the brake pedal following the procedure below.
1. Release the parking brake.
2. Loosen the lock nut and turn the turnbuckle to adjust the rod length so that the brake pedal free travel is 10 mm (0.4 in.).
3. Extend the turnbuckle one additional turn.
4. Retighten the lock nut.
5. Depress the brake pedal several times and make sure the brake pedal free travel is from 25 to 35 mm (1.0 to 1.4 in.).
Brake pedal free travel Factory spec.
25 to 35 mm
1.0 to 1.4 in.
(1) Turnbuckle
(2) Lock Nut
A : Free Travel
W1018144
[5] CHECK POINTS OF EVERY 200 HOURS
Changing Engine Oil
1. See page G-13.
W1015501
Replacing Transmission Oil Filter
1. See page G-14.
W1019345
Replacing Engine Oil Filter
1. See page G-13.
W1018516
Checking Radiator Hoses and Hose Clamps
Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first.
1. If hose clamps are loose or water leaks, tighten clamps securely.
2. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen, hardened or cracked.
3. Properly dispose of used coolant.
Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.
Q
Precaution at Overheating
Take the following actions in the event the coolant temperature be nearly or more than the boiling point, what is called
“Overheating”
.
1. Stop the machine operation in a safe place and keep the engine idling unloaded.
2. Don’t stop the engine suddenly, but stop it after about 5 minutes of unloaded idling.
3. Keep yourself well away from the machine for an additional 10 minutes or until the steam has blown out.
4. Checking that there is no danger such as burn, get rid of the cause of overheating according to the manual, see “
ENGINE
” section, and then, start the engine again.
(1) Radiator Hose (2) Hose Clamp
W1018562
G-22
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Checking Power Steering Line
CAUTION
• Be sure to stop the engine and remove the key before checking power steering line.
1. Check to see that all lines are tight and not damaged.
2. If hoses are found to be worn or damaged, replace or repair them at once.
(1) Power Steering Hose
W1018751
Checking Intake Air Line
1. Check to see that hose and hose clamps are tight and not damaged.
2. If hose and clamps are found to be worn or damaged, replace or repair them at once.
(1) Hose (2) Clamp
W1018915
Adjusting Toe-in
1. Park tractor on a firm, flat and level place.
2. Turn steering wheel so front wheels are in the straight ahead position.
3. Lower the implement to the ground, lock the parking brake, stop the engine and remove the key.
4. Measure distance between tire beads at front of tire at hub height.
5. Measure distance between tire beads at rear of tire at hub height.
6. Front distance should be 0 to 5.0 mm (0 to 0.2 in.) less that rear distance. If not, adjust tie rod length.
Toe-in (
B
–
A
) Factory spec.
0 to 5.0 mm
0 to 0.2 in.
Q
Adjusting
1. Loosen the lock nuts and turn the steering tie-rod to adjust the rod length until the proper toe-in measurement is obtained.
2. Retighten the lock nuts.
(1) Lock Nut
(2) Tie-rod
A : Wheel to Wheel Distance at Front
B : Wheel to Wheel Distance at Rear
C : Front
W1019009
G-23
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[6] CHECK POINTS OF EVERY 400 HOURS
Changing Transmission Fluid
CAUTION
• Allow engine to cool down sufficiently, oil can be hot and can burn.
1. To drain the used oil, remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan.
2. After draining reinstall the drain plug.
3. Clean the transmission strainer.
4. Fill with new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick.
5. After running the engine for a few minutes, stop it and check the oil level again, add oil to prescribed level.
6. Properly dispose of used oil.
Q
IMPORTANT
• Use only multi-grade transmission oil. Use of other oils may damage the transmission or hydraulic system.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
Transmission fluid Capacity
11.6 L
3.1 U.S.gals
2.6 Imp.gals
(1) Drain Plug
(2) Filling Plug
(3) Dipstick
(A) Oil level is acceptable within this range.
W1014665
Changing Front Axle Case Oil
1. Park the machine on a firm, flat and level surface.
2. To drain the used oil, remove the right and left drain plugs and oil gauge at the front axle case and drain the oil completely into the oil pan.
3. After draining, reinstall the drain plugs.
4. Remove the right and left breather plugs.
5. Fill with new oil up to the upper notch on the dipstick.
Q
IMPORTANT
• After ten minutes, check the oil level again; add oil to prescribed level.
6. After filling, reinstall the oil gauge and breather plugs.
Front axle case oil Capacity
BX1860
BX2360
BX2660
2.3 L
2.4 U.S.qts
2.0 Imp.qts
4.7 L
5.0 U.S.qts
4.1 Imp.qts
(1) Breather Plug
(2) Oil Gauge with Dipstick
(3) Drain Plug
(A) Oil level is acceptable within this range.
W1019508
G-24
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Adjusting Front Axle Pivot
1. Remove the split pin (2), tighten the adjusting nut (1).
2. Make sure that one of the nut slots aligns with the split pin hole, tighten the nut slightly if necessary to align.
3. Replace the split pin.
Tightening torque Factory spec.
20 N·m
2.0 kgf·m
14 lbf·ft
(1) Adjusting Nut (2) Split Pin
W1019713
[7] CHECK POINT OF EVERY 500 HOURS
Replacing Fuel Filter Element
1. Disconnect the fuel hoses and replace the fuel filter (2).
2. Disconnect the fuel hoses and loosen the pipe clamp to replace the fuel filter (5).
Q
NOTE
• If the fuel line is removed, be sure to properly bleed the fuel system. (See page G-30.)
(1) Fuel Pump
(2) Fuel Filter
(3) Fuel Line
(4) Hose Clamp
(5) Fuel Filter
W1019858
[8] CHECK POINT OF EVERY 800 HOURS
Adjusting Engine Valve Clearance
1. See page 1-S18.
[9] CHECK POINT OF EVERY 1500 HOURS
Checking Fuel Injection Nozzle Injection Pressure
1. See page 1-S24.
[10] CHECK POINT OF EVERY 3000 HOURS
Checking Injection Pump
1. See page 1-S23.
[11] CHECK POINT OF EVERY 1 YEAR
Replacing Air Cleaner Element
1. See page G-19.
W1019995
W1020203
W1020260
W1020343
G-25
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[12] CHECK POINTS OF EVERY 2 YEARS
Replacing Radiator Hoses (Water Pipes)
1. Replace the hoses and clamps.
Refer to “
Checking Radiator Hoses and Hose Clamps
”.
(See page G-22.)
W1020468
Replacing Power Steering Hoses
1. Replace the hoses.
Refer to “
Checking Power Steering Line
”.
(See page G-23.)
W1020513
Replacing Fuel Line
1. Replace the hoses and clamps.
Refer to “
Checking Fuel Line and Fuel Filter
”.
(See page G-20.)
W1020558
Replacing Intake Air Line
1. Replace the intake hose.
2. Refer to “
Checking Intake Air Line
”.
(See page G-23.)
W1020422
G-26
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Flush Cooling System and Changing Coolant
CAUTION
• Be sure to stop the engine and remove the key before checking coolant level.
• Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
1. Stop the engine, remove the key and let cool down.
2. To drain the coolant, open the radiator drain plug, and remove radiator cap. The radiator cap must be removed to completely drain the coolant.
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the radiator cap.
Install the radiator cap securely.
7. Fill with coolant up to
“H”
mark on the recovery tank.
8. Start and operate the engine for few minutes.
9. Stop the engine, remove the key and let cool.
10.Check coolant level of recovery tank and add coolant if necessary.
11.Properly dispose of used coolant.
Q
IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh water and anti-freeze to fill the radiator.
• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.
• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.
Coolant
Capacity
(with recovery tank)
BX1860
BX2360
BX2660
2.9 L
3.1 U.S.qts
2.6 Imp.qts
3.1 L
3.3 U.S.qts
2.7 Imp.qts
3.3 L
3.5 U.S.qts
2.9 Imp.qts
(1) Radiator Cap (2) Drain Plug
W1021307
G-27
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Flush Cooling system and Changing Coolant (Continued)
Q
Anti-Freeze
CAUTION
• When using antifreeze, put on some protection such as rubber gloves (Antifreeze contains position.).
• If should drink antifreeze, throw up at once and take medical attention.
• When antifreeze comes in contact with the skin or clothing, wash it off immediately.
• Do not mix different types of Antifreeze.
The mixture can produce chemical reaction causing harmful substances.
• Antifreeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze.
• When draining fluids from the engine, place some container underneath the engine body.
• Do not pour waste onto the grounds, down a drain, or into any water source.
• Also, observe the relevant environmental protection regulations when disposing of antifreeze.
If it freezes, coolant can damage the cylinders and radiator. If the ambient temperature falls below 0 °C (32 °F) or before a long-term storage, let out coolant completely, or mix fresh water with long-life coolant and fill the radiator and reserve tank with the mixture.
1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol (EG) type for this engine.
2. Before employing LLC-mixed coolant, fill the radiator with fresh water and empty it again.
Repeat this procedure 2 or 3 times to clean up the inside.
3. Mixing the LLC.
Put the LLC in coolant in the percentage (%) for a target temperature. When mixing, stir it up well, and then fill into the radiator.
4. The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature. Refer to SAE J1034 standard, more specifically also to SAE J814c.
Q
IMPORTANT
• When the antifreeze is mixed with water, thee antifreeze mixing ratio must be less than 50 %.
Freezing Point Boiling Point*
Vol % Anti-freeze
°C °F °C °F
40
50
−
24
−
37
−
−
12
34
106
108
222
226
* At 1.013
×
10
5
Pa (760 mmHg) pressure (atmospheric).
A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.
W1022492
G-28
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Flush Cooling system and Changing Coolant (Continued)
5. Adding the LLC.
- Add only water if the mixture reduces in amount by evaporation.
- If there is a mixture leak, add the LLC of the same manufacture and type in the same mixture percentage.
* Never add any long-life coolant of different manufacture.
(Different brands may have different additive components, and the engine may fail to perform as specified.)
6. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts.
7. Kubota’s genuine long-life coolant has a service life of 2 years.
Be sure to change the coolant every 2 years.
W1032576
G-29
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[13] OTHERS
G
GENERAL
Bleeding Fuel System
Air must removed:
1. When the fuel filter (2) or lines are removed.
2. When tank is completely empty.
3. After the tractor has not been used for a long period of time.
Q
Bleeding procedure is as follows:
1. Fill the fuel tank with fuel.
2. Turn the key switch to
“ON”
position for about 30 seconds.
Doing so allows fuel pump (1) to work and pump air out of the fuel system.
3. Start the engine and run for about 30 seconds, and then stop the engine.
(1) Fuel Pump (2) Fuel Filter
W1021149
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.
Q
IMPORTANT
• Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the tractor electrical system.
If any of the fuses should blow, replace with a new one of the same capacity.
Q
Protected Circuit
[Fuse Box]
Fuse No.
(1)
(2)
(3)
(4)
(5)
(6)
Capacity (A)
15
15
15
20
10
10
Protected circuit
Solenoid
Hazard
ACC
Working Light
DC Outlet
Timer Relay
Fuse No.
(7)
Capacity (A)
Slow Blow Fuse
(50A)
Protected circuit
Check circuit against wrong battery connection
(B) Fuse Box
W1023430
G-30
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Replacing Light Bulb
1. Head lights:
Take the bulb out of the light body and replace with a new one.
2. Other lights:
Detach the lens and replace the bulb.
Light
Head light
Tail light
Hazard light
Capacity
37.5 W
12.8 W
23 W
(1) Head Light
(2) Tail Light
(3) Hazard Light
W1023802
G-31
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.: 07909-32111
Application: Use exclusively for pushing in the piston with piston rings into the cylinder.
W1024100
Piston Ring Tool
Code No.: 07909-32121
Application: Use exclusively for removing or installing the piston ring with ease.
W1024150
Diesel Engine Compression Tester (for Injection Nozzle)
Code No.: 07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F) 07909-31271 (I)
07909-31211 (E and F) 07909-31281 (J)
07909-31231 (H)
Application: Use to measure diesel engine compression and diagnostics of need for major overhaul.
(1) Gauge
(2)
L
Joint
(3) Adaptor
A
(4) Adaptor
B
(5) Adaptor
C
(6) Adaptor
E
(7) Adaptor
F
(8) Adaptor
G
(9) Adaptor
H
(10) Adaptor
I
(11) Adaptor
J
W1024200
G-32
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Diesel Engine Compression Tester (for Glow Plug)
Code No.: 07909-39081 (Assembly) 07909-31301 (L)
07909-31291 (K) 07909-31311 (M)
Application: Use to measure diesel engine compression and diagnostics of need for major overhaul.
(1) Gauge
(2)
L
Joint
(3) Adaptor
K
(4) Adaptor
L
(5) Adaptor
M
0000001398E
Oil Pressure Tester
Code No.: 07916-32032
Application: Use to measure lubricating oil pressure.
(1) Gauge
(2) Cable
(3) Threaded Joint
(4) Adaptor
1
(5) Adaptor
2
(6) Adaptor
3
(7) Adaptor
4
(8) Adaptor
5
W1024318
Valve Seat Cutter
Code No.: 07909-33102
Application: Use to reseat valves.
Angle: 0.785 rad (45
°
)
0.262 rad (15
°
)
Diameter: 28.6 mm (1.126 in.) 38.0 mm (1.496 in.)
31.6 mm (1.244 in.) 41.3 mm (1.626 in.)
35.0 mm (1.378 in.) 50.8 mm (2.000 in.)
W1024458
Radiator Tester
Code No.: 07909-31551
Application: Use to check of radiator cap pressure, and leaks from cooling system.
Remarks: Adaptor (1) BANZAI Code No. RCT-2A-30S
W1024532
Connecting Rod Alignment Tool
Code No.: 07909-31661
Application: Use to check the connecting rod alignment.
Applicable: Connecting rod big end I.D.
range 30 to 75 mm (1.18 to 2.95 in.) dia.
Connecting rod length
65 to 300 mm (2.56 to 11.81 in.)
W1024583
G-33
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Nozzle Tester
Code No.: 07909-31361
Application: Use to check the fuel injection pressure and spray pattern of nozzle.
Measuring: 0 to 50 MPa range (0 to 500 kgf/cm
2
, 0 to 7000 psi)
W1024653
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 ....... 0.102 to 0.229 mm (0.004 to 0.009 in.)
W1024719
Red Check
Code No.: 07909-31371
Application: Use to check cracks on cylinder head, cylinder block, etc..
W1024909
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
G
H
I
J
C
D
A
B
E
F
K
L
C1
C2
C0.3
20 mm dia. (0.79 in. dia.)
11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.)
6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)
225 mm (8.86 in.)
70 mm (2.76 in.)
45 mm (1.77 in.)
25 mm (0.98 in.)
5 mm (0.197 in.)
6.7 to 7.0 mm dia. (0.263 to 0.275 in. dia.)
20 mm dia. (0.787 in. dia.)
12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
8.9 to 9.1 mm (0.350 to 358 in.)
Chamfer 1.0 mm (0.039 in.)
Chamfer 2.0 mm (0.079 in.)
Chamfer 0.3 mm (0.012 in.)
W1025017
G-34
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
C1
C2
C0.3
a b
C
D
A
B
E
F
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
G
H
I
J
C
D
A
B
E
F
K
L
C1
C2
C0.3
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.)
220 mm (8.66 in.)
80 mm (3.15 in.)
40 mm (1.58 in.)
25 mm dia. (0.98 in. dia.)
5 mm (0.197 in.)
6.0 to 6.1 mm dia. (0.236 to 0.240 in. dia.)
18 mm dia. (0.71 in. dia.)
10.6 to 10.7 mm dia. (0.417 to 0.421 in. dia.)
6.9 to 7.1 mm (0.272 to 0.280 in.)
Chamfer 1.0 mm (0.039 in.)
Chamfer 2.0 mm (0.079 in.)
Chamfer 0.3 mm (0.012 in.)
W12345689
Bushing Replacing Tool
Application: Use to press out and press fit the bushing.
1. For small end bushing
C
D
E
A
B
F
C1
145 mm (5.71 in.)
20 mm (0.79 in.)
100 mm (3.94 in.)
19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
25 mm dia. (0.98 in. dia.)
Chamfer 1.0 mm (0.039 in.)
C2
C0.3
Chamfer 2.0 mm (0.079 in.)
Chamfer 0.3 mm (0.012 in.)
a b
6.3
μ m (250
μ in.)
6.3
μ m (250
μ in.)
2. For idle gear bushing
150 mm (5.91 in.)
23 mm (0.91 in.)
100 mm (3.94 in.)
19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
25 mm dia. (0.98 in. dia.)
Chamfer 1.0 mm (0.039 in.)
Chamfer 2.0 mm (0.079 in.)
Chamfer 0.3 mm (0.012 in.)
6.3
μ m (250
μ in.)
6.3
μ m (250
μ in.)
W12358870
G-35
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Flywheel Stopper
Application: Use to loosen and tighten the flywheel screw.
C
D
A
B
E
F
200 mm (7.87 in.)
30 mm (1.18 in.)
20 mm (0.79 in.)
15 mm (0.59 in.)
8 mm (0.31 in.)
10 mm dia. (0.39 in. dia.)
W98765423
Crankshaft Bearing 1 Replacing Tool
Application: Use to press out and press fit the crankshaft bearing 1.
[Press Out]
A
135 mm (5.31 in.)
G
H
C1
C2
C0.3
B
C
D
E
F
72 mm (2.83 in.)
40 mm radius (1.57 in. radius)
10 mm (0.39 in.)
22 mm (0.87 in.)
20 mm dia. (0.79 in. dia.)
56.80 to 56.90 mm dia. (2.2362 to 2.2402 in. dia.)
51.80 to 51.90 mm dia. (2.0393 to 2.0433 in. dia.)
Chamfer 1.0 mm (0.039 in.)
Chamfer 2.0 mm (0.079 in.)
Chamfer 0.3 mm (0.012 in.)
[Press Fit]
A
130 mm (5.12 in.)
F
G
H
C1
B
C
D
E
C2
C0.3
72 mm (2.83 in.)
40 mm radius (1.57 in. radius)
9 mm (0.35 in.)
24 mm (0.95 in.)
20 mm dia. (0.79 in. dia.)
68 mm dia. (2.68 in. dia.)
47.38 to 47.48 mm dia. (1.865 to 1.869 in. dia.)
Chamfer 1.0 mm (0.039 in.)
Chamfer 2.0 mm (0.079 in.)
Chamfer 0.3 mm (0.012 in.)
W56478912
G-36
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[2] SPECIAL TOOLS FOR TRACTOR
Tie-rod End Lifter
Code No.: 07909-39051
Application: Use for removing the tie-rod end with ease
W1026472
Relief Valve Pressure Tester
Code No.: 07916-50045
Application: This allows easy measurement of relief set pressure.
(1) Gauge (07916-50322)
(2) Cable (07916-50331)
(3) Threaded Joint (07916-50401)
(4) Threaded Joint (07916-50341)
(5) Adaptor
B
(M18
×
P1.5)
(07916-50361)
(6) Adaptor
C
(PS3/8) (07916-50371)
(7) Adaptor
D
(PT1/8) (07916-50381)
(8) Adaptor
E
(PS3/8) (07916-50392)
(9) Adaptor
F
(PF1/2) (07916-62601)
(10) Adaptor
58
(PT1/4) (07916-52391)
W1026741
Hydrostatic Transmission Tester and HST Adaptor Set
Code No.: 07916-52040 (Hydrostatic Transmission Tester)
07916-53072 (HST Adaptor Set)
Application: This allows easy measurement of hydrostatic transmission pressure.
(1) Hydrostatic Transmission Tester
(07916-52040)
(2) Gasket (04714-00200)
(3) Connector 3 (07916-51331)
(4) Vacuum Gauge (07916-51331)
(5) Pressure Gauge (Low Pressure)
(07916-51301)
(6) Pressure Gauge (High Pressure)
(in Relief Valve Set Pressure Tester)
(07916-50321)
(7) HN Tube (in Relief Valve Set
Pressure Tester) (07916-50331)
(8) Valve Seat Driver (07916-60841)
(9) Connector
1
(07916-60811)
(10) Connector
2
(07916-60821)
(11) Long Connector (07916-60831)
(12) Adaptor
1
(07916-52621)
(13) Adaptor
2
with Collar
(07916-52632)
(14) Adaptor
3
with Collar
(07916-52642)
(15) HST Adaptor Set (07916-53072)
W1023682
G-37
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
G
H
I
J
C
D
A
B
E
F
K
L
M
Independent PTO Clutch Spring Compression Tool
Application: Use for compressing the spring into the spline boss.
This tool can be used for B30 series, BX50 series,
BX60 series, BX24 and BX25 tractor.
12 mm (0.47 in.)
25.4 mm (1.00 in.)
19 mm radius (0.75 in.) Hex.
2.7 mm (0.11 in.)
8 mm (0.31 in.)
15 mm dia. (0.59 in. dia.)
37 mm (1.46 in.)
70 mm (2.76 in.)
M14
×
1.5
R 3 mm (0.12 in.)
30 mm (1.18 in.)
17 mm (0.67 in.)
38 mm (1.50 in.)
W10301570
G-38
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Disassembling and Assembling Stand (1/2)
G
GENERAL
Application: Use to disassembling transaxle assembly and to assembling transaxle assembly.
D
E
F
G
A
B
C
J
K
H
I
φ
9 mm (
φ
0.35 in.) 3 Holes
225 mm (8.86 in.)
φ
13 mm (
φ
0.51 in.) 3 Holes
140 mm (5.51 in.)
99.5 to 100.5 mm (3.92 to 3.95 in.)
59.5 to 60.5 mm (2.35 to 2.38 in.)
92.5 to 93.5 mm (3.65 to 3.68 in.)
12.5 to 13.5 mm (0.50 to 0.53 in.)
55 mm (2.17 in.)
20 mm (0.79 in.)
17 mm (0.67 in.)
O
P
Q
R
L
M
N
U
W
S
T
30.5 to 31.5 mm (1.21 to 1.24 in.)
226 mm (8.90 in.)
125.5 to 126.5 mm (4.95 to 4.98 in.)
352 mm (13.86 in.)
25 mm (0.98 in.)
9.5 mm (0.37 in.)
397 mm (15.63 in.)
46 mm (1.81 in.)
R 25 mm (0.98 in.)
11 mm (0.43 in.)
20 mm (0.79 in.)
G-39
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Disassembling and Assembling Stand (2/2)
G
GENERAL
Application: Use to disassembling transaxle assembly and to assembling transaxle assembly.
I
J
K
G
H
C
D
A
B
E
F
311 mm (12.24 in.)
40 mm (1.57 in.)
38.1 mm (1.50 in.)
235 mm (9.25 in.)
170 mm (6.69 in.)
9.5 mm (0.37 in.)
6.4 mm (0.25 in.)
365 mm (14.37 in.)
377.8 mm (14.87 in.)
50.8 mm (2.00 in.)
40 mm (1.57 in.)
T
U
V
R
S
N
O
L
M
P
Q
38.1 mm (1.50 in.)
1.9 mm (0.07 in.)
4.8 mm (0.19 in.)
200 mm (7.87 in.)
φ
9 mm (
φ
0.35 in.), 3 Holes
25 mm (0.98 in.)
39.5 to 40.5 mm (1.56 to 1.59 in.)
140 mm (5.51 in.)
260 mm (10.24 in.)
99.5 to 100.5 mm (3.92 to 3.95 in.)
45 mm (1.77 in.)
G-40
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
9. TIRES
[1] TIRE PRESSURE
WARNING
• Do not attempt to mount a tire on a rim. 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 shown in the operator’s manual.
Q
IMPORTANT
• Do not use tires larger than specified.
• When you intend to mount different size of tires from equipped ones, consult your distributor about front drive gear ratio for detail.
Excessive wear of tires may occur due to improper gear ratio.
[BX1860]
Rear
Front
Tire sizes
24
×
12.00 – 12 Turf
24
×
12.00 – 12 Bar
16
×
7.50 – 8 Turf
16
×
7.50 – 8 Bar
Inflation pressure
100 kPa (1.0 kgf/cm
120 kPa (1.2 kgf/cm
2
2
, 14 psi)
, 17 psi)
120 kPa (1.2 kgf/cm
150 kPa (1.5 kgf/cm
2
2
, 17 psi)
, 22 psi)
[BX2360, BX2660]
Tire sizes
Rear
Front
26
×
12.00 – 12 Turf
26
×
12.00 – 12 Bar
26
×
12.00 – 12 Ind.
18
×
8.50 – 10 Turf
18
×
8.50 – 10 Bar
18
×
8.50 – 10 Ind.
Inflation pressure
100 kPa (1.0 kgf/cm
120 kPa (1.2 kgf/cm
120 kPa (1.2 kgf/cm
2
2
2
, 14 psi)
, 17 psi)
, 17 psi)
120 kPa (1.2 kgf/cm
150 kPa (1.5 kgf/cm
150 kPa (1.5 kgf/cm
2
2
2
, 17 psi)
, 22 psi)
, 22 psi)
Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time.
Thus, check it everyday and inflate as necessary.
Q
NOTE
• Maintain the maximum pressure in front tires, if using a front loader or when equipped with a full load of front weights.
G-41
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[2] WHEEL TREAD
(1) Front Wheels
Front tread can not be adjusted.
Q
IMPORTANT
• Do not turn discs to obtain wider tread.
Q
NOTE
• Use the tapered bolts for wheels with beveled or tapered holes.
Models
Tire
BX1860
16
×
7.50 – 8 Turf, 16
×
7.50 – 8 Bar
BX2360, BX2660
18
×
8.50 – 10 Turf, 18
×
8.50 – 10 Bar,
18
×
8.50 – 10 Ind.
Tread
Tightening torque Front wheel
(1) Wheel Mounting Screw
149.2 to 179.0 N·m
15.2 to 18.3 kgf·m
110 to 132 lbf·ft
A : 880 mm (34.6 in.)
B : 910 mm (35.8 in.)
W1045824
G-42
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
(2) Rear Wheels
Rear tread can not be adjusted.
Q
IMPORTANT
• Do not turn discs to obtain wider tread.
• Always attach tires as shown in the drawing.
• If not attached as illustrated, transmission parts may be damaged.
• When re-fitting or adjusting a wheel, tighten the bolts to the following torques then recheck after driving the tractor 200 m (200 yards) and thereafter daily check service.
Q
NOTE
• Use the tapered bolts for wheels with beveled or tapered holes.
Models
Tire
BX1860
16
×
7.5 – 8 Turf, 16
×
7.5 – 8 Bar
BX2360, BX2660
26
×
12.00 – 12 Turf, 26
×
12.00 – 12 Bar,
26
×
12.00 – 12 Ind.
Tread
Tightening torque Rear wheel
(1) Wheel Mounting Screw
108.5 to 130.2 N·m
11.1 to 13.3 kgf·m
80 to 96 lbf·ft
A : 820 mm (32.2 in.)
W1038060
G-43
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[3] BALLAST
(1) Front Ballast
Add weights needed for stability and improve traction.
Heavy pulling and heavy rear mounted implements tend to lift front wheels. Add enough ballast to maintain steering control and prevent tip over.
Remove weight when no longer needed.
Front End Weights (Option)
1. The front end weights can be attached to the bumper.
See your implement operator’s manual for required number of weights.
Q
NOTE
• Besides the weight, a front weight bracket and mounting bolt kit(s) are required for mounting the weight.
Q
IMPORTANT
• Do not overload tires.
• Add no more weight than indicated in chart.
Maximum weight Factory spec.
125 kg
275 lbs
(1) Front End Weights (2) Front Weight Bracket (Option)
W1029958
G-44
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
(2) Rear Ballast
Add weights to rear wheels if needed to improve traction or for stability. The amount of rear ballast should be matched to job and the ballast should be remove when it is not needed.
The weight should be added to the tractor in the form of liquid ballast.
Liquid Ballast in Rear Tires
1. Water and calcium chloride solution provides safe economical ballast. Used properly, it will not damage tires, tubes or rims.
2. The addition of calcium chloride is recommended to prevent the water from freezing.
3. Use of this method of weighting the wheels has the full approval of the tire companies.
Q
IMPORTANT
• Do not fill tires with water or solution more than 75 % of full capacity (to the level of valve stem at 12 o’clock position).
• To avoid damage of transmission, do not use rear wheel weights and liquid ballast at the same time.
26
×
12.00 – 12 Tire sizes
Slush free at
−
10 °C (14 °F)
Solid at
−
30 °C (
−
22 °F)
[Approx. 1 kg (2 lbs) CaCl
2
per 4 L
(1 gal.) of water]
Slush free at
−
24 °C (
−
11 °F)
Solid at
−
47 °C (
−
52 °F)
[Approx. 1.5 kg (3.5 lbs) CaCl
2
per 4 L
(1 gal.) of water]
Slush free at
−
47 °C (
−
53 °F)
Solid at
−
52 °C (
−
62 °F)
[Approx. 2.25 kg (5 lbs) CaCl
2
per 4 L
(1 gal.) of water]
45 kg
(99 lbs)
50 kg
(110 lbs)
56 kg
(123 lbs)
(1) Air
(2) Water
(3) Valve Stem
(A) Correct : 75 % Full Air
Compresses Like A Cushion
(B) Incorrect : 100 % Full
Water Can Not Be Compressed
W1033435
Attaching Injector
1. Lift the rear tires off the ground.
2. Turn the tire so that the air valve is at the top.
3. Remove the air valve, and attach the injector. (Code No. 07916-
52511)
(1) Injector (2) Hose
W1033331
G-45
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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 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. [Any malfunctions or failures of the tractor resulting from use with improper implements are not covered by the warranty.]
BX1860
BX2360
BX2660
Tread (max. width) with farm tires
Front Rear
880 mm (34.6 in.)
820 mm (32.2 in.)
910 mm (35.8 in.)
Lower link end max. loading weight W
0
550 kg (1210 lbs)
Actual figures
Implement weight W
1
and / or size
Max. Drawbar Load W
2
Trailer loading weight W
Max. capacity
3
BX1860
BX2360
As in the following list
(Shown on the next page)
250 kg (550 lbs) 800 kg (1765 lbs)
BX2660
Lower link end max. hydraulic lifting capacity .....
W
0
Implement weight..............................................The implement’s weight which can be put on the lower link :
W
1
Max. drawbar load .............................................
W
2
Trailer loading weight .........................................The max. loading weight for trailer (without trailer’s weight) :
W
3
Q
NOTE
• Implement size may vary depending on soil operating conditions.
G-46
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Mower
Implement
Mid-Mount
Rotary-Cutter
(1 Blade)
Rear-Mount
(2 or 3 Blade)
Flail Mower
Sickle Bar
Rotary Tiller
Bottom Plow
Disc Plow
Cultivator
Disc Harrow
Sprayer
Front Blade
Rear Blade
Front Loader
Box Blade
Snow Blower (Front)
Post Hole Digger
Rotary Broom
Trailer
Remarks
Max. Cutting Width
Max.Weight
Max. Cutting Width
Max.Weight
Max. Cutting Width
Max.Weight
Max. Cutting Width
Max. Cutting Width
Max. Tilling Width
Max. Weight
Max. Size
Max. Size
Max. Width
Max. Harrowing Width
Max. Weight
Max. Tank Capacity
Max. Cutting Width
Sub Frame
Max. Cutting Width
Max. Weight
Max. Lifting Capacity
Max. Width
Max. Cutting Width
Max. Weight
Max. Working Width
Max. Weight
Sub Frame
Digging Depth
Cleaning Width
Max. Load Capacity
BX1860 BX2360 BX2660
1370 mm
(54 in.)
1520 mm (60 in.)
95 kg (210 lbs) 115 kg (254 lbs) 140 kg (309 lbs)
1070 mm (42 in.)
140 kg (300 lbs)
1520 mm (60 in.) 1220 mm
(48 in.)
115 kg (250 lbs)
12 in.
×
1
140 kg (300 lbs)
1070 mm (42 in.)
1220 mm (48 in.)
1070 mm (42 in.)
170 kg (375 lbs)
14 in.
×
1
22 in.
×
1
1220 mm
(48 in.)
120 kg (265 lbs)
1220 mm (48 in.) 1 Row
1370 mm (54 in.)
140 kg (300 lbs)
1370 mm
(54 in.)
150 L
(40 U.S.gals, 33 Imp.gals)
1520 mm (60 in.)
Necessary
1520 mm (60 in.) 1370 mm
(54 in.)
140 kg (300 lbs)
200 kg (440 lbs)
160 kg (350 lbs)
240 kg (530 lbs)
1220 mm (48 in.)
1220 mm (48 in.)
170 kg (375 lbs)
1270 mm (50 in.)
160 kg (350 lbs)
Necessary
1140 mm (45 in.)
1190 mm (47 in.)
800 kg (1765 lbs)
Q
NOTE
• Backhoe cannot be attached.
• Implement size may very depending on soil operating conditions.
• Reduce speed and trailer loads when operating in slippery conditions or when operating on slopes and utilize front wheel drive.
W1012736
G-47
KiSC issued 06, 2009 A
1
ENGINE
KiSC issued 06, 2009 A
NOTICE
Regarding engine mechanism information, please refer ENGINE
MECHANISM WSM (Code No. 9Y021-01876).
KiSC issued 06, 2009 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................1-S1
2. SERVICING SPECIFICATIONS ....................................................................1-S4
[1] BX1860, BX2360......................................................................................1-S4
[2] BX2660 ...................................................................................................1-S10
3. TIGHTENING TORQUES ............................................................................1-S15
4. CHECKING, DISASSEMBLING AND SERVICING....................................1-S17
[1] CHECKING AND ADJUSTING .............................................................1-S17
(1) Engine Body......................................................................................1-S17
(2) Lubricating System ...........................................................................1-S19
(3) Cooling System.................................................................................1-S20
(4) Fuel System ......................................................................................1-S22
[2] DISASSEMBLING AND ASSEMBLING................................................1-S26
(1) Separating Engine ............................................................................1-S26
(2) Removing Outer Parts ......................................................................1-S29
(3) Cylinder Head and Valves ................................................................1-S29
(4) Gear Case and Timing Gears ...........................................................1-S33
(5) Piston and Connecting Rod ..............................................................1-S37
(6) Flywheel and Crankshaft ..................................................................1-S39
[3] SERVICING ............................................................................................1-S41
(1) Cylinder Head and Valves ................................................................1-S41
(2) Timing Gears, Camshaft and Governor Gear ...................................1-S49
(3) Piston and Connecting Rod ..............................................................1-S53
(4) Crankshaft.........................................................................................1-S57
(5) Cylinder.............................................................................................1-S65
(6) Oil Pump (BX1860, BX2360) ...........................................................1-S66
(7) Oil Pump (BX2660) ...........................................................................1-S67
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
1. TROUBLESHOOTING
Symptom Probable Cause Solution
Engine Does Not
Start
Starter Does Not Run
No fuel
Air in the fuel system
Water in the fuel system
Fuel pipe clogged
Fuel filter clogged
Excessively high viscosity of fuel or engine oil at low temperature
Fuel with low cetane number
Injection pump malfunctioning
Seizure of crankshaft, camshaft, piston, cylinder or bearing
Compression leak from cylinder
Improper valve timing
Piston ring and cylinder worn
Excessive valve clearance
Battery discharged
Starter malfunctioning
Replenish fuel
Bleed
Change fuel and repair or replace fuel system
Clean
Change
Use specified fuel or engine oil
Use specified fuel
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut
Incorrect injection timing Adjust
Fuel camshaft worn
Injection nozzle clogged
Replace
Clean or replace
Replace
Repair or replace
Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder
Correct or replace timing gear
Replace
Adjust
Charge
Repair or replace
Engine Revolution Is
Not Smooth
Main switch malfunctioning
Safety switches malfunctioning
Wiring disconnected
Fuel filter clogged or dirty
Repair or replace
Adjust or replace
Connect
Replace
Air cleaner clogged Clean or replace
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut
Injection pump malfunctioning
Incorrect nozzle injection pressure
Replace
Adjust
Injection nozzle stuck or clogged
Governor malfunctioning
Repair or replace
Repair
Reference
Page
G-7
G-30
–
G-25
G-25
G-7
G-7
1-S30
1-S22
1-S36
1-S30
1-S35
1-S37, S40
1-S31
1-S36
1-S38
1-S18
G-18
6-S28
6-S9
6-S11
–
G-25
G-19
1-S30
1-S35
1-S24
1-S30
1-S35
W1014322
1-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Symptom
Either White or Blue
Exhaust Gas Is
Observed
Probable Cause
Excessive engine oil
Either Black or Dark
Gray Exhaust Gas Is
Observed
Piston ring and cylinder worn or stuck
Incorrect injection timing
Deficient compression
Overload
Low grade fuel used
Fuel filter clogged
Air cleaner clogged
Deficient nozzle injection
Deficient Output
Incorrect injection timing
Engine’s moving parts seem to be seizing
Injection pump malfunctioning
Deficient nozzle injection
Compression leak
Excessive Lubricant
Oil Consumption
Air cleaner dirty or clogged
Piston ring’s gap facing the same direction
Fuel Mixed into
Lubricant Oil
Water Mixed into
Lubricant Oil
Oil ring worn or stuck
Piston ring groove worn
Valve stem and valve guide worn
Oil leaking due to defective seals or packing
Injection pump’s plunger worn
Deficient nozzle injection
Injection pump broken
Head gasket defective
Cylinder block or cylinder head flawed
ENGINE
Solution
Reduce to specified level
Repair or replace
Adjust
Check
Reduce the load
Use specified fuel
Replace
Clean or replace
Repair or replace nozzle
Adjust
Repair or replace
Repair or replace
Repair or replace nozzle
Replace head gasket, tighten cylinder head screws, glow plug and nozzle holder
Clean or replace
Shift ring gap direction
Replace
Replace piston
Replace
Replace
Repair or replace
Repair or replace nozzle
Replace
Replace
Replace
Reference
Page
G-13
1-S38
1-S22
1-S17
–
G-7
G-25
G-19
1-S30
1-S22
–
1-S35
1-S30
1-S31
G-19
1-S38
1-S38
1-S38
1-S43
–
1-S35
1-S30
1-S35
1-S31
–
W1014322
1-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Symptom
Low Oil Pressure
High Oil Pressure
Engine Overheated
Battery Quickly
Discharged
Probable Cause
Engine oil insufficient
Oil strainer clogged
Oil filter clogged
Relief valve stuck with dirt
Relief valve spring weaken or broken
Excessive oil clearance of crankshaft bearing
Excessive oil clearance of crankpin bearing
Excessive oil clearance of rocker arm
Oil passage clogged
Different type of oil
Oil pump defective
Different type of oil
Relief valve defective
Engine oil insufficient
Fan belt broken or elongated
Coolant insufficient
Radiator net and radiator fin clogged with dust
Inside of radiator corroded
Coolant flow route corroded
Radiator cap defective
Overload running
Head gasket defective
Incorrect injection timing
Unsuitable fuel used
Battery electrolyte insufficient
Fan belt slips
Wiring disconnected
Rectifier defective
Alternator defective
Battery defective
ENGINE
Solution
Replenish
Clean
Replace
Clean
Replace
Replace
Replace
Replace
Clean
Use specified type of oil
Repair or replace
Use specified type of oil
Replace
Replenish
Replace or adjust
Replenish
Clean
Clean or replace
Clean or replace
Replace
Reduce the load
Replace
Adjust
Use specified fuel
Replenish distilled water and charge
Adjust belt tension or replace
Connect
Replace
Replace
Replace
Reference
Page
G-7
1-S33
G-13
1-S19
1-S19
1-S40
1-S37
1-S31
–
G-7
1-S34
G-7
G-20
1-S21
–
1-S31
1-S22
G-7
G-17
1-S19
1-S26
G-20
G-7
–
–
G-27
–
–
–
–
W1014322
W1014322
1-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
[1] BX1860, BX2360
ENGINE BODY
Item
Valve Clearance (Cold)
Compression Pressure
[BX1860]
Difference among Cylinders
Compression Pressure
[BX2360]
Difference among Cylinders
Top Clearance
Cylinder Head Surface Flatness
Factory Specification
0.145 to 0.185 mm
0.00571 to 0.00728 in.
2.85 to 3.23 MPa
29.0 to 33.0 kgf/cm
2
413 to 469 psi
–
3.53 to 4.02 MPa
36.0 to 41.0 kgf/cm
2
512 to 583 psi
–
0.55 to 0.70 mm
0.022 to 0.027 in.
–
Valve Recessing
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Valve Face
Valve Seat
Valve Spring
Intake and Exhaust
Clearance
O.D.
I.D.
Angle (Intake)
Angle (Exhaust)
Angle (Intake and exhaust)
Width
Free Length
Tilt
−
0.10 to 0.10 mm
−
0.0039 to 0.0039 in.
0.030 to 0.057 mm
0.0012 to 0.0022 in.
5.968 to 5.980 mm
0.2350 to 0.2354 in.
6.010 to 6.025 mm
0.2367 to 0.2372 in.
0.79 rad
45 °
0.79 rad
45 °
0.79 rad
45 °
2.12 mm
0.0835 in.
31.3 to 31.8 mm
1.24 to 1.25 in.
–
Setting Load 65 N / 27.0 mm
6.6 kgf / 27.0 mm
15 lbf / 1.06 in.
–
–
–
–
ENGINE
–
28.4 mm
1.12 in.
1.2 mm
0.047 in.
55 N / 27.0 mm
5.6 kgf / 27.0 mm
12 lbf / 1.06 in.
W10138740
Allowable Limit
–
2.26 MPa
23.0 kgf/cm
327 psi
2
10 % or less
2.55 MPa
26.0 kgf/cm
370 psi
2
10 % or less
–
0.05 mm
0.002 in.
0.30 mm
0.012 in.
0.10 mm
0.0039 in.
–
1-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Rocker Arm Shaft to Rocker Arm
Rocker Arm Shaft
Rocker Arm
Clearance
O.D.
I.D.
Factory Specification
0.016 to 0.045 mm
0.00063 to 0.0017 in.
10.473 to 10.484 mm
0.41233 to 0.41275 in.
10.500 to 10.518 mm
0.41339 to 0.41409 in.
– Push Rod
Tappet to Tappet Guide
Alignment
Clearance
Tappet
Tappet Guide
O.D.
I.D.
0.016 to 0.052 mm
0.00063 to 0.0020 in.
17.966 to 17.984 mm
0.70733 to 0.70803 in.
18.000 to 18.018 mm
0.70867 to 0.70937 in.
Timing Gear
Crank Gear to Idle Gear Backlash
Idle Gear 1 to Cam Gear
Idle Gear 1 to Injection Pump Gear
Crank Gear to Oil Pump Drive Gear
Backlash
Backlash
Backlash
0.0430 to 0.124 mm
0.00170 to 0.00488 in.
0.0470 to 0.123 mm
0.00185 to 0.00484 in.
0.0460 to 0.124 mm
0.00182 to 0.00488 in.
0.0410 to 0.123 mm
0.00162 to 0.00484 in.
Idle Gear Shaft to Gear Bushing
Idle Gear 1 Clearance
Idle Gear Bushing
Idle Gear Shaft 1
I.D.
O.D.
0.020 to 0.084 mm
0.00079 to 0.0021 in.
20.000 to 20.051 mm
0.78741 to 0.78940 in.
19.967 to 19.980 mm
0.78611 to 0.78661 in.
Idle Gear
Idle Gear 1
Camshaft
Side Clearance
Side Clearance
Alignment
0.20 to 0.51 mm
0.0079 to 0.020 in.
0.15 to 0.31 mm
0.0059 to 0.012 in.
–
Allowable Limit
0.15 mm
0.0059 in.
–
–
0.25 mm
0.0098 in.
0.10 mm
0.0039 in.
–
–
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.10 mm
0.0039 in.
–
–
ENGINE
0.80 mm
0.031 in.
0.50 mm
0.020 in.
0.01 mm
0.0004 in.
W1013874
1-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Cam Height
Camshaft Journal to Cylinder Block Bore
Camshaft Journal
Cylinder Block Bore
Piston Pin Bore
Piston Pin to Small End Bushing
Piston Pin
Small End Bushing
Piston Ring Gap
[BX1860]
Piston Ring Gap
[BX2360]
Intake
Exhaust
Oil Clearance
O.D.
I.D.
I.D.
Clearance
O.D.
I.D.
Top Ring
Second Ring
Oil Ring
Top Ring
Second Ring
Oil Ring
Factory Specification
26.88 mm
1.058 in.
26.88 mm
1.058 in.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
32.934 to 32.950 mm
1.2967 to 1.2972 in.
33.000 to 33.025 mm
1.2993 to 1.3001 in.
20.000 to 20.013 mm
0.78741 to 0.78791 in.
0.015 to 0.075 mm
0.0059 to 0.0029 in.
20.002 to 20.011 mm
0.78748 to 0.78783 in.
20.025 to 20.040 mm
0.78839 to 0.78897 in.
0.15 to 0.30 mm
0.0059 to 0.011 in.
0.30 to 0.45 mm
0.012 to 0.017 in.
0.15 to 0.30 mm
0.0059 to 0.011 in.
0.20 to 0.35 mm
0.0079 to 0.013 in.
0.35 to 0.50 mm
0.014 to 0.019 in.
0.20 to 0.35 mm
0.0079 to 0.013 in.
Piston Ring to Piston Ring Groove
Second Ring Clearance
Oil Ring
Connecting Rod
Clearance
Alignment
0.0900 to 0.0120 mm
0.00355 to 0.00472 in.
0.040 to 0.080 mm
0.0016 to 0.0031 in.
–
Crankshaft Alignment –
–
20.05 mm
0.7894 in.
0.15 mm
0.0059 in.
–
ENGINE
Allowable Limit
26.83 mm
1.056 in.
26.83 mm
1.056 in.
0.15 mm
0.0059 in.
–
–
1.2 mm
0.0472 in.
1.25 mm
0.0492 in.
1.2 mm
0.0472 in.
1.25 mm
0.0492 in.
1.25 mm
0.0492 in.
1.25 mm
0.0492 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.05 mm
0.002 in.
0.02 mm
0.0008 in.
W10138740
1-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Crankshaft to Crankshaft Bearing 1
[BX1860]
Crankshaft
Crankshaft Bearing 1
Crankshaft to Crankshaft Bearing 1
[BX2360]
Crankshaft Journal
Crankshaft Bearing 1
Crankshaft to Crankshaft Bearing 2
Crankshaft Journal
Crankshaft Bearing 2
Crankshaft to Crankshaft Bearing 3
[BX1860]
Crankshaft Journal
Crankshaft Bearing 3
Crankshaft to Crankshaft Bearing 3
[BX2360]
Crankshaft Journal
Crankshaft Bearing 3
Crankpin to Crankpin Bearing
Crankpin
Crankpin Bearing
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Factory Specification
0.0340 to 0.114 mm
0.00134 to 0.00448 in.
39.934 to 39.950 mm
1.5722 to 1.5728 in.
39.984 to 40.040 mm
1.5742 to 1.5763 in.
0.0340 to 0.106 mm
0.00134 to 0.00417 in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
43.984 to 44.040 mm
1.7317 to 1.7338 in.
0.028 to 0.059 mm
0.0011 to 0.0023 in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
43.978 to 43.993 mm
1.7315 to 1.7320 in.
0.028 to 0.059 mm
0.0011 to 0.0023 in.
39.934 to 39.950 mm
1.5722 to 1.5728 in.
39.978 to 39.993 mm
1.5740 to 1.5745in.
0.028 to 0.059 mm
0.0011 to 0.0023 in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
43.978 to 43.993 mm
1.7315 to 1.7320.
0.020 to 0.051 mm
0.00079 to 0.0020 in.
33.959 to 33.975 mm
1.3370 to 1.3375 in.
33.995 to 34.010 mm
1.3384 to 1.3389 in.
Allowable Limit
0.20 mm
0.0079 in.
–
–
ENGINE
0.20 mm
0.0079 in.
–
–
0.20 mm
0.0079 in.
–
–
0.20 mm
0.0079 in.
–
–
0.20 mm
0.0079 in.
–
–
0.15 mm
0.0059 in.
–
–
W10795780
1-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Crankshaft
Cylinder Liner
[BX1860]
Cylinder Liner
[BX2360]
Cylinder (Oversized)
[BX1860]
Cylinder (Oversized)
[BX2360]
Side Clearance
I.D.
I.D.
Factory Specification
0.15 to 0.31 mm
0.0059 to 0.012 in.
67.000 to 67.019 mm
2.6378 to 2.6385 in.
72.000 to 72.019 mm
2.8347 to 2.8353 in.
67.250 to 67.269 mm
2.6477 to 2.6483 in.
72.250 to 72.269 mm
2.8445 to 2.8452 in.
ENGINE
Allowable Limit
0.50 mm
0.020 in.
67.150 mm
2.6437 in.
72.150 mm
2.8406 in.
67.400 mm
2.6535 in.
72.400 mm
2.8504 in.
W10138740
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed –
Inner Rotor to Outer Rotor
Outer Rotor to Pump Body
Inner Rotor to Cover
At Rated Speed
Clearance
Clearance
Clearance
More than 49 kPa
0.50 kgf/cm
2
7.1 psi
197 to 441 kPa
2.00 to 4.50 kgf/cm
2
28.5 to 64.0 psi
0.030 to 0.14 mm
0.0012 to 0.0055 in.
0.070 to 0.15 mm
0.0028 to 0.0059 in.
0.0750 to 0.135 mm
0.00296 to 0.00531 in.
147 kPa
1.50 kgf/cm
2
21.3 psi
–
–
–
W10139730
COOLING SYSTEM
Fan Belt
Thermostat
Item
Tension
Factory Specification
7.0 to 9.0 mm / 98 N
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
69.5 to 72.5 °C
157.1 to 162.5 °F
Allowable Limit
–
–
Radiator Cap
Radiator
Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened
Completely)
Pressure Falling
Time
Water Leakage
Test Pressure
88
85 °C
185 °F
10 seconds or more
→
59 kPa
0.90
→
0.60 kgf/cm
2
13
→
8.5 psi
No leak at specified pressure
–
–
–
W10135990
1-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
FUEL SYSTEM
Item Factory Specification
Injection Pump
Pump Element
Delivery Valve
Injection Nozzle
Injection Nozzle Valve Seat
Injection Timing
(3200 min
-1
(rpm))
Fuel Tightness
Fuel Tightness
Injection Pressure
Valve Seat
Tightness
ENGINE
Allowable Limit
0.3360 to 0.3622 rad
(19.25 to 20.75°) before T.D.C.
–
–
140.0
10 seconds
13.73
→
1991
→
12.75 MPa
130.0 kgf/cm
→
1849 psi
2
13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm
2
1992 to 2133 psi
When the pressure is
12.75 MPa
(130.0 kgf/cm
2
, 1849 psi), the valve seat must be fuel tightness.
13.73 MPa
140.0 kgf/cm
2
1991 psi
5 seconds
13.73
→
12.75 MPa
140.0
→
130.0 kgf/cm
2
1991
→
1849 psi
–
–
W10701990
1-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] BX2660
ENGINE BODY
Valve Clearance (Cold)
Compression Pressure
Difference among Cylinders
Top Clearance
Cylinder Head Surface
Valve Recessing
Valve Stem to Valve Guide
Valve Stem
Valve Guide
Valve Face
Valve Seat
Valve Spring
Item
ENGINE
Flatness
Intake and Exhaust
Clearance
O.D.
I.D.
Angle (Intake)
Angle (Exhaust)
Angle (Intake)
Angle (Exhaust)
Width
Free Length
Tilt
Setting Load
Factory Specification
0.145 to 0.185 mm
0.00571 to 0.00728 in.
3.73 to 4.11 MPa
38.0 to 42.0 kgf/cm
2
541 to 597 psi
–
0.55 to 0.75 mm
0.022 to 0.029 in.
–
Allowable Limit
–
2.26 MPa
23.0 kgf/cm
327 psi
10 % or less
–
2
– 0.050 to 0.25 mm
– 0.0020 to 0.0098 in.
0.035 to 0.065 mm
0.0014 to 0.0025 in.
6.960 to 6.975 mm
0.2741 to 0.2746 in.
7.010 to 7.025 mm
0.2760 to 0.2765 in.
1.0 rad
60 °
0.79 rad
45 °
1.0 rad
60 °
0.79 rad
45 °
2.12 mm
0.0835 in.
37.0 to 37.5 mm
1.46 to 1.47 in.
–
117.4 N / 31.0 mm
11.97 kgf / 31.0 mm
26.39 lbf / 1.22 in.
0.05 mm
0.002 in.
0.40 mm
0.016 in.
0.10 mm
0.0039 in.
–
–
–
–
–
–
–
36.5 mm
1.44 in.
1.0 mm
0.039 in.
100.0 N / 31.0 mm
10.20 kgf / 31.0 mm
22.48 lbf / 1.22 in.
W10138740
1-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Rocker Arm Shaft to Rocker Arm
Rocker Arm Shaft
Rocker Arm
Clearance
O.D.
I.D.
Factory Specification
0.016 to 0.045 mm
0.00063 to 0.0017 in.
11.973 to 11.984 mm
0.47138 to 0.47181 in.
12.000 to 12.018 mm
0.47244 to 0.47314 in.
– Push Rod
Tappet to Tappet Guide
Alignment
Clearance
Tappet
Tappet Guide
O.D.
I.D.
0.020 to 0.062 mm
0.00079 to 0.0024 in.
19.959 to 19.980 mm
0.78579 to 0.78661 in.
20.000 to 20.021 mm
0.78740 to 0.78822 in.
Timing Gear
Crank Gear to Idle Gear 1 Backlash
Idle Gear 1 to Cam Gear
Idle Gear 1 to Injection Pump Gear
Governor Gear
Governor Gear to Injection Pump
Gear (Fuel Cam Gear)
Idle Gear Shaft to Gear Bushing
Idle Gear 1
Backlash
Backlash
Backlash
Clearance
0.0320 to 0.115 mm
0.00126 to 0.00452 in.
0.0360 to 0.114 mm
0.00142 to 0.00448 in.
0.0340 to 0.116 mm
0.00134 to 0.00456 in.
0.0300 to 0.117 mm
0.00119 to 0.00460 in.
Idle Gear Bushing
Idle Gear Shaft 1
Idle Gear
Idle Gear 1
I.D.
O.D.
Side Clearance
0.020 to 0.054 mm
0.00079 to 0.0021 in.
26.000 to 26.021 mm
1.0237 to 1.0244 in.
25.967 to 25.980 mm
1.0224 to 1.0228 in.
Camshaft Side Clearance
Alignment
0.20 to 0.51 mm
0.0079 to 0.020 in.
0.070 to 0.22 mm
0.0028 to 0.0086 in.
–
–
0.25 mm
0.0098 in.
0.07 mm
0.003 in.
–
ENGINE
Allowable Limit
0.10 mm
0.0039 in.
–
–
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.15 mm
0.0059 in.
0.10 mm
0.0039 in.
–
–
0.80 mm
0.031 in.
0.30 mm
0.012 in.
0.01 mm
0.0004 in.
W1013874
1-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Cam Height
Camshaft Journal to Cylinder Block Bore
Camshaft Journal
Cylinder Block Bore
Piston Pin Bore
Piston Pin to Small End Bushing
Piston Pin
Small End Bushing
Piston Ring Gap
Intake
Exhaust
Oil Clearance
O.D.
I.D.
I.D.
Clearance
O.D.
I.D.
Top Ring
Second Ring
Oil Ring
Factory Specification
28.80 mm
1.134 in.
29.00 mm
1.142 in.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
35.934 to 35.950 mm
1.4148 to 1.4153 in.
36.000 to 36.025 mm
1.4174 to 1.4183 in.
22.000 to 22.013 mm
0.86615 to 0.86665 in.
0.014 to 0.038 mm
0.00056 to 0.0014 in.
22.002 to 22.011 mm
0.86622 to 0.86657 in.
22.025 to 22.040 mm
0.86713 to 0.86771 in.
0.30 to 0.45 mm
0.012 to 0.017 in.
0.30 to 0.45 mm
0.012 to 0.017 in.
0.25 to 0.40 mm
0.0098 to 0.015 in.
Piston Ring to Piston Ring Groove
Second Ring Clearance
Oil Ring
Connecting Rod
Clearance
Alignment
0.0850 to 0.112 mm
0.00335 to 0.00440 in.
0.020 to 0.055 mm
0.00079 to 0.0021 in.
–
Crankshaft
Crankshaft to Crankshaft Bearing 1
Crankshaft
Crankshaft Bearing 1
Alignment
Oil Clearance
O.D.
I.D.
–
0.0340 to 0.114 mm
0.00134 to 0.00448 in.
47.934 to 47.950 mm
1.8872 to 1.8877 in.
47.984 to 48.048 mm
1.8892 to 1.8916 in.
–
22.03 mm
0.8673 in.
0.15 mm
0.0059 in.
–
ENGINE
Allowable Limit
28.75 mm
1.132 in.
28.95 mm
1.140 in.
0.15 mm
0.0059 in.
–
–
1.25 mm
0.0492 in.
1.25 mm
0.0492 in.
1.25 mm
0.0492 in.
0.2 mm
0.008 in.
0.15 mm
0.0059 in.
0.05 mm
0.002 in.
0.02 mm
0.0008 in.
0.20 mm
0.0079 in.
–
–
W10138740
1-S12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
ENGINE BODY (Continued)
Item
Crankshaft to Crankshaft Bearing 2
Crankshaft Journal
Crankshaft Bearing 2
Crankshaft to Crankshaft Bearing 3
Crankshaft Journal
Crankshaft Bearing 3
Crankpin to Crankpin Bearing
Crankpin
Crankpin Bearing
Crankshaft
Cylinder Liner
Cylinder (Oversized)
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Oil Clearance
O.D.
I.D.
Side Clearance
I.D.
Factory Specification
0.034 to 0.095 mm
0.0014 to 0.0037 in.
47.934 to 47.950 mm
1.8872 to 1.8877 in.
47.984 to 48.029 mm
1.8892 to 1.8908 in.
0.034 to 0.098 mm
0.0014 to 0.0038 in.
51.921 to 51.940 mm
2.0442 to 2.0448 in.
51.974 to 52.019 mm
2.0463 to 2.0479 in.
0.029 to 0.091 mm
0.0012 to 0.0035 in.
39.959 to 39.975 mm
1.5732 to 1.5738 in.
40.040 to 40.050 mm
1.5764 to 1.5767 in.
0.15 to 0.31 mm
0.0059 to 0.012 in.
76.000 to 76.019 mm
2.9922 to 2.9928 in.
76.500 to 76.519 mm
3.0119 to 3.0125 in.
Allowable Limit
0.20 mm
0.0079 in.
–
–
0.20 mm
0.0079 in.
–
–
ENGINE
0.20 mm
0.0079 in.
–
–
0.50 mm
0.020 in.
76.15 mm
2.998 in.
76.65 mm
3.018 in.
W10138740
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed –
Inner Rotor to Outer Rotor
Outer Rotor to Pump Body
Inner Rotor to Cover
At Rated Speed
Clearance
Clearance
Clearance
More than 49 kPa
0.50 kgf/cm
2
7.1 psi
197 to 441 kPa
2.00 to 4.50 kgf/cm
2
28.5 to 64.0 psi
0.060 to 0.18 mm
0.0024 to 0.0071 in.
0.100 to 0.180 mm
0.00394 to 0.00708 in.
0.025 to 0.075 mm
0.00099 to 0.0029 in.
147 kPa
1.50 kgf/cm
21.3 psi
–
–
–
2
W10139730
1-S13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
COOLING SYSTEM
Fan Belt
Thermostat
Item
Tension
Factory Specification
7.0 to 9.0 mm / 98 N
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
69.5 to 72.5 °C
157.1 to 162.5 °F
Radiator Cap
Radiator
Valve Opening
Temperature
(At Beginning)
Valve Opening
Temperature
(Opened
Completely)
Pressure Falling
Time
Water Leakage
Test Pressure
85 °C
185 °F
10 seconds or more
88
→
59 kPa
0.90
→
0.60 kgf/cm
2
13
→
8.5 psi
No leak at specified pressure
Allowable Limit
–
–
–
–
–
ENGINE
W10135990
FUEL SYSTEM
Injection Pump
Item
Pump Element
Delivery Valve
Injection Nozzle
Injection Nozzle Valve Seat
Factory Specification Allowable Limit
Injection Timing
(3200 min
-1
(rpm))
Fuel Tightness
Fuel Tightness
Injection Pressure
Valve Seat
Tightness
0.3360 to 0.3622 rad
(19.25 to 20.75°) before T.D.C.
–
–
140.0
10 seconds
13.73
→
→
1991
12.75 MPa
130.0 kgf/cm
→
1849 psi
2
13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm
1992 to 2133 psi
2
When the pressure is
12.75 MPa
(130.0 kgf/cm
2
, 1849 psi), the valve seat must be fuel tightness.
13.73 MPa
140.0 kgf/cm
2
1991 psi
5 seconds
13.73
→
12.75 MPa
140.0
→
130.0 kgf/cm
2
1991
→
1849 psi
–
–
W10443110
1-S14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(Tractor section for general use screws, bolts and nuts : See page G-9.)
Tractor Section
Item
Front coupling mounting bolt
Engine mounting nut
Cushion mounting nut
Engine support mounting screw
N·m
24 to 27
24 to 27
24 to 27
48 to 55
kgf·m
2.4 to 2.8
2.4 to 2.8
2.4 to 2.8
4.9 to 5.7
ENGINE
lbf·ft
18 to 20
18 to 20
18 to 20
36 to 41
W1012736
1-S15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Engine Section
Item
Cylinder head cover screw
[BX1860, BX2360]
Cylinder head cover screw [BX2660]
Cylinder head screw [BX1860, BX2360]
Cylinder head screw [BX2660]
*Main bearing case screw 1
[BX1860, BX2360]
*Main bearing case screw 1 [BX2660]
*Main bearing case screw 2
[BX1860, BX2360]
*Main bearing case screw 2 [BX2660]
*Flywheel screw
*Connecting rod screw
[BX1860, BX2360]
*Connecting rod screw [BX2660]
*Rocker arm bracket screw
[BX1860, BX2360]
*Rocker arm bracket nut [BX2660]
*Idle gear shaft mounting screw
*Fan drive pulley screw
[BX1860, BX2360]
*Fan drive pulley screw [BX2660]
Bearing case cover mounting screw
Glow plug
Nozzle holder assembly
Nozzle holder
Oil pressure switch
Injection pipe retaining nut
Overflow pipe retaining nut
Drain plug with copper gasket
Oil filter joint
Size x Pitch
M6 x 1.0
M6 x 1.0
M8 x 1.25
M8 x 1.25
M6 x 1.0
M7 x 1.0
M7 x 1.0
M8 x 1.25
M10 x 1.25
M7 x 0.75
M7 x 0.75
M6 x 1.0
M7 x 1.0
M6 x 1.0
M12 x 1.5
M14 x 1.5
M6 x 1.0
M8 x 1.0
M20 x 1.5
–
PT 1/8
M12 x 1.5
M12 x 1.5
M12 x 1.25
–
N·m
9.81 to 11.2
7 to 8
37.3 to 42.2
64 to 68
13 to 15
30 to 34
27 to 30
49 to 53
54 to 58
27 to 30
42 to 46
9.81 to 11.2
22 to 26
9.81 to 11.2
118 to 127
236 to 245
9.81 to 11.2
7.9 to 14
49 to 68
35 to 39
15 to 19
25 to 34
20 to 24
33 to 37
40 to 49
kgf·m
1.00 to 1.15
0.7 to 0.9
3.8 to 4.3
6.5 to 7.0
1.3 to 1.6
3.0 to 3.5
2.7 to 3.1
5.0 to 5.5
5.5 to 6.0
2.7 to 3.1
4.2 to 4.7
1.00 to 1.15
2.2 to 2.7
1.00 to 1.15
12.0 to 13.0
24.0 to 25.0
1.00 to 1.15
0.80 to 1.5
5.0 to 7.0
3.5 to 4.0
1.5 to 2.0
2.5 to 3.5
2.0 to 2.5
3.3 to 3.8
4.0 to 5.0
lbf·ft
7.24 to 8.31
5 to 6
28 to 31
47 to 50
9.4 to 11
22 to 25
20 to 22
37 to 39
40 to 43
20 to 22
31 to 33
7.24 to 8.31
16 to 19
7.24 to 8.31
86.8 to 94.0
174 to 180
7.24 to 8.31
5.8 to 10
37 to 50
26 to 28
11 to 14
18 to 25
15 to 18
24 to 27
29 to 36
Q
NOTE
• In removing and applying the bolts and nuts marked with “ * ”, a pneumatic wrench or similar pneumatic tool, if employed, must be used with enough care not to get them seized.
• For * marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening.
• The letter “M” in Size
×
Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads.
W1013236
1-S16
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine.
3. Remove the air cleaner, the muffler and all glow plugs (or nozzles).
4. Set a compression tester with the adaptor to the glow plug hole
(or nozzle hole).
Nozzle hole : Adaptor
H
(07909-31231)
Glow plug hole : Adaptor
L
(07909-31301)
5. Disconnect the connector of engine stop solenoid and keep the engine stop position (non-injection). Then, run the engine with the starter and measure the compression pressure.
6. Repeat steps 4 and 5 for each cylinder.
7. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the glow plug hole (or nozzle hole) and measure the compression pressure again.
8. If the compression pressure is still less than the allowable limit, check the top clearance, valve clearance and cylinder head.
9. If the compression pressure increases after applying oil, check the cylinder wall and piston rings.
Q
NOTE
• Check the compression pressure with the specified valve clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
[BX1860]
Compression pressure
Factory spec.
Allowable limit
2.85 to 3.23 MPa
29.0 to 33.0 kgf/cm
2
413 to 469 psi
2.26 MPa
23.0 kgf/cm
2
327 psi
[BX2360]
Compression pressure
Factory spec.
Allowable limit
3.53 to 4.02 MPa
36.0 to 41.0 kgf/cm
2
512 to 583 psi
2.55 MPa
26.0 kgf/cm
2
370 psi
[BX2660]
Compression pressure
Factory spec.
Allowable limit
3.73 to 4.11 MPa
38.0 to 42.0 kgf/cm
2
541 to 597 psi
2.26 MPa
23.0 kgf/cm
2
327 psi
W10178940
1-S17
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Checking Valve Clearance
Q
IMPORTANT
• 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. 1 piston comes to the compression top dead center.
3. Check the following valve clearance marked with “
+
” using a feeler gauge.
4. If the clearance is not within the factory specifications, adjust with the adjusting screw.
5. Then turn the flywheel 6.28 rad (360 °), and align the
“1TC”
mark
(1) on the flywheel and alignment mark (3) on the rear end plate so that the No. 1 piston comes to the overlap position.
6. Check the following valve clearance marked with “
,
” using a feeler gauge.
7. If the clearance is not within the factory specifications, adjust with the adjusting screw.
Number of cylinders
Valve arrangement
Intake valve
Adjustable cylinder location of piston
No. 1
No. 2
+
,
No. 3
+
Valve clearance marked with “
+
” can be adjusted.
Intake and exhaust valve clearance (cold)
Factory spec.
Exhaust valve
+
+
,
0.145 to 0.185 mm
0.00571 to 0.00728 in.
Q
NOTE
• The sequence of cylinder numbers is given as No. 1, No. 2 and No. 3 starting from the gear case side.
• After adjusting the valve clearance, secure the adjusting screw with the lock nut.
(1)
“1TC”
Mark
(2) Alignment Mark
A : Gear Case Side
W10172470
1-S18
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Lubricating System
ENGINE
Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil pressure tester.
2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the following.
• Engine oil insufficient
• Oil pump defective
• Oil strainer clogged
• Oil filter cartridge clogged
• Oil gallery clogged
• Excessive oil clearance
• Foreign matter in the relief valve
Engine oil pressure
At idle speed
At rated speed
Factory spec.
Factory spec.
Allowable limit
More than 49 kPa
0.50 kgf/cm
2
7.1 psi
197 to 441 kPa
2.00 to 4.50 kgf/cm
2
28.5 to 64.0 psi
147 kPa
1.50 kgf/cm
2
21.3 psi
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.
Tightening torque Oil pressure switch
15 to 19 N·m
1.5 to 2.0 kgf·m
11 to 14 lbf·ft
W10349520
Relief Valve
1. Remove the oil filter base
2. Check the relief valve for dirt, and the seat and ball for damage.
3. If damaged, replace.
4. Check the free length of spring.
5. If less than the allowable limit, replace.
Relief valve spring
Factory spec.
Allowable limit
32 mm
1.26 in.
28 mm
1.10 in.
Tightening torque Joint
40 to 49 N·m
4.0 to 5.0 kgf·m
29 to 36 lbf·ft
(1) Relief Valve
(2) Joint
(3) Spring
W10756890
1-S19
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(3) Cooling System
ENGINE
Fan Belt Tension
1. Measure the deflection
(A)
, depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.
Deflection
(A)
Factory spec.
7.0 to 9.0 mm
0.28 to 0.35 in.
(A) Deflection
W10356670
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
(A) Good (B) Bad
W1016443
1-S20
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
CAUTION
• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.
2. Apply the specified pressure 88 kPa (0.90 kgf/cm
2
, 13 psi), and measure the time for the pressure to fall to 59 kPa (0.60 kgf/cm
2
,
8.5 psi).
3. If the measurement is less than the factory specification, replace the radiator cap.
Pressure falling time Factory spec.
More than 10 seconds for pressure fall
88
→
59 kPa
(0.90
→
0.60 kgf/cm
13
→
8.5 psi)
2
,
(1) Radiator Tester (2) Adaptor
W1054156
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester (1) and an adaptor (2) and raise the water pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, repair with the radiator cement.
When water leak is excessive, replace the radiator.
Radiator water leakage test pressure
Factory spec.
No leak at specified pressure
Q
NOTE
• The pressure of the leak test is different from each radiator specification.
Thus, do the leak test, refer to the test pressure of each radiator specification.
(1) Radiator Tester (2) Adaptor
W1016903
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.
3. Continue heating and read the temperature when the valve opens approx. 8 mm (0.3 in.).
4. If the measurement is not within the factory specifications, replace the thermostat.
Thermostat’s valve opening temperature
Temperature at which thermostat completely opens
Factory spec.
Factory spec.
69.5 to 72.5 °C
157.1 to 162.5 °F
85 °C
185 °F
W1035849
1-S21
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(4) Fuel System
ENGINE
Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for
No. 1 cylinder.
4. After the fuel fills up to the hole of the delivery valve holder for No.
1 cylinder, turn back (clockwise) the flywheel around 1.6 rad
(90 °).
5. Turn the flywheel counterclockwise to set at around 0.44 rad
(25 °) before T.D.C..
6. Slowly turn the flywheel counterclockwise and stop turning when the fuel begins to come up, to get the present injection timing.
7. Check to see the degree on flywheel.
The flywheel gas mark “
1TC
”, “
10
” and “
20
” for the crank angle before the top dead center of No. 1 cylinder.
8. If injection timing is out of adjustment, readjust the timing with shims.
Injection timing
(3200 min
-1
(rpm))
Factory spec.
0.3360 to 0.3622 rad
(19.25 to 20.75 °) before
T.D.C.
Q
NOTE
• The liquid gasket is not required for assembling.
• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25
mm (0.0098 in.), 0.30 mm (0.012 in.) and 0.175 mm (0.00689
in.). Combine these shims for adjustments.
• Addition or reduction of shim (0.05 mm, 0.002 in.) delays or advances the injection timing by approx. 0.009 rad (0.5 °).
• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.
• The 0.175 mm thick shim is coated only on the lower face.
Therefore, do not use the 0.175 mm thick shim as the top shim of the combination (injection pump side), because this can cause oil leakage.
(1) Timing Line
(2) Alignment Mark
(3) Delivery Valve Holder
(4) Shim (Soft Metal Gasket Shim)
(5) Two-holes : 0.20 mm (0.0079 in.)
Two-holes : 0.175 mm (0.00689 in.)
(6) One-hole : 0.25 mm (0.0098 in.)
(7) Without hole : 0.30 mm (0.012 in.)
W1017170
1-S22
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Fuel Tightness of Pump Element
1. Remove the engine stop solenoid.
2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1). (Refer to the photo.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.
Fuel tightness of pump element
Allowable limit
13.73 MPa
140.0 kgf/cm
2
1991 psi
Q
NOTE
• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.
(1) Injection Pump Pressure Tester
(2) Injection Nozzle
(3) Protection Cover for Jetted Fuel
W1017430
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. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and raise the pressure to approx. 13.73 MPa (140.0 kgf/cm
2
, 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from
140.0 to 130.0 kgf/cm
2
, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to
12.75 MPa (140.0 to 130.0 kgf/cm
2
, 1991 to 1849 psi).
9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.
Fuel tightness of delivery valve
Factory spec.
Allowable limit
10 seconds
13.73
→
12.75 MPa
140.0
→
130.0 kgf/cm
1991
→
1849 psi
2
5 seconds
13.73
→
12.75 MPa
140.0
→
130.0 kgf/cm
1991
→
1849 psi
2
Q
NOTE
• Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubotaauthorized pump service shop.
(1) Injection Pump Pressure Tester
(2) Injection Nozzle
(3) Protection Cover for Jetted Fuel
W1017786
1-S23
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester, and check the nozzle spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a) Good (b) Bad
W10181310
Fuel Injection Pressure
1. Set the injection nozzle to a nozzle tester.
2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.
(Reference)
• Pressure variation with 0.01 mm (0.0004 in.) difference of adjusting washer thickness.
Approx. 235 kPa (2.4 kgf/cm
2
, 34 psi)
Fuel injection pressure Factory spec.
13.73 to 14.70 MPa
140.0 to 150.0 kgf/cm
2
1992 to 2133 psi
(1) Adjusting Washer
W10182100
Valve Seat Tightness
1. Set the injection nozzle to a nozzle tester.
2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm
2
,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
Valve seat tightness Factory spec.
No fuel leak at
12.75 MPa
130.0 kgf/cm
2
1849 psi
W10183690
1-S24
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
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.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection pressure.
Tightening torque
Nozzle holder
Overflow pipe retaining nut
Nozzle holder assembly
35 to 39 N·m
3.5 to 4.0 kgf·m
26 to 28 lbf·ft
20 to 24 N·m
2.0 to 2.5 kgf·m
15 to 18 lbf·ft
49 to 68 N·m
5.0 to 7.0 kgf·m
36 to 50 lbf·ft
(1) Nozzle Holder
(2) Adjusting Washer
(3) Nozzle Spring
(4) Push Rod
(5) Distance Piece
(6) Nozzle Piece
(7) Nozzle Retaining Nut
W1018491
1-S25
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
[2] DISASSEMBLING AND ASSEMBLING
(1) Separating Engine
Draining Engine Oil
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug (1).
(When refilling)
• Fill the engine oil up to the upper line on the dipstick (3).
Q
IMPORTANT
• Never mix two different type of oil.
• Use the proper SAE Engine Oil according to ambient temperature.
Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-7.).
Engine oil Capacity
BX1860
BX2360
BX2660
2.9 L
3.1 U.S.qts
2.6 Imp.qts
3.1 L
3.3 U.S.qts
2.7 Imp.qts
3.5 L
3.7 U.S.qts
3.1 Imp.qts
(1) Drain Plug
(2) Oil Inlet
(3) Dipstick
(A) Oil level is acceptable within this range
W1023464
Battery Cables and 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.
2. Disconnect the negative cable (2) from the battery (1).
3. Disconnect the positive cable (3) from the battery (1) and remove the battery (1).
(1) Battery
(2) Negative cable
(3) Positive Cable
W1045893
1-S26
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Bonnet and Under Cover
1. Open the bonnet (1), and then loosen the knob bolts and pull forward to remove the under cover (2).
2. Disconnect the connectors (3) for head light and remove the bonnet bracket (4) with bonnet.
(1) Bonnet
(2) Under Cover
(3) Connector
(4) Bonnet Bracket
W1064425
Accelerator Wire, Bonnet Post, Fuel Hoses, Wiring Harness and
Others
1. Disconnect the wiring harness (4) from coolant temperature switch, stop solenoid, glow plug, starter motor, engine oil switch, alternator and ground cable.
2. Disconnect the accelerator wire (2) and fuel hoses (3).
3. Remove the bonnet post (1).
(1) Bonnet Post
(2) Accelerator Wire
(3) Fuel Hose
(4) Wiring Harness
W1023496
1-S27
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Separating Engine from Front Axle
1. Disconnect the ground cable.
2. Disconnect the front coupling (1).
3. Remove the engine mounting nuts (3).
4. Remove the engine support (4).
5. Hook the engine and separate the engine assembly with the radiator from the frame.
(When reassembling)
Tightening torque
Front coupling mounting bolt
Engine mounting nut
Cushion mounting nut
Engine support mounting screw
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Front Coupling
(2) Front Coupling Mounting Bolt
(3) Engine Mounting Nut
(4) Engine Support
W1049824
1-S28
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Removing Outer Parts
ENGINE
Draining Coolant, Radiator, Air Cleaner and Muffler etc.
CAUTION
• Never open the radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap
1. Set the engine stands (9) to the crankcase.
2. Open the radiator drain plug, and remove radiator cap to completely drain the coolant.
3. After all coolant is drained, close the drain plug.
4. Loosen the inlet hose band and the radiator hose bands, and remove the radiator (1) with the radiator hoses (2) and the air cleaner (3).
5. Loosen the fan belt. Remove the alternator (6), the starter motor
(8), the fan and the fan belt.
6. Remove the heat proof cover (7), the muffler (5) and the exhaust manifold.
Coolant with recovery tank
Capacity
BX1860
BX2360
BX2660
2.5 L
2.6 U.S.qts
2.2 Imp.qts
2.7 L
2.8 U.S.qts
2.4 Imp.qts
3.3 L
3.5 U.S.qts
2.9 Imp.qts
(1) Radiator
(2) Radiator Hose
(3) Air Cleaner
(4) Inlet Hose
(5) Muffler
(6) Alternator
(7) Heat Proof Cover
(8) Starter Motor
(9) Engine Stand
W1051348
(3) Cylinder Head and Valves
Cylinder Head Cover
1. Disconnect the breather hose.
2. Remove the cylinder head cover nuts.
3. Remove the cylinder head cover (1).
(When reassembling)
• Check to see if the cylinder head cover gasket is not defective.
[BX1860, BX2360]
Tightening torque Cylinder head cover screw
9.81 to 11.2 N·m
1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
[BX2660]
Tightening torque Cylinder head cover screw
7 to 8 N·m
0.7 to 0.9 kgf·m
5 to 6 lbf·ft
(1) Cylinder Head Cover
W1028468
1-S29
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Injection Pipes
1. Loosen the screws to the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
• Send compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order.
Tightening torque Injection pipe retaining nut
25 to 34 N·m
2.5 to 3.5 kgf·m
18 to 25 lbf·ft
(1) Pipe Clamp (2) Injection Pipe
Nozzle Holder Assembly and Glow Plug
1. Remove the overflow pipe (1).
2. Remove the nozzle holder assemblies (4).
3. Remove the copper gasket (5) and heat seal (6).
4. Remove the lead (2) from the glow plugs (3).
5. Remove the glow plugs (3).
(When reassembling)
• Replace the copper gasket and heat seal with new one.
W1061858
Tightening torque
Overflow pipe retaining nut
Nozzle holder assembly
Glow plug
20 to 24 N·m
2.0 to 2.5 kgf·m
15 to 18 lbf·ft
49 to 68 N·m
5.0 to 7.0 kgf·m
37 to 50 lbf·ft
7.9 to 14 N·m
0.80 to 1.5 kgf·m
5.8 to 10 lbf·ft
(1) Overflow Pipe
(2) Lead
(3) Glow Plug
(4) Nozzle Holder Assembly
(5) Copper Gasket
(6) Heat Seal
W1062243
Nozzle Heat Seal Removal Procedure
Q
IMPORTANT
• Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6 mm (1/4 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal (4) out together with the injection nozzle gasket (3).
4. If the heat seal drops, repeat the above procedure.
(When reassembling)
• Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.
(1) Plus Screw Driver
(2) Injection Nozzle
(3) Injection Nozzle Gasket
(4) Heat Seal
W1062698
1-S30
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Rocker Arm and Push Rod
1. Remove the rocker arm bracket screw. [BX1860, BX2360]
Remove the rocker arm bracket nut. [BX2660]
2. Detach the rocker arm assembly (1).
3. Remove the push rods (2).
(When reassembling)
• When refitting the push rods (2) into the tappets (3), make sure the push rod locates correctly into the tappet seat.
Q
IMPORTANT
• After installing the rocker arm, be sure to adjust the valve clearance.
[BX1860, BX2360]
Tightening torque Rocker arm bracket screw
9.81 to 11.2 N·m
1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
[BX2660]
Tightening torque Rocker arm bracket nut
22 to 26 N·m
2.2 to 2.7 kgf·m
16 to 19 lbf·ft
(1) Rocker Arm Assembly
(2) Push Rod
(3) Tappet
W1063063
Cylinder Head and Cylinder Head Gasket
1. Loosen the pipe clamps (1), and remove the water return pipe
(2).
2. Remove the cylinder head screw in the order of (
n
) to (
a
) and remove the cylinder head.
3. Remove the cylinder head gasket.
(When reassembling)
• Replace the cylinder head gasket with new one.
• When mounting the gasket, set it to the pin pipe holes. Take care not to mount it reversely.
• The cylinder head should be free of scratches and dust.
• Install the cylinder head, using care not to damage the gasket.
• After applying engine oil to the thread of screws, tighten them in several steps and specified sequence (
a
) to (
n
).
Q
NOTE
• Do not use O-ring on the pin pipe.
• It is not necessary to retighten the cylinder head screw and to readjust valve clearance after engine warmed up.
[BX1860, BX2360]
Tightening torque Cylinder head screw
37.3 to 42.2 N·m
3.8 to 4.3 kgf·m
28 to 31 lbf·ft
[BX2660]
Tightening torque
(1) Clamp
(2) Return Pipe
(3) Pin Pipe
Cylinder head screw
64 to 68 N·m
6.5 to 7.0 kgf·m
47 to 50 lbf·ft
n to a : To Loosen a to n : To Tighten
W10777620
1-S31
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
• Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets.
• Before installing the tappets, apply engine oil thinly around them.
Q
IMPORTANT
• Do not change the combination of tappet and tappet guide.
(1) Tappet
W10781410
Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1).
3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).
4. Remove the valve (7).
(When reassembling)
• Wash the valve stem and valve guide hole, and apply engine oil sufficiently.
• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.
Q
IMPORTANT
• Do not change the combination of valve and valve guide.
(1) Valve Spring Replacer
(2) Valve Cap
(3) Valve Spring Collet
(4) Valve Spring Retainer
(5) Valve Spring
(6) Valve Stem Seal
(7) Valve
W10783650
Thermostat Assembly
1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2).
2. Remove the thermostat assembly (4).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3).
(1) Thermostat Cover Mounting Screw
(2) Thermostat Cover
(3) Thermostat Cover Gasket
(4) Thermostat Assembly
W10786510
1-S32
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(4) Gear Case and Timing Gears
ENGINE
Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws.
2. Remove the oil pan (2).
3. Remove the oil strainer (1).
(When reassembling)
• After cleaning the oil strainer, check to see that the filter mesh in clean, and install it.
• Visually check the O-ring, apply engine oil, and install it.
• Securely fit the O-ring to the oil strainer.
• To avoid uneven tightening, tighten oil pan mounting screws in diagonal order form the center.
Q
IMPORTANT
• Scrape off the old adhesive completely. Wipe the sealing surface clean using waste cloth soaked with gasoline. Now apply new adhesive 3.0 to 5.0 mm (0.12 to 0.19 in.) thick all over the contact surface. Apply the adhesive also on the center of the flange as well as on the inner wall of each screw hole.
• Cut the nozzle of the “liquid gasket” container at its second notch. Apply “liquid gasket” about 5.0 mm (0.19 in.) thick.
Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase.
(1) Oil Strainer (2) Oil Pan
W10788640
Fan Drive Pulley
1. Secure the flywheel to keep it from turning.
2. Remove the fan drive pulley screw.
3. Draw out the fan drive pulley with a puller.
(When reassembling)
• Install the pulley to crankshaft, aligning the mark (1) on them (3cylinder engine).
• Apply engine oil to the fan drive pulley retaining screw. And tighten it.
[BX1860, BX2360]
Tightening torque Fan drive pulley screw
118 to 127 N·m
12.0 to 13.0 kgf·m
86.8 to 94.0 lbf·ft
[BX2660]
Tightening torque Fan drive pulley screw
236 to 245 N·m
24.0 to 25.0 kgf·m
174 to 180 lbf·ft
(1) Aligning Mark
W10791380
1-S33
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Gear Case
1. Remove the fuel feed pump.
2. Remove the gear case.
(When reassembling)
• Grease thinly to the oil seal, and install it, ensuring the lip does not come off.
(1) Gear Case
a : Bolt Length = 45 mm (1.8 in.) b : Bolt Length = 50 mm (2.0 in.) c : Bolt Length = 55 mm (2.2 in.) d : Bolt Length = 65 mm (2.6 in.) e : Bolt Length = 68 mm (2.7 in.) f : Bolt Length = 70 mm (2.8 in.) g : Bolt Length = 85 mm (3.3 in.) h : Nut
W1079380
Speed Control Plate
1. Remove the engine stop solenoid.
2. Remove the speed control plate (1).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the solenoid cover gasket and control plate gasket.
• Be careful not to drop the governor spring (2) into the crankcase.
(1) Speed Control Plate (2) Governor Spring
W1073180
1-S34
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Injection Pump
1. Disconnect the start spring (4) on the thrust lever side (5).
2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3).
3. Remove the injection pump shims.
4. In principle, the injection pump should not be disassembled.
(When reassembling)
• When installing the injection pump, insert the control rack pin (2) firmly into the groove (7) of the thrust lever of fork lever.
Q
NOTE
• Addition or reduction of shim (0.05 mm, 0.002 in.) delays or advances the injection timing by approx. 0.0087 rad (0.50 °).
• In disassembling and replacing, be sure to use the same number or new gasket shims with the same thickness.
(1) Notch
(2) Control Rack Pin
(3) Injection Pump
(4) Start Spring
(5) Thrust Lever
(6) Governor Spring
(7) Groove
W1073414
1-S35
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Cam Gear, Idle Gear 1, 2 and Governor Gear
1. Remove the idle gear 1 (4).
2. Remove the fuel camshaft stopper (7).
3. Draw out the fuel cam gear (1) with fuel camshaft (8).
4. Remove the camshaft stopper bolt.
5. Remove the cam gear (3) with camshaft.
6. Remove the external snap ring (10) from the governor shaft (11).
7. Remove the governor gear (6) with governor shaft (11).
Q
NOTE
• Three-lever type fork lever
To remove the governor shaft, follow the procedures in 5, 6 above and never remove fork lever and the max torque limiter.
(When reassembling)
• Apply engine oil thinly to the fuel camshaft before installation.
• Make sure to assemble the external snap ring of the governor shaft.
• Check the governor shaft for smooth rotation.
Q
IMPORTANT
• When replacing the ball bearing of governor shaft, securely fit the ball bearing (9) to the crankcase, apply an adhesive
(Three Bond 1324B or equivalent) to the set screw (12), and fasten the screw until its tapered part contacts the circumferential end of the ball bearing.
• When installing the idle gear, be sure to align the alignment marks (2) on each gears.
(1) Fuel Cam Gear
(2) Alignment Mark
(3) Cam Gear
(4) Idle Gear 1
(5) Crank Gear
(6) Governor Gear
(7) Fuel Camshaft Stopper
(8) Fuel Camshaft
(9) Ball Bearing
(10) External Snap Ring
(11) Governor Shaft
(12) Set Screw
W1074222
1-S36
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(5) Piston and Connecting Rod
ENGINE
Connecting Rod
1. Remove the connecting rod cap.
(When reassembling)
• Align the marks
(a)
with each other. (Face the marks toward the injection pump.)
• Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.
If the connecting rod screw won’t be screwed in smoothly, clean the threads.
If the connecting rod screw is still hard to screw in, replace it.
[BX1860, BX2360]
Tightening torque Connecting rod screw
27 to 30 N·m
2.7 to 3.1 kgf·m
20 to 22 lbf·ft
[BX2660]
Tightening torque Connecting rod screw
42 to 46 N·m
4.2 to 4.7 kgf·m
31 to 33 lbf·ft
(a) Mark
W10801990
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.
3. Draw out the other piston in the same method as above.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine oil to the piston.
• When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.
Q
IMPORTANT
• Do not change the combination of cylinder and piston. Make sure of the position of each piston by marking. For example, mark “1” on the No.1 piston.
• When installing the piston into the cylinder, place the gaps of all the piston rings as shown in the figure.
• Carefully insert the pistons using a piston ring compressor
(1). Otherwise, their chrome-plated section may be scratched, causing trouble inside the cylinder.
(1) Piston Ring Compressor
(A) Top Ring Gap
(B) Second Ring Gap
(C) Oil Ring Gap
(D) Piston Pin Hole
(a) 0.79 rad (45
°
)
(b) 0.79 rad (45
°
)
(c) 1.6 rad (90
°
)
W10803770
1-S37
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5).
(When reassembling)
• Install the rings so that the manufacturer’s mark (12) near the gap faces the top of the piston.
• When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin.
• When installing the connecting rod to the piston, immerse the piston in 80
°
C (176
°
F) oil for 10 to 15 minutes and insert the piston pin to the piston.
• When installing the connecting rod to the piston, align the mark
(8) on the connecting rod to the fan-shaped concave (9).
Q
NOTE
• Mark the same number on the connecting rod and the piston so as not to change the combination.
(1) Top Ring
(2) Second Ring
(3) Oil Ring
(4) Piston Pin Snap Ring
(5) Piston
(6) Connecting Rod
(7) Piston Pin
(8) Mark
(9) Fan-shaped Concave
(10) Expander Joint
(11) Oil Ring Gap
(12) Manufacturer’s Mark
W10811300
1-S38
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(6) Flywheel and Crankshaft
ENGINE
Flywheel
1. Secure the flywheel to keep it from turning, using a flywheel stopper.
2. Remove all flywheel screws (1) and then remove the flywheel (2).
(When reassembling)
• Align the “
1TC
” mark
(a)
on the outer surface of the flywheel horizontally with the alignment mark
(b)
on the rear end plate.
Now fit the flywheel in position.
• Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw.
Tightening torque Flywheel screw
54 to 58 N·m
5.5 to 6.0 kgf·m
40 to 43 lbf·ft
(1) Flywheel Screw
(2) Flywheel
(a) 1TC Mark
(b) Alignment Mark
W10818970
Bearing Case Cover
1. Remove the bearing case cover mounting screws.
2. Remove the bearing case cover (6).
(When reassembling)
• Fit the bearing case gasket (3) and the bearing case cover gasket
(4) with correct directions.
• Install the bearing case cover (6) to position the casting mark
“UP”
on it upward.
• Apply engine oil to the oil seal (5) lip and take care that it is not rolled when installing.
• Tighten the bearing case cover mounting screws with even force on the diagonal line.
Tightening torque
Bearing case cover mounting screw
9.81 to 11.2 N·m
1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
(1) Bearing Case Cover Mounting Screw
(Inside)
(2) Bearing Case Cover Mounting Screw
(Outside)
(3) Bearing Case Gasket
(4) Bearing Case Cover Gasket
(5) Oil Seal
(6) Bearing Case Cover
(a) Top Mark “UP”
(b) Upside
W10825950
1-S39
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Crankshaft Assembly
1. Remove the main bearing case screw 2 (1).
2. Pull out the crankshaft assembly.
Q
IMPORTANT
• Take care to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.)
(When reassembling)
• Clean the oil passage of the crankshaft with compressed air.
• Apply oil to the main bearing case screw 2 (1).
• Install the crankshaft assembly, aligning the screw hole of main bearing case with the screw hole of crankcase.
• Clean the oil passage of the crankshaft with compressed air.
[BX1860, BX2360]
Tightening torque Main bearing case screw 2
27 to 30 N·m
2.7 to 3.1 kgf·m
20 to 22 lbf·ft
[BX2660]
Tightening torque Main bearing case screw 2
49 to 53 N·m
5.0 to 5.5 kgf·m
37 to 39 lbf·ft
(1) Main Bearing Case Screw 2
W10833190
Main Bearing Case Assembly
1. Remove the two main bearing case screws 1 (2) of each main bearing cases.
2. Remove the main bearing case from crankshaft.
(When reassembling)
• Clean the oil passage in the main bearing cases.
• Apply clean engine oil on the bearings.
• Install the main bearing case assemblies in the original positions.
Since diameters of main bearing cases vary, install them in order of makings
(b)
(
A
,
B
,
C
) from the gear case side.
• Match the alignment numbers
(a)
on the main bearing case assembly 1.
• When installing the main bearing case 1 and 2, face the mark
“FLYWHEEL”
to the flywheel.
• Install the thrust bearing (3) with its oil groove facing outward.
• Confirm that the main bearing case moves smoothly after tightening the main bearing case screw 1 to the specified torque.
[BX1860, BX2360]
Tightening torque Main bearing case screw 1
13 to 15 N·m
1.3 to 1.6 kgf·m
9.4 to 11 lbf·ft
[BX2660]
Tightening torque
(1) Main Bearing Case Assembly 1
(2) Main Bearing Case Screw 1
(3) Thrust Bearing
Main bearing case screw 1
30 to 34 N·m
3.0 to 3.5 kgf·m
22 to 25 lbf·ft
(a) Alignment Number
(b) Marking (A, B, C)
W1083973
1-S40
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[3] SERVICING
(1) Cylinder Head and Valves
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.
3. Lower the piston, and install the cylinder head and tighten the cylinder head screws to the specified torque.
4. Turn the flywheel until the piston exceeds top dead center.
5. Remove the cylinder head, and measure the thickness of the squeezed fuses.
6. If the measurement is not within the factory specifications, check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing.
Q
NOTE
• After checking the top clearance, be sure to assemble the cylinder head with a new cylinder head gasket.
Top clearance Factory spec.
0.55 to 0.70 mm
0.022 to 0.027 in.
[BX1860, BX2360]
Tightening torque Cylinder head screw
38 to 42 N·m
3.8 to 4.3 kgf·m
28 to 31 lbf·ft
[BX2660]
Tightening torque Cylinder head screw
64 to 68 N·m
6.5 to 7.0 kgf·m
47 to 50 lbf·ft
(1) Fuse (2) Fuse
W1020190
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head’s four sides and two diagonal as shown in the figure.
3. Measure the clearance with a thickness gauge.
4. If the measurement exceeds the allowable limit, correct it with a surface grinder.
Q
IMPORTANT
• Do not place the straightedge on the combustion chamber.
• Be sure to check the valve recessing after correcting.
Cylinder head surface flatness
Allowable limit
0.05 mm
0.002 in.
W1027737
1-S41
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Cylinder Head Flaw
1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the read permeative liquid on the cylinder head surface with the detergent (2).
5. Spray the cylinder head surface with white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid
(2) Detergent
(3) White Developer
W1076542
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the valve.
5. If it still exceeds the allowable limit after replacing the valve, replace the cylinder head.
[BX1860, BX2360]
Valve recessing
Factory spec.
Allowable limit
-0.10 (protrusion) to
0.10 (recessing) mm
-0.0039 (protrusion) to
0.0039 (recessing) in.
0.30 (recessing) mm
0.012 (recessing) in.
[BX2660]
Valve recessing
(1) Cylinder Head Surface
Factory spec.
Allowable limit
0.050 (protrusion) to
0.25 (recessing) mm
0.0020 (protrusion) to
0.0098 (recessing) in.
0.40 (recessing) mm
0.016 (recessing) in.
(A) Recessing
(B) Protrusion
W10768800
1-S42
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
[BX1860, BX2360]
Clearance between valve stem and valve guide
Factory spec.
Allowable limit
0.030 to 0.057 mm
0.0012 to 0.0022 in.
0.10 mm
0.0039 in.
Valve stem O.D.
Valve guide I.D.
Factory spec.
Factory spec.
5.968 to 5.980 mm
0.2350 to 0.2354 in.
6.010 to 6.025 mm
0.2367 to 0.2372 in.
[BX2660]
Clearance between valve stem and valve guide
Factory spec.
Allowable limit
0.035 to 0.065 mm
0.0014 to 0.0025 in.
0.10 mm
0.0039 in.
Valve stem O.D.
Valve guide I.D.
Factory spec.
Factory spec.
6.960 to 6.975 mm
0.2741 to 0.2746 in.
7.010 to 7.025 mm
0.2760 to 0.2765 in.
W10774950
Replacing Valve Guide
(When removing)
1. Press out the used valve guide using a valve guide replacing tool.
(See page
“SPECIAL TOOLS”
.)
(When installing)
1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream precisely the I.D. of the valve guide to the specified dimension.
[BX1860, BX2360]
Valve guide I.D.
(Intake and exhaust)
Factory spec.
6.010 to 6.025 mm
0.2367 to 0.2372 in.
[BX2660]
Valve guide I.D.
(Intake and exhaust)
Factory spec.
7.010 to 7.025 mm
0.2760 to 0.2765 in.
Q
IMPORTANT
• Do not hit the valve guide with a hammer during replacement.
(A) When Removing (B) When Installing
W10278890
1-S43
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
3. If the valve contact does not comply with the reference value, replace the valve or correct the contact of valve seating.
Valve seat width Factory spec.
2.12 mm
0.0835 in.
(1) Correct
(2) Incorrect
(3) Incorrect
W10282190
1-S44
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Correcting Valve and Valve Seat
Q
NOTE
• Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary.
• After correcting the valve seat, be sure to check the valve recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
[BX1860, BX2360]
Valve face angle Factory spec.
0.79 rad
45 °
[BX2660]
Valve face angle
Factory spec.
IN.
EX.
1.0 rad
60 °
0.79 rad
45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 1.0 rad (60 °) (intake valve) or 0.79 rad (45 °) (exhaust valve) valve seat cutter.
2. Resurface the seat surface with a 0.52 rad (30 °) valve seat cutter to intake valve seat and with a 0.26 rad (15 °) valve seat cutter to exhaust valve seat so that the width is close to specified valve seat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for even valve seating, apply a thin film of compound between the valve face and valve seat, and fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating surface should show good contact all the way around.
[BX1860, BX2360]
Valve seat angle Factory spec.
0.79 rad
45 °
[BX2660]
Valve seat angle
Factory spec.
IN.
EX.
1.0 rad
60 °
0.79 rad
45 °
(1) Valve Seat Width
(2) Identical Dimensions
(A) Check Contact
(B) Correct Seat Width
(C) Check Contact
(a) 0.26 rad (15 °) or 0.52 rad (30 °)
(b) 0.79 rad (45 °) or 1.0 rad (60 °)
(c) 0.52 rad (30 °) or 0.26 rad (15 °)
W10283500
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.
4. Apply prussian blue to the contact surface to check the seated rate. If it is less than 70 %, repeat valve lapping again.
Q
IMPORTANT
• When valve lapping is performed, be sure to check the valve recessing and adjust the valve clearance after assembling the valve.
W10288140
1-S45
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Free Length and Tilt of Valve Spring
1. Measure the free length
(B)
of valve spring with vernier calipers.
If the measurement is less than the allowable limit, replace it.
2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt
(A)
.
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
[BX1860, BX2360]
Tilt
(A)
Free length
(B)
Allowable limit
Factory spec.
Allowable limit
1.2 mm
0.047 in.
31.3 to 31.8 mm
1.24 to 1.25 in.
28.4 mm
1.12 in.
[BX2660]
Tilt
(A)
Free length
(B)
Allowable limit
Factory spec.
Allowable limit
1.0 mm
0.039 in.
37.0 to 37.5 mm
1.46 to 1.47 in.
36.5 mm
1.44 in.
(A) Tilt (B) Free Length
W10289350
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.
[BX1860, BX2360]
Setting load /
Setting length
Factory spec.
Allowable limit
65 N / 27.0 mm
6.6 kgf / 27.0 mm
15 lbf / 1.06 in.
55 N / 27.0 mm
5.6 kgf / 27.0 mm
12 lbf / 1.06 in.
[BX2660]
Setting load /
Setting length
Factory spec.
Allowable limit
117.4 N / 31.0 mm
11.97 kgf / 31.0 mm
26.39 lbf / 1.22 in.
100.0 N / 31.0 mm
10.20 kgf / 31.0 mm
22.48 lbf / 1.22 in.
W10784360
1-S46
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again. If it still exceeds the allowable limit, replace also the rocker arm shaft.
[BX1860, BX2360]
Oil clearance between rocker arm and rocker arm shaft
Rocker arm shaft O.D.
Rocker arm I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.016 to 0.045 mm
0.00063 to 0.0017 in.
0.15 mm
0.0059 in.
10.473 to 10.484 mm
0.41233 to 0.41275 in.
10.500 to 10.518 mm
0.41339 to 0.41409 in.
[BX2660]
Oil clearance between rocker arm and rocker arm shaft
Rocker arm shaft O.D.
Factory spec.
Allowable limit
Factory spec.
0.016 to 0.045 mm
0.00063 to 0.0017 in.
0.10 mm
0.0039 in.
11.973 to 11.984 mm
0.47138 to 0.47181 in.
Rocker arm I.D.
Factory spec.
12.000 to 12.018 mm
0.47244 to 0.47314 in.
W10291500
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.
Push rod alignment Allowable limit
0.25 mm
0.0098 in.
W10292900
1-S47
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Tappet and Tappet Guide Bore
1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is damaged, replace the tappet.
[BX1860, BX2360]
Oil Clearance between tappet and tappet guide bore
Tappet O.D.
Tappet guide bore I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.016 to 0.052 mm
0.00063 to 0.0020 in.
0.10 mm
0.0039 in.
17.966 to 17.984 mm
0.70733 to 0.70803 in.
18.000 to 18.018 mm
0.70867 to 0.70937 in.
[BX2660]
Oil Clearance between tappet and tappet guide bore
Tappet O.D.
Tappet guide bore I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.020 to 0.062 mm
0.00079 to 0.0024 in.
0.07 mm
0.003 in.
19.959 to 19.980 mm
0.78579 to 0.78661 in.
20.000 to 20.021 mm
0.78740 to 0.78822 in.
W1051412
1-S48
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
(2) Timing Gears, Camshaft and Governor Gear
Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
4. If the oil clearance is proper, replace the gear.
[BX1860, BX2360]
Backlash between idle gear and crank gear
Backlash between idle gear and cam gear
Backlash between idle gear and injection pump gear
Backlash between oil pump drive gear and crank gear
Factory spec.
Allowable limit
Factory spec.
Allowable limit
Factory spec.
Allowable limit
Factory spec.
Allowable limit
0.0430 to 0.124 mm
0.00170 to 0.00488 in.
0.15 mm
0.0059 in.
0.0470 to 0.123 mm
0.00185 to 0.00484 in.
0.15 mm
0.0059 in.
0.0460 to 0.124 mm
0.00182 to 0.00488 in.
0.15 mm
0.0059 in.
0.0410 to 0.123 mm
0.00162 to 0.00484 in.
0.15 mm
0.0059 in.
[BX2660]
Backlash between idle gear 1 and crank gear
Backlash between idle gear 1 and cam gear
Backlash between idle gear 1 and injection pump gear
[A] BX1860, BX2360
Factory spec.
Allowable limit
Factory spec.
Allowable limit
Factory spec.
Allowable limit
[B] BX2660
0.0320 to 0.115 mm
0.00126 to 0.00452 in.
0.15 mm
0.0059 in.
0.0360 to 0.114 mm
0.00142 to 0.00448 in.
0.15 mm
0.0059 in.
0.0340 to 0.116 mm
0.00134 to 0.00456 in.
0.15 mm
0.0059 in.
W10280630
Governor Gear Backlash (BX2660 only)
Backlash between injection pump gear and governor gear
Factory spec.
Allowable limit
0.0300 to 0.117 mm
0.00119 to 0.00460 in.
0.15 mm
0.0059 in.
W1041576
1-S49
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Idle Gear 1 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.
Idle gear 1 side clearance
Factory spec.
Allowable limit
0.20 to 0.51 mm
0.0079 to 0.020 in.
0.80 mm
0.031 in.
W10285590
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. measure the side clearance by moving the cam gear to the front to rear.
3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
[BX1860, BX2360]
Camshaft side clearance
Factory spec.
Allowable limit
0.15 to 0.31 mm
0.0059 to 0.012 in.
0.50 mm
0.020 in.
[BX2660]
Camshaft side clearance
Factory spec.
Allowable limit
0.070 to 0.22 mm
0.0028 to 0.0086 in.
0.30 mm
0.012 in.
W10295630
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
4. If the measurement exceeds the allowable limit, replace the camshaft.
Camshaft alignment Allowable limit
0.01 mm
0.0004 in.
W10296710
1-S50
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
[BX1860, BX2360]
Cam height of intake and exhaust
Factory spec.
Allowable limit
26.88 mm
1.058 in.
26.83 mm
1.056 in.
[BX2660]
Cam height of intake
Factory spec.
Allowable limit
28.80 mm
1.134 in.
28.75 mm
1.132 in.
Factory spec.
29.00 mm
1.142 in.
Cam height of exhaust
Allowable limit
28.95 mm
1.140 in.
W10297880
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the camshaft.
[BX1860, BX2360]
Oil clearance of camshaft journal
Camshaft journal O.D.
Factory spec.
Allowable limit
Factory spec.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
0.15 mm
0.0059 in.
32.934 to 32.950 mm
1.2967 to 1.2972 in.
Camshaft bearing I.D.
(Cylinder block bore
I.D.)
Factory spec.
33.000 to 33.025 mm
1.2993 to 1.3001 in.
[BX2660]
Oil clearance of camshaft journal
Camshaft journal O.D.
Factory spec.
Allowable limit
Factory spec.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
0.15 mm
0.0059 in.
35.934 to 35.950 mm
1.4147 to 1.4153 in.
Camshaft bearing I.D.
(Cylinder block bore
I.D.)
Factory spec.
36.000 to 36.025 mm
1.4173 to 1.4183 in.
W10299330
1-S51
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Idle Gear 1 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.
3. If the oil clearance exceeds the allowable limit, replace the bushing.
If it still exceeds the allowable limit, replace the idle gear shaft.
[BX1860, BX2360]
Oil clearance between idle gear shaft 1 and idle gear bushing
Idle gear shaft 1 O.D.
Idle gear bushing 1 I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.020 to 0.084 mm
0.00079 to 0.0033 in.
0.10 mm
0.0039 in.
19.967 to 19.980 mm
0.78611 to 0.78661 in.
20.000 to 20.051 mm
0.78741 to 0.78940 in.
[BX2660]
Oil clearance between idle gear shaft 1 and idle gear bushing
Idle gear shaft 1 O.D.
Factory spec.
Allowable limit
Factory spec.
0.020 to 0.054 mm
0.00079 to 0.0021 in.
0.10 mm
0.0039 in.
25.967 to 25.980 mm
1.0223 to 1.0228 in.
Idle gear bushing 1 I.D.
Factory spec.
26.000 to 26.021 mm
1.0237 to 1.0244 in.
W10301050
Replacing Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing using an idle gear bushing replacing tool. (See page
“SPECIAL TOOLS”
.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing tool, until it is flush with the end of the idle gear.
(A) When Removing (B) When Installing
W10302410
1-S52
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(3) Piston and Connecting Rod
ENGINE
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.
[BX1860, BX2360]
Piston pin bore I.D.
Factory spec.
Allowable limit
20.000 to 20.013 mm
0.78741 to 0.78791 in.
20.05 mm
0.7894 in.
[BX2660]
Factory spec.
22.000 to 22.013 mm
0.86615 to 0.86665 in.
Piston pin bore I.D.
Allowable limit
22.03 mm
0.8673 in.
W10304770
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the piston pin.
[BX1860, BX2360]
Oil clearance between piston pin and small end bushing
Piston pin O.D.
Small end bushing I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.015 to 0.075 mm
0.00059 to 0.0029 in.
0.15 mm
0.0059 in.
20.002 to 20.011 mm
0.78748 to 0.78783 in.
20.025 to 20.040 mm
0.78839 to 0.78897 in.
[BX2660]
Oil clearance between piston pin and small end bushing
Piston pin O.D.
Small end bushing I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.014 to 0.038 mm
0.00056 to 0.0014 in.
0.15 mm
0.0059 in.
22.002 to 22.011 mm
0.86622 to 0.86657 in.
22.025 to 22.040 mm
0.86713 to 0.86771 in.
W10305740
1-S53
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing replacing tool. (See page
“SPECIAL TOOLS”
.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to them.
2. Using a small end bushing replacing tool, press in a new bushing
(service parts) taking due care to see that the connecting rod oil hole matches the bushing hole.
[BX1860, BX2360]
Oil clearance between piston pin and small end bushing (Spare parts)
Small end bushing I.D.
(Spare parts)
Factory spec.
Allowable limit
Factory spec.
0.015 to 0.075 mm
0.00059 to 0.0029 in.
0.15 mm
0.0059 in.
20.026 to 20.077 mm
0.78843 to 0.79043 in.
[BX2660]
Oil clearance between piston pin and small end bushing (Spare parts)
Small end bushing I.D.
(Spare parts)
Factory spec.
Allowable limit
Factory spec.
0.015 to 0.038 mm
0.00056 to 0.0014 in.
0.15 mm
0.0059 in.
22.025 to 22.040 mm
0.86713 to 0.86771 in.
(1) Seam
(2) Oil Hole
(A) When Removing
(B) When Installing
(a) 0.79 rad (45 °)
W10307120
Connecting Rod Alignment
Q
NOTE
• Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand.
1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod alignment tool.
3. Put a gauge over the piston pin, and move it against the face plate.
4. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate.
5. If the measurement exceeds the allowable limit, replace the connecting rod.
Connecting rod alignment
Allowable limit
0.05 mm
0.002 in.
W10314620
1-S54
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
2. Measure the ring gap with a thickness gauge.
3. If the measurement exceeds the allowable limit, replace the piston ring.
[BX1860]
Piston ring gap
Top ring
Second ring
Oil ring
Factory spec.
Allowable limit
Factory spec.
Allowable limit
Factory spec.
Allowable limit
0.15 to 0.30 mm
0.0059 to 0.011 in.
1.20 mm
0.0472 in.
0.30 to 0.45 mm
0.012 to 0.017 in.
1.20 mm
0.0472 in.
0.15 to 0.30 mm
0.0059 to 0.011 in.
1.20 mm
0.0472 in.
[BX2360]
Piston ring gap
Top ring
Second ring
Oil ring
Factory spec.
Allowable limit
Factory spec.
Allowable limit
Factory spec.
Allowable limit
0.20 to 0.35 mm
0.0079 to 0.013 in.
1.25 mm
0.0492 in.
0.35 to 0.50 mm
0.014 to 0.019 in.
1.25 mm
0.0492 in.
0.20 to 0.35 mm
0.0079 to 0.013 in.
1.25 mm
0.0492 in.
[BX2660]
Piston ring gap
Top ring
Second ring
Oil ring
Factory spec.
Allowable limit
Factory spec.
Allowable limit
Factory spec.
Allowable limit
0.30 to 0.45 mm
0.012 to 0.017 in.
1.25 mm
0.0492 in.
0.30 to 0.45 mm
0.012 to 0.017 in.
1.25 mm
0.0492 in.
0.25 to 0.40 mm
0.0099 to 0.015 in.
1.25 mm
0.0492 in.
W10310120
1-S55
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Clearance between Piston ring and Piston Ring Groove
1. Clean the rings and the ring grooves, and install each ring in its groove.
2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge.
3. If the clearance exceeds the allowable limit, replace the piston ring.
4. If the clearance still exceeds the allowable limit with new ring, replace the piston.
[BX1860, BX2360]
Clearance between piston ring and piston ring groove
Second ring
Oil ring
Factory spec.
Allowable limit
Factory spec.
Allowable limit
0.0900 to 0.120 mm
0.00355 to 0.00472 in.
0.15 mm
0.0059 in.
0.040 to 0.080 mm
0.0016 to 0.0031 in.
0.15 mm
0.0059 in.
[BX2660]
Clearance between piston ring and piston ring groove
Second ring
Oil ring
Factory spec.
Allowable limit
Factory spec.
Allowable limit
0.0850 to 0.112 mm
0.00335 to 0.00440 in.
0.2 mm
0.008 in.
0.020 to 0.055 mm
0.00079 to 0.0021 in.
0.15 mm
0.0059 in.
Factory specification :
a
(A) Top Ring (Key Stone Type)
More than 0.2 mm
0.008 in.
(B) 2nd Oil Ring
W10312390
1-S56
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(4) Crankshaft
ENGINE
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front and rear.
3. If the measurement exceeds the allowable limit, replace the thrust bearings.
4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an oversize one referring to the table and figure.
Crankshaft side clearance
Factory spec.
Allowable limit
0.15 to 0.31 mm
0.0059 to 0.012 in.
0.50 mm
0.020 in.
(Reference)
[BX1860, BX2360]
• Oversize thrust bearing
Oversize Bearing Code Number
0.20 mm
0.0079 in.
Thrust bearing 1 02
Thrust bearing 2 02
Thrust bearing 1 04
15261-23950
15261-23970
15261-23960
0.40 mm
0.016 in.
Thrust bearing 2 04 15261-23980
• Oversize dimensions of crankshaft journal
Marking
020 OS
020 OS
040 OS
040 OS
Oversize
Dimension
Dimension
A
B
0.20 mm
0.0079 in.
46.10 to 46.30 mm
1.815 to 1.822 in.
23.40 to 23.45 mm
0.9213 to 0.9232 in.
0.40 mm
0.016 in.
46.30 to 46.50 mm
1.823 to 1.830 in.
23.80 to 23.85 mm
0.9370 to 0.9389 in.
Dimension
C
1.8 to 2.2 mm radius
0.071 to 0.086 in. radius
1.8 to 2.2 mm radius
0.071 to 0.086 in. radius
(0.8S)
The crankshaft journal must be fine-finished to higher than
∇∇∇∇
.
[BX2660]
Oversize
Dimension
Dimension
A
B
0.20 mm
0.0079 in.
51.50 to 51.70 mm
2.028 to 2.035 in.
28.20 to 28.25 mm
1.111 to 1.112 in.
0.40 mm
0.016 in.
51.60 to 51.80 mm
2.032 to 2.039 in.
28.40 to 28.45 mm
1.119 to 1.120 in.
Dimension
C
2.3 to 2.7 mm radius
0.091 to 0.10 in. radius
2.3 to 2.7 mm radius
0.091 to 0.10 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than
∇∇∇∇
W10317070
1-S57
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
4. If the measurement exceeds the allowable limit, replace the crankshaft.
Crankshaft alignment Allowable limit
0.02 mm
0.0008 in.
W10330010
Oil Clearance between Crankpin and Crankpin Bearing
(BX1860, BX2360)
1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the oil clearance.
5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing.
6. If the same size bearing is useless because of the crankpin wear, replace it with an undersize one referring to the table and figure.
Q
NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod screws are tightened.
Oil clearance between crankpin and crankpin bearing
Factory spec.
Allowable limit
0.020 to 0.051mm
0.00079 to 0.0020 in.
0.15 mm
0.0059 in.
Crankpin O.D.
Crankpin bearing I.D.
Factory spec.
Factory spec.
33.959 to 33.975 mm
1.3370 to 1.3375 in.
33.995 to 34.010 mm
1.3384 to 1.3389 in.
(Reference)
• Undersize crankpin bearing
Undersize
0.20 mm
0.0079 in.
Bearing
Crankpin bearing 02
Code Number
15861-22970
0.40 mm
0.016 in.
Crankpin bearing 04
• Undersize dimensions of crankpin
15861-22980
Marking
020 US
040 US
Undersize
Dimension
A
0.20 mm
0.0079 in.
2.3 to 2.7 mm radius
0.091 to 0.10 in.radius
0.40 mm
0.016 in.
2.3 to 2.7 mm radius
0.091 to 0.10 in.radius
*Dimension
Dimension
B
C
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
33.759 to 33.775 mm dia.
1.3291 to 1.3297 in. dia.
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
33.559 to 33.575 mm dia.
1.3213 to 1.3218 in. dia.
(0.8S)
The crankpin must be fine-finished to higher than
∇∇∇∇
.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
W11625390
1-S58
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Crankpin and Crankpin Bearing
(BX2660)
1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the oil clearance.
5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing.
6. If the same size bearing is useless because of the crankpin wear, replace it with an undersize one referring to the table and figure.
Q
NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod screws are tightened.
Oil clearance between crankpin and crankpin bearing
Factory spec.
Allowable limit
0.029 to 0.091 mm
0.0011 to 0.0036 in.
0.20 mm
0.0079 in.
Crankpin O.D.
Crankpin bearing I.D.
Factory spec.
Factory spec.
39.959 to 39.975 mm
1.5732 to 1.5738 in.
40.040 to 40.050 mm
1.5764 to 1.5767 in.
(Reference)
• Undersize dimensions of crankpin
Undersize
Dimension
*Dimension
Dimension
A
B
C
0.20 mm
0.0079 in.
2.8 to 3.2 mm radius
0.11 to 0.12 in. radius
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
39.759 to 39.775 mm dia.
1.5654 to 1.5659 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than
∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
0.40 mm
0.016 in.
2.8 to 3.2 mm radius
0.11 to 0.12 in. radius
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
39.559 to 39.575 mm dia.
1.5575 to 1.5580 in. dia.
W10331060
1-S59
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 1 (BX1860, BX2360)
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.
3. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 1.
4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and the figure.
Oil Clearance between crankshaft journal and crankshaft bearing 1
Factory spec.
Allowable limit
0.0340 to 0.106 mm
0.00134 to 0.00417 in.
0.20 mm
0.0079 in.
Crankshaft journal O.D.
Crankshaft bearing 1 I.D.
Factory spec.
Factory spec.
BX1860
BX2360
BX1860
BX2360
39.934 to 39.950 mm
1.5722 to 1.5728 in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
39.984 to 40.040 mm
1.5742 to 1.5763 in.
43.984 to 44.040 mm
1.7317 to 1.7338 in.
(Reference)
• Undersize crankshaft bearing 1
Undersize
0.20 mm
0.0079 in.
Models
BX1860
BX2360
Bearing
Crankshaft bearing 1 02
Code Number
15861-23910
1G460-23910
0.40 mm
0.016 in.
BX1860
BX2360
Crankshaft bearing 1 04
15861-23920
1G460-23920
• Undersize dimensions of crankshaft journal
Marking
020 US
040 US
Undersize
Dimension
A
*Dimension
B
Models
All models
All models
0.20 mm
0.0079 in.
1.8 to 2.2 mm radius
0.071 to 0.086 in.radius
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
0.40 mm
0.016 in.
1.8 to 2.2 mm radius
0.071 to 0.086 in.radius
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
Dimension
C
BX1860
BX2360
39.734 to 39.750 mm dia.
1.5644 to 1.5649 in. dia.
43.734 to 43.750 mm dia.
1.7219 to 1.7224 in. dia.
39.534 to 39.550 mm dia.
1.5565 to 1.5570 in. dia.
43.534 to 43.550 mm dia.
1.7140 to 1.7145 in. dia.
(0.8S)
The crankshaft journal must be fine-finished to higher than
∇∇∇∇
.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
W10323470
1-S60
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 1 (BX2660)
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.
3. If the clearance exceeds the allowable limit, replace the crankshaft bearing 1.
4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.
Oil clearance between crankshaft journal and crankshaft bearing 1
Factory spec.
Allowable limit
0.0340 to 0.114 mm
0.00134 to 0.00448 in.
0.20 mm
0.0079 in.
Crankshaft journal O.D.
Factory spec.
47.934 to 47.950 mm
1.8872 to 1.8877 in.
Crankshaft bearing 1
I.D.
Factory spec.
47.984 to 48.048 mm
1.8892 to 1.8916 in.
(Reference)
• Undersize dimensions of crankshaft journal
Undersize
Dimension
A
0.020 mm
0.0079 in.
2.3 to 2.7 mm radius
0.091 to 0.10 in. radius
0.40 mm
0.016 in.
2.3 to 2.7 mm radius
0.091 to 0.10 in. radius
*Dimension
Dimension
B
C
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
47.734 to 47.750 mm dia.
1.8793 to 1.8799 in. dia.
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
47.534 to 47.550 mm dia.
1.8715 to 1.8720 in. dia.
(0.8-S)
The crankshaft journal must be fine-finished to higher than
∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
W10337170
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (See page
“SPECIAL TOOLS”
.)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new bearing 1 (2) so that its seam (1) directs toward the exhaust manifold side. (See figure.)
Dimension
(A)
Factory spec.
0 to 0.3 mm
0 to 0.01 in.
(1) Seam
(2) Crankshaft Bearing 1
(3) Cylinder Block
(A) Dimension
W10339460
1-S61
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 and Crankshaft Bearing 3 (BX1860, BX2360)
1. Put a strip of plastigage on the center of the journal.
2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale, and get the oil clearance.
4. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 2 (crankshaft bearing 3).
5. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.
Q
NOTE
• Be sure not to move the crankshaft while the bearing case screws are tightened.
Oil clearance between crankshaft journal and crankshaft bearing 2
(crankshaft bearing 3)
Factory spec.
Allowable limit
0.028 to 0.059 mm
0.0011 to 0.0023 in.
0.20 mm
0.0079 in.
Crankshaft journal O.D.
(Flywheel side)
Crankshaft bearing 2
I.D.
Factory spec.
Factory spec.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
43.978 to 43.993 mm
1.7315 to 1.7320 in.
Crankshaft journal O.D.
(Intermediate)
Factory spec.
Crankshaft bearing 3 I.D.
Factory spec.
BX1860
BX2360
BX1860
BX2360
39.934 to 39.950 mm
1.5722 to 1.5728 in.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
39.978 to 39.993 mm
1.5740 to 1.5745 in.
43.978 to 43.993 mm
1.7315 to 1.7320 in.
W10344030
1-S62
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 and Crankshaft Bearing 3 (BX1860, BX2360)
(Continued)
(Reference)
• Undersize crankshaft bearing 2 and 3 (0.20 mm (0.0079 in.))
Models Bearing
Crankshaft bearing 2 02
Code Number
15694-23930
Marking
BX1860
Crankshaft bearing 3 02 15861-23860
020 US
Crankshaft bearing 2 02 1G460-23930
BX2360
Crankshaft bearing 3 02 1G460-23940
• Undersize crankshaft bearing 2 and 3 (0.40 mm (0.016 in.))
Marking Models
BX1860
Bearing
Crankshaft bearing 2 04
Crankshaft bearing 3 04
Code Number
15694-23940
15861-23870
BX2360
Crankshaft bearing 2 04
Crankshaft bearing 3 04
1G460-23950
1G460-23960
• Undersize dimensions of crankshaft journal
040 US
Undersize
Dimension
A
*Dimension
B
Dimension
C
Models
All models
All models
BX1860
BX2360
0.20 mm
0.0079 in.
1.8 to 2.2 mm radius
0.071 to 0.086 in.radius
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
39.734 to 39.750 mm dia.
1.5644 to 1.5649 in. dia.
43.734 to 43.750 mm dia.
1.7219 to 1.7224 in. dia.
0.40 mm
0.016 in.
1.8 to 2.2 mm radius
0.071 to 0.086 in.radius
1.0 to 1.5 mm relief
0.040 to 0.059 in. relief
39.534 to 39.550 mm dia.
1.5565 to 1.5570 in. dia.
43.534 to 43.550 mm dia.
1.7140 to 1.7145 in. dia.
Dimension
D
All models
43.734 to 43.750 mm dia.
1.7219 to 1.7224 in. dia.
43.534 to 43.550 mm dia.
1.7140 to 1.7145 in. dia.
(0.8S)
The crankshaft journal must be fine-finished to higher than
∇∇∇∇
.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
W1047088
1-S63
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing 2 (Crankshaft Bearing 3) (BX2660)
1. Put a strip of plastigage on the center of the journal.
2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale and get the oil clearance.
4. If the clearance exceeds the allowable limit, replace the crankshaft bearing 2 (1) and crankshaft bearing (3).
5. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.
Q
NOTE
• Be sure not to move the crankshaft while the bearing case screws are tightened.
Oil clearance between crankshaft journal and crankshaft bearing 2
Crankshaft journal O.D.
(Intermediate)
Crankshaft bearing 2
I.D.
Factory spec.
Allowable limit
Factory spec.
Factory spec.
0.034 to 0.095 mm
0.0014 to 0.0037 in.
0.20 mm
0.0079 in.
47.934 to 47.950 mm
1.8872 to 1.8877 in.
47.984 to 48.029 mm
1.8892 to 1.8909 in.
Oil clearance between crankshaft journal and crankshaft bearing 3
Factory spec.
Allowable limit
0.034 to 0.098 mm
0.0013 to 0.0038 in.
0.20 mm
0.0079 in.
Crankshaft journal O.D.
(Flywheel side)
Crankshaft bearing 3
I.D.
Factory spec.
Factory spec.
(Reference)
• Undersize dimensions of crankshaft journal
51.921 to 51.940 mm
2.0442 to 2.0448 in.
51.974 to 52.019 mm
2.0463 to 2.0479 in.
Undersize
Dimension
*Dimension
Dimension
A
B
C
0.20 mm
0.0079 in.
2.3 to 2.7 mm radius
0.091 to 0.10 in. radius
1.0 to 1.5 mm relief
0.040 to 0.0591 in. relief
47.734 to 47.750 mm dia.
1.8793 to 1.8799 in. dia.
0.40 mm
0.016 in.
2.3 to 2.7 mm radius
0.091 to 0.10 in. radius
1.0 to 1.5 mm relief
0.040 to 0.0591 in. relief
47.534 to 47.550 mm dia.
1.8715 to 1.8720 in. dia.
Dimension
D
51.721 to 51.740 mm dia.
2.0362 to 2.0370 in. dia.
51.521 to 51.540 mm dia.
2.0284 to 2.0291 in. dia.
(0.8-S)
The crankshaft journal must be fine-finished to higher than
∇∇∇∇
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
W10340750
1-S64
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(5) Cylinder
ENGINE
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.
3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension. (Refer to
“Correcting Cylinder”
.)
4. Visually check the cylinder wall for scratches. If deep scratches are found, the cylinder should be bored. (Refer to
“Correcting
Cylinder”
.)
Cylinder liner I.D.
Factory spec.
BX1860
BX2360
BX2660
BX1860
Allowable limit
BX2360
BX2660
67.000 to 67.019 mm
2.6378 to 2.6385 in.
72.000 to 72.019 mm
2.8347 to 2.8353 in.
76.000 to 76.019 mm
2.9922 to 2.9929 in.
67.150 mm
2.6437 in.
72.150 mm
2.8406 in.
76.15 mm
2.998 in.
(A) Top
(B) Middle
(C) Bottom (Skirt)
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
W10343890
Correcting Cylinder (Oversize) (BX1860, BX2360)
1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension.
Factory spec.
BX1860
BX2360
67.250 to 67.269 mm
2.6477 to 2.6483 in.
72.250 to 72.269 mm
2.8445 to 2.8452 in.
Cylinder liner I.D.
Allowable limit
BX1860
BX2360
67.400 mm
2.6535 in.
72.400 mm
2.8504 in.
Finishing
Hone to 2.2 to 3.0
μ m Rz
(87 to 110
μ in. Rz)
∇∇∇
.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.25 mm (0.0098 in.)
Marking : 025
Q
NOTE
• When the oversize cylinder is worn beyond the allowable limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. [Oversize]
W10367470
1-S65
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ENGINE
Correcting Cylinder (BX2660)
1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension.
Oversized cylinder liner
I.D.
Factory spec.
Allowable limit
76.500 to 76.519 mm
3.0119 to 3.0125 in.
76.65 mm
3.018 in.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.5 mm (0.02 in.)
Q
NOTE
• When the oversize cylinder is worn beyond the allowable limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
W10344480
(6) Oil Pump (BX1860, BX2360)
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Rotor lobe clearance Factory spec.
0.030 to 0.14 mm
0.0012 to 0.0055 in.
W10378950
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump body with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Clearance between outer rotor and pump body
Factory spec.
0.070 to 0.15 mm
0.0028 to 0.0059 in.
W10381420
Clearance between Rotor and Cover
1. Put a strip of plastigage 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.
4. If the clearance exceeds the factory specifications, replace oil pump rotor assembly.
Clearance between rotor and cover
Factory spec.
0.0750 to 0.135 mm
0.00296 to 0.00531 in.
W10382660
1-S66
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(7) Oil Pump (BX2660)
ENGINE
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge.
2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Rotor lobe clearance Factory spec.
0.060 to 0.18 mm
0.0024 to 0.0071 in.
W10355630
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump body with a feeler gauge.
2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Clearance between outer rotor and pump body
Factory spec.
0.100 to 0.180 mm
0.00394 to 0.00708 in.
W10356560
Clearance between Rotor and Cover
1. Put a strip of plastigage 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.
4. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Clearance between rotor and cover
Factory spec.
0.025 to 0.075 mm
0.00099 to 0.0029 in.
W10357320
1-S67
KiSC issued 06, 2009 A
2
TRANSAXLE
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 2-M1
2. TRAVELING SYSTEM .................................................................................. 2-M2
[1] HYDROSTATIC TRANSMISSION .......................................................... 2-M2
(1) Structure ............................................................................................ 2-M2
(2) Oil Flow .............................................................................................. 2-M3
(3) HST Control Linkage.......................................................................... 2-M8
(4) Speed Set Linkage............................................................................. 2-M9
[2] RANGE GEAR SHIFT SECTION........................................................ 2-M11
[3] FRONT WHEEL DRIVE SECTION ..................................................... 2-M11
[4] DIFFERENTIAL GEAR SECTION ....................................................... 2-M12
(1) Differential Gears ............................................................................. 2-M12
(2) Differential Lock ............................................................................... 2-M13
[5] BRAKE SECTION ................................................................................. 2-M14
3. PTO SYSTEM ............................................................................................. 2-M15
[1] PTO CLUTCH AND VALVE ................................................................ 2-M15
[2] MID AND REAR PTO SECTION........................................................ 2-M18
4. OTHERS ...................................................................................................... 2-M19
[1] HYDRAULIC PUMP DRIVE GEAR SECTION................................... 2-M19
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. STRUCTURE
TRANSAXLE
(1) Hydrostatic Transmission
(2) PTO Clutch Section
(3) Range Gear Shift Section
(4) Front Wheel Drive Gear
Section
(5) Mid-PTO Section
(6) PTO Gear Shift Section
(7) Rear PTO Section
(8) Differential Gear Section
(9) Brake Section
A : Front Side
B : Rear Side
2-M1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. TRAVELING SYSTEM
[1] HYDROSTATIC TRANSMISSION
(1) Structure
TRANSAXLE
(1) Check and High Pressure
Relief Valve
(2) Trunnion Arm
(3) Center Section
(4) Piston Spring
(5) Piston
(6) Thrust Ball Bearing
(7) Swashplate
(8) Cradle Bearing
(9) Spring
(10) Cir-Clip
(11) Spring
(12) Cir-Clip
(13) Thrust Ball Bearing
(14) Cylinder Block (Motor)
(15) Plug
(16) Motor Shaft
(17) Needle Bearing
(18) Ball Bearing
(19) Pump Shaft
(20) Cylinder Block (Pump)
(21) Charge Relief Valve
The hydrostatic transmission consists of variable displacement piston pump, fixed displacement piston motor and valve system.
2-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Oil Flow
TRANSAXLE
(1) Cylinder Block (Pump)
(2) Swashplate
(3) Piston
(4) Cylinder Block (Motor)
(5) Check and High Pressure
Relief Valve (Forward)
(6) Check and High Pressure
Relief Valve (Reverse)
(7) High Pressure Relief Port
Plug (Forward)
(8) Charge Relief Valve
(9) High Pressure Relief Port
Plug (Reverse)
(10) PTO Clutch Valve
(11) PTO Relief Valve
(12) Oil Filter Cartridge
(13) Power Steering Controller
(14) Hydraulic Pump
(15) Flow Priority Valve (Hydraulic
Control Valve)
(16) Position Control Valve
(17) Oil Strainer
(18) Transmission Case
A : A Port
B : B Port
C : C Port
D : D Port
The pump and motor are joined in a closed hydraulic loop and most of oil circulates within the main oil circuit. A little oil lubricates and oozes out from the clearance between the moving parts of the case. Then oil in the main oil circuit of the HST needs to be supplied a want.
The oil from the power steering circuit flows into the HST for charging.
The charge oil aids smooth operation of pistons for pump and motor. The charge oil passes through the oil filter cartridge to charge relief valve port. The rest of oil passes through the charge relief valve into the HST housing. And overflow oil from HST housing return to the transmission case.
2-M3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Neutral
TRANSAXLE
(1) Cylinder Block (Pump)
(2) Swashplate
(3) Piston
(4) Cylinder Block (Motor)
(5) Check and High Pressure
Relief Valve (Forward)
(6) Check and High Pressure
Relief Valve (Reverse)
(7) High Pressure Relief Port
Plug (Forward)
(8) Charge Relief Valve
(9) High Pressure Relief Port
Plug (Reverse)
(10) PTO Clutch Valve
(11) PTO Relief Valve
(12) Oil Filter Cartridge
(13) Power Steering Controller
(14) Hydraulic Pump
(15) Flow Priority Valve (Hydraulic
Control Valve)
(16) Position Control Valve
(17) Oil Strainer
(18) Transmission Case
A : A Port
B : B Port
C : C Port
D : D Port
X : High Pressure
Y : Low Pressure
Z : Free Oil
When the speed control pedal is in neutral, the variable swashplate is not tilted as shown in figure above. The pump pistons only rotate with cylinder block without reciprocating. Since the oil is not being pumped to the motor, the cylinder block in the motor is stationary and the output shaft does not move.
2-M4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Forward
TRANSAXLE
(1) Cylinder Block (Pump)
(2) Swashplate
(3) Piston
(4) Cylinder Block (Motor)
(5) Check and High Pressure
Relief Valve (Forward)
(6) Check and High Pressure
Relief Valve (Reverse)
(7) High Pressure Relief Port
Plug (Forward)
(8) Charge Relief Valve
(9) High Pressure Relief Port
Plug (Reverse)
(10) PTO Clutch Valve
(11) PTO Relief Valve
(12) Oil Filter Cartridge
(13) Power Steering Controller
(14) Hydraulic Pump
(15) Flow Priority Valve (Hydraulic
Control Valve)
(16) Position Control Valve
(17) Oil Strainer
(18) Transmission Case
A : A Port
B : B Port
C : C Port
D : D Port
X : High Pressure
Y : Low Pressure
Z : Free Oil
When the speed control pedal is stepped on and in forward, the variable swashplate is tilted as shown in figure above.
As the pump cylinder block rotates with the input shaft, oil is forced out of pump port
B
at high pressure. As pressure oil enters motor port
D
, the pistons, which align with port
D
, are pushed against the swashplate and slide down the inclined surface.
Then the output shaft rotates with the motor cylinder block. This drives the machine forward and the angle of pump swashplate determines the output shaft speed.
As the motor cylinder block continues to rotate, oil is forced out of motor port
C
at low pressure and returns to the pump.
2-M5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Reverse
TRANSAXLE
(1) Cylinder Block (Pump)
(2) Swashplate
(3) Piston
(4) Cylinder Block (Motor)
(5) Check and High Pressure
Relief Valve (Forward)
(6) Check and High Pressure
Relief Valve (Reverse)
(7) High Pressure Relief Port
Plug (Forward)
(8) Charge Relief Valve
(9) High Pressure Relief Port
Plug (Reverse)
(10) PTO Clutch Valve
(11) PTO Relief Valve
(12) Oil Filter Cartridge
(13) Power Steering Controller
(14) Hydraulic Pump
(15) Flow Priority Valve (Hydraulic
Control Valve)
(16) Position Control Valve
(17) Oil Strainer
(18) Transmission Case
A : A Port
B : B Port
C : C Port
D : D Port
X : High Pressure
Y : Low Pressure
Z : Free Oil
When the speed control pedal is stepped on and in reverse, the variable swashplate is tilted as shown in figure above.
As the pump cylinder block rotates with the input shaft, oil is forced out of pump port
A
at high pressure. As pressure oil enters motor port
C
, the pistons, which align with port
C
, are pushed against the swashplate and slide down the inclined surface.
Then the output shaft rotates with the motor cylinder block. This drives the machine rearward and the angle of pump swashplate determines the output shaft speed.
As the motor cylinder block continues to rotate, oil is forced out of motor port
D
at low pressure and returns to the pump.
2-M6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Relief (Reverse)
TRANSAXLE
(1) Cylinder Block (Pump)
(2) Swashplate
(3) Piston
(4) Cylinder Block (Motor)
(5) Check and High Pressure
Relief Valve (Forward)
(6) Check and High Pressure
Relief Valve (Reverse)
(7) High Pressure Relief Port
Plug (Forward)
(8) Charge Relief Valve
(9) High Pressure Relief Port
Plug (Reverse)
(10) PTO Clutch Valve
(11) PTO Relief Valve
(12) Oil Filter Cartridge
(13) Power Steering Controller
(14) Hydraulic Pump
(15) Flow Priority Valve (Hydraulic
Control Valve)
(16) Position Control Valve
(17) Oil Strainer
(18) Transmission Case
A : A Port
B : B Port
C : C Port
D : D Port
X : High Pressure
Y : Low Pressure
Z : Free Oil
When the speed control pedal is in reverse, the variable swashplate is tilted as shown in figure above.
As the pump cylinder block rotates with the input shaft, oil is forced out of pump port
A
at high pressure. As pressure oil enters motor port
C
, the pistons, which align with port
C
, are pushed against the swashplate and slide down the inclined surface. Since the oil pressure in the check and high pressure relief valve (Reverse) increase, the high oil pressure opens the check and high pressure relief valve (Reverse) and the flows through the charge relief valve to the transmission case.
Then the output shaft rotates with the motor cylinder block. This drives the machine rearward and the angle of pump swashplate determines the output shaft speed.
As the motor cylinder block continues to rotate, oil is forced out of motor port
D
at low pressure and returns to the pump.
2-M7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(3) HST Control Linkage
TRANSAXLE
The speed control pedal (5) and the trunnion arm are linked with the HST pedal link (10) and the speed change rod (11). As the front of the pedal is depressed, the swashplate connected to the trunnion arm (2) rotates and forward travelling speed increases. Depressing the rear end increases reverse speed.
The trunnion arm (2) is returned to neutral position by the neutral arm and the tension of neutral spring. At the same time, the swashplate is returned to neutral, when the pedal is released. The damper (12) connected to the
HST pedal link (10) restricts the movement of the linkage to prevent abrupt operation or reversing.
Moreover, the feeling of the dynamic braking can be adjusted by changing the arm (13) position of damper
(12).
(Reference)
[A]
: Force of the damper is large.
[B]
: Force of the damper is small.
(1) Neutral Spring
(2) Trunnion Arm
(3) Cruise Rod
(4) Brake Pedal
(5) Speed Control Pedal
(6) Parking Plate
(7) Cruise Arm
(8) Cruise Lock
(9) Cruise Lock
(10) HST Pedal Link
(11) Speed Change Rod
(12) Damper
(13) Arm
W1020319
2-M8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(4) Speed Set Linkage
Q
Speed Set
TRANSAXLE
(1) Speed Set Rod
(2) Brake Pedal
(3) Speed Control Pedal
(4) Parking Brake Lock Pedal
(5) Cruise Lock
(6) Cruise Lock
(7) Cruise Arm
(8) HST Pedal Link
(9) Speed Change Rod
(10) Damper
(11) Trunnion Arm
(12) Release Plate
(13) Brake Rod
A : Speed Set Rod “OFF”
B : Speed Set Rod “ON”
C : Speed Control Pedal
“Forward”
D : Cruise Lock “Locked”
W1020771 set.
When pushing and holding the speed set rod (1) and depressing the speed control pedal (3), the desired speed is
When pushing the speed set rod (1), the cruise arm (7) is rotated counter clockwise.
When depressing the speed control pedal (3) forward, the HST pedal link clockwise.
Since both the cruise lock (5) of the cruise arm (7) and the cruise lock (6) of HST pedal link (8) are locked, the speed control pedal (3) is held at a selected position.
2-M9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
When the Brake Pedal is Depressed
TRANSAXLE
(1) Brake Rod
(2) Speed Control Pedal
(3) Parking Brake Lock Pedal
(4) Brake Pedal
(5) Release Plate
(6) Speed Set Rod
(7) Cruise Arm
(8) Cruise Lock
(9) Cruise Lock
(10) HST Pedal Link
(11) Speed Change Rod
(12) Trunnion Arm
A : Brake Pedal “Depressed”
B : Release Plate “Pushed
Down”
C : Cruise Rod “Pushed Up”
D : Cruise Arm Rotates
“Clockwise”
E : HST Pedal Link “Pushed
Up”
W1022896
When the brake pedal (1) is depressed, the release plate (5) located under the brake pedal (1) is pushed down.
Since the release plate (5) rotates, the HST pedal link (10) is pushed up.
The lock between the cruise lock (9) of the HST pedal link (10) and the cruise lock (8) of the cruise arm (7) is released.
The speed control pedal (2) is not held at a selected position.
Since the spring pulls the speed set rod (6) upward, the speed set rod (6) is pushed up.
2-M10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] RANGE GEAR SHIFT SECTION
TRANSAXLE
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).
Q
Low Range
17T Gear Shaft (2)
→
Shifter Gear (24T) (4)
→
Spiral
Bevel Pinion Shaft (3).
Q
High Range
25T Gear (1)
→
Shifter Gear (16T) (4)
→
Spiral Bevel
Pinion Shaft (3).
(1) 25T Gear
(2) 17T Gear
(3) Spiral Bevel Pinion Shaft
(4) 16T-24T Shifter Gear
L : Low Range
H : High Range
W1014705
[3] FRONT WHEEL DRIVE SECTION
2-wheel drive or 4-wheel drive is selected by changing the position of 19T shifter gear (2) with the front wheel drive lever.
Q
Front Wheel Drive “Disengaged”
When the front wheel drive lever is set to
“Disengaged”
position, the 19T shifter gear (2) is neutral and power is not transmitted to the front wheel drive shaft (1).
Q
Front Wheel Drive “Engaged”
When the front wheel drive lever is set to
“Engaged”
position, the 19T shifter gear (2) slides to the right to engage with 13T-25T gear shaft (5). Therefore, the power from spiral bevel pinion shaft (3) is transmitted to the front wheel drive shaft (1) through the gears.
(1) Front Wheel Drive Shaft
(2) 19T Shifter Gear
(3) Spiral Bevel Pinion Shaft
(4) 12T Gear
(5) 13T-25T Gear Shaft
A : Front Wheel Drive
“Engaged”
W1014843
2-M11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[4] DIFFERENTIAL GEAR SECTION
(1) Differential Gears
TRANSAXLE
(1) Differential Case
(2) Differential Pinion
(3) 37T Spiral Bevel Gear
(4) 10T Final Gear Shaft
(5) Differential Side Gear
(6) Differential Pinion Shaft
(7) 66T Final Gear
(8) Differential Pinion
(9) Differential Side Gear
W1018746
1. During Straight Running
Rotation of the spiral bevel pinion is transmitted to the 37T spiral bevel gear (3), 10T final gear shaft (4), 66T final gear (7) and differential case (1).
When road resistance to the right and left wheels are equal, differential pinions (2), (8) and differential side gears
(5), (9) all rotate as a unit. Both rear axles received equal input, and both wheels turn at the same speed, allowing the tractor to go straight ahead.
At this time, differential pinions (2), (8) do not rotate around the differential pinion shaft (6).
2. During Turning
When the tractor turns, the road resistance to the inside tire increases. In other words, if one of tires slows down, revolution difference is generated in the differential side gears (5), (9). When rotation of one differential side gear becomes lower than the other, differential pinions (2), (8) begin rotating around differential pinion shaft (6). The other differential side gear is increased in speed by the speed increment of differential pinion shaft (6). This means that rotation of one rear axle is slowed down and that of the other rear axle is increased. Thus, the tractor turn smoothly without power loss.
The combined number of revolutions of the right and left differential side gears is always twice that of the spiral bevel gear (3). When spiral bevel gear revolution is 100 min moving, the revolution of the other differential side gear becomes 200 min the other rotates at 150 min
−
1
(rpm).
−
1
(rpm), and if one of the differential side gears stops
−
1
(rpm) and if one rotates at 50 min
−
1
(rpm),
2-M12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Differential Lock
TRANSAXLE
(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
(10) Differential Pinion Shaft
(11) Differential Pinion
W1015160
When resistance to the right and left tires are greatly different due to ground conditions or type of work, the tire with less resistance slips and prevents the tractor from moving ahead. To compensate for this drawback, the differential lock restricts the differential action and causes both rear axles to rotate as a unit.
When the differential lock pedal is stepped on, it causes the differential lock arm (6) and differential lock shaft (7) to rotate, which will move the differential lock shift fork (8) and the differential lock shifter (2) toward the differential side gear (9). The pins on the differential lock shifter (2) go into the holes in the differential case (3) to cause the differential case (3), differential lock shifter (2) and differential side gear (9) to rotate as a unit.
Therefore, differential pinions (4), (11) are unable to rotate around differential pinion shaft (10) and identical revolutions are transmitted to the right and left rear axle (1), (5).
2-M13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[5] BRAKE SECTION
TRANSAXLE
(1) Rear Axle LH
(2) Final Gear Shaft
(3) Shim
(4) Bearing Holder
(5) Friction Plate
(6) Actuator
(7) Steel Ball
(8) Cam Lever
(9) O-ring
(10) Rear Axle RH
(11) Brake Disc
(12) Internal Cir-Clip
(13) Brake Pedal
(14) Brake Rod
(15) Parking Brake Lock Pedal
A : Connects with Brake Cam
Lever and Brake Rod
W1019428
The mechanical wet disc brakes are used for the travelling brake. The brake is operated by the brake pedal (13) through the mechanical linkages and provide stable braking and require little adjustment.
The brake body is incorporated in the transmission case and axle cover filled with transmission oil.
For greater braking force, four brake discs (11) are provided at the brake shaft, and the friction plates (5) fixed to the transmission case is arranged between the brake discs (11).
Q
Travelling Brake
When the brake pedal (13) is depressed, the brake rod pulls the brake cam lever (8).
Therefore, the cam plates also moves and rides on the steel balls set in the grooves of the transmission case to press the brake disc, the final gear shaft is braked by the frictional force generated by the cam plate and brake disc.
Q
Parking Brake
When the parking brake is applied, the brake pedal (13) is locked by the parking brake lock pedal (15).
2-M14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
3. PTO SYSTEM
[1] PTO CLUTCH AND VALVE
TRANSAXLE
(1) PTO Select Gear
(2) PTO Clutch Pack
(3) Rear PTO Shaft
(4) Transmission Case
(5) PTO Clutch Valve
(6) PTO Clutch Relief Valve
(7) Oil Filter Cartridge
A : From HST Pump Shaft
B : To Mid-PTO
C : From Power Steering
Controller
D : To Hydrostatic Transmission
The BX 50 series equipped with hydraulic independent PTO clutch (wet multi-plates type). Therefore, the engine power engages or disengages to the PTO shafts without stopping the tractor movement.
The PTO clutch pack (2) has four clutch discs, four drive plates, pressure plate, clutch piston and so on.
The clutch piston is actuated by hydraulic oil flow from the power steering controller.
The PTO clutch valve (5) controls the hydraulic oil flow from power steering controller to the PTO clutch pack (2) by operating the PTO clutch lever through the linkage.
2-M15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Q
PTO Clutch Relief Valve
The PTO clutch 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.
(Reference)
• Relief valve setting pressure : 490 kPa
5.0 kgf/cm
71.2 psi
2
(1) Plug
(2) O-ring
(3) Spring
(4) Steel Ball
(5) PTO Clutch Valve
(6) HST Charge Relief Valve
(7) PTO Clutch Relief Valve
(8) Poppet
A : From Power Steering
Controller
B : To Hydrostatic
Transmission
C : To PTO Clutch Valve
(a) Old Type
(b) New Type
W1015382
Q
PTO Clutch “Engaged”
The oil from power steering controller flows into the
PTO clutch valve.
When the PTO clutch lever is set at the
“Engaged”
position, the PTO clutch valve rotates. Oil flows from the oil line through transmission case to the PTO clutch pack.
Oil entering the clutch pack pushes the clutch piston
(4) to engage the clutch pack. Power is transmitted from the HST pump shaft (1) through the PTO clutch to the clutch gear (2) and the PTO shafts.
(1) HST Pump Shaft
(2) Clutch Gear
(3) Clutch Case
(4) Clutch Piston
(5) Clutch Plate
(6) Clutch Disc
(7) Spring
(8) Spline Boss
(9) O-ring
(10) Transaxle Case
(11) Brake Disc
A : From PTO Clutch Valve
B : Power to PTO Shaft
C : PTO Clutch “Engaged”
W1015610
2-M16
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Q
PTO Clutch “Disengaged”
When the PTO clutch lever is set at the
“Disengaged”
position, the PTO clutch valve closes the oil passage to the PTO clutch pack. The oil in the PTO clutch pack drain into the transaxle case (10). Thus the clutch piston (4) is pushed back by the spring (7).
When the clutch piston (4) is pushed back by the spring (7), the brake plate (11) is also moved to contract the brake disc (12) so as to stop the rotation and drag of the PTO shafts.
(1) HST Pump Shaft
(2) Clutch Gear
(3) Clutch Case
(4) Clutch Piston
(5) Clutch Plate
(6) Clutch Disc
(7) Spring
(8) Spline Boss
(9) O-ring
(10) Transaxle Case
(11) Brake Plate
(12) Brake Disc
C : PTO Clutch “Disengaged”
W1015793
2-M17
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] MID AND REAR PTO SECTION
TRANSAXLE
(1) HST Pump Shaft
(2) 12T Clutch Gear
(3) PTO Clutch Pack
(4) Rear PTO Shaft
(5) 23T Mid PTO Gear
(6) 24T Mid PTO Idle Gear
(7) Mid-PTO Shaft
(8) 28T PTO Select Gear
(9) 11T Gear Shaft
Three kinds of power flow are selected by operating the PTO select lever to shift the PTO select gear (8) on the
11T gear shaft (9).
Q
Mid-PTO Position (A)
PTO Clutch Pack (3)
→
12T Gear Clutch (2)
→
PTO Select Gear (8)
→
23T Mid PTO Gear (5)
→
24T Mid PTO
Idle Gear (6)
→
Mid-PTO Shaft (7).
Q
Rear PTO Position (B)
PTO Clutch Pack (3)
→
12T Gear Clutch (2)
→
PTO Select Gear (8)
→
11T Gear Shaft (9)
→
Rear PTO Shaft (4).
Q
Mid and Rear PTO Position
A
and
B
at the same time.
2-M18
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
4. OTHERS
[1] HYDRAULIC PUMP DRIVE GEAR SECTION
TRANSAXLE
(1) HST Pump Shaft
(2) Spline Boss
(3) Idle Gear
(4) Hydraulic Pump Drive Gear
Shaft
(5) Hydraulic Pump Drive Gear
(6) Hydraulic Pump Drive Gear
Shaft
(7) Hydraulic Pump
(8) Flow Priority Valve
(9) Relief Valve (3P Hitch)
(10) Transmission Case
W1016433
The hydraulic pump (7) is mounted to the transmission case (10) and driven by the hydraulic pump drive gear (5).
The spline boss (2) mounted on the HST pump shaft drives the hydraulic pump drive gear (5) mounted on the hydraulic pump drive gear shaft (4) through the idle gear (3).
2-M19
KiSC issued 06, 2009 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................2-S1
2. SERVICING SPECIFICATIONS ....................................................................2-S5
3. TIGHTENING TORQUES ..............................................................................2-S7
4. CHECKING, DISASSEMBLING AND SERVICING......................................2-S8
[1] CHECKING AND ADJUSTING ...............................................................2-S8
[2] PREPARATION ......................................................................................2-S16
(1) Separating Transaxle........................................................................2-S16
[3] DISASSEMBLING AND ASSEMBLING................................................2-S24
(1) Hydrostatic Transmission..................................................................2-S24
(2) Hydraulic Cylinder.............................................................................2-S30
(3) Transaxle Shafts ...............................................................................2-S31
(4) Assembling Shafts ............................................................................2-S39
[4] SERVICING ............................................................................................2-S41
(1) Hydrostatic Transmission..................................................................2-S41
(2) Transaxle Case.................................................................................2-S43
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
HYDROSTATIC TRANSMISSION
Symptom Probable Cause
System Will Not
Operate in Either
Direction
Oil level is low
Speed control pedal linkage defective
Charge pressure is too low
Vibration and Noise
Check and high pressure relief valve does not move smoothly
Component parts defective
Oil level is too low
Speed control pedal linkage defective
Charge pressure is too low
Check and high pressure relief valve does not move smoothly
Component part is defective
Solution
Check oil level or fill oil to proper level
Repair linkage
Solution order
1. Replace oil filter cartridge
2. Check charge pressure
3. Inspect or flush charge relief valve
Inspect or replace check and high pressure relief valve
Replace hydrostatic transmission assembly
Check oil level or fill oil to proper level
Repair linkage
Solution order
1. Replace oil filter cartridge
2. Check charge pressure
3. Inspect or flush charge relief valve
Inspect or replace check and high pressure relief valve
Replace hydrostatic transmission assembly
TRANSAXLE
Reference
Page
G-24
2-S21
G-24
2-S12
2-S41
2-S41
2-S25
G-24
2-S21
G-24
2-S12
2-S41
2-S41
2-S25
W1022927
2-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
HYDROSTATIC TRANSMISSION (Continued)
Symptom Probable Cause
Loss of Power
Oil level is low
Transmission Oil
Over Heats
Machine Will Not
Stop in Neutral
Position
System Operates in
One Direction Only
Speed control pedal linkage defective
Charge pressure is too low
Check and high pressure relief valve does not move smoothly
Component parts defective
Low transmission oil level
Radiator net clogged
Excessive machine load
Improper charge pressure
Speed control linkage is out of adjustment or sticking
Speed control linkage defective
Check and high pressure relief valve defective
Solution
Check oil level or fill oil to proper level
Repair linkage
1. Replace oil filter cartridge
2. Check charge pressure
3. Inspect or flush charge relief valve
Inspect or replace check and high pressure relief valve
Replace hydrostatic transmission assembly
Fill transmission oil level up to proper level
Clean radiator net
Reduce machine load
1. Check high relief pressure
2. Replace transmission oil filter cartridge
3. Replace check and high pressure relief valve
4. Inspect and replace charge relief valve
Repair or replace linkage
Adjust neutral position
Repair or replace linkage
Replace check and high pressure relief valve
TRANSAXLE
Reference
Page
G-24
2-S21, S23
G-24
2-S12
2-S41
2-S41
2-S41
G-24
–
–
2-S12
G-24
2-S41
2-S41
2-S21, S23
2-S10
2-S21, S23
2-S41
W1026435
2-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
TRAVELLING GEAR SHIFT SECTION
Symptom
Noise from
Transmission
Gear Slip Out of
Mesh
Probable Cause
Transmission oil insufficient
Gear worn or broken
Bearings worn
Shift fork spring tension insufficient
Shift fork or shifter worn
Shift fork bent
Solution
Refill
Replace
Replace
Replace
Replace
Replace
TRANSAXLE
Reference
Page
2-S16
–
–
2-S39, S40
2-S39, S40
2-S39, S40
W1013580
DIFFERENTIAL GEAR SECTION
Excessive or
Unusual Noise at All
Time
Improper backlash between spiral bevel pinion and bevel gear
Improper backlash between differential pinion and differential side gear
Adjust
Adjust
2-S46
2-S45
Noise while Turning
Differential Lock Can
Not Be Set
Bearing worn
Insufficient or improper type of transmission fluid used
Differential pinions or differential side gears worn or damaged
Differential lock binding (does not disengaged)
Bearing worn
Differential lock shift fork damaged
Replace –
Replenish or change G-7, 2-S16
Replace
Replace
Replace
Replace
2-S35,
2-S40
2-S36
–
2-S36
Differential Lock
Pedal Does Not
Return
Differential lock shifter mounting pin damaged
Differential lock pin damaged
Differential lock pedal return spring weaken or damaged
Differential lock fork shaft rusted
Replace
Replace
Replace
Repair
2-S36
2-S36
2-S22
2-S36
W1013718
BRAKE SECTION
Brake Drags
Poor Braking Force
Brake pedal free travel too small
Ball holes of actuator for uneven wear
Brake pedal return spring weaken or broken
Brake cam rusted
Brake pedal free travel excessive
Brake disc worn
Actuator warped
Brake cam or lever damaged
Transmission fluid improper
Adjust
Replace
Replace
Repair
Adjust
Replace
Replace
Replace
Change
G-22
2-S47
2-S22
2-S37
G-22
2-S37
2-S37
2-S37
2-S16
W1010878
2-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
PTO SECTION
Symptom
PTO Clutch Slip
PTO Shaft Does Not
Rotate
PTO Clutch
Operating Pressure is Low
PTO Clutch Drags
Probable Cause
Operating pressure is low
PTO clutch valve malfunctioning
Clutch disc or drive plate excessively worn
Deformation of clutch piston
PTO clutch malfunctioning
Transmission oil improper or insufficient
Relief valve malfunctioning
Brake plate excessive worn
Clutch spring weaken or broken
Deformation of pressure plate or steel plate
Solution
Check
Repair or replace
Replace
Replace
Repair or replace
Replenish or change
Check or replace
Replace
Replace
Replace
TRANSAXLE
Reference
Page
2-S15
2-S24
2-S38
2-S38
2-S38
2-S16
2-M16
2-S38
2-S38
2-S38
W1011002
2-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
Item
Charge Relief Valve
[Oil temperature at 50
°
C, 122
°
F]
Setting Pressure
High Pressure Relief Valve
(Forward and Reverse)
[Oil temperature at 50
°
C, 122
°
F]
PTO Clutch
PTO Clutch Disc
Separate Plate
Back Plate
Clutch Piston
Setting Pressure
Operating
Pressure
Thickness
Thickness
Thickness
Flatness
Factory Specification
0.55 to 0.75 MPa
5.6 to 7.7 kgf/cm
2
80 to 100 psi
20.1 to 21.1 MPa
205 to 215 kgf/cm
2
2920 to 3060 psi
1.0 to 1.3 MPa
11 to 13 kgf/cm
2
150 to 180 psi
1.50 to 1.70 mm
0.0591 to 0.0669 in.
0.9450 to 1.055 mm
0.03721 to 0.04153 in.
1.9 to 2.1 mm
0.075 to 0.082 in.
–
Pressure Plate and Steel Plate
Clutch Spring
PTO Brake Disc
PTO Brake Plate
Differential Case to Differential Side Gear
Differential Case
Differential Side Gear
Differential Pinion Shaft to Differential
Pinion
Differential Pinion
Differential Pinion Shaft
Flatness
Free Length
Thickness
Thickness
Clearance
I.D.
O.D.
Clearance
I.D.
O.D.
–
38.5 mm
1.52 in.
2.90 to 3.10 mm
0.115 to 0.122 in.
1.9 to 2.1 mm
0.075 to 0.082 in.
0.0500 to 0.151 mm
0.00197 to 0.00594 in.
38.000 to 38.062 mm
1.4961 to 1.4985 in.
37.911 to 37.950 mm
1.4926 to 1.4940 in.
0.0800 to 0.122 mm
0.00315 to 0.00480 in.
20.060 to 20.081 mm
0.78977 to 0.79059 in.
19.959 to 19.980 mm
0.78579 to 0.78661 in.
TRANSAXLE
Allowable Limit
–
–
1.35 mm
0.0531 in.
0.80 mm
0.031 in.
1.85 mm
0.0728 in.
0.15 mm
0.0059 in.
0.20 mm
0.0079 in.
34.5 mm
1.36 in.
2.70 mm
0.11 in.
1.85 mm
0.073 in.
0.30 mm
0.012 in.
–
–
0.30 mm
0.012 in.
–
W1013874
2-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(Continued)
Item
Differential Pinion to Differential Side Gear Backlash
Spiral Bevel Pinion Shaft to Spiral Bevel
Gear
Actuator and Bearing Holder
Backlash
Flatness
Factory Specification
0.15 to 0.30 mm
0.0059 to 0.011 in.
0.10 to 0.30 mm
0.0040 to 0.011 in.
–
Cam Plate and Ball
Brake Disc
Friction Plate
Height
Thickness
Thickness
22.89 to 22.99 mm
0.9012 to 0.9051 in.
3.30 to 3.50 mm
0.130 to 0.137 in.
1.92 to 2.08 mm
0.0756 to 0.0818 in.
TRANSAXLE
Allowable Limit
0.40 mm
0.016 in.
–
0.30 mm
0.012 in.
22.40 mm
0.8819 in.
3.0 mm
0.12 in.
1.52 mm
0.0598 in.
W1033005
2-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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-9.)
Item
Charge relief valve checking plug (R 1/4)
Hexagon socket head plug (R 1/4)
Check and high pressure valve screw
PTO clutch operating pressure plug (R 1/8)
ROPS mounting nut
Fuel tank stay mounting bolt and nut
Fender bracket mounting bolt and nut
Rear wheel mounting screw
Hitch plate mounting bolt and nut
Transaxle assembly mounting screw (M12)
Transaxle assembly mounting screw (M14)
Rear coupling mounting screw (M8)
Front coupling mounting screw (M8)
HST fan mounting screw (M8)
Hydraulic control lever mounting bolt and nut
HST front cover mounting bolt and nut
Check and High pressure relief valve plug
Hydraulic cylinder mounting screw
Transaxle case front cover mounting bolt (M8)
Hydraulic pump assembly mounting bolt (M6)
Hydraulic pump assembly mounting bolt (M8)
Rear PTO cover mounting bolt (M8)
Rear axle case (RH) mounting bolt (M8)
66T final gear mounting screw
N·m
30 to 44
30 to 44
25 to 29
13 to 21
124 to 147
48 to 55
124 to 147
109 to 129
124 to 147
63 to 72
124 to 147
24 to 27
24 to 27
9.8 to 11
18 to 20
18 to 20
59 to 78
40 to 44
30 to 34
7.9 to 8.8
18 to 20
18 to 20
18 to 20
61 to 70
kgf·m
3.0 to 4.5
3.0 to 4.5
2.5 to 3.0
1.3 to 2.2
12.6 to 15.0
4.9 to 5.7
12.6 to 15.0
11.1 to 13.2
12.6 to 15.0
6.4 to 7.4
12.6 to 15.0
2.4 to 2.8
2.4 to 2.8
1.0 to 1.2
1.8 to 2.1
1.8 to 2.1
6.0 to 8.0
4.0 to 4.5
3.0 to 3.5
0.80 to 0.90
1.8 to 2.1
1.8 to 2.1
1.8 to 2.1
6.2 to 7.2
TRANSAXLE
lbf·ft
22 to 32
22 to 32
18 to 21
9.4 to 15
91.2 to 108
36 to 41
91.2 to 108
80.3 to 95.4
91.2 to 108
47 to 53
91.2 to 108
18 to 20
18 to 20
7.3 to 8.6
13 to 15
13 to 15
44 to 57
29 to 32
22 to 25
5.8 to 6.5
13 to 15
13 to 15
13 to 15
45 to 52
W1012736
2-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Adjusting Maximum Speed
Q
Forward
1. Depress the speed control pedal (1) all the way and lengthen the stopper bolt (2) until it touches the speed control pedal (2).
2. Adjust the stopper bolt (2) length
A
to 17.0 mm (0.669 in.) and lock it securely.
Q
Reverse
1. Adjust the stopper bolt (3) length
B
to 17.5 mm (0.689 in.) and lock it securely.
(Reference)
Stopper bolt length Reference
Forward
Reverse
17.0 mm
0.669 in.
17.5 mm
0.689 in.
Maximum speed
(1) Speed Control Pedal
(2) Stopper Bolt (Forward)
(3) Stopper Bolt (Reverse)
Reference
Forward
Reverse
13.0 to 14.0 km/h
8.08 to 8.69 mph
10.0 to 11.0 km/h
6.22 to 6.83 mph
A : Stopper Bolt Length (Forward)
B : Stopper Bolt Length (Reverse)
W1012590
2-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Preparation before HST Adjustment
CAUTION
• Park the machine on a firm and level ground.
1. Place the wooden blocks at the front and the rear side of the wheels not to move the tractor.
2. Lift up the rear wheels (1) safely by the rigid jacks.
3. Shift the front wheel drive lever (2) to
“OFF”
position
(A)
.
4. Remove the rear right wheel from the tractor.
(1) Rear Wheel
(2) Front Wheel Drive Lever
(3) Neutral Adjuster
(4) Lock Screw
(A) “OFF” Position
W1047776
2-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Adjustment of HST Neutral Position
1. Start the engine.
2. Keep the engine at the maximum revolution.
3. Shift the range shift lever (1) to “
Hi
” position
(B)
.
4. Loosen the locking screw (5).
Q
NOTE
• When adjusting the HST neutral position, loosen the locking screw approximately 2 turns counterclockwise not to drop the nut inside.
• Make sure 4WD lever is set to 2WD before making adjustment.
(Forward to Neutral Position)
5. Depress the speed control pedal (3) to “
Forward
” speed position, and release the foot from the speed control pedal (3). Check that the rear axle (or the wheel) stops rotating.
If the rear axle (or the wheel) does not stop rotating, move the position of the locking screw (5) to the machine front side to stop rotating.
(Reverse to Neutral Position)
6. Depress the speed control pedal (3) to “
Reverse
” speed position, and release the foot from the speed control pedal (3). Check the rear axle (or the wheel) stops rotating. If the rear axle (or the wheel) does not stop rotating, adjust the locking screw (5) to stop rotating.
7. After adjusting the neutral position, tighten the lock screw (5) securely.
(1) Range Gear Shift Lever
(2) Front Wheel Drive
(3) Speed Control Pedal
(4) Neutral Adjust Lever
(5) Locking Screw
(6) Screw Driver
(A) 4WD “OFF” Position
(B) “Hi” Position
(C) FORWARD
(D) REVERSE
W1012819
2-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Checking and Adjusting HST Neutral Spring (for Dynamic
Braking)
WARNING
• Do not operate if tractor move on level ground with foot off speed control pedal.
• If tractor moves on level ground with foot off the pedal, or, if the pedal is too slow in returning to “Neutral” position when removing the foot from the pedal, adjust the HST neutral spring.
The HST neutral spring located under the front right side of the fender can adjust returning speed of speed control pedal.
Since the HST neutral spring tension is weakened, the HST tension should be checked and adjusted every 100 hours.
1. Checking the HST neutral spring tension : Dynamic braking
- Start the engine and hold the maximum engine speeds.
- Operate the machine on the concrete level ground.
- Shift the range gear shift lever to “
High
” position.
- Depress the speed control pedal to “
Forward
”.
- Release the foot from the speed control pedal.
- Check the distance between the foot releasing point and the machine stopping point.
- If the distance is more than approximately 3 m (10 feet), strengthen the HST neutral spring tension so that the machine will stop in approximately 3 m (10 feet) after releasing the foot from the speed control pedal.
(Reference)
Distance (
L
) between the foot releasing point and the machine stopping point
Reference
Approximately 3 m (10 feet)
2. Remove the step from the machine.
- Loosen the lock nut (2).
- Turn the adjusting nut (3) half turn to pull the HST neutral spring
(1).
- Tighten and lock the lock nut (2).
- Start the engine and check dynamic brake as mentioned former.
- If the machine will not stop with dynamic brake in approximately
3 m (10 feet), adjust the neutral spring again.
(Reference)
• The feeling of dynamic braking can be adjusted by changing the arm (6) position of damper (5).
Length (
M
) of adjusting rod at shipping the machine from the factory
Reference
10 mm
0.39 in.
(1) HST Neutral Spring
(2) Lock Nut
(3) Adjusting Nut
(4) Adjusting Rod
(5) Damper
(6) Arm
(A) Foot Releasing Point
(B) Machine Stopping Point
L : Distance between Foot Releasing
Point and the Machine Stopping
Point
M : Length of Adjusting Rod from
Stay
W1079634
2-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Charge Relief Pressure
CAUTION
• When checking, park the tractor on flat ground, and apply the parking brake.
1. Remove the plug (R 1/4) (1) from the front cover, then install the adaptor (R 1/4) and pressure gauge.
2. Set the range gear shift lever to “
Neutral
” position.
3. Start the engine and run it at the maximum speed.
4. Read the pressure gauge to measure the charge relief pressure.
5. If the measurement is not within the factory specifications, check the charge relief valve and related hydraulic components.
Q
NOTE
• When reinstalling the hexagon socket head plug, apply liquid lock (Three Bond 1324 or its equivalent) to the plug.
Charge relief pressure
Factory spec. (Oil temperature at 50 °C,
122 °F)
0.55 to 0.75 MPa
5.6 to 7.7 kgf/cm
2
80 to 100 psi
Tightening torque
Charge relief pressure port plug (R 1/4)
29 to 44 N·m
3.0 to 4.5 kgf·m
22 to 32 lbf·ft
(1) Plug
W1013009
High Relief Pressure (Forward)
CAUTION
• When checking, park the tractor on flat ground, and apply the parking brake.
1. Remove the hexagon socket head plug (R 1/4) from
P2
(2), then install the adaptor, cable and pressure gauge.
2. Start the engine and run it at maximum speed.
3. Set the range gear shift lever to “
Hi
” position.
4. Depress the speed control pedal to “
Forward
”, and read the pressure gauge to measure the high relief pressure.
5. If the measurement is not same as factory specification, check the high pressure relief valve and related hydraulic components.
High relief pressure
(Forward)
Factory spec. (Oil temperature at 50 °C,
122 °F)
20.1 to 21.1 MPa
205 to 215 kgf/cm
2
2920 to 3060 psi
Tightening torque
Hexagon socket head plug
(
P1
and
P2
port)
30 to 44 N·m
3.0 to 4.5 kgf·m
22 to 32 lbf·ft
Q
IMPORTANT
• Measure quickly the high relief pressure within about 10 seconds.
Q
NOTE
• When reinstalling the hexagon socket head plug, apply liquid lock (Three Bond 1324 or its equivalent) to the plug.
(1)
P1
Port (Reverse) (2)
P2
Port (Forward)
W1013275
2-S12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
High Relief Pressure (Reverse)
CAUTION
• When checking, park the tractor on flat ground, and apply the parking brake.
1. Remove the hexagon socket head plug (R 1/4) from
P1
(1), then install the adaptor, cable and pressure gauge.
2. Start the engine and run it at maximum speed.
3. Set the range gear shift lever to “
Hi
” position.
4. Depress the speed control pedal to “
Reverse
”, and read the pressure gauge to measure the high relief pressure.
5. If the measurement is not same as factory specification, check the high pressure relief valve and related hydraulic components.
High relief pressure
(Reverse)
Factory spec. (Oil temperature at 50 °C,
122 °F)
20.1 to 21.1 MPa
205 to 215 kgf/cm
2
2920 to 3060 psi
Tightening torque
Hexagon socket head plug
(
P1
and
P2
port)
30 to 44 N·m
3.0 to 4.5 kgf·m
22 to 32 lbf·ft
Q
IMPORTANT
• Measure quickly the high relief pressure within about 10 seconds.
Q
NOTE
• When reinstalling the hexagon socket head plug, apply liquid lock (Three Bond 1324 or its equivalent) to the plug.
(1)
P1
Port (Reverse) (2)
P2
Port (Forward)
W1040164
2-S13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Readjustment of Relief Valve (When the HST does not Work
Due to its Loose Hexagon Socket Head Screw)
Q
IMPORTANT
• KUBOTA does not recommend the readjustment of relief valve. KUBOTA recommends with genuine parts.
• As the HST may be damaged if the pressure is set to high by mistake, be careful when adjusting it.
Q
NOTE
• The relief pressure is set in between 20.1 to 21.1 MPa (205 to
215 kgf/cm
2
, 2920 to 3060 psi) when shipped from the factory. But, for the purpose of after-sales services, as it is impossible to reset the pressure precisely as set in the factory, its setting range is defined as a slightly wider range between 15.0 to 20.0 MPa (153 to 203 kgf/cm
2
, 2180 to 2900 psi).
1. Measure the pre-adjustment distance
A
.
2. Compress the spring of the relief valve with a relief valve assembling tool (3).
3. Then, find the distance
A
by turning the poppet (4) with a screwdriver.
Reference: The distance
A
changes by about 0.5 mm (0.02 in.) per one turn of the poppet (4).
4. Repeat the same operation a few times to find the distance
A
as it is difficult to acquire at the first time.
5. After finding the distance
A
, hold the setscrew (6) to a vice and fasten the hexagon socket head screw (2) with specified torque.
On this occasion, use a copper plate, etc. for the vice jaws not to damage the setscrew (6).
6. Install the relief valve in the HST.
7. Check the relief pressure as indicated in page 2-S12 and 2-S13.
The distance
A
is for refresh only. Make sure to check the relief pressure after readjustment.
8. If the relief pressure does not fall within the readjustment pressure range, repeat the processes of the above.
Reference: The pressure changes by 1.5 MPa (15 kgf/cm
2
, 210 psi) per 0.1 mm (0.004 in.) in distance
A.
Tightening torque
Hexagon socket head screw
25 to 29 N·m
2.5 to 3.0 kgf·m
18 to 21 lbf·ft
Relief valve readjusting pressure
Factory spec.
15.0 to 20.0 MPa
153 to 203 kgf/cm
2
2180 to 2900 psi
Distance
A
of relief valve (Forward)
Distance
A
of relief valve (Reverse,
φ
1.5 mm orifice)
Reference value
Reference value
(1) Relief Valve Assembly
(2) Hexagon Socket Head Screw
(3) Relief Valve Assembling Tool
(4) Poppet
A : Distance
39.10 to 39.20 mm
1.540 to 1.543 in.
38.60 to 38.70 mm
1.520 to 1.523 in.
(5) Valve Seat
(6) Setscrew
W1082809
2-S14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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 (R 1/8), then install the adaptor (R 1/8), cable and pressure gauge.
3. Start the engine and set at maximum speed.
4. Move the PTO clutch lever to
“Engaged”
position, and measure the pressure.
5. If the measurement is not same as factory specifications, check the PTO relief valve and related hydraulic components.
Q
IMPORTANT
• Do not connect the universal joint of the implement to the mid and rear PTO shaft.
Q
NOTE
• When reinstall the hexagon socket head plug, apply liquid lock (Three Bond 1324 or its equivalent) to the plug.
PTO clutch operating pressure
Factory spec.
1.0 to 1.3 MPa
11 to 13 kgf/cm
2
150 to 180 psi
Tightening torque
PTO clutch valve plug
(R 1/8)
Condition
• Engine speed : Maximum
• Oil temperature : 45 to 55 °C
113 to 131 °F
13 to 21 N·m
1.3 to 2.2 kgf·m
9.4 to 15 lbf·ft
W1013552
Brake Pedal Free Travel
1. See page G-22.
W1013715
2-S15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] PREPARATION
(1) Separating Transaxle
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 plug (1) at the bottom of the transmission case.
3. Drain the transmission fluid and reinstall the drain plug.
(When refilling)
• Fill new oil from filling port after removing the filling plug (2) up to the upper notch on the dipstick (3).
• After running the engine for few minutes, stop it and check the oil level again, if low, add oil to prescribed level.
Q
IMPORTANT
• Use only multi-grade transmission oil. Use of other oils may damage the transmission or hydraulic system.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
• Never work the tractor immediately after changing the transmission oil. Keeping the engine at medium speed for a few minutes to prevents damage to the transmission.
• Do not mix different brands oil together.
Transmission fluid capacity
11.6 L
3.1 U.S.gals
2.6 Imp.gals
(1) Drain Plug
(2) Filling Plug
(3) Dipstick
(A) Oil level is acceptable within this range
W1014039
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.
2. Disconnect the negative cable (2) from the battery.
3. Disconnect the positive cable (3) form the battery (1) and remove the battery (1).
(1) Battery
(2) Negative Cable
(3) Positive Cable
W1032888
2-S16
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Lift Rod and Lower Link
1. Remove the top link (2).
2. Remove the stopper pin (6) and remove the check chain plate
(3).
3. Move the bushes (8) to inside.
4. Move the shaft (9) to right side and remove the lower link as a unit.
(1) Lift Rod LH
(2) Top Link
(3) Check Chain Plate
(4) Lift Rod RH
(5) Lower Link RH
(6) Stopper Pin
(7) Lower Link LH
(8) Bush
(9) Shaft
W1045015
Roll-Over Protective Structures (ROPS)
1. Disconnect the lead wires from the hazard lights (2), (4) and turn signal lights (3), (5).
2. Remove the ROPS mounting nuts, and remove the ROPS (1).
(When reassembling)
Tightening torque ROPS mounting nut
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
(1) ROPS
(2) Hazard Light LH
(3) Turn Signal Light LH
(4) Hazard Light RH
(5) Turn Signal Light RH
W1014508
2-S17
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Seat
1. Disconnect the seat switch connectors.
2. Remove the snap pins(2) to remove the seat (1).
(1) Seat (2) Snap Pin
TRANSAXLE
W1014409
Speed Control Pedal and Step
1. Remove the valve covers (3).
2. Remove the speed control pedals (1) and step (2).
(1) Speed Control Pedal
(2) Step
(3) Valve Cover
W1014726
Lever Grips and Fender
1. Disconnect the electric outlet connector (6).
2. Remove the lowering speed adjusting knob (5) and cutting height adjusting dial knob (4).
3. Remove the lever grips (3) and lever guide mounting screw.
4. Remove the fender (1) with lever guide (2).
(1) Fender
(2) Lever Guide
(3) Lever Grip
(4) Cutting Height Adjusting Dial Knob
(5) Lowering Speed Adjusting Knob
(6) Electric Outlet
W1014865
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).
4. Remove the PTO cover (4).
(When reassembling)
Tightening torque
Fuel tank stay mounting bolt and nut
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Fuel Tank
(2) Fuel Tank Stay LH
(3) Fuel Tank Stay RH
(4) PTO Cover
W1015094
2-S18
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Fender Center Stay
1. Remove the fender bracket (2).
2. Remove the fender center stay (1).
(When reassembling)
Tightening torque
(1) Fender Center Stay
Fender bracket mounting bolt
124 to 147 N·m
12.6 to 15.0 Kgf·m
91.2 to 108 lbf·ft
(2) Fender Bracket
W1045749
Rear Wheel
1. Remove the rear wheels (1) and (2).
(When reassembling)
Tightening torque
(1) Rear Wheel LH
Rear wheel mounting bolt
109 to 129 N·m
11.1 to 13.2 kgf·m
80.3 to 95.4 lbf·ft
(2) Rear Wheel RH
W1014976
2-S19
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Fender Bracket, Hitch Plate
1. Remove the hitch plate (2).
2. Remove the parking brake return spring (4) and the fender brackets (1), (3).
(When reassembling)
• Do not firmly tighten all screws, bolts and nuts until most components are attached.
Tightening torque
Hitch plate mounting bolt and nut (M14)
Fender bracket mounting bolt and nut (M14)
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
(1) Fender Bracket LH
(2) Hitch Plate
(3) Fender Bracket RH
(4) Return Spring
W1024983
2-S20
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Transaxle Assembly
1. Remove the differential lock rod (1) and disconnect the mower link (2).
2. Remove the brake rod (4).
3. Disconnect the pipes (3). (If equipped.)
4. Disconnect the connector (5).
5. Remove the rear coupling mounting bolt (8).
6. Disconnect the power steering pipes (9).
7. Remove the speed control rod (7).
8. Remove the wire harness clamps
9. Remove the frame brackets (10).
(When reassembling)
• Tighten the smaller bolt (M12) first.
• Before mounting the transaxle assembly on the tractor main frame, check the flatness of the frame brackets with a straight edge securely.
Tightening torque
Transaxle assembly mounting bolt (M12)
Transaxle assembly mounting bolt (M14)
63 to 72 N·m
6.4 to 7.4 kgf·m
47 to 53 lbf·ft
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
Rear coupling mounting bolt (M8)
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(Reference)
• Speed control rod length (7) : 371 mm (14.6 in.)
(1) Differential Lock Rod
(2) Mower Link
(3) Pipe
(4) Brake Rod
(5) Connector
(6) Front Wheel Drive Shaft
(7) Speed Control Rod
(8) Rear Coupling Mounting Bolt
(9) Power Steering Pipe
(10) Frame Bracket
W1016000
2-S21
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Brake Pedal and Propeller Shaft
1. Unhook the spring (3) and the parking plate (4).
2. Removing the spring pin (5) from the brake pedal (1). Disconnect the brake spring (2) and remove the brake pedal (1).
3. Disconnect the front coupling (6) from the engine.
4. Remove the propeller shaft assembly.
5. Remove the HST fan from the propeller shaft.
(When reassembling)
• Apply grease to inside of the front coupling and the rear coupling.
Tightening torque
Front coupling mounting bolt (M8)
HST fan mounting bolt
(M8)
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
9.8 to 11 N·m
1.0 to 1.2 kgf·m
7.3 to 8.6 lbf·ft
(1) Brake Pedal
(2) Brake Spring
(3) Spring
(4) Parking Plate
(5) Spring Pin
(6) Front Coupling
(7) Rear Coupling
(8) HST Fan
W1016476
Differential Lock Pedal
1. Remove the differential lock return spring (1).
2. Remove the rue ring cotter (3).
3. Turn and remove the differential lock pedal (2).
(1) Spring
(2) Differential Lock Pedal
(3) Rue Ring Cotter
(4) Differential Lock Rod
W1016728
2-S22
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Speed Control Pedal, HST Damper and Cruise Rod
1. Remove the speed control pedal (1).
2. Remove the rue ring cotter (4).
3. Remove the HST dumper (2).
4. Remove the release arm (7).
5. Remove the spring (6) and the cruise rod (5).
6. Remove the cruise lock (8).
(1) Speed Control Pedal
(2) HST Dumper
(3) HST Pedal Link
(4) Rue Ring Cotter
(5) Cruise Rod
(6) Spring
(7) Release Arm
(8) Cruise Lock
TRANSAXLE
W1016858
2-S23
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
[3] DISASSEMBLING AND ASSEMBLING
(1) Hydrostatic Transmission
Levers and Mower Lift Arm
1. Tap out the spring pin from the range gear shift lever (1) and front wheel drive lever (3), then remove the both levers.
2. Remove the hydraulic control lever (2).
3. Remove the PTO select lever (4) and PTO clutch control lever
(5).
(When reassembling)
• Apply grease to inside of the front coupling and rear mounting.
Tightening torque
Hydraulic control lever mounting bolt and nut
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
(1) Range Gear Shift Lever
(2) Hydraulic Control Lever
(3) Front Wheel Drive Lever
(4) PTO Select Lever
(5) PTO Clutch Control Lever
W1017118
PTO Clutch Valve
1. Remove the stopper (1).
2. Draw out the PTO clutch valve (2) from the transaxle assembly.
(When reassembling)
1. Clean the oil passages (4).
2. Apply the transmission fluid to the O-rings (3).
(1) Stopper
(2) PTO Clutch Valve
(3) O-ring
(4) Oil Passage
W1086372
2-S24
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Oil Cooler Cover
1. Remove the HST front cover.
2. Remove the HST front cover (1) not to damage the oil seal (5).
3. Remove the center section (6).
(When reassembling)
1. Do not damage the oil seal (5).
2. Tighten the HST mounting bolts and the nut to the factory specifications.
Tightening torque
Oil cooler cover mounting bolt (M8)
Oil cooler cover mounting nut (M8)
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
(1) HST Front Cover
(2) Transaxle Assembly
(3) Bolt
(4) Internal Cir-clip
(5) Oil Seal
(6) Center Section
W1086612
Center Section and Valve Plates
1. Remove the valve plates (2).
(When reassembling)
1. Check the direction of the groove (3).
2. Install the valve plates (2) to the anchor pins (4) securely.
3. Install the groove of the valve plate (pump plate) to the engine side.
(1) Center Section
(2) Valve Plate
(3) Groove
(4) Anchor Pin
W1086956
2-S25
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Check and High Pressure Relief Valve Plug
1. Remove the check and high pressure relief plug (G 1/2).
(When reassembling)
Tightening torque
Check and high pressure relief valve plug (G 1/2)
59 to 78 N·m
6.0 to 8.0 kgf·m
44 to 57 lbf·ft
(1) Center Section
(2) Plug
(3) Plug
W1087469
Check and High Pressure Relief Valve
1. After removing the plug (1), draw out the spring (3) and the check and high pressure relief valve assembly (4) (5).
(When reassembling)
• Take care not to damage the O-ring (2) on the plug (1).
• Since there is an orifice (1.5 mm, 0.059 in.) in the check and relief valve body (reverse) (5), re-install the check and relief valve (4)
(5) to their original positions.
(1) Plug
(2) O-ring
(3) Spring
(4) Check and Relief Valve (Forward)
(5) Check and Relief Valve (Reverse)
W1087625
2-S26
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Cylinder Block
1. Remove the gasket (1).
2. Remove the O-ring (2).
3. Remove the cylinder block assembly (4) (5) from the transaxle.
(When reassembling)
• Turn the disassembling and the assembling stand vertically.
• Install the cylinder block assembly (4) (5) to the shafts not to drop the pistons from the cylinder block assembly (4) (5) carefully.
(1) Gasket
(2) O-ring
(3) Pump Shaft
(4) Cylinder Block Assembly (Pump
Side)
(5) Cylinder Block Assembly (Pump
Side)
(6) Cylinder Block Assembly (Motor
Side)
W1087850
Cylinder Block and Piston
1. Remove the piston (3) and the spring (2) from the cylinder block
(1).
(When reassembling)
• Apply clean transmission oil to the cylinder block and the piston.
Q
NOTE
• Take care not to damage the surface of the cylinder block and the piston.
(1) Cylinder Block
(2) Spring
(3) Piston
W1088078
2-S27
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Swashplate and Trust Roller Bearing
1. Remove the cir-clip (6) from the pump shaft (3) and the motor shaft (1).
2. Remove the thrust bearing (2).
3. Remove the swashplate (5) and the thrust roller bearing (4).
(When reassembling)
• Apply clean transmission oil to the cradle bearing and the trunnion arm.
• Hold the slot guide with a minus screw driver.
• Apply clean transmission oil to the thrust roller bearing.
(1) Motor Shaft
(2) Thrust Roller Bearing
(3) Pump Shaft
(4) Thrust Roller Bearing
(5) Swashplate
(6) Cir-Clip
(7) Slot Guide
(8) Cradle Bearing
W1088366
2-S28
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
4WD Detent Ball
1. Remove the 4WD detent bolt (1), the detent spring (2) and the detent ball (3) before removing the transaxle front case, not to drop the detent ball (3) into the transaxle case.
(1) 4WD Detent Bolt
(2) Detent Spring
(3) Detent Ball
(4) Transaxle Front Case
W1102203
Neutral Arm and Trunnion Arm
1. Disconnect the neutral spring(2) from the HST front cover.
2. Loosen the neutral adjuster (5).
3. Remove the external cir-clip (7).
4. Remove the bolts (1).
5. Remove the neutral adjuster (5) and the neutral arm (3).
6. Remove the trunnion arm (6).
(When reassembling)
• Adjust the HST neutral position. Refer to “
Checking and
Adjusting
” section.
(1) Bolt
(2) Neutral Spring
(3) Neutral Arm
(4) Lock Screw
(5) Neutral Adjuster
(6) Trunnion Arm
(7) External Cir-clip
W1088807
2-S29
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Hydraulic Cylinder
TRANSAXLE
Hydraulic Cylinder
1. Disconnect the delivery pipe (1).
2. Remove the hydraulic cylinder mounting bolts (3).
3. Remove the hydraulic cylinder (2).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D or equivalent) to the joint surface of the transaxle case to the hydraulic cylinder.
Tightening torque
Hydraulic cylinder mounting bolt
40 to 44 N·m
4.0 to 4.5 kgf·m
29 to 32 lbf·ft
(1) Delivery Pipe
(2) Hydraulic Cylinder
(3) Bolt
W1089147
2-S30
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(3) Transaxle Shafts
TRANSAXLE
Transaxle Case Front Cover
Q
NOTE
• Before removing the transaxle case front cover (4), remove the 4WD detent bolt (1), the detent spring (2) and the detent ball (3) from the transaxle case front cover (4).
• Remove the cir-clip (5) from the HST pump shaft (PTO shaft) from the HST pump shaft (5) and the HST motor shaft securely.
1. Remove the transaxle case front cover mounting bolts (2).
2. Remove the transaxle case front cover as an unit.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D or equivalent) to the joint surface of the transaxle case to the front cover.
Tightening torque
Transaxle case front cover mounting bolt (M18)
30 to 34 N·m
3.0 to 3.5 kgf·m
22 to 25 lbf·ft
(1) Transaxle Case Front Cover
(2) Detent Spring
(3) Detent Ball
(4) Transaxle Case Front Cover
(5) HST Pump Shaft (PTO Shaft)
(6) Bolt
(7) 4WD Shaft
(8) Pinion Shaft
(9) HST Motor Shaft
(10) Mid-PTO Shaft
(11) Mid-PTO Idle Gear Shaft
(12) PTO Select Shaft
W1089420
2-S31
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Hydraulic Pump Assembly
1. Remove the hydraulic pump assembly mounting bolt (2), (3).
2. Remove the hydraulic pump assembly (1) as an unit from the transaxle case.
(When reassembling)
• Apply transmission oil to the O-rings.
• Since the mounting bolt (2) is installed through the hydraulic pump to the transaxle case, bind the sealing tape to the mounting bolt (2) securely.
Tightening torque
Hydraulic pump assembly mounting bolt (M6)
Hydraulic pump assembly mounting bolt (M8)
7.9 to 8.8 N·m
0.80 to 0.90 kgf·m
5.8 to 6.5 lbf·ft
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
(1) Hydraulic Pump
(2) Bolt (Through Bolt)
(3) Bolt
(4) O-ring
(5) O-ring
(6) O-ring
(7) O-ring
W1089827
2-S32
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Rear PTO Cover Assembly
1. Remove the rear PTO cover mounting bolts (1).
2. Remove the rear PTO cover (2).
3. Remove the rear PTO shaft (5) from the rear PTO cover (2).
(When reassembling)
• Pull the 11T PTO select shaft with the bearing approximately the bearing thickness.
• Apply liquid gasket (Three Bond 1208D or equivalent) to the joint surface of transaxle case to the rear PTO cover.
• Bind the vinyl tape to the rear PTO shaft not to damage the oil seal.
Tightening torque
Rear PTO cover mounting bolt (M8)
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
(1) Bolt
(2) Rear PTO Cover
(3) Bearing
(4) 11T PTO Select Shaft
(5) Rear PTO Shaft
(6) Oil Seal
(7) Vinyl Tape
W1090219
2-S33
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Rear Axle (LH)
Q
NOTE
• Prepare a specially bent snap ring pillar.
1. Draw out the oil seal with a screw driver.
2. Remove the internal cir-clip from the rear axle case.
3. Draw out the rear axle from the rear axle case.
(When reassembling)
• Do not damage the oil seal.
(1) Rear Axle
(2) Oil Seal
(3) Internal Cir-clip
(4) Ball Bearing
(5) Rear Axle Case
W1090759
2-S34
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Rear Axle Case (RH)
1. Remove the rear axle case (RH) mounting bolts.
2. Remove the rear axle case (RH) (1) as an assembly from the transaxle case.
Q
NOTE
• Since the adjusting shims are installed behind the 37T spiral bevel gear, check the shims.
3. Remove the 37T spiral bevel gear (2).
4. Remove the 10T final gear shaft (3).
5. Remove the 66T final gear with the differential lock shift fork.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D or equivalent) to the joint surface of transaxle case to the rear axle (RH) case.
Tightening torque
Rear axle case (RH) mounting bolt (M8)
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
(1) Rear Axle Case (RH)
(2) 37T Spiral Bevel Gear
(3) 10T Final Gear Shaft (Brake Shaft)
(4) 66T Final Gear
W1091120
2-S35
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
66T Final Gear
1. Remove the bearing (2) with a puller.
2. Remove the bearing (4) with a puller.
3. Remove the differential lock shifter (5) and 66T final gear (6).
4. Put parting marks on the differential pinions (12), (16) and the differential side gears (9), (14).
5. Tap out the differential pinion shaft (8).
6. Remove the differential pinions (12), (16), the differential pinion washers (13), (16), differential side gears (9), (14) and the differential side gear washers (10), (15).
(When reassembling)
• Install the differential pinion and differential gear, aligning the parting marks.
• Lock the differential pinion shaft (8) by setting the key (11).
Tightening torque
66T final gear mounting bolt
61 to 70 N·m
6.2 to 7.2 kgf·m
45 to 52 lbf·ft
(1) 66T Final Gear
(2) Bearing
(3) Differential Lock Shift Folk
(4) Bearing
(5) Differential Lock Shifter
(6) 66T Final Gear
(7) Differential Case
(8) Differential Pinion Shaft
(9) Differential Side Gear
(10) Differential Side Gear Washer
(11) Key
(12) Differential Pinion
(13) Differential Pinion Washer
(14) Differential Side Gear
(15) Differential Side Gear Washer
(16) Differential Pinion
(17) Differential Pinion Washer
W1091475
2-S36
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Rear Axle Case, RH and Brake
1. Remove the internal cir-clip (1).
2. Remove the shim (9), the bearing holder (8) and the other brake parts from the brake case.
(When reassembling)
• Apply grease to the steel balls.
• Take care not to damage the O-ring on the brake cam lever.
• Check that the brake cam lever moves smoothly.
(1) Internal Cir-clip
(2) Brake Cam Lever
(3) External Cir-clip
(4) Steel Ball
(5) Actuator
(6) Brake Disc
(7) Friction Plate
(8) Bearing Holder
(9) Shim
W1091813
2-S37
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
PTO Clutch Assembly
1. Remove the bearing (2).
2. Remove the external cir-clip and the outlet gear (3).
3. Remove the seal rings (6).
4. Remove the bearing (5).
5. Remove the external cir-clip (18) using a clutch spring compressor.
6. Disassembling the clutch pack inner parts as show in the figure.
(When reassembling)
• Change the seal rings (6) with a new one.
(1) Pump Shaft (PTO Clutch Shaft)
(2) Bearing
(3) Clutch Gear
(4) Clutch Pack
(5) Bearing
(6) Seal Ring
(7) Clutch Case
(8) O-ring
(9) Brake Disc
(10) Brake Plate
(11) Clutch Piston
(12) Separate Plate
(13) Disc Plate
(14) Backing Plate
(15) Internal Cir-clip
(16) Brake Spring
(17) Washer
(18) External Cir-clip
(19) Clutch Spring Compressor
W1092125
2-S38
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(4) Assembling Shafts
TRANSAXLE
Assembling Select Arms and HST Pump Shaft (PTO Clutch
Shaft)
1. Install the PTO select arm (1).
2. Install the range shift arm (2) and the front wheel drive shaft arm
(3).
3. Install the idle gear shaft.
Q
NOTE
• Install the rear PTO cover and the PTO select gear shaft before installing HST pump shaft assembly.
4. After installing the rear PTO cover to the transaxle case, install the PTO select gear shaft (6).
5. Install the HST pump shaft (PTO clutch shaft) (6).
(When reassembling)
• Take care not to damage the O-rings on the arms.
(1) PTO Select Arm
(2) Range Shift Arm
(3) Front Wheel Drive Shift Arm
(4) Mid-PTO Idle Gear Shaft
(5) HST Pump Shaft (PTO Clutch Shaft)
(6) PTO Select Gear Shaft
W1092555
2-S39
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Front Wheel Drive Shaft, Shifter, Spiral Bevel Pinion Shaft and
Mid-PTO Shaft
1. Install the front drive shaft (1).
2. Install the shifter (2) and the spiral bevel pinion shaft (3) together.
3. Install the mid-PTO idle gear shaft (5) and the mid-PTO shaft (6) and the HST motor shaft (4) together.
(1) Front Wheel Drive Shaft
(2) Shifter
(3) Spiral Bevel Pinion Shaft
(4) HST Motor Shaft
(5) Mid-PTO Idle Gear Shaft
(6) Mid-PTO Shaft
W1092968
2-S40
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[4] SERVICING
(1) Hydrostatic Transmission
TRANSAXLE
Center Section
1. Check the center section surface (1) for scratches or wear.
2. If deep scratch or excessive wear is found, replace the hydrostatic transmission assembly.
(1) Center Section Surface
W1093581
Charge Relief Valve
1. Check the charge relief valve (1) and the spring (2).
2. If defects are found, replace it.
(1) Charge Relief Valve
(2) Spring
(3) Plug
W1093691
Check and High Pressure Relief Valve
1. Check the check and high pressure relief valve (4), (5) for scratches and damage.
2. Check the spring (3) for breakage and wear.
3. If anything are unusual, replace the check and high pressure relief valve as complete assembly.
Q
NOTE
• Check and high pressure relief valve (reverse) has a pin hole
(1.5 mm, 0.059 in.).
(1) Plug
(2) O-ring
(3) Spring
(4) Check and High Pressure Relief
Valve (Forward)
(5) Check and High Pressure Relief
Valve (Reverse)
W1093783
Cylinder Block Assembly
1. Check the cylinder blocks (1) and the pistons (2) for scratches and wear.
2. If there are scratch or worn, replace the cylinder block assembly.
3. Check the pistons for their free movement in the cylinder block bores.
4. If the piston or the cylinder block is scored, replace the cylinder block assembly.
5. Check the polished face (4) of the cylinder block for scoring. If it is scored, replace the cylinder block assembly.
Q
IMPORTANT
• Do not interchange the pistons between the pump cylinder block and the motor cylinder block. Pistons and cylinder blocks are matched.
(1) Cylinder Block
(2) Piston
(3) Spring
(4) Polished Face
W1093936
2-S41
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Cylinder Block Assembly
1. Check the cylinder blocks (1) and the pistons (2) for scratches and wear.
2. If there are scratch or worn, replace the cylinder block assembly.
3. Check the pistons for their free movement in the cylinder block bores.
4. If the piston or the cylinder block is scored, replace the cylinder block assembly.
5. Check the polished face (4) of the cylinder block for scoring. If it is scored, replace the cylinder block assembly.
Q
IMPORTANT
• Do not interchange the pistons between the pump cylinder block and the motor cylinder block. Pistons and cylinder blocks are matched.
(1) Cylinder Block
(2) Piston
(3) Spring
(4) Polished Face
W1094117
Thrust Washer, Thrust Roller Bearing, Thrust Plate and Cradle
Bearing
1. Check the thrust bearing (3) for scratches and excessive wear.
2. If it is worn, replace it.
3. Check the thrust plate (4) for scratches and excessive wear. If it is worn or scored, replace it.
4. Check the cradle bearing (5) for excessive wear. If it is worn, replace it.
(1) Swashplate
(2) Thrust Washer
(3) Thrust Bearing
(4) Thrust Plate
(5) Cradle Bearing
W1094264
2-S42
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Pump Shaft (PTO Clutch Shaft)
1. Check the seal surface (1) and the bearing surface.
2. If the pump shaft is rough or grooved, replace it.
3. If the ball bearing or the needle bearing is worn, replace it.
(1) Seal Surface (2) Bearing Surface
W1094465
(2) Transaxle Case
Needle Bearing
1. Check the needle bearing (1) for wear.
2. If the needle bearing (1) are worn, replace them.
(1) Needle Bearing
W1094709
Bearing
1. Hold the inner race, and push and pull the outer race in all directions to check wear and roughness.
2. Apply the transmission oil to the bearing, and hold the inner race.
And turn the outer race to check rotation.
3. If there are any defect, replace the bearing.
W1094849
PTO Clutch Disc Wear
1. Measure the thickness of PTO clutch disc with vernier calipers.
2. If the thickness is less than the allowable limit, replace it.
Thickness of PTO clutch disc
Factory spec.
Allowable limit
1.50 to 1.70 mm
0.0591 to 0.0669 in.
1.35 mm
0.0531 in.
W1024320
2-S43
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Separate Plate and Back Plate Wear
1. Measure the thickness of pressure plate and steel back with vernier calipers.
2. If the thickness is less than the allowable limit, replace it.
Thickness of separate plate
Factory spec.
Allowable limit
0.9450 to 1.055 mm
0.03721 to 0.04153 in.
0.80 mm
0.031 in.
Thickness of back plate
Factory spec.
Allowable limit
1.9 to 2.1 mm
0.075 to 0.082 in.
1.85 mm
0.0728 in.
W1017226
Flatness of Clutch Piston, Pressure Plate and Steel Plate
1. Place the part on a surface plate.
2. Check the flatness by inserting a feeler gauge (allowable limit size) underneath it at least four points.
3. If the gauge can be inserted, replace it.
Flatness of clutch piston Allowable limit
0.15 mm
0.0059 in.
Flatness of pressure plate and steel plate
Allowable limit
0.20 mm
0.0079 in.
W1017358
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.
Clutch spring free length
Factory spec.
Allowable limit
38.5 mm
1.52 in.
34.5 mm
1.36 in.
W1017533
PTO Brake Disc Wear
1. Measure the PTO brake disc thickness with a vernier caliper.
2. If the thickness is less than allowable limit, replace it.
PTO brake disc thickness
Factory spec.
Allowable limit
2.90 to 3.10 mm
0.115 to 0.122 in.
2.70 mm
0.11 in.
W1029590
PTO Brake Plate
1. Measure the PTO brake plate thickness with a vernier caliper.
2. If the thickness is less than allowable limit, replace it.
PTO brake plate thickness
Factory spec.
Allowable limit
1.9 to 2.1 mm
0.075 to 0.082 in.
1.85 mm
0.0728 in.
W1095464
2-S44
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Clearance between Differential Case and Differential Side Gear
1. Measure the differential side gear boss O.D. with an outside micrometer.
2. Measure the differential case I.D. with a cylinder gauge and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace faulty parts.
Clearance between differential case and differential side gear
Factory spec.
Allowable limit
0.0500 to 0.151 mm
0.00197 to 0.00594 in.
0.30 mm
0.012 in.
Differential case I.D.
Differential side gear
O.D.
Factory spec.
Factory spec.
38.000 to 38.062 mm
1.4961 to 1.4985 in.
37.911 to 37.950 mm
1.4926 to 1.4940 in.
W1029693
Clearance between Differential Pinion Shaft and Differential
Pinion
1. Measure the differential pinion shaft O.D. with an outside micrometer.
2. Measure the differential pinion I.D. with a cylinder gauge, and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace faulty parts.
Clearance between differential pinion shaft and differential pinion
Factory spec.
Allowable limit
0.0800 to 0.122 mm
0.00315 to 0.00480 in.
0.30 mm
0.012 in.
Differential pinion I.D.
Differential pinion shaft
O.D.
Factory spec.
Factory spec.
20.060 to 20.081 mm
0.78977 to 0.79059 in.
19.959 to 19.980 mm
0.78579 to 0.78661 in.
W1029832
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.
4. Hold the differential pinion and move the differential side gear to measure the backlash.
5. If the backlash exceeds the allowable limit, adjust with differential side gear shims.
Backlash between differential pinion and differential side gear
Factory spec.
Allowable limit
0.15 to 0.30 mm
0.0059 to 0.011 in.
0.40 mm
0.016 in.
(Reference)
• Thickness of shims :
1.5 mm (0.059 in.), 1.6 mm (0.063 in.), 1.7 mm (0.067 in.)
W1029971
2-S45
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Backlash between Spiral Bevel Pinion Gear and Bevel Gear
1. Temporarily assemble the spiral bevel pinion gear (2) and the bevel gear (1) in the transaxle case.
2. Prepare the fuse bent already three to four times.
3. Hold the fuse on the bevel gear teeth upper surface
(A)
.
4. Turn the front drive shaft one turn clockwise by hands.
5. Measure the thickness of the fuse as a backlash between the spiral bevel pinion gear and the bevel gear.
6. If the backlash exceeds the factory specifications, adjust the shims (3), (4).
Backlash between spiral bevel pinion and bevel gear
Factory spec.
0.10 to 0.30 mm
0.0040 to 0.011 in.
(1) Bevel Gear
(2) Spiral Bevel Pinion Gear
(3) Shim
(4) Shim
(5) Final Gear Shaft (Brake Shaft)
(A) Bevel Gear Teeth Upper Surface
W1095931
Brake Cam Lever Movement
1. Move the brake cam lever by hand to check its movement.
2. If its movement is heavy, refine the brake cam with a emery paper.
W1096217
Flatness of Actuator and Bearing Holder
1. Place a straightedge of 150 mm (5.91 in.) or more in length on the contacting surface of the actuator and the bearing holder.
2. Inspect the friction surface of the actuator and the bearing holder with the straightedge, and determine if a 0.30 mm (0.0118 in.) feeler gauge will fit on the part of wear.
3. If it will fit, resurface.
Flatness of actuator and bearing holder
Allowable limit
0.30 mm
0.0118 in.
W1030671
2-S46
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM TRANSAXLE
Height of Cam Plate and Ball
1. Measure the height of the cam plate with the ball installed.
2. If the measurement is less than the allowable limit, replace the cam plate and balls.
3. Inspect the ball holes of cam plate for uneven wear.
4. If the uneven wear is found, replace it.
Height of cam plate and ball
Factory spec.
Allowable limit
22.89 to 22.99 mm
0.9012 to 0.9051 in.
22.40 mm
0.8819 in.
W1030769
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.
Brake disc thickness
Factory spec.
Allowable limit
3.30 to 3.50 mm
0.130 to 0.137 in.
3.0 mm
0.12 in.
Friction plate thickness
Factory spec.
Allowable limit
1.92 to 2.08 mm
0.0756 to 0.0818 in.
1.52 mm
0.0598 in.
W1030890
2-S47
KiSC issued 06, 2009 A
3
FRONT AXLE
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 3-M1
2. FRONT WHEEL ALIGNMENT ..................................................................... 3-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. STRUCTURE
FRONT AXLE
(1) Axle
(2) Axle Flange
(3) Bevel Gear
(4) Bevel Gear
(5) Bevel Gear Case
(6) Bevel Gear
(7) Differential Yoke Shaft, RH
(8) Front Axle Case
(9) Bevel Pinion Shaft
(10) Differential Gear Assembly
(11) Differential Pinion Shaft
(12) Differential Yoke Shaft, LH
(13) Differential Side Gear
(14) Differential Pinion Gear
(15) Bevel Gear
(16) Bevel Gear Shaft
(17) Front Gear Case
(18) Bevel Gear
(19) Collar
The front axle of the 4WD is constructed as shown above. Power is transmitted from the transmission through the propeller shaft to the bevel pinion shaft (9), then to the bevel gear (15) and to the differential side gear (13).
The power through the differential side gear is transmitted to the differential yoke shaft (7), (12), and to the bevel gear shaft (16) through the bevel gears (4), (6) in the bevel gear case (5).
The revolution is greatly reduced by the bevel gears (18), (3), then the power is transmitted to the axle (1).
The differential system allows each wheel to rotate at a different speed to make turning easier.
3-M1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
Q
Camber
The front wheels are tilted from the vertical as viewed from the front, upper wheels are spreader than lower ones.
This inclination is called camber (
a
). Camber reduces bending or twisting of the front axle caused by vertical load or running resistance, and also maintains the stability in running.
Camber
0.035 rad
2 °
W1012811
Q
Kingpin Angle
The Kingpin is titled from the vertical as viewed from the front.
This angle is called kingpin angle (
a
). As with the camber, kingpin angle reduces rolling resistance of the wheels, and prevents any shimmy motion of the steering wheel.
It also reduces steering effort.
Kingpin angle
0.209 rad
12 °
W1013073
Q
Caster
The kingpin is titled forward as viewed from the side.
The point
(b)
of the wheel center line is behind the point
(a)
of the kingpin shaft center line.
This inclination is called caster
(c)
. Caster helps provide steering stability.
As with the kingpin inclination, caster reduces steering effort.
Camber
0 rad
0 °
F : Front R : Rear
W1013142
3-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT AXLE
Q
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. Another purpose of toe-in is to prevent excessive and uneven wear of tires.
Toe-in
0 to 5 mm
0 to 0.19 in.
F : Front R : Rear
W1013242
3-M3
KiSC issued 06, 2009 A
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] PREPARATION ........................................................................................3-S5
(1) Separating Front Axle Assembly.........................................................3-S5
[3] DISASSEMBLING AND ASSEMBLING..................................................3-S8
(1) Front Axle Assembly ...........................................................................3-S8
[4] SERVICING ............................................................................................3-S12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
Symptom
Front Wheels
Wander to Right or
Left
Front Wheels Can
Not Be Driven
Probable Cause Solution
Tire pressure uneven Adjust
Improper toe-in adjustment (improper alignment) Adjust
Clearance between center pin and pin support bushing excessive
Replace
Front axle rocking force too small
Tie-rod end loose
Air sucked in power steering circuit
Front wheel driving gears in front axle gear case broken
Universal joint broken
Front wheel drive gears in transmission broken
Adjust
Tighten
Bleed
Replace
Replace
Replace
Noise
Front differential gear broken
Gear backlash excessive
Oil insufficient
Bearings damaged or broken
Gears damaged or broken
Spiral bevel pinion shaft turning force improper
Replace
Adjust or replace
Replenish
Replace
Replace
Adjust
FRONT AXLE
Reference
Page
G-41
G-23, 3-S4
3-S14
3-S4
4-S8
–
3-S11
3-S7
–
3-S13, S14
3-S12, S13
3-S5
–
–
3-S13
W1014322
3-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
Item
Front Wheel Alignment Toe-in
Front Axle
Differential Case to Differential Side Gear
Differential Case
Differential Side Gear
Differential Pinion Shaft to Differential
Pinion
Differential Pinion Shaft
Differential Pinion
Differential Pinion to Differential Side Gear Backlash
Bevel Pinion Shaft
Bevel Pinion Shaft to Bevel Gear
12T Bevel Gear to 15T Bevel Gear
Center Pin to Pin Support Bushing
Center Pin
Bushing
Rocking Force
Clearance
I.D.
O.D.
Clearance
O.D.
I.D.
Turning Torque
Backlash
Backlash
Clearance
O.D.
I.D.
Factory Specification
0 to 5 mm
0 to 0.2 in.
49.1 to 117 N
5.00 to 12.0 kgf
11.1 to 26.4 lbf
0.040 to 0.082 mm
0.0016 to 0.0032 in.
26.000 to 26.021 mm
1.0237 to 1.0244 in.
25.939 to 25.960 mm
1.0213 to 1.0220 in.
0.025 to 0.055 mm
0.0009 to 0.0021 in.
9.960 to 9.975 mm
0.3922 to 0.3927 in.
10.000 to 10.015 mm
0.39370 to 0.39429 in.
0.1 to 0.3 mm
0.004 to 0.01 in.
0.80 to 1.0 N·m
0.082 to 0.10 kgf·m
0.59 to 0.73 lbf·ft
0.1 to 0.3 mm
0.004 to 0.01 in.
0.1 to 0.3 mm
0.004 to 0.01 in.
0 to 0.231 mm
0 to 0.00909 in.
19.850 to 20.000 mm
0.78150 to 0.78740 in.
20.000 to 20.081 mm
0.78741 to 0.79059 in.
FRONT AXLE
Allowable Limit
–
–
0.17 mm
0.0067 in.
–
–
0.25 mm
0.0098 in.
–
–
–
–
–
–
0.70 mm
0.028 in.
–
–
W1016639
3-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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-9.)
Item
Front wheel mounting screw
Front wheel mounting screw
Tie-rod slotted nut
Power steering cylinder mounting screw
Power steering cylinder hose
Bevel gear case mounting screw (M10)
Bevel gear case mounting screw (M12)
Front gear case cover mounting screw
N·m
149 to 179
149 to 179
18 to 34
48 to 55
24 to 27
48 to 55
78 to 90
48 to 55
kgf·m
15.2 to 18.3
15.2 to 18.3
1.8 to 3.5
4.9 to 5.7
2.4 to 2.8
4.9 to 5.7
7.9 to 9.2
4.9 to 5.7
FRONT AXLE
lbf·ft
110 to 132
110 to 132
13 to 25
36 to 41
18 to 20
36 to 41
58 to 66
36 to 41
W1012736
3-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
Toe-in (
(B)
-
(A)
) Factory spec.
0 to 5 mm
0 to 0.2 in.
Q
Adjusting procedure
1. Loosen the lock nuts and turn the tie-rod to adjust the rod length until the proper toe-in measurement is obtained.
2. Retighten the lock nuts.
(1) Tie-rod
(2) Lock Nut
(A) Wheel to Wheel Distance at Front
(B) Wheel to Wheel Distance at Rear
(C) Front
W1011333
Front Axle Rocking Force
1. Jack up the front side of tractor and remove the front wheel.
2. Set a spring balance to the front gear case cover.
3. Measure the front axle rocking force.
4. If the measurement is not within the factory specifications, adjust as following.
Q
Adjusting procedure
1. Remove the cotter pin (1).
2. Tighten or loosen the adjusting nut (2) so that the measurement of rocking force comes to factory specifications.
3. If the slot and pin hole do not meet, align the nut until they do meet within factory specifications.
4. Install the new cotter pin.
(When reassembling)
• Be sure to split the cotter pin like an anchor.
(Reference)
• Tightening torque of adjusting nut:
20 N·m (2.0 kgf·m, 14 lbf·ft)
Front axle rocking force Factory spec.
49.1 to 177 N
5.00 to 12.0 kgf
11.1 to 26.4 lbf
(1) Cotter Pin (2) Adjusting Nut
W1011602
3-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
4. Lengthen the length of stopper bolt (1) until the stopper bolt contacts with the bevel gear case (3).
5. Return the steering wheel to straight ahead and lengthen the stopper bolt four turn from above position further.
6. Lock the stopper bolt by lock nut (2).
7. For adjusting the right steering angle, perform the same procedure as mentioned in left steering angle.
(Reference)
Steering angle
Right side
Left side
0.84 to 0.87 rad
48 to 50
°
0.93 to 0.95 rad
53 to 55
°
Length of adjusting bolt
(
L
)
Right side
Left side
26 mm
1.0 in.
21 mm
0.83 in.
(3) Bevel Gear Case (1) Stopper Bolt LH
(2) Lock Nut
W1011846
[2] PREPARATION
(1) Separating Front Axle Assembly
Draining Front Axle Case Oil
1. Place the oil pans underneath the front axle case.
2. Remove both right and left hand side drain plugs (3) and filling plug (2) to drain the oil.
3. After draining, reinstall the drain plugs (3).
(When reassembling)
• When re-filling, remove the right and left breather plugs (1).
Q
IMPORTANT
• After ten minutes, check the oil level again, add oil to prescribed level.
• Use KUBOTA SUPER UDT fluid or SAE80, 90 gear oil.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-7.)
Oil Capacity
BX1860
BX2360
BX2660
2.3 L
2.4 U.S.qts
2.0 Imp.qts
4.7 L
5.0 U.S.qts
4.1 Imp.qts
(1) Breather Plug
(2) Filling Plug with Dipstick
(3) Drain Plug
(A) Oil level is acceptable within this range.
W1012192
3-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT AXLE
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.
(1) Under Panel
(2) Battery
(3) Negative Cable
W1012394
Bonnet and Under Cover
1. Open the bonnet (1), disconnect the connectors (3) for the head lights, then remove the bonnet with the bonnet bracket (4).
2. Remove the under cover (2).
(1) Bonnet
(2) Under Cover
(3) Connector
(4) Bonnet Bracket
W1012507
Front Wheel and Propeller Shaft Cover
1. Lift up the front 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).
(When reassembling)
Tightening torque
Front wheel mounting screw
149 to 179 N·m
15.2 to 18.3 kgf·m
110 to 132 lbf·ft
(1) Propeller Shaft Cover
W1012838
3-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT AXLE
Disconnecting Propeller Shaft
1. Tap out the spring pins (2) and disconnect the universal joint (1) and spiral bevel pinion shaft.
(When reassembling)
• Apply grease to the splines of the propeller shaft and universal joint.
(1) Universal Joint (2) Spring Pin
W1013075
Front Axle Assembly
1. Remove the power steering hose cramp (1).
2. Place the garage jack under the front axle.
3. Remove the cotter pin (1).
4. Remove the slotted nut (2) of center pin and separate the front axle from the frame.
5. Disconnect the power steering cylinder hoses (4).
(When reassembling)
• After mounting the front axle assembly to the frame, be sure to adjust the front axle rocking force. (See page 3-S4.)
• Installing the cotter pin, be sure to split the cotter pin like an anchor
Tightening torque
Power steering cylinder hose
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) Hose Cramp
(2) Cotter Pin
(3) Slotted Nut (Adjusting Nut for Front
Axle Rocking Force)
(4) Power Steering Hose
W1023380
3-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT AXLE
[3] DISASSEMBLING AND ASSEMBLING
(1) 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.
(When reassembling)
Q
NOTE
• Tighten the slotted nut to 18 N·m (1.8 kgf·m, 13 lbf·ft). If the slot and pin hole do not meet, tighten the nut until they do meet, and install the cotter pin.
• Be sure to split the cotter pin like an anchor.
Tightening torque
Tie-rod slotted nut
Power steering cylinder mounting screw
18 to 34 N·m
1.8 to 3.5 kgf·m
13 to 25 lbf·ft
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Tie-rod (2) Power Steering Cylinder
W1013368
Bevel Gear Case and Front Gear Case
1. Remove the bevel gear case mounting screws.
2. Remove the bevel gear case (2) and front gear case (1) as a unit from the front axle case (3).
(When reassembling)
• Apply grease to the O-ring and take care not to damage it.
• Do not interchange right and left bevel gear case assemblies and right and left gear case assemblies.
Tightening torque
Bevel gear case mounting screw (M10)
Bevel gear case mounting screw (M12)
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
78 to 90 N·m
7.9 to 9.2 kgf·m
58 to 66 lbf·ft
(1) Front Gear Case
(2) Bevel Gear Case
(3) Front Axle Case
W1013787
3-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT AXLE
Front Gear Case Cover
1. Remove the front gear case mounting screws and remove the front gear case cover (1) with bevel gear (2).
(When reassembling)
• Apply grease to the O-ring and take care not to damage it.
Tightening torque
Front gear case cover mounting screw
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Front Gear Case Cover
(2) Bevel Gear
(3) Front Gear Case
W1013952
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)
• Install the oil seal (6) of front gear case cover (1), noting its direction as shown in the figure.
(1) Front Gear Case Cover
(2) Axle Shaft
(3) Collar
(4) 36T Bevel Gear
(5) Ball Bearing
(6) Oil Seal
W1014087
3-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT AXLE
Front Gear Case and Bevel Gear Case
1. Remove the internal snap ring (1).
2. Remove the bevel gear with ball bearing (3) and shim (2).
3. Remove the bevel gear (4).
4. Remove the external snap ring (7).
5. Remove the bevel gear case (5) from front gear case (6).
6. Remove the oil seal (12) and the ball bearing (11).
7. Remove the internal snap ring (10) and remove the ball bearing
(9).
8. Remove the bevel gear shaft (8) with ball bearing.
(When reassembling)
• Install the oil seal (12) of bevel gear case, noting its direction as shown in the figure.
• Install the adjusting shims (2) to their original position.
(1) Internal Snap Ring
(2) Shim
(3) Ball Bearing
(4) Bevel Gear
(5) Bevel Gear Case
(6) Front Gear Case
(7) External Snap Ring
(8) Bevel Gear Shaft
(9) Ball Bearing
(10) Internal Snap Ring
(11) Ball Bearing
(12) Oil Seal
(13) Ball Bearing
W1014354
3-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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).
5. Take out the differential gear assembly (5), from right side of front axle case (6).
6. Remove the stake of lock nut (10), and then remove the lock nut
(10).
7. Remove the taper roller bearing (9).
(When reassembling)
• Apply gear oil to the taper roller bearings (9) and install them correctly, noting their direction.
• Replace the lock nut (10) and oil seal (11) with new ones.
• After tighten the lock nut (10) to the specified torque, stake it firmly.
• Install the adjusting collars (2), (8) to their original position.
(1) Internal Snap Ring
(2) Adjusting Collar
(3) Bevel Pinion Shaft
(4) Differential Yoke Shaft LH
(5) Differential Gear Assembly
(6) Front Axle Case
(7) Differential Yoke Shaft RH
(8) Adjusting Collar
(9) Taper Roller Bearing
(10) Lock Nut
(11) Oil Seal
(12) Collar
W1017911
Differential Gear
1. Remove the bevel gear (5) with bearing (6) and bearing (9) by puller.
2. Remove the spring pin (10).
3. Remove the differential pinion shaft (8).
4. Remove the differential pinions (2), differential side gears (4) and shims (1), (3).
Q
NOTE
• Arrange the parts to know their original position.
(When reassembling)
• Apply molybdenum disulfide (Three Bond 1901 or equivalent) to the inner circumferential surface of the differential side gears, differential pinions and shims.
(1) Shim
(2) Differential Pinion
(3) Shim
(4) Differential Side Gear
(5) Bevel Gear
(6) Bearing
(7) Differential Gear Case
(8) Differential Pinion Shaft
(9) Ball Bearing
(10) Spring Pin
W1028857
3-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[4] SERVICING
FRONT AXLE
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.
4. If the clearance exceeds the allowable limit, replace faulty parts.
Clearance between differential case and differential side gear
Factory spec.
Allowable limit
0.040 to 0.082 mm
0.0016 to 0.0032 in.
0.17 mm
0.0067 in.
Differential case bore
I.D.
Differential side gear
O.D.
Factory spec.
26.000 to 26.021 mm
1.0237 to 1.0244 in.
25.939 to 25.960 mm
1.0213 to 1.0220 in.
W1015523
Clearance between Differential Pinion Shaft and Differential
Pinion
1. Measure the differential pinion shaft O.D..
2. Measure the differential pinion I.D., and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace faulty parts.
Clearance between differential pinion shaft and differential pinion
Factory spec.
Allowable limit
0.025 to 0.055 mm
0.00099 to 0.0021 in.
0.25 mm
0.0096 in.
Differential pinion shaft
O.D.
Factory spec.
Differential side gear I.D.
Factory spec.
9.960 to 9.975 mm
0.3922 to 0.3927 in.
10.000 to 10.015 mm
0.39370 to 0.39429 in.
W1015675
Backlash between Differential Pinion and Differential Side Gear
1. Set a dial gauge (lever type) on a tooth of the differential pinion.
2. Fix the differential side gear, and move the differential pinion to measure the backlash.
3. If the measurement exceeds the factory specifications, adjust with the differential side gears shims.
Backlash between differential pinion and differential side gear
Factory spec.
0.1 to 0.3 mm
0.004 to 0.01 in.
(Reference)
• Thickness of adjusting shims :
For side gear : 0.80 mm (0.031 in.), 1.0 mm (0.039 in.)
1.2 mm (0.047 in.)
For pinion : 3.30 mm (0.130 in.), 3.50 mm (0.138 in.)
3.70 mm (0.146 in.), 3.90 mm (0.154 in.)
W1015817
3-S12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
Turning torque Factory spec.
0.8 to 1.0 N·m
0.082 to 0.10 kgf·m
0.59 to 0.73 lbf·ft
Q
NOTE
• After turning force adjustment, be sure to stake the lock nut.
W10206520
Backlash between Bevel Pinion Shaft and Bevel Gear
1. Put the solder (0.5 mm (0.02 in.) thickness) on the position where the tooth proper contact of bevel pinion shaft.
2. Fix the bevel gear and rotate the bevel pinon shaft carefully.
3. Measure the backlash by thickness of the point where solder is the thinnest.
4. If the backlash is not within the factory specifications, change the adjusting collars (3), shims (4). For example change the adjusting shim (4) to 0.1 mm (0.004 in.) smaller size, and change the adjusting collar (3) to 0.1 mm (0.004 in.) larger size.
5. Adjust the backlash properly by repeating the above procedures.
Backlash between bevel pinion shaft and bevel gear
Factory spec.
0.1 to 0.3 mm
0.004 to 0.01 in.
(Reference)
• Thickness of adjusting collars (3), (4) :
3.40 mm (0.134 in.) 4.10 mm (0.161 in.)
3.60 mm (0.142 in.) 4.20 mm (0.165 in.)
3.80 mm (0.150 in.) 4.40 mm (0.173 in.)
3.90 mm (0.154 in.) 4.50 mm (0.177 in.)
4.00 mm (0.157 in.) 4.60 mm (0.181 in.)
(1) Bevel Gear
(2) Bevel Pinion Shaft
(3) Adjusting Collar
(4) Adjusting Collar
W10301800
3-S13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
3. Turn the axle.
4. Remove the bevel gear case from front axle case and measure the thickness of the fuses with an outside micrometer.
5. If the backlash is not within the factory specifications, adjust with shim (3).
Backlash between 12T bevel gear and 15T bevel gear
Factory spec.
0.1 to 0.3 mm
0.004 to 0.01 in.
(Reference)
• Thickness of adjusting shims (3) :
0.8 mm (0.03 in.) 1.2 mm (0.047 in.)
1.0 mm (0.039 in.) 1.4 mm (0.055 in.)
• Tooth contact : More than 35 %
(1) 15T Bevel Gear
(2) 12T Bevel Gear
(3) Shim
W10211780
Clearance between Center Pin and Pin Support Bushing
1. Measure the center pin O.D. with an outside micrometer.
2. Measure the pin support bush I.D. of the front axle with a cylinder gauge.
3. If the clearance exceeds the allowable limit, replace it.
Clearance between center pin and pin support bush
Factory spec.
Allowable limit
0 to 0.231 mm
0 to 0.00909 in.
0.70 mm
0.028 in.
Center pin O.D.
Bush I.D.
Factory spec.
Factory spec.
19.850 to 20.000 mm
0.78150 to 0.78740 in.
20.000 to 20.081 mm
0.78741 to 0.79059 in.
W1016540
3-S14
KiSC issued 06, 2009 A
4
STEERING
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. HYDRAULIC CIRCUIT .................................................................................. 4-M1
2. STEERING CONTROLLER .......................................................................... 4-M2
3. STEERING CYLINDER................................................................................. 4-M3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. HYDRAULIC CIRCUIT
STEERING
(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
W1012655
This model is provided with a full hydrostatic power steering.
In the full hydrostatic power steering, the steering controller is connected to the steering cylinder with only the hydraulic piping. Accordingly, it does not have mechanical transmitting parts such as steering gear, pitman arm, drag link, etc.. Therefore, it is simple in construction. This steering system consists of the oil strainer (6), hydraulic pump
(5), flow priority valve (3), steering controller (1), steering cylinder (2), etc..
Flow priority valve (3) which located in the hydraulic control valve assembly (4) divides the oil into two direction.
One is the control flow to power steering (constantly 9.5 L/min., 2.5 U.S.gals/min., 2.1 Imp.gals/min.), and the other is excessive flow to control valve of implement lift control.
By operating the power steering body, the required amount of oil is fed to the steering cylinder (2).
4-M1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. STEERING CONTROLLER
STEERING
The steering controller consists of a control valve (4) and a metering device (3).
Q
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). This causes the forming of a
“Neutral” oil circuit.
When the steering wheel is turned either clockwise or counterclockwise, the position of the spool and sleeve changes in relation to the centering spring. This allows the forming of a “Right Turning” or “Left Turning” oil circuit. At the same time, the gear pump (Metering device) rotates with the spool and sends the oil to the cylinder corresponding to the rotation of the steering wheel.
Q
Metering Device
Oil sent from the hydraulic pump to the steering cylinder, passes through the metering device (3).
Namely, when the rotor is driven, two chambers suck in oil due to volumetric change in the pump chambers formed between the rotor (12) and the stator (13), while oil is discharged from other two chambers. On the other hand, rotation of the steering wheel is directly transmitted to the rotor through the spool (7), drive shaft (10), etc.
Accordingly, the metering device serves to supply the steering cylinder with oil, amount of which corresponds to the rotation of the steering wheel. The wheels are thus turned by the angle corresponding to the rotation of the steering wheel.
When the engine stops or the hydraulic pump malfunctions, the metering device functions as a manual trochoid pump, which makes manual steering possible.
Q
Relief Valve
The relief valve (1) is located in the steering controller. It controls the maximum pressure of the power steering system.
Its setting pressure is as follows.
8.33 to 8.83 MPa
85 to 90 kgf/cm
2
1209 to 1280 psi
(1) Relief Valve
(2) Steering Controller
(3) Metering Device
(4) Control Valve
(5) Steering Cylinder
(6) Check Valve
(7) Spool
(8) Centering Spring
(9) Sleeve
(10) Drive Shaft
(11) Distributor Plate
(12) Rotor
(13) Stator
A : Control Valve
B : Matering Divice
P : P Port (From flow priority valve)
T : T Port (To PTO clutch valve and HST circuit)
W1012783
4-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
3. STEERING CYLINDER
STEERING
(1) Rod
(2) Wiper Seal
(3) Internal Snap Ring
(4) Guide
(5) O-ring
(6) Seal Ring
(7) Center Piston
(8) Piston O-ring
(9) External Snap Ring
(10) Cylinder Tube
(11) Rod O-ring
The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.
The tie-rods connected to both knuckle arm guarantees equal steering movement to both front wheels.
The steering cylinder provide force in both directions. Depending upon direction the steering wheel is turned pressure oil enters at one end of the cylinder to extend, or the other end to retract it, thereby turning front wheel of the tractor.
4-M3
KiSC issued 06, 2009 A
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] PREPARATION ........................................................................................4-S4
(1) Separating Power Steering Controller ................................................4-S4
(2) Separating Power Steering Cylinder...................................................4-S6
[3] DISASSEMBLING AND ASSEMBLING..................................................4-S8
(1) Power Steering Cylinder .....................................................................4-S8
[4] SERVICING ..............................................................................................4-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
Symptom
Cannot Be Steered
Hard Steering
Probable Cause
Steering controller malfunctioning
Power steering oil improper
Steering Force
Fluctuates
Hydraulic pump malfunctioning
Flow priority valve malfunctioning
Steering controller malfunctioning
Steering controller malfunctioning
Flow priority valve malfunctioning
Air sucked in pump due to lack of oil
Air sucked in pump from suction circuit
Steering controller malfunctioning
Steering Wheel Turns
Spontaneously When
Released
Front Wheels
Wander to Right and
Left
Oil Temperature
Increases Rapidly
Steering controller malfunctioning
Air sucked in pump due to lack of oil
Air sucked in pump from suction circuit
Insufficient bleeding
Cylinder malfunctioning
Improper toe-in adjustment
Tire pressure uneven
Cylinder piping connected in reverse
Wheels Are Turned to a Direction
Opposite to Steering
Direction
Steering Wheel Turns
Idle in Manual
Steering
Noise
Insufficient bleeding
Air sucked in due to lack of oil
Air sucked in pump due to lack of oil
Air sucked in pump from suction circuit
Pipe deformed
Steering controller (relief valve) malfunctioning
Solution
Replace
Change with specified oil
Replace
Repair or replace
Replace
Replace
Replace
Replenish
Repair
Replace
Replace
Replenish
Repair
Bleed
Repair or replace
Adjust
Inflate
Repair
Bleed
Replenish
Replenish
Repair
Replace
Replace
STEERING
Reference
Page
4-S5
G-7
5-S13
5-M6
4-S5
4-S5
5-M6
G-7
5-S13
4-S5
4-S5
G-7
5-S13
G-30
4-S8
3-S4
G-41
4-S6, S7
G-30
G-7
G-7
5-S13
–
4-S5
W1014322
4-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
POWER STEERING BODY
Item
Relief Valve Operating
Pressure
Factory Specification
8.34 to 8.82 MPa
85.0 to 90.0 kgf/cm
2
1210 to 1280 psi
STEERING
Allowable Limit
–
W1013874
STEERING CYLINDER
Steering Cylinder
Piston Rod to Guide
I.D.
Clearance
40.000 to 40.062 mm
1.5748 to 1.5772 in.
0.020 to 0.070 mm
0.00079 to 0.0027 in.
40.100 mm
1.5787 in.
0.200 mm
0.00787 in.
W1013973
4-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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-9.)
Item
Steering wheel mounting nut
Power steering hose
Power steering cylinder mounting screw
Tie-rod slotted nut
Tie-rod screw
N·m
20 to 25
24 to 27
48 to 55
18 to 34
74 to 84
kgf·m
2.0 to 2.6
2.4 to 2.8
4.9 to 5.7
1.8 to 3.5
7.5 to 8.6
STEERING
lbf·ft
15 to 18
18 to 20
36 to 41
13 to 25
55 to 62
W1012736
4-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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 hose.
(Reference)
• Hose and adaptor size : 9/16-18UNF, 37 ° flare
2. Start the engine and set at maximum speed.
3. Fully turn the steering wheel to the left (or right) to check the feeling which the steering wheel lightly locks. Read the relief valve operating pressure when the steering wheel to the abovementioned lock position by operation force at approximately 9.8
N (1.0 kgf, 2.2 lbf) of outer.
Q
NOTE
• After set a pressure gauge, be sure to bleed air.
• Note that the pressure value changes by the pump action of the power steering controller when the steering operation is continued after the steering wheel is lightly locked and accurate relief valve pressure cannot be measured.
Relief valve operating pressure
Factory spec.
8.34 to 8.82 MPa
85.0 to 90.0 kgf/cm
2
1210 to 1280 psi
W1011481
[2] PREPARATION
(1) Separating Power Steering Controller
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.
(1) Under Panel
(2) Battery
(3) Negative Cable
W1014990
4-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM STEERING
Steering Wheel
1. Remove the steering wheel cap (1).
2. Remove the steering wheel mounting nut and remove the steering wheel.
(When reassembling)
Tightening torque
Steering wheel mounting nut
20 to 25 N·m
2.0 to 2.6 kgf·m
15 to 18 lbf·ft
(1) Steering Wheel Cap
W1011793
Meter Panel
1. Disconnect the main switch connector and combination switch connector (7).
2. Remove the hand accelerator lever grip and cruise control lever knob.
3. Disconnect the hand accelerator wire (3) and then turn the hand accelerator lever (2) to the operator seat side.
4. Open the bonnet, remove the panel mounting screws and dismount the meter panel.
(1) Meter Panel
(2) Hand Accelerator Lever
(3) hand Accelerator Wire
(4) Cruise Control Lever
(5) Main Switch
(6) Combination Switch
(7) Connector for Combination Switch
W1011901
Steering Controller
1. Disconnect the power steering hoses (1), (2), (3), (4).
2. Remove the steering controller mounting screws and remove the steering controller (5).
(When reassembling)
• Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.
Tightening torque Power steering hose
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) Cylinder Hose RH
(2) Cylinder Hose LH
(3) Delivery Hose
(4) Return Hose
(5) Steering Controller
A : Bottom View
P : Pump Port
(Connect to Delivery Hose)
T : Tank Port
(Connect to Return Hose)
L : L Port
(Connect to Cylinder LH Hose)
R : R Port
(Connect to Cylinder RH Hose) a : Right b : Front
W1012133
4-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM STEERING
(2) Separating Power Steering Cylinder
Bonnet and Under Cover
1. Open the bonnet (1), and then loosen the knob bolts and pull forward to remove the under cover (2).
2. Disconnect the connectors (3) for head light and remove the bonnet bracket (4) with bonnet.
(1) Bonnet
(2) Under Cover
(3) Connector
(4) Bonnet Bracket
W1017472
Front Axle Assembly
1. Remove the power steering hose cramp (1).
2. Place the garage jack under the front axle.
3. Remove the cotter pin (1).
4. Remove the slotted nut (2) of center pin and separate the front axle from the frame.
5. Disconnect the power steering cylinder hoses (4).
(When reassembling)
• After mounting the front axle assembly to the frame, be sure to adjust the front axle rocking force. (See page 3-S4.)
• Installing the cotter pin and be sure to split the cotter pin like an anchor
Tightening torque
Power steering cylinder hose
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) Hose Cramp
(2) Cotter Pin
(3) Slotted Nut (Adjusting Nut for Front
Axle Rocking Force)
(4) Power Steering Hose
W1016448
4-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM STEERING
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.
(When reassembling)
Q
NOTE
• Tighten the slotted nut to 18 N·m (1.8 kgf·m, 13 lbf·ft). If the slot and pin hole do not meet, tighten the nut until they do meet, and install the cotter pin.
• Be sure to split the cotter pin like an anchor.
Tightening torque
Tie-rod slotted nut
Power steering cylinder mounting screw
18 to 34 N·m
1.8 to 3.5 kgf·m
13 to 25 lbf·ft
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Tie-rod (2) Power Steering Cylinder
W1016645
4-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM STEERING
[3] DISASSEMBLING AND ASSEMBLING
(1) 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).
(When reassembling)
• Be sure to install the hose adaptors (4), (6) as shown figure left.
• After reassembling the tie-rod, be sure to adjust the toe-in.
(Refer to 3-S4.)
Tightening torque Tie-rod screw
74 to 84 N·m
7.5 to 8.6 kgf·m
55 to 62 lbf·ft
(1) Cylinder Holder
(2) Tie-rod RH
(3) Internal Snap Ring
(4) Hose Adaptor RH
(5) Cylinder
(6) Hose Adaptor LH
(7) Piston Rod
(8) Tie-rod LH
A : 0.26 rad (15 °)
B : Front
W1012941
Steering Cylinder
1. Carefully clamp the cylinder in a vise.
2. Push one of the guide assembly (3) to inside of cylinder tube (2).
3. Drill a hole (2.5 mm dia., 0.098 in. dia.) on the cylinder tube (2) just over the snap ring (4) as shown figure left.
4. Take a little screwdriver and lift off the snap ring (4) from its groove. Simultaneousness support this action by pushing from the outside of the cylinder tube with another little screwdriver or another tool.
5. Push out the piston rod assembly (9) and take off the guide assembly (3).
(When reassembling)
Q
NOTE
• Seals must be exchanged after disassembling.
• Apply transmission fluid to the exchanged seals.
• Enter the piston rod and block the guide assemblies with the snap rings.
(1) Piston Rod
(2) Cylinder Tube
(3) Guide Assembly
(4) Snap Ring
(5) Guide
(6) Seal Ring
(7) Wiper Ring
(8) O-ring
(9) Piston Rod Assembly
(10) Center Piston
A : Drill a Hole
B : 5.25 mm (0.207 in.)
W1013441
4-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[4] SERVICING
STEERING
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.
Steering cylinder I.D.
Factory spec.
Allowable limit
40.000 to 40.062 mm
1.5748 to 1.5772 in.
40.100 mm
1.5787 in.
W1013872
Clearance between Rod and Guide
1. Measure the rod guide I.D. with a cylinder gauge.
2. Measure the rod O.D. with an outside micrometer, and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace as a unit.
Clearance between rod and guide
Factory spec.
Allowable limit
0.020 to 0.070 mm
0.00079 to 0.0027 in.
0.200 mm
0.00787 in.
W1013777
4-S9
KiSC issued 06, 2009 A
5
HYDRAULIC SYSTEM
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. HYDRAULIC CIRCUIT .................................................................................. 5-M1
2. HYDRAULIC PUMP ...................................................................................... 5-M2
3. CONTROL VALVE ........................................................................................ 5-M3
4. FLOW PRIORITY VALVE ............................................................................ 5-M6
5. RELIEF VALVE ............................................................................................. 5-M7
6. HYDRAULIC CYLINDER .............................................................................. 5-M9
7. HYDRAULIC BLOCK TYPE OUTLET....................................................... 5-M10
8. MOWER LINKAGE ..................................................................................... 5-M11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. HYDRAULIC CIRCUIT
HYDRAULIC SYSTEM
(1) Auxiliary Hydraulic Control
Valve Assembly (If equipped)
(2) Hydraulic Cylinder
(3) Control Valve
(4) 3 Point Hitch System
(5) Flow Priority Valve
(6) Relief Valve
(7) Hydraulic Pump
(8) Oil Strainer
(9) PTO Clutch Relief Valve
(10) Oil Filter
(11) PTO Clutch
(12) PTO Clutch Valve
(13) Power Steering Controller
(14) Hydrostatic Transmission
The hydraulic system of this tractor is composed of a hydraulic pump, control valve for front loader, 3 point hitch system and other components.
This system has the following functions :
1. Oil is supplied by hydraulic pump which is driven by pump drive shaft in the transmission case. As the pump drive shaft is connected to the propeller shaft, hydraulic pump starts running when engine is started.
2. The hydraulic pump supplies the high pressured oil to auxiliary hydraulic control valve for front loader, control valve for 3 point hitch system, power steering controller, PTO clutch valve and hydrostatic transmission after dividing oil flow by flow priority valve.
5-M1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. HYDRAULIC PUMP
HYDRAULIC SYSTEM
The hydraulic pump is composed of the casing (1), cover (4), side plate (3), and two spur gears (drive gear
(5) and driven gear (2)) that are in mesh.
Hydraulic pump is driven by the pump drive shaft in the transmission case.
Maximum displacement is as follows.
Engine speed Condition Displacement
23.5 L/min.
6.2 U.S.gals./min.
5.2 Imp.gals./min.
At 3200 min
-1
(rpm) at no load
(1) Casing
(2) Driven Gear
(3) Side Plate
(4) Cover
(5) Drive Gear
(6) Pin
(7) Oil Seal
W1013860
5-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
3. CONTROL VALVE
This position control valve is located under the hydraulic cylinder.
This control valve is mechanically connected to the position control lever.
Since the feedback rod is not equipped to the lift arm, the neutral position adjustment is adjusted by controlling the position control lever.
The control valve controls the oil flow forced from the hydraulic pump and the oil returned back from the hydraulic cylinder.
Q
Neutral
When stopping the position control lever, the spool is stopped.
The spool closes the oil flow from passage between
P
port and
C
port.
Since the oil in the hydraulic cylinder is not drained to
T2
port,
“Neutral”
position is kept.
(1) Lift Arm
(2) Hydraulic Cylinder
(3) Control Valve
(4) Spool
(5) Lowering Adjusting Shaft
P : Pump Port
C : Cylinder Port
T1 :Tank Port
T2 :Tank Port
W1015913
5-M3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Lift
HYDRAULIC SYSTEM
When the control lever is set to the
“Lift”
position, the spool (4) moves to the right.
The oil forced into the control valve flows through
P
port to
C
port and the hydraulic cylinder.
The oil pushes the hydraulic piston in the hydraulic cylinder to lift the implement.
Since the spool shape is step down structure, oil passes slowly through the gap between the control valve body (3) and the spool (4) to
C
port.
In this tractor, when setting the control lever to the
“Slow up”
, implement lifts up with ease in increments of approximately 1/4 inches at lower link end.
(1) Lift Arm
(2) Hydraulic Cylinder
(3) Control Valve
(4) Spool
(5) Lowering Adjusting Shaft
P : Pump Port
C : Cylinder Port
T1 :Tank Port
T2 :Tank Port
W1016112
5-M4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Down
HYDRAULIC SYSTEM
When the control lever is set to the
“Down”
position, the spool (4) moves to the left.
The oil forced from the
P
port flows through the gap between the control valve body and the spool to the
T1
port.
The oil in the hydraulic cylinder flows through the gap between the control valve body (3) and the spool (4) to the
T2
port.
Since the oil in the hydraulic cylinder drains to the transmission case, the implement lowers.
Since the spool shape is step down structure, oil pass slowly from
C
port through the gap between the control valve body (3) and the spool (4) to
T2
port.
In this tractor, when setting the control lever to the
“Slow down”
position, implement lowers down with ease in increments of approximately 1/4 inches at lower link end.
(1) Lift Arm
(2) Hydraulic Cylinder
(3) Control Valve
(4) Spool
(5) Lowering Adjusting Shaft
P : Pump Port
C : Cylinder Port
T1 :Tank Port
T2 :Tank Port
W1016319
5-M5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
4. FLOW PRIORITY VALVE
HYDRAULIC SYSTEM
(1) Hydraulic Pump Gear
(2) Hydraulic Pump Case
(3) Plug
(4) Flow Priority Valve
(5) Relief Valve
EF :EF Port (To 3 Points Hitch
Control Circuit)
PF :PF Port (To Power
Steering, PTO Clutch and
HST Circuit)
P : Pump Port (Suction)
T : Tank Port
W1014933
The flow priority valve is a flow divider that divides single hydraulic source (hydraulic pump) to actuates two circuits simultaneously.
This valve feeds fixedly controlled flow (8.0 L/min., 2.1 U.S.gals./min., 1.8 Imp.gals./min.) to the
PF
port with priority and excessive flow to the
EF
port.
5-M6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
5. RELIEF VALVE
HYDRAULIC SYSTEM
(1) Hydraulic Pump Gear
(2) Hydraulic Pump Case
(3) Plug
(4) Flow Priority Valve
(5) Relief Valve
(6) Seat
(7) Poppet
EF :EF Port (To 3 Points Hitch
Control Circuit)
PF :PF Port (To Power
Steering, PTO Clutch and
HST Circuit)
D.C.:Damping Chamber
P : Pump Port (Suction)
T : Tank Ports
W1015272
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 a guide piston type with damping effect.
Among direct acting relief vales, this type is suited to higher pressure and has large capacity. Furthermore, this type is free from unstable operation, such as chattering, which occurs often in direct acting relief valves.
As shown in the figure, the guide is attached to the poppet (7) and a valve chamber
D.C.
(called the damping chamber) is formed at the top of the guide piston. The inlet of the valve leads to the chamber via a clearance between the sliding portion of the guide and the seat (6), minimizing valve vibration with the damping effect of the chamber.
5-M7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Relief Valve Operating
HYDRAULIC SYSTEM
(1) Hydraulic Pump Gear
(2) Hydraulic Pump Case
(3) Plug
(4) Flow Priority Valve
(5) Relief Valve
EF :EF Port (To 3 Points Hitch
Control Circuit)
PF :PF Port (To Power
Steering, PTO Clutch and
HST Circuit)
D.C.:Damping Chamber
P : Pump Port (Suction)
T : Tank Ports
W1016573
When the oil pressure in the circuit is lower than the setting pressure of the relief valve, the relief valve is not operated and the oil fed to the relief valve from the hydraulic pump flows into the implement control valve.
As the oil pressure in the circuit increases, so does the pressure in the damping chamber
D.C.
. When the pressure rises above the valve setting and overcomes the spring force, the valve opens. Oil then flows out to the transmission case through
T
port, preventing any further rise in pressure. The valve closes again when enough oil is released to drop pressure below the valve setting.
(Reference)
• Relief valve setting pressure : 12.3 to 12.7 MPa
125 to 130 kgf/cm
2
1780 to 1840 psi
• Engine speed : Maximum
• Oil temperature : 40 to 50 °C
104 to 122 °F
5-M8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
6. HYDRAULIC CYLINDER
HYDRAULIC SYSTEM
(1) Lift Arm
(2) Hydraulic Arm
(3) Hydraulic Arm Shaft
(4) Hydraulic Rod
(5) Piston
(6) Spring
(7) Ball
(8) Lowering Speed Adjusting
Shaft
(9) Back-up Ring
(10) O-ring
(11) Hydraulic Cylinder
(12) Control Valve
P : Pump Port
C : Cylinder Port
The main components of the hydraulic cylinder are shown in the figure above.
While the lift arm (1) is rising, oil from the hydraulic pump flows into the hydraulic cylinder through the hydraulic control valve (12) and cylinder port (
C
). Then oil pushes out the piston (5).
While the lift arm (1) is lowering, oil in the hydraulic cylinder is discharged to the transmission case through the hydraulic control valve by the weight of the implement. At this time, the lowering speed of the implement can be controlled by the ball (7) attached to the hydraulic cylinder (11). Turning the lowering speed adjusting knob clockwise decreases the lowering speed, and counterclockwise increases lowering speed. When the lowering speed adjusting valve is completely closed, the lift arm (1) is held at its position since oil in the hydraulic cylinder is sealed between the piston (5) and ball (7).
5-M9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
7. HYDRAULIC BLOCK TYPE OUTLET
The hydraulic block type outlet is located on the hydraulic cylinder 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 snow blade and so on.
(1) Block Cover
(2) Hydraulic Cylinder
(3) Hydraulic Block
P : P Port (Pump)
P.B. :P.B. Port (Power Beyond)
[A] When Auxiliary Control
Valve is not Attached
[B] When Auxiliary Control
Valve is Attached a : To Transmission Case b : To Implement c : From Implement
W1014064
5-M10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
8. MOWER LINKAGE
HYDRAULIC SYSTEM
(1) Mower Rear Link RH
(2) Lift Pin
(3) Mower Rear Link LH
(4) Rear Lift Link LH
(5) Cutting Height Adjusting Dial
(6) Rear Lift Link LH
(7) Lift Arm
(8) Adjusting Bolt
(9) Lift Upper Boss
(10) Lift Lower Boss
(11) Cam
The mower rear link (1), (3) and the lift arm (7) are linked with the rear lift link LH (4), the lift upper boss (9) and the lift lower boss (10).
As the hydraulic control lever moves to lift position, lift arm (7) is raised and the rear lift link LH (6) is pulled to pull the lift links to the rearward. As a result, mower rear link (1), (3) are lifted.
The cutting height adjusting dial (5) adjusts cutting height of mower by rotating the adjusting cam (11). The position of mower rear link (1), (3) are adjusted by changing the length of the adjusting bolt (8).
5-M11
KiSC issued 06, 2009 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................5-S1
2. SERVICING SPECIFICATIONS ....................................................................5-S2
3. TIGHTENING TORQUES ..............................................................................5-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................5-S4
[1] CHECKING AND ADJUSTING ...............................................................5-S4
(1) Relief Valve.........................................................................................5-S4
(2) Pump and Priority Valve .....................................................................5-S5
(3) Mower Lift Linkage..............................................................................5-S6
[2] PREPARATION ........................................................................................5-S7
(1) Separating Hydraulic Cylinder ............................................................5-S7
(2) Separating Hydraulic Pump ..............................................................5-S10
[3] DISASSEMBLING AND ASSEMBLING................................................5-S14
(1) Hydraulic Cylinder and Control Valve ...............................................5-S14
(2) Mower Lift Linkage............................................................................5-S16
[4] SERVICING ............................................................................................5-S17
(1) Hydraulic Pump.................................................................................5-S17
(2) Hydraulic Cylinder.............................................................................5-S18
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
Symptom
Implement Does Not
Rise (No Noise)
Implement Does Not
Rise (Noise)
Probable Cause
Control valve broken
Control valve improperly assembled
Relief valve spring damaged
Spool sticks
Piston O-ring or cylinder damaged
Oil filter cartridge clogged
Suction pipe loosen or broken
Suction pipe connecting hose loosen or broken
Suction pipe O-ring broken
Insufficient transmission oil
Relief valve setting pressure too low
Hydraulic pump broken
Control valve malfunctioning
Implement Does Not
Lower
Implement Drops by
Its Weight
Hydraulic cylinder worn or damaged
Piston O-ring worn or damaged
Control valve malfunctioning
Solution
Replace
Repair
Replace
Repair
Replace
Replace
Repair or replace
Repair or replace
Replace
Refill
Adjust or replace
Replace
Repair or replace
Replace
Replace
Replace
HYDRAULIC SYSTEM
5-S15
5-S15
5-S14
W1014322
Reference
Page
5-S14
5-S14
5-S4
5-S14
5-S15
G-14
–
–
–
G-24
5-S4
5-S13
5-S14
5-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
Item
Relief Valve
Hydraulic Pump
Mower Linkage
Setting Pressure
(Condition)
Engine speed :
Maximum
Oil Temperature :
45 to 55 °C
113 to 131 °F
Power steering oil flow
(Condition)
Engine speed :
1500 min
-1
(rpm)
Oil Temperature :
45 to 55 °C
113 to 131 °F
Clearance L2
Factory Specification
12.3 to 12.7 MPa
125 to 130 kgf/cm
2
1780 to 1840 psi
Above
8.0 L/min.
2.1 U.S.gals/min.
1.8 Imp.gals/min.
0 to 0.5 mm
0 to 0.01 in.
HYDRAULIC SYSTEM
Allowable Limit
–
–
–
[Hydraulic Pump]
Gear to Casing Clearance –
Gear O.D.
0.15 mm
0.0059 in.
–
Case
Gear Shaft to Bushing
Gear Shaft
Bushing
Side Plate
Hydraulic Cylinder
I.D.
Clearance
O.D.
I.D.
Thickness
I.D.
33.520 to 33.530 mm
1.3197 to 1.3200 in.
33.570 to 33.577 mm
1.3217 to 1.3219
0.020 to 0.091 mm
0.00079 to 0.0035 in.
14.970 to 14.980 mm
0.58937 to 0.58976 in.
15.000 to 15.061 mm
0.59056 to 0.59295 in.
2.48 to 2.50 mm
0.0977 to 0.0984 in.
80.05 to 80.15 mm
3.152 to 3.155 in.
–
0.12 mm
0.0047 in.
–
–
2.40 mm
0.094 in.
80.20 mm
3.157 in.
W1013874
5-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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-9.)
Item
ROPS mounting nut
Fuel tank stay mounting bolt and nut
Fender bracket mounting bolt
Hydraulic cylinder block mounting bolt
Hydraulic pump mounting bolt (M6)
Hydraulic pump mounting bolt (M8)
N·m
124 to 147
48 to 55
124 to 147
40 to 44
7.9 to 9.3
18 to 21
kgf·m
12.6 to 15.0
4.9 to 5.7
12.6 to 15.0
4.0 to 4.5
0.80 to 0.95
1.8 to 2.1
HYDRAULIC SYSTEM
lbf·ft
91.2 to 108
36 to 41
91.2 to 108
29 to 32
5.8 to 6.8
13 to 15
W1012736
5-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Relief Valve
Relief Valve Setting Pressure
1. Remove the hydraulic pipe (1).
2. Install the hose and adaptor
A
(3) with pressure gauge (2).
3. Start the engine and set at maximum speed.
4. Move the control lever all way up to operate the relief valve and read the gauge.
5. If the pressure is not within the factory specifications, adjust with the adjusting shim (5).
Relief valve setting pressure
Factory spec.
12.3 to 12.7 MPa
125 to 130 kgf/cm
2
1780 to 1840 psi
Condition
• Engine speed : Maximum
• Oil temperature : 45 to 55 °C
113 to 131 °F
(Reference)
• Thickness of shim (5) :
0.1 mm (0.004 in.), 0.2 mm (0.008 in.), 0.4 mm (0.02 in.)
• 0.269 MPa (2.74 kgf/cm
2
, 39.0 psi) pressure is increased whenever the thickness of adjusting shim is increased by 0.1 mm
(0.004 in.).
(1) Hydraulic Pipe
(2) Pressure Gauge
(3) Adaptor Tee, Swivel (9/16-18)
(4) Relief Valve
(5) Shim
A : Adaptor Tee, Swivel (9/16-18)
B : Adaptor B
(a) Connect Pressure Gauge
(b) Connect Hydraulic Hose
W1011231
5-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Pump and Priority Valve
HYDRAULIC SYSTEM
Checking Hydraulic Oil Flow
Q
IMPORTANT
• Use the instruction with the flowmeter when you use the flowmeter.
• While testing, do not close the flowmeter loading valve completely.
Q
NOTE
• To measure the flow volume of pump, oil flow on the power steering system side should be stopped.
1. Remove the pump hose.
2. Remove the hydraulic pipe behind the hydraulic cylinder and fix the flow meter hose and the flow meter as shown in the photo.
Q
Measure the flow volume of power steering.
1. Make sure that the flow volume of pump is 10 L (2.6 U.S.gals, 2.2
Imp.gals) or higher and verify the content below.
If the flow volume is insufficient, measure it after replacing the pump as its priority-valve is unreadable of its condition.
2. After measuring the flow volume, remove the flow meter then reassembling the hydraulic pipe to the original position.
3. Remove the transmission fluid filling plug, then fix the flow meter hose and the flowmeter.
4. Check that a flow volume meets the specifications when the engine revolution is 1500 min
-1
(rpm).
5. If the flow volume varies from the specification, replace the priority valve then take measurement again.
Condition
• Engine speed : 1500 min
-1
(rpm)
• Oil temperature : 45 to 55 °C
113 to 131 °F
Power steering oil flow Factory spec.
Above 8.0 L/min.
2.1 U.S.gals/min.
1.8 Imp.gals/min.
(Reference)
• Pump Oil Flow
Hydraulic pump delivery at no pressure
Factory spec.
Above 24.9 L/min.
6.6 U.S.gals/min.
5.5 Imp.gals/min.
Condition
• Engine speed : Maximum
• Oil temperature : 45 to 55 °C
113 to 131 °F
(1) Pump Hose
(A) Pump Oil Flow
(B) Power Steering Oil Flow
W12345678
5-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(3) Mower Lift Linkage
HYDRAULIC SYSTEM
Mower Lift Linkage
After reassembling the mower lift linkage, be sure to adjust it as follows.
1. Check the lift arm free play.
2. Loosen the adjusting nut (1) and start the engine.
3. Move the hydraulic control lever to
Lift
position until the relief valve operating. (
Uppermost
position)
4. Adjusting bolt (2) until the clearance between stopper and mower rear link
LH
gets 0 to 0.5 mm (0 to 0.01 in.)
5. Secure the lock nut (1).
Clearance
L2
Factory spec.
0 to 0.5 mm
0 to 0.01 in.
(Reference)
Length
L1
Factory spec.
17 mm
0.67 in.
(1) Nut
(2) Bolt
(A) Upper View
L1 : Length
L2 : Clearance
W1020338
5-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] PREPARATION
(1) Separating Hydraulic Cylinder
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.
(1) Under Panel
(2) Battery
(3) Negative Cable
W1026961
Lift Rod and Lower Link
1. Remove the top link (2).
2. Remove the stopper pin (6) and remove the check chain plate
(3).
3. Move the bushes (8) to inside.
4. Move the shaft (9) to right side and remove the lower link as a unit.
(1) Lift Rod LH
(2) Top Link
(3) Check Chain Plate
(4) Lift Rod RH
(5) Lower Link RH
(6) Stopper Pin
(7) Lower Link LH
(8) Bush
(9) Shaft
W1036139
5-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
Roll-Over Protective Structures (ROPS)
1. Disconnect the lead wires from the hazard lights (2), (4) and turn signal lights (3), (5).
2. Remove the ROPS mounting nuts, and remove the ROPS (1).
(When reassembling)
Tightening torque ROPS mounting nut
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
(1) ROPS
(2) Hazard Light LH
(3) Turn Signal Light LH
(4) Hazard Light RH
(5) Turn Signal Light RH
W1027220
Seat
1. Disconnect the seat switch connectors.
2. Remove the snap pins (2) and remove the seat (1).
(1) Seat (2) Snap Pin
W1014409
Speed Control Pedal and Step
1. Remove the valve covers (3).
2. Remove the speed control pedals (1) and step (2).
(1) Speed Control Pedal
(2) Step
(3) Valve Cover
W1014726
Lever Grips and Fender
1. Disconnect the electric outlet connector (6).
2. Remove the lowering speed adjusting knob (5) and cutting height adjusting dial knob (4).
3. Remove the lever grips (3) and lever guide mounting screw.
4. Remove the fender (1) with lever guide (2).
(1) Fender
(2) Lever Guide
(3) Lever Grip
(4) Cutting Height Adjusting Dial Knob
(5) Lowering Speed Adjusting Knob
(6) Electric Outlet
W1014865
5-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
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).
4. Remove the PTO cover (4).
(When reassembling)
Tightening torque
Fuel tank stay mounting bolt and nut
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Fuel Tank
(2) Fuel Tank Stay LH
(3) Fuel Tank Stay RH
(4) PTO Cover
W1027629
Fender Center Stay
1. Remove the fender bracket (2).
2. Remove the fender center stay (1).
(When reassembling)
Tightening torque
(1) Fender Center Stay
Fender bracket mounting bolt
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
(2) Fender Bracket
W1027820
Mower Linkage and Wire Harness
1. Disconnect the mower linkage (2).
2. Remove the wire harness clamp and wire harness (1) move to the front side.
(1) Wire Harness (2) Mower Linkage
W1027951
5-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
Hydraulic Cylinder Block
1. Remove the hydraulic pipe (1).
2. Remove the hydraulic cylinder block mounting bolt.
3. Remove the hydraulic cylinder block (2).
(When reassembling)
Tightening torque
Hydraulic cylinder block mounting bolt
40 to 44 N·m
4.0 to 4.5 kgf·m
29 to 32 lbf·ft
(1) Hydraulic Pipe (2) Hydraulic Cylinder Block
W1028149
(2) Separating Hydraulic Pump
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 (3) from the battery.
(1) Under Panel
(2) Battery
(3) Negative Cable
W1028561
5-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
Lift Rod and Lower Link
1. Remove the top link (2).
2. Remove the stopper pin (6) and remove the check chain plate
(3).
3. Move the bush (8) inside.
4. Move the shaft (9) to right side and remove the lower link as a unit.
(1) Lift Rod LH
(2) Top Link
(3) Check Chain Plate
(4) Lift Rod RH
(5) Lower Link RH
(6) Stopper Pin
(7) Lower Link LH
(8) Bush
(9) Shaft
W1036365
Roll-Over Protective Structures (ROPS)
1. Disconnect the lead wires from the hazard lights (2), (4) and turn signal lights (3), (5).
2. Remove the ROPS mounting nuts, and remove the ROPS (1).
(When reassembling)
Tightening torque ROPS mounting nut
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
(1) ROPS
(2) Hazard Light LH
(3) Turn Signal Light LH
(4) Hazard Light RH
(5) Turn Signal Light RH
W1028839
Seat
1. Disconnect the seat switch connectors.
2. Remove the snap pins (2) to remove the seat (1).
(1) Seat (2) Snap Pin
W54879632
Speed Control Pedal and Step
1. Remove the valve covers (3).
2. Remove the speed control pedals (1) and step (2).
(1) Speed Control Pedal
(2) Step
(3) Valve Cover
W85236974
5-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
Lever Grips and Fender
1. Disconnect the electric outlet connector (6).
2. Remove the lowering speed adjusting knob (5) and cutting height adjusting dial knob (4).
3. Remove the lever grips (3) and lever guide mounting screw.
4. Remove the fender (1) with lever guide (2).
(1) Fender
(2) Lever Guide
(3) Lever Grip
(4) Cutting Height Adjusting Dial Knob
(5) Lowering Speed Adjusting Knob
(6) Electric Outlet
W1020932
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).
4. Remove the PTO cover (4).
(When reassembling)
Tightening torque
Fuel tank stay mounting bolt and nut
48 to 55 N·m
4.9 to 5.7 kgf·m
36 to 41 lbf·ft
(1) Fuel Tank
(2) Fuel Tank Stay LH
(3) Fuel Tank Stay RH
(4) PTO Cover
W1029258
Fender Center Stay
1. Remove the fender bracket (2).
2. Remove the fender center stay (1).
(When reassembling)
Tightening torque
(1) Fender Center Stay
Fender bracket mounting bolt
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 lbf·ft
(2) Fender Bracket
W1029436
5-S12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
Hydraulic Pump
1. Disconnect the mower linkage (4).
2. Remove the lift arm LH (2).
3. Remove the hydraulic pipes (1).
4. Remove the hydraulic pump (3).
Tightening torque
Hydraulic pump mounting bolt (M6)
Hydraulic pump mounting bolt (M8)
7.9 to 9.3 N·m
0.80 to 0.95 kgf·m
5.8 to 6.8 lbf·ft
18 to 20 N·m
1.8 to 2.1 kgf·m
13 to 15 lbf·ft
(When reassembling)
• Since the mounting bolt (5) is installed through the transaxle case to the transmission oil tank, seal the sealing tape to the mounting bolt (5) securely.
(1) Hydraulic Pipe
(2) Lift Arm LH
(3) Hydraulic Pump
(4) Mower Linkage
(5) Bolt (M8) (Through Bolt)
(6) Bolt (M6)
(7) Bolt (M8)
W1029558
5-S13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM HYDRAULIC SYSTEM
[3] DISASSEMBLING AND ASSEMBLING
(1) Hydraulic Cylinder and Control Valve
Control Valve
1. Remove the control valve (1).
2. Remove the internal snap ring (4) and draw out the spool (2).
(1) Control Valve
(2) Spool
(3) Plain Washer
(4) Internal Snap Ring
W1030131
Control Valve Lever
1. Pull out the pin (1).
2. Remove the control valve lever (3) and arm (2).
(1) Pin
(2) Arm
(3) Control Valve Lever
W1030453
Lift Arm, Hydraulic Arm Shaft and Hydraulic Arm
1. Remove the external snap rings (8), (10), and remove the lift arms (2), (7).
2. Draw out the hydraulic arm shaft (4).
(When reassembling)
• Align the alignment marks of the hydraulic arm (2) and hydraulic arm shaft (4).
• Align the alignment marks of the lift arms (2), (7) and hydraulic arm shaft (4).
• Apply grease to the right and left bushings and O-rings.
• Take care not to damage the O-ring.
(1) Hydraulic Cylinder Block
(2) Lift Arm LH
(3) O-ring
(4) Hydraulic Arm Shaft
(5) Hydraulic Arm
(6) O-ring
(7) Lift Arm RH
(8) External Snap Ring
(9) Cover
(10) External Snap Ring
W1031001
5-S14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
• Replace the O-ring if it is defective, worn or scratched, which may cause oil leakage.
(1) Hydraulic Piston
(2) Back-up Ring
(3) O-ring
W1031555
Lowering Speed Adjusting Valve
1. Remove the internal snap ring (5) and remove the lowering speed adjusting shaft (6).
2. Remove the ball (2) and spring (1).
(When reassembling)
• Take care not to damage the O-rings.
(1) Spring
(2) Ball
(3) O-ring
(4) Stopper
(5) Internal Snap Ring
(6) Lowering Speed Adjusting Shaft
W1032074
5-S15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Mower Lift Linkage
Disassembling Mower Linkage
HYDRAULIC SYSTEM
(1) Mower Rear Link, RH
(2) Lift Link Rear, RH
(3) Cutting Height Adjusting
Dial Knob
(4) Cutting Height Adjusting
Rod
(5) Lift Arm, LH
(6) Link Adjusting Bolt
(7) Lift Link Rear, LH
(8) Mower Rear Link, LH
(9) Adjusting Cam
W1032616
1. Remove the clevis pin and remove the lift link rear LH (7).
2. Remove the pin and remove the mower rear links (1), (8).
3. Remove both side of boss and remove the lift link rear RH (2).
4. Remove the cutting height adjusting dial knob (3).
5. Remove the nut and remove the adjusting cam (9) and cutting height adjusting rod (4).
(When reassembling)
• Adjust the length of the link adjusting bolt. (Refer to page 5-S6.)
W1032750
5-S16
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[4] SERVICING
(1) Hydraulic Pump
HYDRAULIC SYSTEM
Clearance between Tip of Gear Tooth and Casing
1. Measure the gear O.D. with an outside micrometer.
2. Measure the casing I.D. with a cylinder gauge and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace the assembly.
Clearance between tip of gear tooth and casing
Allowable limit
0.15 mm
0.0059 in.
Gear O.D.
Case I.D.
Factory spec.
Factory spec.
33.520 to 33.530 mm
1.3197 to 1.3200 in.
33.570 to 33.577 mm
1.3217 to 1.3219 in.
W1015764
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 and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace it.
Clearance between bushing and shaft
Factory spec.
Allowable limit
0.020 to 0.091 mm
0.00079 to 0.0035 in.
0.12 mm
0.0047 in.
Shaft O.D.
Bushing I.D.
Factory spec.
Factory spec.
14.970 to 14.980 mm
0.58937 to 0.58976 in.
15.000 to 15.061 mm
0.59056 to 0.59295 in.
W1015972
Side Plate Thickness
1. Measure the side plate thickness with an outside micrometer.
2. If the thickness is less than the allowable limit, replace it.
Side plate thickness
Factory spec.
Allowable limit
2.48 to 2.50 mm
0.0977 to 0.0984 in.
2.40 mm
0.094 in.
W1016194
5-S17
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Hydraulic Cylinder
HYDRAULIC SYSTEM
Hydraulic Cylinder Bore
1. Check the cylinder internal surface for scoring or damage.
2. Measure the cylinder I.D. with a cylinder gauge.
3. If the measurement exceeds the allowable limit, replace the hydraulic cylinder block.
Cylinder I.D.
Factory spec.
Allowable limit
80.05 to 80.15 mm
3.152 to 3.155 in.
80.20 mm
3.157 in.
W10171300
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 it.
(Reference)
Hydraulic arm shaft bushing
Alloy thickness (
A
)
0.57 mm
0.022 in.
Hydraulic arm shaft
A : Alloy Thickness
LH
RH
O.D.
O.D.
31.925 to 31.950 mm
1.2569 to 1.2578 in.
29.925 to 29.950 mm
1.1782 to 1.1791 in.
L : Outside Diameter
W1016329
5-S18
KiSC issued 06, 2009 A
6
ELECTRICAL SYSTEM
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. WIRING DIAGRAM ....................................................................................... 6-M1
2. STARTING SYSTEM .................................................................................... 6-M3
[1] MAIN SWITCH POSITION..................................................................... 6-M3
[2] SAFETY SWITCH ................................................................................... 6-M4
[3] OPERATOR PRESENCE CONTROL (OPC) ....................................... 6-M5
3. CHARGING SYSTEM ................................................................................... 6-M6
[1] ELECTRICAL CIRCUIT .......................................................................... 6-M6
[2] IC REGULATOR (3P CONNECTOR TYPE)........................................ 6-M7
4. LIGHTING SYSTEM ..................................................................................... 6-M8
5. GAUGES........................................................................................................ 6-M9
[1] ELECTRICAL CIRCUIT .......................................................................... 6-M9
[2] HOUR AND TACHOMETER................................................................ 6-M10
[3] FUEL LEVEL GAUGE.......................................................................... 6-M10
[4] WATER TEMPERATURE GAUGE ...................................................... 6-M10
6. OTHERS ...................................................................................................... 6-M11
[1] DC OUTLET.......................................................................................... 6-M11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. WIRING DIAGRAM
Head Light (37.5W)
Tail Light (12.8W)
Turn Signal
Lamp
(23W)
20 B
20 R
18 Or
18 B
18 Or
18 B
Illumination
Hazard Lamp (23W)
20 B
20 R
Turn Signal
Lamp
(23W)
20 RW
Oil Pressure
Lamp
Glow Lamp
Blinker (L)
Hour and Tach.
Meter
Battery Charge
Blinker (R) Lamp
1
Ground
2
Ignition (Switched Power)
3
Fuel Sensor SignaL
4
Water Temperature Sensor Signal
5
Left Turn Signal (Blinker)
6
Right Turn Signal (Blinker)
7
NC
8
Battery Charge
9
Glow
10
NC
11
Engine Oil Pressure
12
Tach. Signal
13
Back Lighting
14
NC
Water Temperature
Gauge
TEMP
14 13 12 11
6 5 4 3
9
2
8
1
FUEL
Fuel Gauge
Tail Light (12.8W)
Thermo Unit
20 WY
20 LW
20 RW
20 YL
20 RY
Fuel
Sensor
Oil Pressure Switch
OPC Timer
20 R
20 B
14 13
20 G
2 1
20 RW
16 RG
20 LW
20 WR
20 B
f h j
Flasher Unit
b a d
20 YL
i
20 YR
a
Ground
b
Hazard Switch
d
Left Turn Switch
f
Right Turn Signal
h
Battery
i
Left Turn Signal
j
Right Turn Switch
Blinker Switch
Combination Switch
LW
20 Br
18 RY
18 Or
20 RY
RY
Y
Or
RW
G
GW
B2
R
L
H1
B1
B3
T I
BL
20 RG
Hazard Switch
Light Switch
Fuse
15A
16 RG
15A 16 RW
15A
18 RY
20A
14 RB
10A
20 RL
10A
20 Y
20 B
20 RY
14 B
14 RB
20 RL
20 B
Fuel Pump
Working Light
DC Outlet
3TAAAAK9P001A
OFF(STOP)
ON(RUN)
GLOW
START
BAT
ON
(IG/M)
GLOW ST
Main Switch
6-M1
20 Y
Seat
20 Y
20 Y 20 Y
Seat
Turn Over
R-PTO
20 Y 20 Y
PTO
Safety Switch
20 Y
HST Neutral
Starter Motor
12V 0.98A
S B
50A
Slow Blow Fuse
+ -
12V
Battery
G IC
REG.
Alternator
Solenoid
12V 12A
Timer Relay Frame Earth
Glow Plug
ELECTRICAL SYSTEM
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Color of Wiring
W .......... White
R ........... Red
L ........... Blue
P ........... Pink
B ........... Black
Br .......... Brown
Sb ......... Sky Blue
WR ........... White / Red
WY ........... White / Yellow
RB ............ Red / Black
RW ............ Red / White
RG ............ Red / Green
RY ............. Red / Yellow
BW ......... Black / White
BR .......... Black / Red
GW ........ Green / White
YR .......... Yellow / Red
YL .......... Yellow / Blue
LW ......... Blue / White
ELECTRICAL SYSTEM
W1019456
6-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. STARTING SYSTEM
[1] MAIN SWITCH POSITION
ELECTRICAL SYSTEM
(1) Fuse
(2) Seat
(3) Seat Turn Over
(4) R-PTO
(5) PTO
(6) HST Neutral
(7) Main Switch
(8) Slow Blow Fuse
(9) Starter Motor
(10) Battery
(11) Alternator
(12) Glow Lamp
(13) Timer Relay
(14) Frame Earth
(15) Fuel Pump
(16) Solenoid
(17) Glow Plug
(18) OPC Timer
When the main switch (7) is turned to the
GLOW
position, the terminal
BAT
is connected to the terminal
ON
and
AC
. The glow plugs (17) become red-hot, and the preheat indicator lamp also lights on while preheating.
When the main switch is then turned to the
START
position with the safety switches on, the terminal
BAT
is connected to the terminals
GLOW
and
ST
. Consequently, battery (10) current flows to the starter motor (9) and start the engine.
The main switch automatically returns to the
ON
position, the terminal
BAT
is connected only to the terminal
GLOW
, thereby causing the starting circuit to be opened, stopping the starter motor.
When the main switch turned from the
ON
position to the
OFF
position, the fuel cut-off solenoid moves the fuel injection pump control rack to the
“No Fuel Injection”
position and stops the engine.
The BX2660 tractor (with the OPC timer (18)) equipped the operator presence control (OPC) system which automatically stops the engine in approximately one second when operator stands from the seat while shifting the PTO clutch lever and range gear shift lever
6-M3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
[2] SAFETY SWITCH
This switch is electrically closed in normal condition (normally closed type). The switch operates as sensor detecting and transmitting the position of HST pedal, PTO lever, independent PTO lever, and seat to engine stop solenoid.
Type of Switch
Normal open type
Safety Switch Name
Seat switch
Seat turn over switch
PTO shift lever switch
Independent PTO Lever
Switch (Rear PTO Switch)
HST pedal neutral switch
Number of Switch Contact
1
1
1
2
2
W1014916
Lever / Pedal Position, Engine Condition and Switch Condition
Lever / Pedal Position
No.
HST Pedal
Neutral switch;
Neutral: ON
Forward or reverse: OFF
Independent PTO
Lever Switch;
I-PTO engaged:
ON
I-PTO disengaged: OFF
PTO Shift Lever
Switch;
R-PTO Selected:
ON
M-PTO or M and
R-PTO Selected:
OFF
Operator’s Seat
Switch;
Occupied: ON
Off Seat or
Vacant: OFF
1 On Seat: ON
2
R-PTO Selected:
ON
Off Seat: OFF
3
4
Disengaged: OFF
On Seat: ON
5
6
7
8
Neutral Position:
ON
M-PTO or M and
R-PTO Selected:
OFF
R-PTO Selected:
ON
Off Seat: OFF
On Seat: ON
Off Seat: OFF
9
Engaged: ON
10 On Seat: ON
11
M-PTO or M and
R-PTO Selected:
OFF
Off Seat: OFF
12
13 On Seat: ON
14
R-PTO Selected:
ON
Off Seat: OFF
15
Disengaged: OFF
16
17
18
19
Forward (OFF) or
Reverse (OFF)
M-PTO or M and
R-PTO Selected:
OFF
On Seat: ON
Off Seat: OFF
On Seat: ON
20
21
R-PTO Selected:
ON
Off Seat: OFF
Engaged: ON
22 On Seat: ON
23
24
M-PTO or M and
R-PTO Selected:
OFF
Off Seat: OFF
Seat Turn Over
Switch;
Normal position:
OFF
Turn over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Normal: OFF
Normal: OFF
Turn Over: ON
Engine Condition
Engine
Stopping
Engine
Starting
Running
Running
Stop
Running
Running
Stop
Stop
Running
Stop
Stop
Running
Stop
Stop
Running
Stop
Stop
Running
Stop
Stop
Can Start
Can not
Start
W1015145
6-M4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
[3] OPERATOR PRESENCE CONTROL (OPC)
The BX Tractor equips operator presence control (OPC) system which automatically stops the engine when operator stands up from the operator’s seat while shifting the PTO lever or the speed control pedal.
Tractor without the OPC timer stops quickly and tractor with the OPC timer stops in approximately one second when standing up from the seat.
(1) Slow Blow Fuse
(2) Main Switch
(3) Fuse (10A)
(4) OPC Timer
(5) Seat Switch (From Seat
Switch
ON
or
OFF
)
(6) Fuse
(7) Battery
(8) Engine Stop Solenoid Timer
Relay
(9) Engine Stop Solenoid
W1025506
6-M5
Q
Electrical Circuit (Tractor with OPC Timer)
General electrical circuit of the tractor OPC timer is shown in the figure.
1. When sitting on the operator’s seat in the state of the main switch “
ON
”, the battery voltage passes to the seat switch and the OPC timer (4), and maintain the solenoid relay (8).
2. When standing up from the operator’s seat, the circuit from the seat switch to the OPC timer is cut.
However, if the PTO lever (or the speed control pedal) are set at “
Neutral
” position, the circuit from the battery to the solenoid relay (8) is formed with the
PTO switch (or HST switch).
3. When standing up from the operator’s seat while shifting the levers, the circuit from the battery to the solenoid relay (8) is cut, and the engine is stopped by function of the solenoid (9).
Q
Seat Switch
The seat switch has two positions.
When the operator’s seat is occupied, the switch contact point is at “
ON
” position. When the operator’s seat is not occupied, its contact point is at “
OFF
” position.
Q
OPC Timer
OPC timer is located electrically at between the seat switch (5) and the solenoid relay (8).
When the current supply from the seat switch (5) is cut, the OPC timer (4) adopted for the OPC system has maintained the state of “
ON
” position for approximately one second.
W1025648
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
3. CHARGING SYSTEM
[1] ELECTRICAL CIRCUIT
ELECTRICAL SYSTEM
(1) Illumination Light
(2) Battery Charge Lamp
(3) Fuse
(4) Main Switch
(5) Slow Blow Fuse
(6) Battery
(7) Alternator
(8) Frame Earth
The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.
6-M6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
[2] IC REGULATOR (3P CONNECTOR TYPE)
3P
connector is connected to the IC regulator.
3P
connector consists of three leads, Sb (Sky Blue) lead (1),
RY (Red / Yellow) lead (2), and WR (White / Red) lead
(3).
Sb (Sky Blue) lead (1) is a lead to transmit the pulse from the alternator to hour meter and tachometer. When turning on the main switch to “
ON
” position, the hour meter indicates operated hours.
While the engine runs, the tachometer indicates the present engine revolutions.
RY (Red / Yellow) lead (2) is a lead to chassis.
WR (White / Red) lead (3) is a lead to the charge lamp.
(1) Sb (Sky Blue) Lead
(2) RY (Red / Yellow) Lead
(3) WR (White / Red) Lead
(4) Alternator Assembly
(5) IC Regulator
(6) Load
(7) Load
A : To Main Switch
B : To Hour Meter and
Tachometer
C : To Ground
D : To Charge Lamp
W1013535
6-M7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
4. LIGHTING SYSTEM
ELECTRICAL SYSTEM
(1) Illumination Light
(2) Oil Pressure Lamp
(3) Glow Lamp
(4) Blinker (Left)
(5) Blinker (Right)
(6) Battery Charge Lamp
(7) Water Temperature Gauge
(8) Fuel Gauge
(9) Tail Light (12.8W)
(10) Hazard Lamp (23W)
(11) Thermo Unit
(12) Fuel Sensor
(13) Oil Pressure Switch
(14) Flasher Unit
(15) Head Light (37.5W)
(16) Fuse
(17) Combination Switch
(18) Main Switch
(19) Slow Blow Fuse
(20) Battery
(21) Alternator
(22) Working Light
The lighting system consists of main switch, head light switch, turn signal light switch, hazard switch, head lights, turn signal lights, tail lights, and etc..
6-M8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
5. GAUGES
[1] ELECTRICAL CIRCUIT
ELECTRICAL SYSTEM
(1) Hour and Tachometer
(2) Water Temperature Gauge
(3) Fuel Gauge
(4) Thermo Unit
(5) Fuel Sensor
(6) Fuse
(7) Main Switch
(8) Battery
(9) Frame Earth
The fuel quantity is indicated by the fuel gauge. The coolant temperature is indicated by the water temperature gauge.
6-M9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] HOUR AND TACHOMETER
ELECTRICAL SYSTEM
The electrical hour meter and tachometer is equipped on the meter panel.
This meter indicates the operated hours when the main switch is turned to “
ON
” position.
After starting the engine, this meter indicates the present engine revolution.
The meter picks up the voltage from the IC regulator located in the alternator.
The IC regulator sends a signal of the engine revolution to the meter.
The meter calculates the signal. It changes and indicates the signal to the engine revolution in cooperation with the voltage.
(1) Electrical Hour Meter and
Tachometer
W1013678
[3] FUEL LEVEL GAUGE
Fuel level gauge and fuel level sensor are connected by the wiring.
Fuel level gauge detects the resistance from the fuel level sensor.
Fuel level gauge indicates the fuel level in the fuel tank.
The relationship between the resistance of the fuel level sensor and the fuel level gauges is as follows.
Resistance of Fuel Level
Sensor
Approx. 110
Ω
Approx. 3
Ω
Reading on Fuel Level
Gauge
Empty
Full
(1) Fuel Level Gauge
(2) Fuel Level Sensor
A : Empty
B : Full
[4] WATER TEMPERATURE GAUGE
Water temperature gauge is located on the meter panel board.
The water temperature gauge and the thermo unit are connected by the wiring.
The water temperature gauge detects the resistance from the thermo unit.
The water temperature gauge indicates the coolant temperature in the engine cylinder head.
The relationship between the resistance of thermo unit and reading on the water temperature gauge is as follows.
Resistance of Thermo Unit
Approx. 220
Ω
Approx. 70
Ω
Approx. 3
Ω
Min.
Start of red
Max.
Reading on Water
Temperature gauge
(1) Water Temperature Gauge
(2) Thermo Unit
A : Min.
B : Start of Red
C : Max.
6-M10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
6. OTHERS
[1] DC OUTLET
ELECTRICAL SYSTEM
DC outlet is equipped to this machine.
The capacity of the DC outlet is 12 V / 120 W.
The electrical device as a CD player, a mobile phone battery charger can be used to the DC outlet.
The DC outlet (1) consists of the DC outlet body (3) and the cover (4).
(1) DC Outlet
(2) Electrical Device
(3) DC Outlet Body
(4) Cover
RL : Red / Blue Lead
B : Black Lead
W1021891
6-M11
KiSC issued 06, 2009 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................6-S1
2. SERVICING SPECIFICATIONS ....................................................................6-S5
3. TIGHTENING TORQUES ..............................................................................6-S6
4. CHECKING, DISASSEMBLING AND SERVICING......................................6-S7
[1] CHECKING AND ADJUSTING ...............................................................6-S7
(1) Battery.................................................................................................6-S7
(2) Main Switch.........................................................................................6-S9
(3) Starter ...............................................................................................6-S10
(4) Glow Plug..........................................................................................6-S10
(5) Safety Switch ....................................................................................6-S11
(6) Operator Presence Control (OPC) Switch ........................................6-S13
(7) Fuel Pump.........................................................................................6-S15
(8) Engine Stop Solenoid .......................................................................6-S15
(9) Timer Relay.......................................................................................6-S15
(10)Charging System ..............................................................................6-S16
(11)Alternator ..........................................................................................6-S16
(12)Combination Switch ..........................................................................6-S18
(13)Gauge ...............................................................................................6-S25
(14)DC Outlet ..........................................................................................6-S27
[2] DISASSEMBLING AND ASSEMBLING................................................6-S28
(1) Starter ...............................................................................................6-S28
(2) Alternator ..........................................................................................6-S28
[3] SERVICING ............................................................................................6-S29
(1) Starter ...............................................................................................6-S29
(2) Alternator ..........................................................................................6-S31
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
FUSE AND WIRING
Symptom Probable Cause
All Electrical
Equipments Do Not
Operate
Battery discharged or defective
Battery positive cable disconnected or improperly connected
Battery negative cable disconnected or improperly connected
ELECTRICAL SYSTEM
Solution
Recharge or replace
Repair or replace
Repair or replace
Reference
Page
G-17
–
–
Fuse Blown
Frequently
Slow blow fuse blown
Short-circuited
Replace
Repair or replace
G-30
–
W10143220
BATTERY
Battery Discharges
Too Quickly
Battery defective
Alternator defective
IC Regulator defective
Wiring harness disconnected or improperly connected (between battery positive terminal and regulator
B
terminal)
Cooling fan belt slipping
Replace
Repair or replace
Replace
Repair or replace
Adjust tension
6-S7
6-S28, S31
6-S26, S31
–
G-20
W10137180
STARTING SYSTEM
Starter Motor Does
Not Operate
Engine Does Not
Stop When Main
Switch is Turned OFF
Battery discharged or defective
Slow blow fuse blown
Safety switch improperly adjusted or defective
Wiring harness disconnected or improperly connected (between main switch
50
terminal and safety switches, between safety switches and starter motor, between battery positive terminal and starter motor)
Starter motor defective
Main switch defective
Fuse blown (15 A)
Wiring harness disconnected or improperly connected (between main switch
AC
terminal and engine stop solenoid)
Engine Does Not
Start
Engine stop solenoid defective
Timer relay defective
Engine stop solenoid defective
Timer relay defective
Recharge or replace
Replace
Repair or replace
Repair or replace
Repair or replace
Replace
Replace
Repair or replace
Replace
Replace
Replace
Replace
G-17
G-30
6-S11
–
6-S28
6-S9
G-30
–
6-S15
6-S15
6-S15
6-S15
W10137180
6-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
OPERATOR PRESENCE CONTROL (OPC)
Symptom Probable Cause
Engine Does Not
Stop
Starter Motor Does
Not Operate
Engine Stops When
HST Pedal is Pushed in Forward or in
Reverse
Engine Suddenly
Stops
Solenoid fuse blown (15A)
Engine stop solenoid replay defective
Engine stop solenoid defective
PTO shift lever switch defective
Independent PTO lever switch defective
HST pedal switch defective
Wiring harness disconnected or improperly connected (between key stop solenoid rela11y and engine stop solenoid, between engine stop solenoid relay and battery positive terminal)
Solenoid fuse blown (15A)
Engine stop solenoid defective
Engine stop solenoid relay defective
Seat switch or seat turn over switch defective
PTO shift lever switch defective
Independent PTO lever switch defective
HST pedal switch defective
Wiring harness disconnected or improperly connected (between key stop solenoid relay and engine stop solenoid, between engine stop solenoid relay and battery positive terminal)
Wrong wiring of seat switch and seat turn over switch
Seat reverse switch
Solution
Replace
Replace
Replace
Adjust or replace
Adjust or replace
Adjust or replace
Repair or replace
Replace
Replace
Replace
Adjust or replace
Adjust or replace
Adjust or replace
Adjust or replace
Repair or replace
Proper Wiring
Adjust the switch position
Reference
Page
G-30
6-S15
6-S15
6-S11
6-S12
6-S12
–
G-30
6-S15
6-S15
6-S13
6-S11
6-S12
6-S12
–
6-S13
6-S13
W10236630
CHARGING SYSTEM
Charging Lamp Does
Not Light when Main
Switch is Turned ON
Charging Lamp Does
Not Go Off When
Engine is Running
Fuse blown (15 A)
Wiring harness disconnected or improperly connected (between main switch
AC
terminal and panel board, between panel board and dynamo)
Alternator defective
IC regulator defective
Wiring harness disconnected or improperly connected (between main switch
30
terminal and dynamo, between panel board and dynamo)
Replace
Repair or Replace
Repair or Replace
Replace
Repair or Replace
G-30
–
6-S28, S31
–
–
Alternator defective
IC regulator defective
Repair or Replace
Replace
6-S28, S31
6-S26, S31
W10135800
6-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
LIGHTING SYSTEM
Head Light Does Not
Light
Symptom
Tail Light Does Not
Light
Illumination Light
Does Not Light
Hazard Light Does
Not Light
Hazard Indicator
Lamp Does Not Light
Probable Cause
Fuse blown (15 A)
Bulb blown
Wiring harness disconnected or improperly connected (between main switch
AC
terminal and head light switch, between head light switch and head light)
Fuse blown (15 A)
Bulb blown
Wiring harness disconnected or improperly connected (between main switch
AC
terminal and head light switch, between head light switch and tail light)
Fuse blown (15 A)
Bulb blown
Wiring harness disconnected or improperly connected (between main switch
AC
terminal and head light switch, between head light switch and illumination light)
Fuse blown (15 A)
Bulb blown
Wiring harness disconnected or improperly connected
Flasher unit defective
Hazard switch defective
Bulb blown
Wiring harness disconnected or improperly connected
Flasher unit defective
Hazard Light Does
Not Flicker
Turn Signal Light
Does Not Light
Turn Signal Light
Indicator Lamp Does
Not Light
Turn Signal Light
Does Not Flicker
Fuse blown (15 A)
Bulb blown
Wiring harness disconnected or improperly connected
Flasher unit defective
Blinker switch defective
Bulb blown
Wiring harness disconnected or improperly connected (blinker switch and indicator lamp)
Flasher unit defective
Blinker switch defective
Solution
Replace
Replace
Repair or Replace
Replace
Replace
Repair or Replace
Replace
Replace
Repair or Replace
Replace
Replace
Repair or Replace
Replace
Replace
Replace
Repair or Replace
Replace
Replace
Replace
Repair or Replace
Replace
Replace
Replace
Repair or Replace
Replace
Replace
Reference
Page
G-30
G-31
–
G-30
G-31
–
G-30
–
–
G-30
G-31
–
6-S22
6-S21
–
–
6-S22
G-30
G-31
–
6-S22
6-S21
G-31
–
6-S22
6-S21
W10137180
6-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
LIGHTING SYSTEM (Continued)
Symptom
Glow Lamp Does Not
Light When Main
Switch Is in Pre-heat
Position
Oil Pressure Lamp
Lights Up When
Engine Is Running
Oil Pressure Lamp
Does Not Light When
Main Switch Is
Turned ON and
Engine Is Not
Running
Probable Cause
Battery discharged or defective
Slow blow fuse blown
Wiring harness disconnected or improperly connected (between main switch
19
terminal and pre-heat indicator, between pre-heat indicator and glow plugs)
Main switch defective
Glow lamp defective
Engine oil pressure too low
Engine oil insufficient
Oil pressure switch defective
Short circuit between oil pressure switch lead and chassis
Bulb blown
Oil pressure switch defective
Wiring harness disconnected or improperly connected (between panel board and oil pressure switch)
Replenish
Replace
Repair
Replace
Replace
ELECTRICAL SYSTEM
Solution
Recharge or Replace
Replace
Repair or Replace
Replace
Replace
Repair engine
Repair or Replace
Reference
Page
G-17
G-30
–
6-S9
–
–
G-13
6-S24
–
–
6-S24
–
W10135800
GAUGES
Fuel Warning Lamp
Does Not Light
Coolant Temperature
Gauge Does Not
Function
Fuel gauge defective
Fuel level sensor defective
Wiring harness disconnected or improperly connected (between fuel gauge and fuel level sensor)
Coolant temperature gauge defective
Coolant temperature sensor defective
Wiring harness disconnected or improperly connected (between coolant temperature gauge and coolant temperature sensor)
Replace
Replace
Repair or Replace
Replace
Replace
Repair or Replace
–
6-S25
–
–
6-S25
–
W10137180
6-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
Item
Battery Voltage
Glow Plug
Alternator
Head Light Switch
Blinker Switch
Hazard Light Switch
Potential
Difference
Resistance
Charging Current /
Alternator Speed
Charging Voltage /
Alternator Speed
Switch
OFF
ON
Switch
OFF
R
L
Switch
OFF
ON
Starter
Commutator O.D.
Factory Specification
More than 12 V
Less than 0.1 V
Approx. 0.9
Ω
14 to 15 A /
5200 min
−
1
(rpm)
14 to 15 A /
5200 min
−
1
(rpm)
Infinity
0
Ω
Infinity
0
Ω
0
Ω
Infinity
0
Ω
ELECTRICAL SYSTEM
Allowable Limit
–
–
–
–
–
Mica
Brush
Difference of
O.D.’s
Undercut
Length
30.0 mm
1.181 in.
Less than 0.02 mm
0.0008 in.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
14.0 mm
0.551 in.
29.0 mm
1.142 in.
0.05 mm
0.0020 in.
0.20 mm
0.0079 in.
9.0 mm
0.354 in.
–
–
–
–
–
–
–
Alternator
Starter Resistance
Rotor Resistance
Slip Ring O.D.
Brush Length
Less than 1.0
Ω
2.9
Ω
1.44 mm
0.5669 in.
10.0 mm
0.3937 in.
–
–
14.0 mm
0.5512
1.5 mm
0.0591
W10138740
6-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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-9.)
Item N·m kgf·m
Starter
B
terminal nut 5.9 to 11.8
0.6 to 1.2
ELECTRICAL SYSTEM
lbf·ft
4.3 to 8.7
W10127360
6-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen becomes very explosive.
Q
IMPORTANT
• If the machine is to be operated for a short time without battery (using a slave battery for starting), use additional current (lights) while engine is running and insulate terminal of battery. If this advice is disregarded, damage to alternator and regulator may result.
(1) Battery
Battery Voltage
1. Stop the engine and turn the main switch
OFF
.
2. Connect the COM (
−
) lead of the voltmeter to the battery’s negative terminal post and the (+) lead to the positive terminal post, and measure the battery voltage.
3. If the battery voltage is less than the factory specification, check the battery specific gravity and recharge the battery.
Battery voltage Factory spec.
More than 12 V
(1) Battery
W10125620
Battery Terminal Connection
1. Turn the main switch
ON
, and turn on the head light.
2. Measure the voltage with a voltmeter across the battery’s positive terminal post and the cable terminal, and the voltage across the battery’s negative terminal post and the chassis.
3. If the measurement exceeds the factory specification, clean the battery terminal posts and cable clamps, and tighten them firmly.
Potential difference Factory spec.
Less than 0.1 V
W10126630
6-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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)
.
3. If the specific gravity is less than 1.215 (after it is corrected for temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
Q
NOTE
• Hold the hydrometer tube vertical without removing it from the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye level.
• The hydrometer reading must be taken at the highest electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007
×
(electrolyte temperature
−
20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004
×
(electrolyte temperature
−
68 °F)
Specific Gravity
1.260 Sp. Gr.
1.230 Sp. Gr.
1.200 Sp. Gr.
1.170 Sp. Gr.
State of Charge
100 % Charged
75 % Charged
50 % Charged
25 % Charged
1.140 Sp. Gr.
1.110 Sp. Gr.
Very Little Useful Capacity
Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good
(b) Bad
(c) Bad
W10127630
6-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Main Switch
ELECTRICAL SYSTEM
Main Switch Connector Voltage
1. Remove the under cover panel.
2. Disconnect the
4P
connector (4) and remove the main switch (1).
3. Measure the voltage with a voltmeter across the connector
30
(red) terminal and chassis.
4. If the voltage differs from the battery voltage (11 to 14 V), the wiring harness is faulty.
Voltage
Connector
30
terminal
– chassis
Approx. battery voltage
(1) Main Switch (2)
4P
Connector
W10135530
Main Switch Continuity
1) Main Switch Key at OFF Position
1. Set the main switch
OFF
position.
2. Measure the resistance with an ohmmeter across the
B
terminal and the
ACC
terminal,
B
terminal and
ST
terminal,
B
terminal and
G
terminal.
3. If infinity is not indicated, the contacts of the main switch are faulty.
Resistance
B
terminal –
ACC
terminal
B
terminal –
ST
terminal
B
terminal –
G
terminal
Infinity
2) Main Switch Key at ON Position
1. Set the main switch
ON
position.
2. Measure the resistance with an ohmmeter across the
B
terminal and the
ACC
terminal.
3. If 0 ohm is not indicated, the
B
–
ACC
contact of the main switch are faulty.
Resistance
B
terminal –
ACC
terminal 0
Ω
3) Main Switch Key at PREHEAT Position
1. Set and hold the main switch key at the
PREHEAT
position.
2. Measure the resistance with an ohmmeter across the
B
terminal and the
G
terminal, and measure the resistance across the
B
terminal and the
ACC
terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are faulty.
B
terminal –
G
terminal
Resistance 0
Ω
B
terminal –
ACC
terminal
4) Main Switch Key at START Position
1. Set and hold the main switch key at the
START
position.
2. Measure the resistance with an ohmmeter across the
B
terminal and the
G
terminal, across the
B
terminal and the
ST
terminal, and across the
B
terminal and the
ACC
terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are faulty.
Resistance
B
terminal –
G
terminal
B
terminal –
ST
terminal
B
terminal –
ACC
terminal
0
Ω
(1)
B
Terminal
(2)
ST
Terminal
(3)
ACC
Terminal
(4)
G
Terminal
W10136580
6-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(3) Starter
ELECTRICAL SYSTEM
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.
3. Remove the starter from the engine.
4. Disconnect the connecting lead (2) from the starter
C
terminal
(1).
5. Connect a jumper lead from the connecting lead (2) to the battery positive terminal post.
6. Connect a jumper lead momentarily between the starter motor housing and the battery negative terminal post.
7. If the motor does not run, check the motor.
(1)
C
Terminal (2) Connecting Lead
W10142670
Magnet Switch Test (Pull-in, Holding Coils)
1. Remove the motor from the starter housing.
2. Prepare a 6 V battery for the test.
3. Connect jumper leads from the battery negative terminal to the housing and the starter
C
terminal.
4. The plunger should be attracted and the pinion gear should pop out when a jumper lead is connected from the battery positive terminal to the
S
terminal. It’s a correct.
5. Disconnect the jumper lead to the starter
C
terminal. Then the pinion gear should remain popped out. It’s a correct.
Q
IMPORTANT
• Testing time must be 3 to 5 sec..
C : C Terminal
S : S Terminal
(a) To Negative Terminal
(b) To Positive Terminal
W1015210
(4) Glow Plug
Lead Terminal Voltage
1. Disconnect the wiring lead (2) from the glow plug (1) after turning the main switch off.
2. Turn the main switch key to the
“PREHEAT”
position, and measure the voltage between the lead terminal and the chassis.
3. Turn the main switch key to the
“START”
position, and measure the voltage with a voltmeter between the lead terminal and the chassis.
4. If the voltage at either position differs from the battery voltage, the wiring harness or main switch is faulty.
Voltage
(Lead terminal –
Chassis)
Main switch key at
“PREHEAT”
Main switch key at
“START”
Approx. battery voltage
Approx. battery voltage
(1) Glow Plug (2) Wiring Lead (Positive)
W10149130
6-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, 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.
4. If the factory specification is not indicated, the glow plug is faulty.
Glow plug resistance Factory spec.
Approx. 0.9
Ω
W10151150
(5) Safety Switch
PTO Shift Lever Switch Continuity
1. Remove the left rear wheel.
2. Remove the PTO shift lever switch (1).
3. Measure the resistance with an ohmmeter across the switch terminals.
4. If the resistance values specified below are not indicated, the safety switch is faulty.
Q
Plunger is pushed into the switch body
Resistance
1
terminal (5) -
2
terminal (6)
Factory spec.
0
Ω
Resistance
3
terminal (7) -
4
terminal (8)
Factory spec.
0
Ω
Q
Plunger is released
Resistance
1
terminal (5) -
2
terminal (6)
Factory spec.
Resistance
3
terminal (7) -
4
terminal (8)
Factory spec.
(1) PTO Shift Lever Switch
(2)
2P
Connector (LH)
(3)
2P
Connector (RH)
(4) Plunger
Infinity
Infinity
(5)
1
Terminal
(6)
2
Terminal
(7)
3
Terminal
(8)
4
Terminal
W10158610
6-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
HST Neutral Switch Continuity
1. Remove the right rear wheel.
2. Remove the HST neutral switch (1).
3. Measure the resistance with an ohmmeter across the HST neutral switch terminals.
4. If the resistance values specified below are not indicated, the safety switch is faulty.
Q
Plunger is pushed into the switch body
Resistance
1
terminal (5) -
2
terminal (6)
Factory spec.
0
Ω
Resistance
3
terminal (7) -
4
terminal (8)
Factory spec.
0
Ω
Q
Plunger is released
Resistance
1
terminal (5) -
2
terminal (6)
Factory spec.
Resistance
3
terminal (7) -
4
terminal (8)
Factory spec.
(1) HST Neutral Switch
(2)
2P
Connector (LH)
(3)
2P
Connector (RH)
(4) Plunger
Infinity
Infinity
(5)
1
Terminal
(6)
2
Terminal
(7)
3
Terminal
(8)
4
Terminal
W10384760
6-S12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
(6) Operator Presence Control (OPC) Switch
Seat Switch and Seat Turnover Switch Continuity Check
1. Disconnect the
2P
connectors (2) from the seat turnover switch
(1) and the seat switch.
2. Remove the seat turnover switch (1).
3. Connect the circuit tester to the terminals (5).
(When switch is not pushed / When operator leave the seat)
1. Measure the resistance between terminals (5).
2. If continuity is not infinity, the switch is faulty. Replace it.
(When switch is pushed / When operator sits on the seat)
1. Measure the resistance between terminals (5).
2. If continuity is not 0
Ω
, the switch is faulty. Replace it.
Resistance
When switch is not pushed /
When operator leave the seat
When switch is pushed /
When operator sits on the seat
Infinity
0
Ω
(1) Seat Turnover Switch
(2)
2P
Connector
(3) Seat Switch
2P
Connector
(4) Seat
(5) Terminals
[A] Seat Switch is not Pushed
[B] Seat Switch is Pushed
W10440960
6-S13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Checking OPC Timer
1. Remove the OPC timer. (The OPC timer is located under the fender center stay.)
2. Connect the jumper leads across the battery terminal and the
Red / White terminal (2), and across the battery positive terminal and the Yellow terminal (3).
3. Connect the jumper lead across the battery negative terminal and the Black terminal (5), and across the battery negative terminal and the Blue terminal.
4. Connect the jumper lead across the Red terminal (4) and the bulb terminal.
5. The bulb lights up when disconnecting the jumper lead from the
Red / White terminal (2) 0.7 to 1.3 seconds, the OPC timer (1) is proper.
(1) OPC Timer
(2) Red / White Terminal (From Battery)
(3) Yellow Terminal (From OPC Switch)
(4) Red Terminal (To Key Stop Solenoid)
(5) Black Terminal (To Frame Earth)
(6) Bulb (Load)
(7) Battery
W10647550
6-S14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(7) Fuel Pump
ELECTRICAL SYSTEM
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.
3. If the voltage differs from the battery voltage, the wiring harness or main switch is faulty.
Voltage
Between connector terminals
Approx. battery voltage
W1016341
Fuel Pump Continuity
1. Disconnect the
2P
connector from the fuel pump.
2. Check the continuity between the connector terminals with an ohmmeter.
3. If it does not conduct, the fuel pump is faulty.
W1016134
(8) Engine Stop Solenoid
(9) Timer Relay
Engine Stop Solenoid Test
1. Disconnect the
1P
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
1P
connector, and from the battery negative terminal to the engine stop solenoid body.
4. If the solenoid plunger is not attracted, the engine stop solenoid is faulty.
(1) Battery (12 V)
W1019658
Timer Relay Connector Voltage
1. Disconnect the connector from the timer relay after turning the main switch off.
2. Measure the voltage with a voltmeter across the connector terminal
4
and chassis.
3. Turn the main switch on, and measure the voltage across the connector terminal
3
and chassis.
4. If these voltages differ from the battery voltage, the wiring harness or main switch is faulty.
Voltage
Connector terminal
4
-chassis
Connector terminal
3
-chassis
Approx. battery voltage
Approx. battery voltage
(1) Timer Relay
W1016544
6-S15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Test of Timer Relay
1. Remove the timer relay from the tractor.
2. Connect jumper leads across the battery positive terminal and the timer relay terminal
3
, and across the battery positive terminal and the timer relay terminal
4
.
3. Connect jumper leads across the battery negative terminal and the timer relay terminal
2
, and across the battery negative terminal and the bulb terminal.
4. Connect jumper lead across the timer relay terminal
1
and the bulb terminal.
5. The bulb lights up when disconnecting a jumper lead from the terminal
3
arid goes off 6 to 13 seconds late, the timer relay is proper.
(1) Timer Relay
(2) Load (Lamp)
(3) Battery (12V)
W1016721
(10) Charging System
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.
Q
NOTE
• Connect an ammeter only after starting the engine.
• When the electrical loads is considerably low or the battery is fully charged, the specified reading may not be obtained.
Factory spec.
Current
Voltage
Alternator speed
14 to 15 A
14 to 15 V
5200 min
-1
(rpm)
(1) Battery Positive Cord
W1048417
(11) Alternator
Stator
1. Measure the resistance across each lead of the stator coil with resistance range of circuit tester.
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with resistance range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance Factory spec.
Less than 1.0
Ω
W1019964
Rotor
1. Measure the resistance across the slip rings.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with resistance range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance Factory spec.
2.9
Ω
W1020094
6-S16
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
Slip ring O.D.
Factory spec.
Allowable limit
14.4 mm
0.567 in.
14.0 mm
0.551 in.
W12365478
Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
Brush length
Factory spec.
Allowable limit
10.5 mm
0.413 in.
8.4 mm
0.331 in.
W1020329
Rectifier
1. Check the continuity across each diode of rectifier with resistance range of circuit tester.
2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
W1020452
6-S17
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(12) Combination Switch
ELECTRICAL SYSTEM
Combination Switch
1. Remove the meter panel, and disconnect the combination switch connector.
2. Remove the combination switch (1) and perform the following checks
1)
to
8)
.
(1) Combination Switch
(2) Red / Yellow Lead
(3) Green Lead
(4) Black / Blue Lead
(5) Blue / White Lead
(6) Yellow Lead
(7) Orange Lead
(8) Red / White Lead
(9) Green / White Lead
W1049462
1) Connector Voltage
1. Connect the combination switch connector to the main wire harness.
2. Measure the voltage with a voltmeter across the connector
B1
terminal and chassis when the main switch is
ON
position.
3. If the voltage differs from the battery voltage, the wiring harness and main switch is faulty.
Voltage
Main switch at
“
ON
” position
B1
terminal -
Chassis
Battery voltage
W1050272
2) Head Light Switch Continuity when Setting Switch at “OFF”
Position
1. Set the light switch to the
OFF
position.
2. Measure the resistance with an ohmmeter across the red / yellow lead (1) to the orange lead (4), the red / yellow lead (1) to the yellow lead (3).
3. If infinity is not indicated, the head light switch is faulty.
Resistance
(Switch at
OFF
position)
Red / Yellow lead (1) -
Orange lead (4)
Red / Yellow lead (1) -
Yellow lead (3)
Infinity
(1) Red / Yellow Lead
(2) Blue / White Lead
(3) Yellow Lead
(4) Orange Lead
(5) Red / White Lead
A : Head Light “OFF” Position
W1050981
6-S18
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
3) Head Light Switch Continuity when Setting Switch at “ON”
Position
1. Set the light switch to the
ON
position.
2. Measure the resistance with an ohmmeter across the red / yellow lead (1) to the orange lead (4) and the red / yellow lead (1) to the yellow lead (3).
3. If infinity is not indicated, the head light switch is faulty.
Resistance
(Switch at
ON
position)
Red / Yellow lead (1) -
Orange lead (4)
Red / Yellow lead (1) -
Yellow lead (3)
0
Ω
(1) Red / Yellow Lead
(2) Blue / White Lead
(3) Yellow Lead
(4) Orange Lead
(5) Red / White Lead
A : Head Light “OFF” Position
W1051881
4) Turn Signal Light Switch Continuity when Setting Switch
Knob “OFF” Position
1. Set the turn signal switch knob to the
OFF
position.
2. Measure the resistance with an ohmmeter across the green lead
(1) and red / white lead (2), and across to the green lead (1) and green / white lead (3).
3. If infinity is not indicated, the combination switch is faulty.
Resistance
(Switch knob at
OFF
position)
Green lead (1) - Red /
White lead (4)
Green lead (1) -
Green / White lead (3)
0
Ω
(1) Green Lead
(2) Red / White Lead
(3) Green / White Lead
A : Turn Signal Light Switch “OFF”
Position
W1052305
6-S19
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
5) Turn Signal Light Switch Continuity when Setting Switch
Knob “RIGHT” Position
1. Set the turn signal switch knob to the
RIGHT
position.
2. Measure the resistance with an ohmmeter across the green lead
(1) and red / white lead (2), and across to the green lead (1) and green / white lead (3).
3. If 0
Ω
is not indicated, the combination switch is faulty.
Resistance
(Switch knob at
RIGHT
position)
Green lead (1) - Red /
White lead (4)
Green lead (1) -
Green / White lead (3)
0
Ω
Infinity
(1) Green Lead
(2) Red / White Lead
(3) Green / White Lead
A : Turn Signal Light Switch “RIGHT”
Position
W1052995
6) Turn Signal Light Switch Continuity when Setting Switch
Knob “LEFT” Position
1. Set the turn signal switch knob to the
LEFT
position.
2. Measure the resistance with an ohmmeter across the green lead
(1) and red / white lead (2), and across to the green lead (1) and green / white lead (3).
3. If 0
Ω
is not indicated, the combination switch is faulty.
Resistance
(Switch knob at
LEFT
position)
Green lead (1) - Red /
White lead (4)
Green lead (1) -
Green / White lead (3)
Infinity
0
Ω
(1) Green Lead
(2) Red / White Lead
(3) Green / White Lead
A : Turn Signal Light Switch “LEFT”
Position
W1053450
6-S20
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
7) Hazard Switch Continuity when Setting Switch Knob at
“OFF” Position
1. Set the hazard switch knob to the
OFF
position.
2. Measure the resistance with an ohmmeter across the black / blue lead (1) and blue / white lead (2).
3. If infinity is not indicated, the combination switch is faulty.
Resistance
(Hazard switch at
OFF
position)
Black / Blue lead (1) -
Blue / White lead (2)
Infinity
(1) Black / Blue Lead
(2) Blue / White Lead
A : Hazard Switch “OFF” Position
W1053841
8) Hazard Switch Knob at “ON” Position
1. Set the hazard switch knob to the
ON
position.
2. Measure the resistance with an ohmmeter across the black / blue lead (1) and blue / white lead (2).
3. If 0
Ω
is not indicated, the combination switch is faulty.
Resistance
(Hazard switch at
ON
position)
Black / Blue lead (1) -
Blue / White lead (2)
0
Ω
(1) Black / Blue Lead
(2) Blue / White Lead
A : Hazard Switch “ON” Position
W1054637
6-S21
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Flasher Unit
1. Remove the under panel.
2. Disconnect the coupler (2) from flasher unit.
3. Measure the voltage with a voltmeter across the terminal
h
and terminal
c
or chassis.
4. If the voltage differs from the battery voltage, the wiring harness is faulty.
Voltage
Terminal
h
–
Terminal
c
or Chassis
Approx. battery voltage
(1) Flasher Unit (2) Coupler
W1055033
Flasher Unit Actuation Test
1. Set the hazard switch to the
ON
position, and make sure the hazard light gives 60 to 85 flashes for a minute.
2. With the main switch and the hazard switch at the
ACC
and
ON
positions, respectively, move the turn signal light switch to the left. Make sure that the right-hand light stays on and the left-hand light gives flashes earlier (by about 20 flashes) than when the hazard lamp is activated. Then move the turn signal light switch to the right and make sure the corresponding actions take place.
3. Now set the main switch to the
ACC
position and move the blinker switch alone. Make sure the same actions as above result.
4. If both the hazard switch and the turn signal light switch function but the above actions do not take place, replace the flasher unit with new one.
(1) Hazard Light Switch
(2) Turn Signal Light Switch
(3) Flasher Unit
W36974125
6-S22
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Charge Lamp (Charging Circuit)
1. Disconnect the
3P
connector from the alternator after turning the main switch
OFF
.
2. Turn the main switch
ON
and connect a jumper lead from the wiring harness connector terminal (White / Red) to the chassis.
Q
NOTE
• If you connect the jumper lead from the wiring harness connector terminal (White / Red) to the chassis, 15A fuse will be blown. Do not connect the lead to Red / Yellow terminal.
3. If the charge lamp does not light, the wiring harness or fuse is faulty.
(1) Alternator
(2)
3P
Connector
(3)
Sb
(Sky Blue) Terminal
(4)
RY
(Red / Yellow) Terminal
(5)
WR
(White / Red) Terminal
A : To Main Switch
B : To Hour Meter and Tachometer
C : To Change Lamp
D : To Ground
W123698547
6-S23
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Engine Oil Pressure Lamp
1. Disconnect the lead (2) from the engine oil pressure switch (1) after turning the main switch
OFF
.
2. Turn the main switch
ON
and connect a jumper lead from the lead to the chassis.
3. If the engine oil pressure indicator lamp does not light, the wiring harness is faulty.
(1) Engine Oil Pressure Switch
(2) Lead
(a) From Oil Pressure Lamp
W78965432
Engine Oil Pressure Switch Continuity
1. Disconnect the lead (2) from the engine oil pressure switch (1).
2. Measure the resistance with an ohmmeter across the switch terminal and the chassis.
3. If 0 ohm is not indicated in the normal state, the switch is faulty.
4. If infinity is not indicated at pressure over 4.9 kPa (0.5 kgf/cm
2
, 7 psi), the switch is faulty.
0
Ω
Resistance
(Switch terminal –
Chassis)
In normal state
At pressure over approx. 4.9 kPa
(0.5 kgf/cm
2
, 7 psi)
Infinity
(1) Engine Oil Pressure Switch (2) Lead
W1055934
6-S24
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(13) Gauge
ELECTRICAL SYSTEM
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.
3. If the reference values are not indicated, the sensor is faulty.
Resistance
(Sensor terminal – its body)
Reference value
Float at upper-most position
Float at lower-most position
1 to 5
Ω
103 to 117
Ω
E : Empty F : Full
W56478923
Coolant Temperature Sensor (Thermo Unit)
1) Lead Terminal Voltage
1. Disconnect the lead from the coolant temperature sensor after turning the main switch
OFF
.
2. Turn the main switch
ON
and measure the voltage with a voltmeter across the lead terminal and the chassis.
If the voltage differs from the battery voltage, the wiring harness, fuse or coolant temperature gauge is faulty.
Voltage Lead terminal – Chassis Approx. battery voltage
2) Sensor Continuity
1. Measure the resistances with an ohmmeter across the sensor terminal and the chassis.
2. If the reference value is not indicated, the sensor is faulty.
Resistance
(Sensor terminal –
Chassis)
Reference value
Approx. 16.1
Ω
at 120 °C (248 °F)
Approx. 27.4
Ω
at 100 °C (212 °F)
Approx. 51.9
Ω
at 80 °C (176 °F)
Approx. 153.9
Ω
at 50 °C (122 °F)
(1) Coolant Temperature Sensor
(a) From Temperature Gauge
W56874921
6-S25
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Hour Meter and Tachometer
1. Disconnect the
3P
connector (4) from the IC regulator (9) located in the alternator (5) after starting the engine.
2. Measure the voltage with a voltmeter across the hour meter terminal (6) and the alternator body when the hour meter or tachometer does not indicated the proper value.
3. If the measured voltages differ from the specified voltage, the hour meter and tachometer is faulty.
Voltage while engine runs at idling speeds
Hour meter terminal –
Alternator body
Approx. battery voltage
(1) Sb (Sky Blue) Lead
(2) RY (Red / Yellow) Lead
(3) WR (White / Red) Lead
(4)
3P
Connector
(5) Alternator
(6) Hour Meter and Tachometer
Terminal
(7) Ground Terminal
(8) Charge Lamp Terminal
(9) IC Regulator
A : To Main Switch
B : To Hour Meter and Tachometer
C : To Ground
D : To Charge Lamp
W1057349
6-S26
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(14) DC Outlet
ELECTRICAL SYSTEM
DC Outlet Connector Voltage and DC Outlet Continuity
1. Disconnect the connector from the DC outlet. And turn the main switch “
ON
”.
2. Measure the voltage with a voltmeter across the connector red / blue lead and the chassis.
If the voltage differs from the battery voltage the wiring harness is faulty.
3. Disconnect the connector from the DC outlet. Since the DC outlet can not be removed easily, measure the continuity with a ohm meter across the plus terminal (4) and the nut (3), and across the earth terminal (5) and the DC outlet case (6).
4. If the resistance differs from 0 ohm, the DC outlet body (1) is faulty.
DC outlet connector voltage
Red / Blue lead – Chassis Battery voltage
DC outlet continuity
Plus terminal – Nut
Earth terminal – DC outlet case
0
Ω
(1) DC Outlet Body
(2) Fuse
(3) Nut
(4) Plus Terminal (for Battery)
(5) Earth Terminal (for Chassis)
(6) DC Outlet Case
W1063447
6-S27
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
[2] DISASSEMBLING AND ASSEMBLING
(1) Starter
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).
3. Remove the two screws (5), and then take out the brush holder
(3) from the end frame (4).
(When reassembling)
• Apply grease to the spline teeth (
A
) of the armature (1).
Tightening torque Nut (7)
5.9 to 11.8 N·m
0.6 to 1.2 kgf·m
4.3 to 8.7 lbf·ft
(1) Armature
(2) Yoke
(3) Brush Holder
(4) End Frame
(5) Screw
(6) Screw
(7) Nut
(8) Magnet Switch
(9) Connecting Lead
A : Spline Teeth
W1016288
Magnet Switch
1. Remove the drive end frame (1) mounting screws.
2. Take out the overrunning clutch (2), ball (3), spring (4), gears (5), rollers (6) and retainer (7).
(When reassembling)
• Apply grease to the gear teeth of the gears (5) and overrunning clutch (2), and ball (3).
(1) Drive End Frame
(2) Overrunning Clutch
(3) Ball
(4) Spring
(5) Gear
(6) Roller
(7) Retainer
W1016728
Plunger
1. Remove the end cover (1).
2. Take out the plunger (2).
(1) End Cover (2) Plunger
W1016883
(2) Alternator
Alternator
1. Check the battery charging voltage while engine runs.
2. Check the increasing voltage when increasing the engine revolution.
3. If the battery charging voltage does not increase, the alternator is faulty.
4. Replace the alternator as an assembly.
(1) Battery
W1058597
6-S28
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[3] SERVICING
(1) Starter
ELECTRICAL SYSTEM
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
4. If the pinion slips or does not rotate in the both directions, replace the overrunning clutch assembly.
W1016990
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.
3. If the minimum O.D. is less than the allowable limit, replace the armature.
4. If the difference of the O.D.’s exceeds the allowable limit, correct the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a saw blade and chamfer the segment edges.
Commutator O.D.
Factory spec.
Allowable limit
30.0 mm
1.181 in.
29.0 mm
1.142 in.
Difference of O.D.’s
Mica undercut
(1) Segment
(2) Undercut
(3) Mica
Factory spec.
Allowable limit
Less than 0.02 mm
0.0008 in.
0.05 mm
0.0020 in.
Factory spec.
Allowable limit
(a) Correct
(b) Incorrect
0.50 to 0.80 mm
0.0197 to 0.0315 in.
0.20 mm
0.0079 in.
W1017092
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with emery paper.
2. Measure the brush length
(A)
with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke assembly and brush holder.
Brush length
(A)
Factory spec.
Allowable limit
14.0 mm
0.551 in.
9.0 mm
0.354 in.
W1017544
6-S29
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM ELECTRICAL SYSTEM
Brush Holder
1. Check the continuity across the brush holder and the holder support with an ohmmeter.
2. If it conducts, replace the brush holder.
W1017672
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.
4. If it does not conduct, replace the armature.
W1017767
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.
4. If it conducts, replace the yoke assembly.
(1) Lead
(2) Brush
(3) Yoke
W1018015
6-S30
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
(2) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
ELECTRICAL SYSTEM
W1019790
Alternator Components
1. When the alternator does not generator or does not charge the battery, replace the alternator as an assembly.
W1060576
6-S31
KiSC issued 06, 2009 A
7
MOWER
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
SAFETY INSTRUCTIONS
SAFETY DECALS
SAFETY INSTRUCTIONS
The following safety decals are installed on the mower.
If a decal becomes damaged, illegible or is not on the mower, replace it. The decal part number is listed in the parts list.
7-1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
7-2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
7-3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SPECIFICATIONS
SPECIFICATIONS
Model
Suitable tractor
Mounting method
Adjustment of cutting height
Cutting width
Cutting height
Weight (Approx.)
Blade spindle speed
Blade tip velocity
Blade length
Number of blades
Dimensions
Overall length
Overall width
Overall height (Min.)
RCK60B-23BX RCK54P-23BX
BX2360
BX2660
BX2360
RCK54-23BX
BX1860
BX2360
RCK48P-18BX
Quick-Joint, Parallel linkage
RCK48-18BX
BX1860
Self-balance suspended linkage
Suspended linkage
1524 mm
(60 in.)
1375 mm
(54 in.)
Dial gauge
1372 mm
(54 in.)
1225 mm
(48 in.)
1219 mm
(48 in.)
115 kg (250 lbs) 86 kg (190 lbs)
44.1 r/s
(2647 rpm)
72.5 m/s
(14271 fpm)
523 mm
(20.6 in.)
25 to 102 mm (1.0 to 4.0 in.)
95 kg (210 lbs)
49.5 r/s
(2969 rpm)
73.8 m/s
(14527 fpm)
475 mm
(18.7 in.)
82 kg (181 lbs) 75 kg (165 lbs)
54.7 r/s
(3281 rpm)
72.8 m/s
(14331 fpm)
424 mm
(16.7 in.)
1000 mm
(39.4 in.)
1930 mm
(76.0 in.)
281 mm
(11.0 in.)
908 mm
(35.7 in.)
1700 mm
(67.0 in.)
291 mm
(11.5 in.)
3
928 mm
(36.5 in.)
1780 mm
(66.5 in.)
281 mm
(11.0 in.)
881 mm
(34.7 in.)
1550 mm
(61.0 in.)
291 mm
(11.5 in.)
895 mm
(35.2 in.)
1544 mm
(60.8 in.)
268 mm
(10.5 in.)
W1028770
7-4
KiSC issued 06, 2009 A
GENERAL
CONTENTS
1. MOWER IDENTIFICATION........................................................................... 7-G1
2. LUBRICANTS ................................................................................................ 7-G2
3. TIGHTENING TORQUES ............................................................................. 7-G3
4. MAINTENANCE CHECK LIST ..................................................................... 7-G5
5. CHECK AND MAINTENANCE ..................................................................... 7-G6
[1] CHECK POINTS OF DAILY OR EACH USE ..................................... 7-G6
[2] CHECK POINT OF INITIAL 50 HOURS ............................................. 7-G8
[3] CHECK POINT OF EVERY 150 HOURS ........................................... 7-G8
[4] CHECK POINT OF EVERY 2 YEARS ................................................ 7-G9
6. SETTING UP MOWER .............................................................................. 7-G10
7. MOWER ADJUSTMENT ............................................................................. 7-G13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
1. MOWER IDENTIFICATION
When contacting your local KUBOTA distributor, always specify mower serial number.
(1) Mower Serial Number
A : RCK60B-23BX, RCK54P-23BX,
RCK54-23BX, RCK48-18BX
B : RCK48P-18BX
W1020623
7-G1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. LUBRICANTS
2
3
4
5
6
7
No.
1 Gear Box
Place
RCK60B-23BX
RCK54-23BX
RCK48-18BX
RCK54P-23BX
RCK48P-18BX
Capacity
0.36 L
0.38 U.S.qts
0.32 lmp.qts
0.15 L
0.16 U.S.qts
0.13 lmp.qts
Greasing
Universal joint
Three spindle shafts
Belt tension pulley
Belt tension pivot
Balance shaft (RCK60B-23BX only)
Front and rear anti-scalp roller
Until grease overflows.
G
GENERAL
Lubricants
SAE 90 gear oil
(API Service GL-5 gear oil)
SAE multi-purpose type grease
NLGI-2 or NLGI-1(GC-LB)
7-G2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
3. TIGHTENING TORQUES
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below.
Q
GENERAL USE SCREWS, BOLTS AND NUTS
Indication on top of bolt
No-grade or 4T 7T 9T
Material of bolt SS400, S20C S43C, S48C
SCr435,
SCM435
Material of opponent part
Unit
Diameter
Ordinariness Aluminum Ordinariness Aluminum Ordinariness
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
246 to
284
334 to
392
108 to
125
167 to
191
40 to
45
63 to
72
7.9
to
9.3
18 to
20
25.0
to
29.0
34.0
to
40.0
11.0
to
12.8
17.0
to
19.5
4.0
to
4.6
6.4
to
7.4
0.80
to
0.95
1.8
to
2.1
181 to
209
246 to
289
79.6
to
92.5
123 to
141
29 to
33
47 to
53
5.8
to
6.8
13 to
15
7.9
to
8.8
17 to
19
32 to
34
–
–
–
–
–
0.80
to
0.90
1.7
to
2.0
3.2
to
3.5
–
–
–
–
–
5.8
to
6.5
13 to
14
24 to
25
–
–
–
–
–
275 to
318
368 to
431
124 to
147
197 to
225
48 to
55
78 to
90
9.81
to
11.2
24 to
27
28.0
to
32.5
37.5
to
44.0
12.6
to
15.0
20.0
to
23.0
4.9
to
5.7
7.9
to
9.2
1.00
to
1.15
2.4
to
2.8
203 to
235
272 to
318
91.2
to
108
145 to
166
36 to
41
58 to
66
7.24
to
8.31
18 to
20
40 to
44
63 to
72
7.9
to
8.8
18 to
20
–
–
–
–
4.0
to
4.5
6.4
to
7.4
0.80
to
0.90
1.8
to
2.1
–
–
–
–
29 to
32
47 to
53
5.8
to
6.5
13 to
15
–
–
–
–
344 to
402
491 to
568
167 to
196
260 to
304
61 to
70
103 to
117
12.3
to
14.2
30 to
34
6.2
to
7.2
10.5
to
12.0
1.25
to
1.45
3.0
to
3.5
35.0
to
41.0
50.0
to
58.0
17.0
to
20.0
26.5
to
31.0
123 to
144
192 to
224
254 to
296
362 to
419
W1034542
45 to
52
76.0
to
86.7
9.05
to
10.4
22 to
25
Q
STUD BOLTS
Material of opponent part
Unit
Diameter
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
Ordinariness Aluminum
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
12 to
15
25 to
31
29.5
to
49.0
1.2
to
1.6
2.5
to
3.2
3.0
to
5.0
8.7
to
11
18 to
23
21.7
to
36.1
8.9
to
11
20 to
25
31.4
0.90
to
1.2
2.0
to
2.6
3.2
6.5
to
8.6
15 to
18
23.1
W1048139
7-G3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF THREADS
SAE GR.5
SAE GR.8
Grade
G
GENERAL
Unit
Nominal
Diameter
5/16
3/ 8
1/ 2
9/16
5/ 8
N·m
23.1 to 27.7
48 to 56
109 to 130
149.2 to 178.9
203.4 to 244
kgf·m
2.35 to 2.83
4.9 to 5.8
11.1 to 13.2
15.21 to 18.24
20.74 to 24.88
lbf·ft
17.0 to 20.5
35.0 to 42.0
80.0 to 96.0
110.0 to 132.0
150.0 to 180.0
N·m
32.6 to 39.3
61.1 to 73.2
149.2 to 178.9
217.0 to 260.3
298.3 to 357.9
kgf·m
3.32 to 4.00
6.23 to 7.46
15.21 to 18.24
22.12 to 26.54
30.42 to 36.49
lbf·ft
24.0 to 29.0
45.0 to 54.0
110.0 to 132.0
160.0 to 192.0
220.0 to 264.0
W1022485
Q
PLUGS
Material of opponent part
Shape
Tapered screw
Size
R1/8
N·m
13 to 21
Ordinariness kgf·m
1.3 to 2.2
lbf·ft
9.4 to 15
N·m
13 to 21
Aluminum kgf·m
1.3 to 2.0
lbf·ft
9.4 to 15
R1/4
25 to 44 2.5 to 4.5
18 to 32 25 to 34 2.5 to 3.5
18 to 25
Straight screw
G1/4
G3/8
G1/2
25 to 34
62 to 82
49 to 88
2.5 to 3.5
6.3 to 8.4
5.0 to 9.0
18 to 25
46 to 60
37 to 65
–
–
–
–
–
–
–
–
–
0000001666E
7-G4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
4. MAINTENANCE CHECK LIST
To keep the mower working in good condition as well as to avoid any accident and trouble, carry out periodic inspection and maintenance. Check the following points before use.
Period Service Interval
No.
Daily check Every 50 hrs Every 150 hrs Every 2 years
Reference page
Item
1 Oil leakage check
2 Make sure blade bolts are tight
3 Blade wear check
4 All hardware check
5 Make sure all pins are in place
6 Mower deck cleaning
7 Greasing universal joint
8 Greasing three spondle shafts
9 Greasing belt tension pulley
10 Greasing balance shaft
11
Greasing front and rear anti-scalp rollers
12 Gear box oil check
13 Gear box oil change
14 Gear box oil seal charge
,
,
,
,
,
,
,
,
,
,
,
,
+ ,
,
7-G6
7-S5
7-S4
–
–
–
7-G6, G7
7-G6, G7
7-G6, G7
7-G6, G7
7-G6, G7
7-G6
7-G8
7-G9
Q
IMPORTANT
• The jobs indicated by
+
must be done after the first 50 hours of operation.
W1035769
7-G5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
5. CHECK AND MAINTENANCE
[1] CHECK POINTS OF DAILY OR EACH USE
Retightening Mower Blade Screw
CAUTION
• To avoid injury, always handle the mower blade with care.
1. Dismount the mower and turn it over to expose the mower blades.
2. Wedge a block of wood securely between the mower blade and mower deck.
3. Retighten the mower blade screw to the specified torque.
4. If the mower blade screw is worn or broken, replace it.
Tightening torque Mower blade screw
98.1 to 117 N·m
10.0 to 12.0 kgf·m
72.4 to 86.7 lbf·ft
(1) Mower Blade Screw
W12345678
Checking Gear Box Oil Level
1. Place the mower on level ground.
2. Loosen the check plug (1), and check to see if oil seems from the opening.
3. If the oil level is low, remove the oil filler plug (2) and add new gear oil.
Q
IMPORTANT
• Use the specified gear oil.
Refer to “LUBRICANTS”. (See page 7-G2.)
(1) Check Plug
(2) Oil Filler Plug
(3) Drain Plug
[A] RCK60B-23BX, RCK54-23BX,
RCK48-18BX
[B] RCK48P-18BX, RCK54P-23B
W12378945
Greasing Universal Joint
1. Grease the internal splines (1) and grease nipples (2) of the universal joint if the amount of grease is insufficient.
(1) Spline (2) Grease Nipple
W78945645
7-G6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Greasing Spindle Shafts, Belt Tension Pivot and Tension Pulley
1. Grease the grease nipples (1), (2) of the spindle shafts if the amount of grease is insufficient.
(1) Grease Nipple (Spindle Shaft)
(2) Grease Nipple (Belt Tension Pulley)
(3) Grease Nipple (Belt Tension Pivot)
W98745632
Greasing Spindle Shafts, Belt Tension Pivot and Tension Pulley
1. Grease the grease nipples (1), (2) of the spindle shafts if the amount of grease is insufficient.
(1) Grease Nipple (Splindle Shaft)
(2) Grease Nipple (Belt Tension Pulley)
(3) Grease Nipple (Belt Tension Pivot)
[A] RCK60B-23BX, RCK54-23BX,
RCK48-18BX
[B] RCK54P-23BX, RCK48P-18BX
Greasing Balance Shaft [RCK60B-23BX]
1. Grease the grease nipple (1) of the balance shaft if the amount of grease is insufficient.
(1) Grease Nipple
W74136985
7-G7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Greasing Front and Rear Anti-scalp Rollers [RCK60B-23BX,
RCK54P-23BX, RCK54-23BX]
1. Grease the grease nipple (1), (2) of the front and rear anti-scalp rollers if the amount of grease is insufficient.
(1) Grease Nipple (Front Anti-scalp
Roller)
(2) Grease Nipple (Rear Anti-scalp
Roller)
W1026897
[2] CHECK POINT OF INITIAL 50 HOURS
Changing Gear Box Oil
CAUTION
• Be sure to stop the engine and remove the key before changing the oil.
1. Dismount the mower from the tractor, and place the mower on level ground.
2. Remove the oil filler plug (2).
3. Remove the drain plug (1), and drain the used oil completely.
4. After draining the used oil, reinstall the drain plug.
5. Fill with new oil up to the specified level.
Q
IMPORTANT
• Use the specified gear oil.
Refer to “LUBRICANTS”. (See page 7-G2.)
(1) Drain Plug (2) Oil Filter Plug
W1027307
[3] CHECK POINT OF EVERY 150 HOURS
Changing Gear Box Oil
1. See above.
W1027627
7-G8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[4] CHECK POINT OF EVERY 2 YEARS
Replacing Gear Box Oil Seal
1. Replace the gear box oil seals (1), (2) with new ones.
(1) Oil Seal (2) Oil Seal
W1027687
7-G9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
6. SETTING UP MOWER
Assembling Mower
1. Place the mower on blocks as illustrated.
Turn the anti-scalp rollers sideways and attach to the arms of the deck at the upper position with clevis pins and snap rings.
Remove the blocks. (RCK60B-23BX, RCK54P-23BX, RCK54-
23BX)
2. Attach the front anti-scalp rollers to the deck with clevis pins and snap rings. (RCK48P-18BX, RCK48-18BX)
3. Attach the discharge to the deck with the spring, discharge pin and cotter pin.
Secure the spring to the discharge deflector as illustrated.
(1) Anti-scalp Roller
(2) Block
(3) Clevis Pin
(4) Snap Ring
(5) Deck
(6) Discharge Pin
(7) Discharge Deflector
(8) Spring
(9) Cotter Pin
W85236974
Setting Mower
CAUTION
• Park the tractor on a firm, flat and level surface, set the parking brake, stop the engine and remove the key.
1. Start the engine and the hydraulic lever rearward to raise the mower rear link to the highest position.
2. Stop the engine and remove the key.
3. Roll the mower under the tractor from right side.
(1) Hydraulic Control Lever
W96321478
7-G10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Universal Joint
1. Pull back the coupler (3) of the universal joint (2).
2. Push the universal joint (2) onto the mid-PTO shaft (1), until the coupler locks.
3. Slide the universal joint back and forward to make sure the universal joint is locked securely.
Q
IMPORTANT
• Finally, tug on the universal joint to make sure it is locked on the PTO shaft.
(1) Mid-PTO Shaft
(2) Universal Joint
(3) Coupler
A : Tug
W69724158
Rear Link
1. Set the cutting height control dial (1) to zero inch position.
2. Operate the tractor’s hydraulic control lever (2) forward to lower the mower rear links (3).
Attach the rear link (3) to the mower with the L-pins (4).
(1) Cutting Height Control Dial
(2) Hydraulic Control Lever
(3) Rear Link
(4) L-pin
W96472687
7-G11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Front Link
1. Hook the front link (1) to the front bracket groove (2) as shown in the figure.
(Reference)
• Make sure the length (
L
) of the front link (1) is 47 mm (1.85 in.).
(1) Front Link (2) Front Bracket Groove
W74569821
Mounting Front Link
1. Position the front lever to the front link bracket.
2. Pull and lock the L pin. Then lower the front lever.
3. Hook the front link to the lever fulcrum, and lift the front lever.
4. Release the L pin to lock the front lever.
Q
NOTE
• When hooking the front link to the lever fulcrum, normal position of the lever fulcrum groove is open to downward.
Q
IMPORTANT
• Check that the front lever is locked securely with the L pin.
(1) L pin
(2) Lever Fulcrum
(3) Front Link Bracket
(4) Front Lever
(5) Lever Fulcrum Groove
(6) Front Link
W1028530
7-G12
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
7. MOWER ADJUSTMENT
G
GENERAL
CAUTION
• Park the tractor on a firm, flat and level surface and set the parking brake.
• Stoop the engine, remove the key, and allow the blades to stop before making adjustments.
• Wear heavy gloves or wrap end of blade with a rag when you handle blades.
• Before starting the engine, set the PTO clutch lever to off position and range gear shift lever to the neutral position.
Adjusting Mower Link
1. Tire pressure must be correct.
2. Move the hydraulic control lever rearward to raise the mower to the highest position.
3. Stop the engine and remove the key.
4. Adjust the left side links with bolt so that the clearance
L
is as follows.
Clearance (
L
) between stopper and rear link
Factory spec.
0 to 0.5 mm
0 to 0.01 in.
(1) Bolt
(2) Lock Nut
(3) Stopper
(4) Rear Link
L : 0 to 0.5 mm (0 to 0.01 in.)
(A) Adjustment Point
(B) Check Point
W8796512
7-G13
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Adjusting Front and Rear Cutting Height
1. Tire pressure must be correct.
2. Make sure the level of the mower blades is adjusted as shown below. Then tighten the lock nuts securely.
3. Turn the cutting height control dial to “2.0” and the anti-scalp roller’s height to keep clearance between rollers and ground from
6 to 13 mm (0.25 to 0.5 in.).
4. Turn right blade by hand parallel to direction of travel.
5. Adjust (L) of front links with lock nuts so that A is 0 to 5 mm (0 to
0.2 in.) A = (
R
)-(
F
).
6. If the difference between front tip and rear tip of blade is not within the factory specification, adjust the length
L
of front link with lock nut (3). The height of rear blade tip
R
should be bigger than the front.
Difference (
R
-
F
) (
R
≥
F
) between front tip and rear tip of blade
Factory spec.
0.0 to 5.0 mm
0.0 to 0.20 in.
(1) Cutting Height Control Dial
(2) Hydraulic Control Lever
(3) Lock Nut
L : Length of Front Link
F : Height of Blade Tip (Front)
R : Height of Blade Tip (Rear)
W98765412
7-G14
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Adjusting Left and Right Cutting Height
1. Tire pressure must be correct.
2. Operate the hydraulic control lever (2) rearward to raise the mower deck to the highest position.
3. Stop the engine and remove the key.
4. Turn the cutting height control dial to the desired height.
5. Set the anti-scalp roller’s height to keep clearance between rollers and ground from 6 to 13 mm (0.2 to 0.5 in.).
6. Lower the mower deck by moving the hydraulic control lever forward.
7. Turn left blade by hand parallel to tractor axle and turn right blade parallel to axle to measure from the outside blade tip at
L
and
R
to the level surface.
8. The difference between measurement should be less than 3 mm
(0.12in.).
9. If the difference between measurement is more than 3 mm (0.12
in.), loosen the lock nut of the left side.
10.Adjust the cutting height fine turning bolts so that the difference between measurement
L
and
R
is less than 3 mm (0.12 in.).
Then lock the nut.
Difference (
L
-
R
) between left tip and right tip of blade
Factory spec.
Less than 3 mm
0.12 in.
(1) Cutting Height Control Dial
(2) Hydraulic Control Lever
(3) Cutting Height Fine Turning Bolt
(4) Lock Nut
L : Left Blade Measurement Position
R : Right Blade Measurement
Position
A : Blade Height
W12398745
Adjusting Self-Balance Suspended Linkage [RCK60B-23BX only]
1. Check the length (
L
) of balancer spring (2).
2. If the length (
L
) is not within the factory specification, adjust the length of balancer spring (2) with lock nut (3).
Q
NOTE
• Check the left and right cutting height difference after adjusting the self-balancer linkage.
Balancer spring length
(
L
) (Right and left)
Factory spec.
55.0 mm
2.17 in.
(1) Self-Balancer
(2) Balancer Spring
(3) Lock Nut
(4) Plain Washer
(5) Mower Deck
L : Balancer Spring Length
W87945612
7-G15
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
Cutting Height
DANGER
• Never operate the mower in transport position.
Q
IMPORTANT
• (for self-balance suspended linkage)
To reduce the stepped difference in cutting height when mowing rolling terrain, follow the procedure below.
1. To set the cutting height, move the hydraulic control lever rearward to raise the mower to the highest position. Turn the cutting height control dial (1) to adjust height.
2. Set the anti-scalp roller’s (3) height as shown to keep clearance between rollers and ground from 6 to 13 mm (0.2 to 0.5 in.).
3. Lower the mower deck by moving the hydraulic control lever (2) forward.
4. Use the higher settings for mowing in a rough area or when mowing tall grass. Lower settings should be used only for smooth lawns where short grass is desired.
5. To set the cutting height, move the hydraulic control lever (2) rearward to raise the mower to the highest position. Turn the cutting height control dial to adjust height.
6. Set the anti-scalp roller’s (3) position as shown to have the same cutting height.
Dial (Cutting Height)
25 mm (1.0 in.), 32 mm (1.25 in.)
38 mm (1.5 in.), 45 mm (1.75 in.)
51 mm (2.0 in.), 57 mm (2.25 in.)
64 mm (2.5 in.), 70 mm (2.75 in.)
76 mm (3.0 in.), 83 mm (3.25 in.)
89 mm (3.5 in.), 95 mm (3.75 in.)
102 mm (4.0 in.)
Anti-scalp Roller
G
F
E
D
C
B
A
(1) Cutting Height Control Dial
(2) Hydraulic Control Lever
(3) Anti-scalp Roller
[A] RCK60B-23BX, RCK54P-23BX,
RCK54-23BX
[B] RCK48P-18BX, RCK48-18BX
7-G16
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. POWER TRANSMISSION ............................................................................ 7-M1
2. LIFTING MECHANISM ................................................................................. 7-M2
3. SELF-BALANCER SYSTEM ......................................................................... 7-M3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. POWER TRANSMISSION
MOWER
(1) 18T Bevel Gear
(2) 17T Bevel Gear
(3) Pinion Shaft
(4) Universal Joint
(5) Mid-PTO Shaft
(6) Center Blade
(7) Center Pulley
(8) Bevel Gear Shaft
(9) Mower Belt
(10) Blade Shaft
(11) Outer Pulley
(12) Outer Blade
The power is transmitted from mid-PTO to blades as follows:
Q
Center Blade
Mid-PTO Shaft (5)
→
Universal Joint (4)
→
Pinion Shaft (3)
→
Bevel Gear (1)
→
Bevel Gear (2)
→
Bevel Gear
Shaft (8)
→
Center Blade (6)
Q
Outer Blade
Mid-PTO Shaft (5)
→
Universal Joint (4)
→
Pinion Shaft (3)
→
Bevel Gear (1)
→
Bevel Gear (2)
→
Bevel Gear
Shaft (8)
→
Center Pulley (7)
→
Mower Belt (9)
→
Outer Pulley (11)
→
Blade Shaft (10)
→
Outer Blade (12)
7-M1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. LIFTING MECHANISM
MOWER
(1) Front Link
(2) Rear Link
(3) Lift Link
(4) Rear Lift Link (RH)
(5) Rear Lift Link (LH) (6) Lift Arm
The lifting of mower is performed by the hydraulic system installed on the tractor.
The mower should be kept lift when traveling. When the position control lever is moved to
“LIFT”
position, the lift arm (6) is lifted up by the oil pressure of hydraulic system, and the rear lift link (LH) (5) is pulled rearward.
Therefore, rear lift links (4), (5) rotate and the mower is lifted by the lift links (3) and rear links (2).
As this link system is a parallel linkage, the mower can be kept parallel at every position.
CAUTION
• Never operate mower in transport position.
7-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
3. SELF-BALANCER SYSTEM
This system reduces the stepped differences in cutting height when mowing rolling terrain.
Q
Self-Balancer
1. The mower deck is held in place via the balancer plate (4) and the support by the rear link (1), (2).
2. The mower deck is suspended by, and is tilted to the right and left by, the balancer support (5). The balancer springs (3) at both sides adjust themselves for suitable tension to keep the mower deck out of excessive tilt.
Q
Without Self-Balancer Type (A)
• When working on a wavy ground, the tractor itself, with the mower deck, goes along the curves of the terrain. If not equipped with the self-balancer, the tractor tends to tilt itself greater than the ground’s waves by its own weight. This may cause an uneven mowing. The wider the mower is, the more unevenness is caused.
Q
With Self-Balancer Type (B)
• When working on a wavy ground, the tractor itself goes along the curves of the terrain like with the tractor that is not equipped with the self-balancer.
The balancer springs (3), however, serve to keep the mower deck in parallel with the ground’s curves until the anti-scalp roller (6) comes in contact with the ground.
• If the tractor temporarily tilts itself more than the ground’s slope or the like, the anti-scalp roller (6) touches the ground. Now the mower deck is brought back in parallel with the ground by the counterforce of the roller (6) just hitting the ground as well as the tension of the balancer springs (3). This helps reduce an uneven mowing.
Q
NOTE
• Always keep the anti-scalp roller with specified position (Refer to Operator’s Manual).
(1) Rear Link (RH)
(2) Rear Link (LH)
(3) Balancer Spring
(4) Balancer Plate
(5) Balancer Support
(6) Anti-scalp Roller
(7) Mower Deck
(A) Without Self-Balancer
(B) With Self-Balancer
(a) Tilt : Tractor
(b) Tilt : Mower Deck
(c) Ground
(d) Grass
W1013200
7-M3
KiSC issued 06, 2009 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................7-S1
2. SERVICING SPECIFICATIONS ....................................................................7-S2
3. TIGHTENING TORQUES ..............................................................................7-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................7-S4
[1] CHECKING AND ADJUSTING ...............................................................7-S4
[2] DISASSEMBLING AND ASSEMBLING..................................................7-S5
[3] SERVICING ............................................................................................7-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
Symptom Probable Cause
Blade Does Not Turn
Mid-PTO system malfunctioning
Mower belt broken
Blade Speed Is Slow
Mower belt loosen
Cutting Is Poor
Mower Is Not Lifted
Grass clogged
Cup washer flattened out or worn
Engine rpm too low
Mower blade worn or broken
Mower blade screw loosen
Cutting height improper
Ground speed too fast
Low tire inflation
Anti-scalp rollers not adjusted correctly
Linkage system broken
Trouble of hydraulic system
MOWER
Solution
Check transmission
Replace mower belt
Replace mower belt or tension spring
Remove grass
Replace cup washer
Mow at full throttle, check and reset engine rpm
Sharpen or replace mower blade
Retighten mower blade screw
Adjust cutting height
Slow-down
Add air to correct
Adjust anti-scalp rollers
Replace linkage system
Check hydraulic system
Reference
Page
2-S31, S40
7-S4
7-S4
–
7-S5
–
7-S5
7-S5
7-G15
–
G-41
7-G16
7-G12
–
W1014322
7-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
Item
Input Shaft (without Mower Belt) Turning Force
Turning Torque
Factory Specification
Less than 118 N
12.0 kgf
26.5 lbf
Less than 1.5 N·m
0.15 kgf·m
1.1 lbf·ft
Bevel Gears in Gear Box
[RCK48-18BX, RCK54-23BX,
RCK60B-23BX]
[RCK48P-18BX, RCK54P-23BX]
Backlash
Backlash
0.10 to 0.20 mm
0.0040 to 0.0078 in.
0.13 to 0.25 mm
0.0051 to 0.0098 in.
Allowable Limit
–
–
MOWER
0.40 mm
0.016 in.
0.40 mm
0.016 in.
W1013874
7-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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 7-G3.)
[RCK48-18BX, RCK54-23BX, RCK60B-23BX]
Item
Gear box mounting screw and nut
Mower blade screw
Center pulley holder bolt and nut
Outer pulley mounting nut
Gear box bracket (RH) mounting bolt and nut
Pulley boss mounting nut
Pulley holder mounting bolt and nut
N·m
78 to 90
103 to 117
78 to 90
197 to 225
78 to 90
24 to 27
78 to 90
kgf·m
7.9 to 9.2
10.5 to 12.0
7.9 to 9.2
20.0 to 23.0
7.9 to 9.2
2.4 to 2.8
7.9 to 9.2
[RCK48P-18BX and RCK54P-23BX]
Item
Mower blade screw
Gear box screw
Gear box mounting screw (for aluminum gear case)
Gear box mounting screw and nut
Center pulley holder bolt and nut
Outer pulley mounting nut
Pulley holder mounting bolt and nut
Gear box bracket (RH) mounting screw (for aluminum gear case)
N·m
103 to 118
24 to 28
39 to 44
77 to 90
77 to 90
167 to 186
77 to 90
39 to 44
kgf·m
10.5 to 12.0
2.4 to 2.8
4.0 to 4.5
7.9 to 9.2
7.9 to 9.2
17.0 to 19.0
7.9 to 9.2
4.0 to 4.5
MOWER
lbf·ft
58 to 66
76.0 to 86.7
58 to 66
145 to 166
58 to 66
18 to 20
58 to 66
W1012736
lbf·ft
76 to 87
17 to 20
49 to 33
57 to 67
57 to 67
123 to 137
57 to 67
29 to 33
W1013579
7-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Checking Mower Blade
1. Check the cutting edge of mower blade.
2. Sharpen the cutting edges, if the mower blades are as shown in figure (2).
3. Replace the mower blades, if they are as shown in figure (3).
Q
IMPORTANT
• Never forget to set the dust cover, cup washer(s) and lock washer, when reassembling the mower blades. (See page 7-
S5.)
Q
NOTE
• To sharpen the mower blades by yourself, clamp the mower blade securely in a vise and use a large mill file along the original bevel.
• To balance the mower blade, place a small rod through the center hole and check to see if the blade balance evenly.
File heavy side of the blade until it balance out even.
(1) New Blade
(2) Worn Blade
(3) Cracked Blade
W1011041
Checking Mower Belt
1. Check to see the mower belt.
2. Replace the mower belt with a new one, if there is found surface split at more than 3 positions.
(When replacing mower belt)
1. Dismount the mower from the tractor.
2. Remove the left and right hand belt cover from the mower deck.
3. Clean around the gear box.
4. Remove the right hand bracket (3) which mounts the gear box to the mower deck.
5. Remove the mower belt (2) from the tension pulley (1). Slip the mower belt over the top of the gear box.
6. To install a new belt, reverse the above procedure.
Tightening torque
Gear box bracket RH mounting bolt and nut
Gear box bracket RH mounting screw (for aluminum gear case)
78 to 90 N·m
7.9 to 9.2 kgf·m
58 to 66 lbf·ft
39 to 44 N·m
4.0 to 4.5 kgf·m
29 to 33 lbf·ft
Q
IMPORTANT
• After setting the gear box bracket mounting screws on the deck without tightening, then mount the other screws on the gear box. And finally tighten them.
(1) Tension Pulley
(2) Mower Belt
(3) Gear Box Bracket (Right)
W1011180
7-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] DISASSEMBLING AND ASSEMBLING
Universal Joint and Belt Cover
1. Unscrew the universal joint screw.
2. Remove the universal joint (1).
3. Remove the left and right belt covers (2), (3).
(1) Universal Joint
(2) Belt Cover (Left)
(3) Belt Cover (Right)
MOWER
W1012580
Mower Blades (Center Blade and Outer Blades)
1. Turn over the mower.
2. Unscrew the mower blade screw (5), and remove the lock washer
(4), cup washer(s) (3), mower blade (2) and dust cover (1).
Q
NOTE
• To remove the blade securely, wedge a block of wood between one blade and the mower deck in such position that it will hold the blade safely while loosing or tightening the blade screw.
(When reassembling)
[RCK48-18BX, RCK54-23BX, RCK48P-18BX, RCK54P-23BX]
• Install the blade in position together with the dust cover and the cup washer. Tighten them up with the screw.
[RCK60B-23BX]
• Install the blade in position together with the dust cover, the lock washer and the 2 cup washers. Tighten them up with the screw.
Q
IMPORTANT
• Make sure the cup washer is not flattened out or worn, causing blade to slip easily.
Replace cup washer(s) if either is damaged.
Tightening torque Mower blade screw
103 to 117 N·m
10.5 to 12.0 kgf·m
76.0 to 86.7 lbf-ft
(1) Dust Cover
(2) Mower Blade
(3) Cup Washer
(4) Lock Washer
(5) Mower Blade Screw
(A) RCK48-18BX, RCK54-23BX,
RCK48P-18BX, RCK54P-23BX
(B) RCK60B-23BX a : Loosen
W1012667
7-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
Blade Boss
1. Remove the external snap ring (2).
2. Remove the blade boss (1).
(1) Blade Boss
(2) External Snap Ring
(A) RCK48P-18BX, RCK54P-23BX
(B) RCK48-18BX, RCK54-23BX,
RCK60B-23BX
Gear Box and Mower Belt
1. Turn over the mower.
2. Remove the mower belt (3) from the tension pulley (5).
3. Unscrew the left and right gear box mounting screws (2), (4) and remove the gear box (1) from the mower deck.
(When reassembling)
• Install the reamer screws (2) at their original positions as shown in the figure.
Tightening torque
Gear box mounting screw and nut
78 to 90 N·m
7.9 to 9.2 kgf·m
58 to 66 lbf·ft
(1) Gear Box
(2) Gear Box Mounting Screw
(Reamer Screw)
(3) Mower Belt
(4) Gear Box Mounting Screw
(5) Tension Pulley
(6) Tension Spring
W1012961
7-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
Disassembling Gear Box [RCK54-23BX, RCK60B-23BX]
1. Unscrew the drain plug (1), and drain the gear box oil.
2. Remove the center pulley (20) with a puller, and remove the feather key (18) on the bevel gear shaft (19).
3. Remove the gear box cap (5).
4. Remove the oil seal (10), internal snap ring (11) and shim (12).
5. Tap out the pinion shaft (14) with the ball bearing (13), and remove the bevel gear (1).
6. Remove the ball bearing (3) and shims (if installed).
7. Remove the external snap ring (6), and draw out the bevel gear shaft (19).
8. Remove the bevel gear (7), ball bearing (8), shim (9) and oil seal
(17).
(When reassembling)
• Replace the oil seals (10), (17) and gear box cap (8) with new ones.
• Check the backlash and turning torque.
If not proper, adjust with the shims.
(See page 7-S10.)
(1) 19T Bevel Gear (RCK54-23BX)
18T Bevel Gear (RCK60B-23BX)
(2) Breather
(3) Gear Box
(4) Ball Bearing
(5) Shim
(6) Internal Snap Ring
(7) Gear Box Cap
(8) Gear Box Cap
(9) External Snap Ring
(10) 16T Bevel Gear (RCK54-23BX)
17T Bevel Gear (RCK60B-23BX)
(11) Ball Bearing
(12) Shim
(13) Oil Seal
(14) Internal Snap Ring
(15) Shim
(16) Ball Bearing
(17) Pinion Shaft
(18) Oil Filler Plug
(19) Drain Plug
(20) Oil Seal
(21) Bevel Gear Shaft
(22) Feather Key
(23) Center Pulley
W1018143
Disassembling Gear Box (RCK54P-23BX)
1. Unscrew the drain plug (6), and drain the gear box oil.
2. Remove the center pulley (20) with a puller.
3. Remove the gear box.
4. Open the gear box.
5. Remove the input shaft (3) and the blade shaft (18).
6. Disassembling the input shaft (3) and the blade shaft (18).
(When reassembling)
• Replace the oil seals (1), (10), (16) and gear box caps with new ones.
• Check the backlash and turning torque.
If not proper, adjust with the shims.
• After cleaning dirty and gear box oil and the gear box surface, apply the liquid gasket.
Tightening torque Gear box screw
24 to 27 N·m
2.4 to 2.8 kgf·m
17 to 20 lbf-ft
(1) Oil Seal
(2) Ball Bearing
(3) Input Shaft
(4) External Cir Clip
(5) Shim
(6) Drain Plug
(7) Bevel Gear
(8) Shim
(9) Ball Bearing
(10) Oil Seal
(11) External Cir Clip
(12) Bevel Gear Case
(13) Bevel Gear
(14) Ball Bearing
(15) Shim
(16) Oil Seal
(17) External Cir Clip
(18) Blade Shaft
(19) Feather Key
(20) Center Pulley
W1015954
7-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
Center Pulley Holder
1. Unscrew the center pulley holder screws (1), (15) / center pulley nut (5), (11).
2. Remove the upper oil seal (6) and lower oil seal (4).
3. Remove the internal snap ring (3) and ball bearing (2).
(When reassembling)
• Replace the oil seals (4), (6) with new ones.
• Install the reamer screws (12) / reamer bolt (15) at their original positions as shown in the figure.
• Be sure to fix the O-rings (7), (13) to the original position.
Q
NOTE
• When reassembling the center pulley holder (14), gear box and gear box stays (9), (10), tighten the bolts and nuts in the order as below, to prevent the incline the gear box.
• Tighten the reamer bolts (12) to the gear box first, then tighten the reamer bolts (15) and nut (11) to the center pulley holder (14) with specified torque.
• Tighten the gear box screws (8) to the gear box, then tighten the center pulley holder bolts (1) and nut (5) with specified torque.
• See page 7-S6 for tightening torque of gear box screw.
Tightening torque
Center pulley holder bolt and nut
78 to 90 N·m
7.9 to 9.2 kgf·m
58 to 66 lbf·ft
(1) Center Pulley Holder bolt
(2) Ball Bearing
(3) Snap Ring
(4) Oil Seal
(5) Nut
(6) Oil Seal
(7) O-ring
(8) O-ring
(9) Gear Box Stay RH
(10) Gear Box Stay LH
(11) Nut
(12) Gear Box Reamer Bolt
(13) O-ring
(14) Center Pulley Holder
(15) Center Pulley Holder Reamer Bolt
(16) Collar
(A)RCK48-18BX, RCK54-23BX,
RCK60B-23BX
(B) RCK48P-18BX, RCK54P-23BX
W1013720
7-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
Outer Pulley and Blade Shaft
1. Unscrew the outer pulley mounting nuts (21), and remove the outer pulley (34).
2. Unscrew the pulley holder mounting nuts (36), and remove the left pulley holder (27).
3. Remove the oil seal (29) and tap out the left blade shaft (30) with the ball bearings (28), (25), taking care not to damage the grease nipple (20).
4. Remove the oil seal (24).
5. Remove the ball bearings (28), (25) and collar (26) from the blade shaft (30).
6. Remove the right pulley holder (12) and blade shaft (16) as above.
(When reassembling)
• Replace the oil seals (33), (39), (13) and (19) with new ones.
Tightening torque
Outer pulley mounting nut
Pulley boss mounting nut
Pulley holder mounting bolt and nut
(RCK48-18BX)
Pulley holder mounting bolt and nut
(RCK54-23BX, RCK60B-
23BX)
197 to 225 N·m
20.0 to 23.0 kgf·m
145 to 166 lbf·ft
24 to 27 N·m
2.4 to 2.8 kgf·m
18 to 20 lbf·ft
48.0 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 lbf·ft
78 to 90 N·m
7.9 to 9.2 kgf·m
58 to 66 lbf·ft
(1) Grease Nipple
(2) Outer Pulley Mounting Nut
(3) Spring Washer
(4) Plain Washer
(5) Outer Pulley Boss (Right)
(6) Outer Pulley (Right)
(7) Oil Seal
(8) Ball Bearing
(9) Pulley Holder Mounting Nut
(10) Spring Washer
(11) Collar
(12) Pulley Holder (Right)
(13) Pulley Holder Mounting Bolt
(14) Ball Bearing
(15) Oil Seal
(16) Blade Shaft (Right)
(17) Pulley Holder Mounting Nut
(18) Spring Washer
(19) Pulley Boss Mounting Bolt
(20) Grease Nipple
(21) Outer Pulley Mounting Nut
(22) Spring Washer
(23) Plain Washer
(24) Oil Seal
(25) Ball Bearing
(26) Collar
(27) Pulley Holder (Left)
(28) Ball Bearing
(29) Oil Seal
(30) Blade Shaft (Left)
(31) Pulley Boss Mounting Nut
(32) Spring Washer
(33) Outer Pulley Boss (Left)
(34) Outer Pulley (Left)
(35) Pulley Boss Mounting Bolt
(36) Pulley Holder Mounting Nut
(37) Spring Washer
(38) Pulley Holder Mounting Bolt
(A) RCK48-18BX
(B) RCK54-23BX, RCK60B-22BX
W1018943
7-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
Balancer
1. Unscrew the lock nut (1) both side.
2. Remove the plain washer (2) and balancer spring (3).
3. Unscrew the center pin bolt (6).
4. Remove the center pin (5) and balancer plate (4).
(When reassembling)
• Apply grease to the center pin (5).
• Adjust the balancer spring (3) length to the factory specification, with lock nut (1).
Balancer spring length
(
L
) (Right and left)
Factory spec.
55.0 mm
2.17 in.
(1) Lock Nut
(2) Plain Washer
(3) Balancer Spring
(4) Balancer Plate
(5) Center Pin
(6) Center Pin Bolt
W1017924
7-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[3] SERVICING
MOWER
Turning Torque of Pinion Shaft
1. Remove the mower belt, and reassemble the gear box to the mower deck.
2. Wind a string around the pinion shaft and set a spring balance (or push-pull gauge) to the tip of the string, and then slowly pull the spring balance horizontally to measure the turning force.
3. If the measurement exceeds the factory specification, check the bearing and gears and adjust the adjusting shims (1), (2), (3).
[RCK48-18BX, RCK54-23BX and RCK60B-23BX]
Turning force Factory spec.
Less than 118 N
12.0 kgf
26.5 lbf
Turning torque Factory spec.
Less than 1.5 N·m
0.15 kgf·m
1.1 lbf·ft
(Reference)
• Thickness of adjusting shims (1), (2) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (3) : 0.1 mm (0.0039 in.)
0.2 mm (0.0079 in.)
[RCK48P-18BX and RCK54P-23BX]
Turning force Factory spec.
Less than 0.7 N·m
0.07 kgf·m
0.52 lbf-ft
(Reference)
• Thickness of adjusting shims (1), (2) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (3) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
(1) Adjusting Shim
(2) Adjusting Shim
(3) Adjusting Shim
(A) RCK48-18BX, RCK54-23BX and
RCK60B-23BX
(B) RCK48P-18BX and RCK54P-23BX
7-S11
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM MOWER
Backlash between Bevel Gears
1. Remove the gear box cap (3).
2. Place fuses the bevel gear (2) on the input shaft (5).
3. Turn the input shaft (5).
4. Take out the fuses, and measure the thickness of fuses with an outside micrometer. (Backlash equal thickness of fuse)
5. If the backlash exceeds the allowable limit, adjust with shims (1),
(4), (6).
[RCK48-18BX, RCK54-23BX and RCK60B-23BX]
Backlash between bevel gears
Factory spec.
0.10 to 0.20 mm
0.0039 to 0.0079 in.
Allowable limit
0.4 mm
0.0157 in.
(Reference)
• Thickness of adjusting shims (1), (4) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (6) : 0.1 mm (0.0039 in.)
0.2 mm (0.0079 in.)
[RCK48P-18BX and RCK54P-23BX]
Backlash between bevel gears
Factory spec.
Allowable limit
0.13 to 0.25 mm
0.0051 to 0.0098 in.
0.40 mm
0.0157 in.
(Reference)
• Thickness of adjusting shims (1), (4) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
• Thickness of adjusting shims (6) : 0.2 mm (0.0079 in.)
0.3 mm (0.0118 in.)
(1) Shim
(2) 21T Bevel Gear
(RCK48-18BX, RCK48P-18BX)
19T Bevel Gear
(RCK54-23BX, RCK54P-23BX)
18T Bevel Gear
(RCK60B-23BX)
(3) Gear Box Cap
(4) Shim
(5) Input Shaft
(6) Shim
(7) External Cir Clip
(A) RCK48-18BX, RCK54-23BX and
RCK60B-23BX
(B) RCK48P-18BX and RCK54P-23BX
W1020126
7-S12
KiSC issued 06, 2009 A
8
FRONT LOADER
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
SAFETY INSTRUCTIONS
SAFETY DECALS
SAFETY INSTRUCTIONS
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.
8-1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM SAFETY INSTRUCTIONS
8-2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
SPECIFICATIONS
Q
Loader Specifications
Loader model
Tractor model
Wheel base (WB)
Front tires
Rear tires
Boom cylinder
Bucket cylinder
Bore
Stroke
Bore
Stroke
Control valve
Rated flow
Maximum pressure
Net weight (Approximate)
SPECIFICATIONS
LA203
BX1860
1340 mm (52.8 in.)
LA243
BX2360, BX2660
1400 mm (55.1 in.)
16 x 7.5-8
24 x 12-12
18 x 8.5-10
26 x 12-12
40 mm (1.57 in.)
281 mm (11.1 in.) 326 mm (12.8 in.)
65 mm (2.56 in.)
204 mm (8.03 in.)
One detente float position, two stage bucket dump, power beyond circuit
14 L/min. (3.7 U.S.gals/min., 3.1 Imp.gals/min.)
12.3 MPa (125 kgf/cm
2
, 1778 psi)
157 kg (346 lbs) 170 kg (375 lbs)
W1027852
Q
Bucket Specifications
Loader model
Model
Type
Width
Depth (L)
Height (M)
Length (N)
Capacity
Weight
Struck
Heaped
LA203 LA243
Squere 48”
Rigid
1219 mm (48.0 in.)
455 mm (17.9 in.)
445 mm (17.5 in.)
498 mm (19.6 in.)
0.12 m
3
(4.2 CU.FT.)
0.14 m 3 (4.9 CU.FT.)
56 kg (123 lbs)
495 mm (19.5 in.)
465 mm (18.3 in.)
538 mm (21.2 in.)
0.14 m
0.17 m
3
3
(4.9 CU.FT.)
(6.1 CU.FT.)
60 kg (132 lbs)
W1030245
Q
Dimensional Specifications
Loader Model
Tractor model
G
H
E
F
C
D
A
B
I
Max. lift height (To bucket pivot pin)
Max. lift height under level bucket
Clearance with bucket dumped
Reach at max. lift height (Dumping reach)
Max. dump angle
Reach with bucket on ground
Bucket roll-back angle
Digging depth
Overall height in carrying position
LA203
BX1860
LA243
BX2350, BX2660
1810 mm (71.3 in.)
1680 mm (66.1 in.)
1350 mm (53.1 in.)
720 mm (28.3 in.)
1330 mm (52.4 in.)
735 mm (28.9 in.)
40 deg. (0.784 rad)
1330 mm (52.4 in.)
30 deg. (0.59 rad)
100 mm (3.9 in.)
970 mm (38.2 in.)
45 deg. (0.785 rad)
1390 mm (54.7 in.)
29 deg. (0.51 rad)
120 mm (4.7 in.)
990 mm (39.0 in.)
W1028417
8-3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Operational Specifications
Loader Model
Tractor model
Lift capacity to max. height (Bucket bottom mid point)
U
V
Lift capacity (Bucket pivot pin, max. height)
Lift capacity (500 mm forward, max. height)
W
X
Lift capacity (Bucket pivot pin, 1500 mm (59 in.) height)
Lift capacity (1500 mm height)
Y
Z
VV
XX
Breakout force (Bucket pivot pin)
Breakout force (500 mm forward)
Bucket roll-back force at max. height
Bucket roll-back force at 1.5M (5.9 in.)
ZZ
Bucket roll-back force at ground level
Raising time
Lowering time
Bucket dumping time
Bucket rollback time
LA203
BX1860
200 kg (441 lbs)
280 kg (617 lbs)
185 kg (408 lbs)
315 kg (694 lbs)
220 kg (485 lbs)
5720 N (1287 lbs)
3920 N (882 lbs)
4460 N (1003 lbs)
5380 N (1210 lbs)
5580 N (1255 lbs)
2.8 sec.
2.0 sec.
1.8 sec.
2.1 sec.
SPECIFICATIONS
LA243
BX2350, BX2660
240 kg (529 lbs)
340 kg (750 lbs)
235 kg (518 lbs)
375 kg (827 lbs)
270 kg (595 lbs)
6290 N (1415 lbs)
4410 N (992 lbs)
4750 N (1069 lbs)
5600 N (1260 lbs)
5490 N (1235 lbs)
3.5 sec.
2.7 sec.
1.7 sec.
2.4 sec.
W1030633
8-4
KiSC issued 06, 2009 A
GENERAL
CONTENTS
1. IDENTIFICATION........................................................................................... 8-G1
2. GENERAL PRECAUTION ............................................................................ 8-G2
3. LUBRICANTS ................................................................................................ 8-G3
4. TIGHTENING TORQUES ............................................................................. 8-G4
[1] GENERAL USE SCREWS, BOLTS AND NUTS (FOR FRONT
LOADER AND BACKHOE) .................................................................... 8-G4
[2] STUD BOLTS.......................................................................................... 8-G4
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS ............................................................................... 8-G5
[4] PLUGS ..................................................................................................... 8-G5
[5] HYDRAULIC FITTINGS .......................................................................... 8-G6
[6] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS ON
THE TABLE BELOW ARE ESPECIALLY SPECIFIED ....................... 8-G6
5. MAINTENANCE CHECK LIST ..................................................................... 8-G7
6. CHECK AND MAINTENANCE ..................................................................... 8-G8
[1] CHECK POINTS OF EACH USE OR DAILY ..................................... 8-G8
[2] CHECK POINTS OF EVERY 10 HOURS ........................................... 8-G8
7. DISMOUNTING AND MOUNTING FRONT LOADER FROM TRACTOR 8-G9
[1] DISMOUNTING FRONT LOADER FROM TRACTOR ........................ 8-G9
[2] MOUNTING FRONT LOADER TO TRACTOR .................................. 8-G10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. IDENTIFICATION
G
GENERAL
When contacting your local KUBOTA distributor, always specify front loader model and serial number.
(1) Model / Serial Number
W1010468
8-G1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
2. GENERAL PRECAUTION
• During disassembly, carefully arrange removed parts in a clean area to prevent later confusion. Screws, bolts and nuts should be replaced in their original positions to prevent reassembly errors.
• When special tools are required, use genuine KUBOTA tools.
Special tools which are not used frequently should be made according to the drawings provided.
• Clean parts before measuring them.
• Use only genuine KUBOTA parts for parts replacement to maintain loader performance and to assure safety.
• O-ring and oil seals must be replaced during reassembly. Apply grease to new O-rings or oil seals before reassembling.
A : Grease
W1010531
8-G2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
3. LUBRICANTS
To prevent serious damage to hydraulic system, use only specified fluid or its equivalent.
Place Lubricants
Transmission Case
Grease fitting
Capacities
11.6 L
3.1 U.S.gals
2.6 lmp.gals
Until grease overflows
KUBOTA SUPER UDT Fluid *
Moly Ep Type grease
Q
NOTE
• * KUBOTA SUPER UDT Fluid.................
KUBOTA original transmission hydraulic fluid
W1010650
8-G3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
4. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLTS AND NUTS (FOR FRONT LOADER
AND BACKHOE)
Screws, bolts, and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below.
Indication on top of bolt
No-grade or 4T 7T or Property class 8.8
9T or
Property class 10.9
Material of opponent part
Unit
Diameter
Ordinariness Aluminum Ordinariness Aluminum Ordinariness
N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
167 to
191
246 to
284
63 to
72
108 to
125
334 to
392
7.9
to
9.3
18 to
20
40 to
45
17.0
to
19.5
25.0
to
29.0
6.4
to
7.4
11.0
to
12.8
34.0
to
40.0
0.80
to
0.95
1.8
to
2.1
4.0
to
4.6
123 to
141
181 to
209
47 to
53
79.6
to
92.5
246 to
289
5.8
to
6.8
13 to
15
29 to
33
7.9
to
8.8
17 to
19
32 to
34
–
–
–
–
–
0.80
to
0.90
1.7
to
2.0
3.2
to
3.5
–
–
–
–
–
5.8
to
6.5
13 to
14
24 to
25
–
–
–
–
–
197 to
225
275 to
318
78 to
90
124 to
147
368 to
431
9.81
to
11.2
24 to
27
48 to
55
20.0
to
23.0
28.0
to
32.5
7.9
to
9.2
12.6
to
15.0
37.5
to
44.0
1.00
to
1.15
2.4
to
2.8
4.9
to
5.7
145 to
166
203 to
235
58 to
66
91.2
to
108
272 to
318
7.24
to
8.31
18 to
20
36 to
41
7.9
to
8.8
18 to
20
40 to
44
63 to
72
–
–
–
–
0.80
to
0.90
1.8
to
2.1
4.0
to
4.5
6.4
to
7.4
–
–
–
–
5.8
to
6.5
13 to
15
29 to
32
47 to
53
–
–
–
–
260 to
304
344 to
402
103 to
117
167 to
196
491 to
568
12.3
to
14.2
30 to
34
61 to
70
26.5
to
31.0
35.0
to
41.0
10.5
to
12.0
17.0
to
20.0
50.0
to
58.0
1.25
to
1.45
3.0
to
3.5
6.2
to
7.2
W1034542
192 to
224
254 to
296
76.0
to
86.7
123 to
144
362 to
419
9.05
to
10.4
22 to
25
45 to
52
[2] STUD BOLTS
Material of opponent part
Unit
Diameter
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
Ordinariness Aluminum
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
29.5
to
49.0
62 to
73
12 to
15
25 to
31
98.1
to
112
172 to
201
1.2
to
1.6
2.5
to
3.2
10.0
to
11.5
17.5
to
20.5
3.0
to
5.0
6.3
to
7.5
8.7
to
11
18 to
23
21.7
to
36.1
46 to
54
72.4
to
83.1
127 to
148
8.9
to
11
20 to
25
31.4
–
–
–
0.9
to
1.2
2.0
to
2.6
3.2
–
–
–
6.5
to
8.6
15 to
18
23.1
–
–
–
W1048139
8-G4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[3] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR
UNF THREADS
SAE GR.5
SAE GR.8
Grade
Unit
Nominal
Diameter
1/4
5/16
3/ 8
1/ 2
9/16
5/ 8
N·m
11.7 to 15.7
23.1 to 27.7
48 to 56
110 to 130
150 to 178
204 to 244
kgf·m
1.19 to 1.61
2.35 to 2.83
4.9 to 5.8
11 to 13
15.2 to 18.2
20.8 to 24.8
lbf·ft
8.61 to 11.6
17.0 to 20.5
35.0 to 42.0
80 to 96
110 to 132
150 to 180
N·m
16.3 to 19.7
33 to 39
61 to 73
150 to 178
217 to 260
299 to 357
kgf·m
1.66 to 2.01
3.4 to 4.0
6.3 to 7.4
15.2 to 18.2
22.2 to 26.5
30.5 to 36.4
lbf·ft
12.0 to 14.6
24 to 29
45 to 54
110 to 132
160 to 192
220 to 264
W1022485
[4] PLUGS
Material of opponent part
Shape
Tapered screw
Straight screw
Size
R1/8
R1/4
R3/8
R1/2
G1/4
G3/8
G1/2
N·m
13 to 21
25 to 44
49 to 88
58.9 to 107
25 to 34
62 to 82
49 to 88
Ordinariness kgf·m
1.3 to 2.2
2.5 to 4.5
5.0 to 9.0
6.00 to 11.0
2.5 to 3.5
6.3 to 8.4
5.0 to 9.0
lbf·ft
9.4 to 15
18 to 32
37 to 65
43.4 to 79.5
18 to 25
46 to 60
37 to 65
N·m
13 to 21
25 to 34
49 to 58
59 to 78
–
–
–
Aluminum kgf·m
1.3 to 2.0
2.5 to 3.5
5.0 to 6.0
6.0 to 8.0
–
–
–
lbf·ft
9.4 to 15
18 to 25
37 to 43
44 to 57
–
–
–
0000001666E
8-G5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[5] HYDRAULIC FITTINGS
Q
Adaptors, Elbows and Others
Item Shape Thread size
9/16
G
GENERAL
N·m
37 to 44
Tightening torque kgf·m
3.8 to 4.5
lbf·ft
27 to 33
Adjustable elbow,
Adaptor (O-ring port) (UNF)
3/4 48 to 54 4.9 to 5.5
35 to 40
[A] Nut Type
[B] No Nut Type a : O-ring
7/8 77 to 85 7.9 to 8.6
57 to 62
9/16 22 to 25 2.3 to 2.6
16 to 19
Hose fitting, Flare nut (UNF)
3/4 36 to 40 3.6 to 4.1
26 to 30
7/8 43 to 50 4.4 to 5.0
32 to 36
1/4
3/8
30 to 50
39 to 60
3.1 to 5.0
4.0 to 6.1
23 to 36
29 to 44
Adaptor (NPT)
1/2 49 to 58 5.0 to 5.9
36 to 43
Q
NOTE
• When connecting a hose with flare nut, after tightening the nut with specified torque, return it approximately 45 degrees (0.79 rad) and re-tighten it to specified torque.
W1015484
[6] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS ON THE
TABLE BELOW ARE ESPECIALLY SPECIFIED
Item
Boom cylinder piston mounting nut
Bucket cylinder piston mounting nut
Main frame mounting bolt and nut (M14)
N·m
150 to 180
350 to 400
147
kgf·m
15.3 to 18.3
35.7 to 40.7
15.0
ft-lbs
111 to 132
259 to 295
108
W1012736
8-G6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
5. MAINTENANCE CHECK LIST
To keep the machine working in good condition as well as to avoid any accident and trouble, carry out periodic inspection and maintenance. Check the following points before use.
Service Internal
Daily (Each use)
Every 10 hours
Check Points
Check the transmission fluid level
Check the hydraulic hoses
Grease all grease fitting
Lubricate joints of control lever linkage
Reference
Page
8-G8
8-G8
8-G8
8-G8
W1010764
8-G7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
6. CHECK AND MAINTENANCE
G
GENERAL
CAUTION
• When checking and repairing, park the tractor on flat ground and apply the parking brake.
• When checking and repairing, lower the bucket and stop the engine.
[1] CHECK POINTS OF EACH USE OR DAILY
Checking Transmission Fluid Level
1. Check the oil level at the dipstick (1).
2. If the level is too low, add new oil to the prescribed level at the oil inlet.
Q
IMPORTANT
• If oil level is low, do not run engine.
(1) Dipstick
A : Oil level is acceptable within this range.
W1010960
Checking Hydraulic Hoses
1. Checking all hydraulic hoses for cuts or wear.
2. If defects are found, replace them.
(1) Hydraulic Hose
(2) Cardboard
(3) Magnifying Glass
W1011064
[2] CHECK POINTS OF EVERY 10 HOURS
Greasing
1. Inject grease in all grease fitting with a hand grease gun.
W1011132
Lubricating
1. Lubricate joints of control lever linkage.
W1011274
8-G8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
7. DISMOUNTING AND MOUNTING FRONT LOADER
FROM TRACTOR
Q
IMPORTANT
• When dismounting the loader, park the tractor on flat and hard ground, apply the parking brake.
• When starting the engine or using the hydraulic control valve, always sit in the operator’s seat.
[1] DISMOUNTING FRONT LOADER FROM TRACTOR
Side Frame
1. Raise the boom until the stands (1) can be rotated.
2. Stop the engine.
3. Remove the spring pin (2) holding the stand (1) to the boom.
4. Slide the stands (1) leftward and rotate it until the hole in the stand and pin on the boom are aligned. Then slide the stand (1) rightward and insert the spring pin (2) as shown.
5. Start the engine and run at idle.
6. Dump the bucket approximately 20 degrees.
7. Lower the boom and raise the front wheels slightly.
Q
IMPORTANT
• Lift the front wheels with the bucket. Do not attempt to lift the with the stand.
8. Stop the engine.
9. Remove the mounting pins from the loader side frames and hold them in the plate of side frame.
10.Start the engine and run at idle. Slowly move the hydraulic control lever (3) to rollback position to raise the loader side frames up and out of the receives of the main frames as shown.
11.Stop the engine.
12.Slowly release all hydraulic pressure by moving the hydraulic control lever (3) in all directions.
13.Disconnect the four hoses with quick couplers at the control valve and place them on the right side of the boom.
14.Place the protective caps and plugs (4) on the quick coupler ends.
15.Start the engine and slowly back the tractor away from the loader.
(1) Stand
(2) Spring Pin
(3) Hydraulic Control Lever
(4) Protective Plug
W1012789
8-G9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
G
GENERAL
[2] MOUNTING FRONT LOADER TO TRACTOR
Side Frame and Hoses
1. Slowly drive the tractor between the loader side frames until the rear portion of both side frames touches the main frames as shown.
2. Stop the engine.
3. Connect four hoses with couplers to the nipple on the control valve as indicated with color marks. Then connect the protective caps and plugs to each other.
4. Start the engine and run at idle.
5. Slowly move the loader control lever to dump position to lower the side frames into the main frames and engage the bosses of the main frames to the guide bosses of the side frames. Then lift the front wheels slightly with the loader.
Q
IMPORTANT
• Do not attempt to lift the front wheels with the stand.
6. Stop the engine. Reinstall the mounting pins and secure them with the locking rods.
7. Start the engine.
8. Raise the boom until the stand can be rotated.
9. Stop the engine.
10.Store the stand to their original positions and secure it with the spring pin as shown.
11.Start the engine.
12.Lower the boom and level the bucket.
(1) Side Frame
(2) Main Frame
(3) Hose
(4) Loader Control Lever
(5) Spring Pin
(6) Stand
W1020231
8-G10
KiSC issued 06, 2009 A
MECHANISM
CONTENTS
1. HYDRAULIC CIRCUIT SCHEMATIC........................................................... 8-M1
2. CONTROL VALVE ASSEMBLY................................................................... 8-M2
[1] STRUCTURE ........................................................................................... 8-M2
[2] OPERATION ............................................................................................ 8-M3
3. BOOM CYLINDER AND BUCKET CYLINDER........................................ 8-M10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. HYDRAULIC CIRCUIT SCHEMATIC
FRONT LOADER
(1) Bucket Control Valve
(2) Bucket Cylinder
(3) Boom Cylinder
(4) Boom Control Valve
(5) Control Valve Assembly
P : From Pump
P.B. :To 3-Point Hydraulic
System
T : To Tank
1A :1A Port
2A :2A Port
1B :1B Port
2B :2B Port
W1016476
To operate the front loader, the hydraulic oil pressurized by the hydraulic pump flows from
P
port through the boom control valve (4) and the bucket control valve (1) to
P.B.
port or
T
port.
Since relief valve is not equipped in the front loader control valve, the main relief valve in the tractor operates.
8-M1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. CONTROL VALVE ASSEMBLY
[1] STRUCTURE
FRONT LOADER
(1) Inlet and Outlet Section
(2) Boom Control Valve
(3) Bucket Control Valve
(4) Power Beyond
P : P Port (From Pump)
T : T Port (To Tank)
A1 : A1 Port
A2 : A2 Port
B1 : B1 Port
B2 : B2 Port
P.B. :P.B. Port
The control valve assembly is composed of one casting block and four major section as shown above.
(1) Inlet and Outlet Section
This section has
P
and
T
ports.
The
P
port is connected to the
OUTLET
port of hydraulic block by the hydraulic hose.
The
T
port is connected to the
TANK
port of hydraulic block by the hydraulic hose.
(2) Boom Control Section
The boom control valve is of 4-position, 6-connection, detent, spring center type, consisting of a mono block valve housing, spool, load check valve, etc. This valve has
A1
and
B1
ports and controls oil flow to the boom cylinder.
(3) Bucket Control Section
The bucket control valve is of 4-position, 6-connection, no detent, spring center type, consisting of a mono block valve housing, spool, load check valve, etc. This valve has
A2
and
B2
ports and controls oil flow to the bucket cylinder.
(4) Power Beyond
This section has
P.B.
port which is connected to the
INLET
port of hydraulic block by the hydraulic hose, and feeds oil to the three point hydraulic control valve.
8-M2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[2] OPERATION
Q
Neutral
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3) Spool
(4) Spool
(5)
P.B.
Passage 1
(6)
P.B.
Passage 2
(7) Load Check Valve
T : T Port (To Tank)
P : P Port (From Pump)
A1 : A1 Port
A2 : A2 Port
B1 : B1 Port
B2 : B2 Port
P.B. :P.B. Port a : Low Pressure
8-M3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Up
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3) Spool
(4)
P.B.
Passage 1
(5) Neutral Passage 1
(6) Load Check Valve
(7) Passage 1
(8) Boom Cylinder
P : P Port (From Pump)
T : T Port (To Tank)
A1 : A1 Port
(From Boom Cylinder)
B1 : B1 Port (To Boom Cylinder)
P.B. :P.B. Port (To 3 Hitch) a : Low Pressure b : High Pressure
1. When the hydraulic control lever is set to the
“UP”
position, the spool (3) of the boom control section (1) moves to the left, which forms oil passages between passage 1 (7) and
B1
port, and between
A1
port and
P.B.
passage 1
(4).
2. As the oil passage from the neutral passage 1 (5) to the
P.B.
passage 1 (4) is closed by the spool (3), the pressurefed oil from the
P
port opens the load check valve (6) and flows through the notched section of the spool (3) and
B1
port to extend the boom cylinder (8).
3. Return oil from the boom cylinder (8) flows from the
A1
port through the passage in the spool (3) and
P.B.
passage
1 (4) to the bucket control section (3).
8-M4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Down
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3) Spool
(4)
P.B.
Passage 1
(5) Neutral Passage 1
(6) Load Check Valve
(7) Passage 1
(8) Boom Cylinder
P : P Port (From Pump)
T : T Port (To Tank)
A1 : A1 Port (To Boom Cylinder)
B1 : B1 Port
(From Boom Cylinder)
P.B. :P.B. Port (To 3 Hitch) a : Low Pressure b : High Pressure
1. When the hydraulic control lever is set to the
“DOWN”
position, the spool (3) moves to the right, which forms oil passages between passage 1 (7) and
A1
port, and between
B1
port and
P.B.
passage 1 (4).
2. As the oil passage from the neutral passage 1 (5) to the
P.B.
passage 1 (4) is closed by the spool (3), the pressurefed oil from the
P
port opens the load check valve (6) and flows through the notched section of the spool (3) and
A1
port to retract the boom cylinder (8).
3. Return oil from the boom cylinder (8) flows from the
B1
port through the passage in the spool (3) and
P.B.
passage
1 (4) to the bucket control section (2).
8-M5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Floating
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3) Spool
(4)
P.B.
Passage 1
(5) Detent Mechanism
(6) Neutral Passage 1
(7) Boom Cylinder
P : P Port (From Pump)
T : T Port (To tank)
A1 : A1 Port
B1 : B1 Port
P.B. :P.B. Port (To 3 Hitch) a : Low Pressure
1. When the hydraulic control lever is set to the
“FLOAT”
position, the spool (3) moves further to the right from the
“DOWN”
position and is retained by the detent mechanism (5).
2. This forms oil passages among the
A1
port,
B1
port and
T
port. As a result, oil in the boom cylinder (7) flows freely from the
A1
port and
B1
port through the
T
port to the transmission case.
3. Oil entering the
P
port flows to the bucket control section (2) through the neutral passage 1 (6) and
P.B.
passage
1 (4).
8-M6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Roll-back
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3)
P.B.
Passage 1
(4) Spool
(5) Neutral Passage 2
(6)
P.B.
Passage 2
(7) Load Check Valve
(8) Passage 2
(9) Bucket Cylinder
P : P Port (From Pump)
T : T Port (To Tank)
P.B. :P.B. Port (To 3 Hitch)
A2 : A2 Port
(From Bucket Cylinder)
B2 : B2 Port
(To Bucket Cylinder) a : Low Pressure b : High Pressure
1. When the hydraulic control lever is set to the
“ROLL-BACK”
position, the spool (4) of the bucket control section
(2) moves to the left, which forms oil passages between passage 2 (8) and
B2
port, and between
A2
port and
T
port.
2. The pressure-fed oil from the
P
port flows to the neutral passage 2 (5) through the boom control section (1) and
P.B.
passage 1 (3). As the oil passage from the neutral passage 2 (5) to the
P.B.
passage 2 (6) is closed by the spool (4), this oil opens the load check valve (7), and flows through the notched section of the spool (4) and
B2
port to retract the bucket cylinder (9).
3. Return oil from the bucket cylinder (9) flows to the transmission case through the
A2
port and
T
port.
8-M7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Dump 1
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3)
P.B.
Passage 1
(4) Spool
(5) Neutral Passage 2
(6)
P.B.
Passage 2
(7) Load Check Valve
(8) Passage 2
(9) Bucket Cylinder
P : P Port (From Pump)
T : T Port (To Tank)
P.B. :P.B. Port (To 3 Hitch)
A2 : A2 Port
(To Bucket Cylinder)
B2 : B2 Port
(From Bucket Cylinder) b : High Pressure
1. When the hydraulic control lever is set to the
“DUMP 1”
position, the spool (4), which forms oil passages among passage 2 (8),
A2
port and
B2
port.
2. The pressure-fed oil from the
P
port flows through the boom control valve, opens the load check valve, and flows to the bucket cylinder to extend the cylinder through the notched section of the spool and
A2
port.
3. Return oil from the bucket cylinder (9) flows from the
B2
port to the passage 2 (8), and flows to the
A2
port together with the pressure-fed oil from the
P
port.
As a result, the dump speed is increased.
(Reference)
• The oil pressure of the
A2
port and
B2
port is identical, but the bucket cylinder extends by the difference of received pressure area (cylinder rod part).
8-M8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
Q
Dump 2
FRONT LOADER
(1) Boom Control Section
(2) Bucket Control Section
(3)
P.B.
Passage 1
(4) Spool
(5) Neutral Passage 2
(6)
P.B.
Passage 2
(7) Load Check Valve
(8) Passage 2
(9) Bucket Cylinder
P : P Port (From Pump)
T : T Port (To Tank)
P.B. :P.B. Port (To 3 Hitch)
A2 : A2 Port
(To Bucket Cylinder)
B2 : B2 Port
(From Bucket Cylinder) a : Low Pressure b : High Pressure
1. When the hydraulic control lever is set to the
“DUMP 2”
position, the spool (4) of the bucket control section (2) moves to the right of the bucket control section (2) moves further to the right from the
“DUMP 1”
position, which forms oil passages between passage 2 (8) and
A2
port, and between
B2
port and
T
port.
2. The pressure-fed oil from the
P
port flows to the neutral passage 2 (5) through the boom control section (1) and
P.B.
passage 1 (3). As the oil passage from the neutral passage 2 (5) to the
P.B.
passage 2 (6) is closed by the spool (4), this oil opens the load check valve (7) and flows through the notched section of the spool (4) and
B2
port to extend the bucket cylinder (9).
3. Return oil from the bucket cylinder (9) flows to the transmission case through the
B2
port and
T
port.
8-M9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
3. BOOM CYLINDER AND BUCKET CYLINDER
FRONT LOADER
(1) Nut
(2) Piston
(3) Cylinder Tube (4) Head (5) Piston Rod
Both boom cylinder and bucket cylinder consists of a head (4), cylinder tube (3), piston rod (5), piston (2), and other parts as shown in the figure above. They are single-rod double acting cylinder in which the reciprocating motion of the piston is controlled by hydraulic force applied to both of its ends.
Cylinder Specifications
Boom Cylinder
Bucket Cylinder
Cylinder I.D.
Rod O.D.
Stroke
Cylinder I.D.
Rod O.D.
Stroke
LA203 LA243
40 mm (1.57 in.)
25 mm (0.98 in.)
281 mm (11.1 in.) 326 mm (12.8 in.)
65 mm (2.56 in.)
30 mm (1.18 in.)
204 mm (8.03 in.)
W1025274
8-M10
KiSC issued 06, 2009 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................8-S1
2. SERVICING SPECIFICATIONS ....................................................................8-S2
3. TIGHTENING TORQUES ..............................................................................8-S3
4. CHECKING, DISASSEMBLING AND SERVICING......................................8-S4
[1] CHECKING AND ADJUSTING ...............................................................8-S1
(1) Control Valve ......................................................................................8-S4
[2] DISASSEMBLING AND ASSEMBLING..................................................8-S1
(1) Control Valve ......................................................................................8-S1
(2) Bucket, Boom and Hydraulic Cylinders...........................................8-S1
(3) Side Frames, Front Guard and Main Frames .....................................8-S1
[3] SERVICING ............................................................................................8-S10
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
1. TROUBLESHOOTING
Symptom Probable Cause
Boom Does Not Rise
Control valve malfunctioning
Boom cylinder defective
Control lever linkage defective
Hydraulic pump malfunctioning
Oil filter clogged
Hydraulic hose damaged
Control valve malfunctioning
Boom Does Not
Lower
Insufficient Boom
Speed
Boom cylinder tube worn or damaged
Boom cylinder piston ring (piston seal and Oring) worn or damaged
Bucket Does Not
Move
Oil leaks from tube joints
Relief valve setting pressure too low
Insufficient transmission fluid
Dirty relief valve
Control valve malfunctioning
Bucket cylinder defective
Control lever linkage defective
Hydraulic pump malfunctioning
Oil filter clogged
Relief valve spring damaged
Insufficient Bucket
Speed
Front End Loader
Drops by its Weight
Hydraulic hose damaged
Dirty relief valve
Bucket cylinder tube worn or damaged
Bucket cylinder piston ring (piston seal and Oring) worn or damaged
Oil leaks from tube joints
Insufficient transmission fluid
Boom cylinder tube worn or damaged
Boom cylinder piston ring (piston seal and Oring) worn or damaged
Oil leaks from tube joints
Control valve malfunctioning
Solution
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Clean or replace
Replace
Repair or replace
Replace
Replace
Repair
Adjust
Refill
Clean
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Clean or replace
Replace
Replace
Clean
Replace
Replace
Repair
Refill
Replace
Replace
Repair
Repair or replace
FRONT LOADER
Reference
Page
8-S5
8-S7
8-S5
5-S13
G-14
–
8-S5
8-S7
8-S8
–
8-G3
8-S7
8-S8
–
8-S5
W1014322
8-S7
5-S4
8-G3
5-S4
8-S5
8-S7
8-S5
5-S13
G-14
5-S4
–
5-S4
8-S7
8-S8
8-S1
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
2. SERVICING SPECIFICATIONS
Item
Piston Rod Bend
Factory Specification
–
FRONT LOADER
Allowable Limit
0.25 mm
0.0098 in.
W1013874
8-S2
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
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 8-G4.)
Item
Boom cylinder piston mounting nut
Bucket cylinder piston mounting nut
Main frame mounting bolt (M14)
N·m
150 to 180
350 to 400
147
kgf·m
15.3 to 18.3
35.7 to 40.7
15.0
FRONT LOADER
lbf·ft
111 to 132
259 to 295
108
W1012736
8-S3
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT LOADER
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Control Valve
Relief Valve Setting Pressure
Q
NOTE
• The relief valve is not installed on this model. However the relief valve of the tractor hydraulic system is used as the relief valve of the front loader. Refer to hydraulic section.
(Reference)
Relief valve setting pressure
Factory spec.
12.3 to 12.7 MPa
125 to 130 kgf/cm
2
1780 to 1840 psi
Condition
• Engine speed....... Maximum
• Oil temperature..... 45 to 55
°
C
113 to 131
°
F
W1014688
[2] DISASSEMBLING AND ASSEMBLING
(1) Control Valve
Step and 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 (3) from the battery (2).
3. Remove the valve covers (4).
4. Remove the HST pedal (5) and the step (6).
(1) Under Panel
(2) Battery
(3) Negative Cable
(4) Valve Cover
(5) HST Pedal
(6) Step
W1012394
8-S4
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT LOADER
Control Valve
1. Remove the loader frame (6).
2. Disconnect the cruise control rod (2).
3. Disconnect the frame loader control rods (3).
4. Remove the brake spring.
5. Remove the arms (4) from spool end.
6. Remove the stay bolt (5).
7. Remove the valve stay (7).
8. Disconnect the pipes (1).
9. Remove the control valve (8) with pipes.
(When reassembling)
• After reassembling a valve, check for oil leakage by starting up engine.
Q
IMPORTANT
• When starting up engine, watch out for the rotating propeller shaft (9).
(Reference)
• When adjusting the length of rods, make the lever come to the neutral position.
A
: 145 mm (5.71 in.)
B
: 315 mm (12.4 in.)
C
: 448 mm (17.6 in.)
(1) Pipe
(2) Cruise Control Rod
(3) Front Loader Control Rod
(4) Arm
(5) Stay
(6) Loader Frame
(7) Valve Stay
(8) Control Valve
(9) Propeller Shaft
(10) Front Loader Control Lever
(11) Rod 1
(12) Rod 2
(13) Rod 3
W1013200
8-S5
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT LOADER
Disassembling Control Valve
(1) Dust Seal
(2) Dust Seal
(3) Load Check Valve
(4) Spring
(5) O-ring
(6) Plug
(7) Bolt
(8) Plug
(9) Seat
(10) Spring
(11) Ball
(12) Stopper
(13) Ring
(14) Bolt
(15) Plug
(16) Seat
(17) Spring
(18) Ball
(19) Stopper
(20) Ring
(21) Spool
(22) O-ring
(23) Back-up Ring
(24) Collar
(25) Spring Holder
(26) Spring
(27) Spring Holder
(28) Valve Body
(29) Spool
(30) O-ring
(31) Back-up Ring
(32) Collar
(33) Spring Holder
(34) Spring
(35) Spring Holder
A, C : Boom Control Section
B, D : Bucket Control Section
W1013558
1. Remove the plugs (6) and take out the spring (4) and load check valve (3).
2. Remove the seal plates (8), (15) with other parts inside plug (
C
), (
D
).
3. Draw out the spools (21), (29) with other component parts (
A
), (
B
) from the valve body (28).
(When reassembling)
• Clean all parts with a suitable solvent, and dry with a lint-free cloth or air.
• Visually inspect all parts for damage,
• Install the spools to the valve body, not to damage the O-ring.
8-S6
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT LOADER
(2) Bucket, Boom and Hydraulic Cylinders
Bucket and Bucket Cylinder
1. Remove the pins (4) the lower pin (1) and remove the bucket (3).
2. Disconnect the hydraulic hoses from the bucket cylinder (2).
3. Remove the upper pin (1) and remove the bucket cylinder (2).
(When reassembling)
• When installing the bucket cylinder (2), the hydraulic port should face inside and be careful of the direction of grease fittings.
(1) Pin
(2) Bucket Cylinder
(3) Bucket
(4) Pin
W1016780
Boom Cylinder and Hydraulic Tubes
1. Disconnect the hydraulic hoses from the boom cylinders (4).
2. Remove the pins (2) and remove the boom cylinders (4).
3. Disconnect the hydraulic hoses (6) with quick couplers at the control valve.
4. Remove the pins (1) and remove the boom (3) from the side frame (5).
5. Remove the hydraulic tubes (7) from the boom (3).
(When reassembling)
• When installing the boom cylinders (4), the hydraulic port should face inside and be careful of the direction of grease fittings.
(1) Pin
(2) Pin
(3) Boom
(4) Boom Cylinder
(5) Side Frame
(6) Hydraulic Hose
(7) Hydraulic Tube
W1016879
8-S7
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT LOADER
Piston Rod Assembly
1. Drain hydraulic oil from the cylinder, and secure the tube end of the cylinder in a vise.
2. Unscrew the cylinder head (1) with the adjustable gland nut wrench (4).
3. Pull out the piston rod assembly (2) from the cylinder tube (3).
(When reassembling)
• Visually inspect the cylinder tube for signs of scoring or damage.
• Insert the piston rod assembly to the cylinder tube, not to damage the piston seal on the piston.
• Install the cylinder head to the cylinder tube, not to damage the
O-ring on the cylinder head.
(1) Cylinder Head
(2) Piston Rod Assembly
(3) Cylinder Tube
(4) Adjustable Gland Nut Wrench
W1017050
Cylinder Head, Piston and Nut
1. Secure the rod end in a vise.
2. Unscrew the nut (4), and remove the piston (3) and cylinder head
(2) from the piston rod (1).
(When reassembling)
• Visually inspect all parts for signs of scoring or damage.
• Insert the piston rod to the cylinder head, not to damage the wiper seal (5) and oil seal (6).
Tightening torque
Boom cylinder piston mounting nut
Bucket cylinder piston mounting nut
150 to 180 N·m
15.3 to 18.3 kgf·m
111 to 132 ft-lbs
350 to 400 N·m
35.7 to 40.7 kgf·m
259 to 295 ft-lbs
(1) Piston Rod
(2) Cylinder Head
(3) Piston
(4) Nut
(5) Wiper Seal
(6) Oil Seal
(7) O-ring
W1017322
Piston Seal and O-ring
1. Remove the piston seal (2) and O-ring (3) from the piston (1).
Q
IMPORTANT
• When installing the O-ring (3) and piston seal (2) to the piston (1), use the slide jig and correcting jig as shown in “
Special Tools” of “GENERAL” section.
(1) Piston
(2) Piston Seal
(3) O-ring
(a) Slide Jig
(b) Correcting Jig
W1017590
8-S8
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM FRONT LOADER
Installing O-ring and Piston Seal
1. Place the slide jig (2) on the piston (4).
2. Install the O-ring (3) to the piston using the slide jig.
3. Install the piston seal (1) over the O-ring using the slide jig.
4. Compress the piston seal to the correct size by installing the piston into the correcting jig (5).
Q
NOTE
• Do not turn (roll) the piston seal as you install it.
(1) Piston Seal
(2) Slide Jig
(3) O-ring
(4) Piston
(5) Correcting Jig
W1018621
(3) Side Frames, Front Guard and Main Frames
Side Frames
1. Remove the pins (2), (5).
2. Remove the side frames (1) from the boom assembly (3) and the boom cylinder (4).
(1) Side Frame
(2) Pin
(3) Boom Assembly
(4) Boom Cylinder
(5) Pin
W1015835
Front Guard
1. Remove the front guard (1).
(1) Front Guard
W1015954
Main Frames
1. Remove the main frame mounting bolts and nuts (2) from the tractor body.
2. Remove the main frame (1).
Tightening torque
Main frame mounting bolt
(M14)
147 N·m
15.0 kgf·m
108 ft-lbs
(1) Main Frame (2) Main Frame Mounting Bolt
W1016042
8-S9
KiSC issued 06, 2009 A
BX1860, BX2360, BX2660, RCK48(P)-18BX, RCK54(P)-23BX, RCK60B-23BX, LA203, LA243, WSM
[3] SERVICING
FRONT LOADER
Piston Rod Bend
1. Place piston rod on V blocks.
2. Set a dial indicator on the center of the rod.
3. Turn the piston rod and read the dial indicator.
4. If the measurement exceeds the allowable limit, replace it.
Piston rod bend Allowable limit
0.25 mm
0.0098 in.
W1017385
8-S10
KiSC issued 06, 2009 A
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : [email protected]
KUBOTA Corporation
Printed in Japan 2009. 06, S, E I , E I , e Code No.9Y111-01951
2008. 08, S, E I , E I , e
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Key features
48-inch cutting width
Height-adjustable cutting deck
Anti-scalping wheels
Mulching kit
Powerful engine
Durable construction
Frequently asked questions
48 inches
Yes, it comes with a mulching kit
BX1860, BX2360, or BX2660
