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Front End Loaders
R540
Kubota R540 User Manual
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CONTROL PEDALS AND LEVERS
(1)
Steering wheel
(2)
Multi function operating lever
(control lever)
(3)
Inching and brake pedal
(4)
Accelerator pedal
INSTRUMENT P
ANEL AND CONTROLS
CONTROL PEDALS AND LEVERS
32
R540
35
37
Table of Contents
Default Chapter
5
Table of Contents
5
Safe Operation
11
Servicing of the Wheel Loader
29
Dealer Service
29
Warranty Policy
29
Procedure for Scrapping the Wheel Loader
30
Specifications
31
Specification Table
31
Machine Parts
33
Description of Machine Parts
33
Instrument Panel and Controls
35
Switches
35
Control Pedals and Levers
36
Instrument Panel
37
Checks before Starting the Machine
38
Daily Check Items
38
Checks for the Switches
38
Parking Brake Switch
38
Starter Switch
38
Horn Switch
39
Multi Function Switch
39
High-Low Beam Changing
39
Turn Signal Blinking
39
Headlight Switch
39
Working Light Switch
40
Hazard Light Switch
40
Attachment Unlock Switch
40
Diesel Particulate Filter (DPF) Switch
40
Differential Lock Switch
41
Hydraulic Lock Switch
41
AUX Port Enable Switch
41
AUX Port Variable Switch
42
AUX Hold Switch
42
Float Switch
42
Display Selector Switch
43
Setting the Clock
43
Checks for the Indicators
44
Battery Charge Indicator
44
Engine Oil Pressure Warning Indicator
45
Grow Plug Indicator
45
Water Separator Filled-Up Indicator
45
LCD for Normal Operation
46
Fuel Gauge
46
How to Use the Fuel Level Audible Indication Switch
46
Coolant Temperature Gauge
47
Engine Tachometer
47
Hour Meter
47
LCD for Warning
47
Battery Charge Indicator
47
Engine Oil Pressure Warning Indicator
47
Warning Indicator
48
Overheat Warning
48
Checks for the Safety Levers and the Appliance
49
Safety Key Start System
49
Lift Arm Support
49
Installing the Lift Arm Support
49
Steering Frame Lock
50
Attaching the Steering Frame Lock
50
Cabin Type Machine
51
Front Wiper / Washer System [Cabin Type Only]
51
Rear Wiper / Washer System [Cabin Type Only]
51
Interior Lamp [Cabin Type Only]
51
Opening and Closing the Cabin Door [Cabin Type Only]
51
Opening and Closing the Side Cabin Window [Cabin Type Only]
52
Emergency Hammer [Cabin Type Only]
52
Sun Visor [Cabin Type Only]
53
Checks for the Air Conditioner
53
Air Flow of the Air Conditioner [Cabin Type Only]
53
Recirculation / Fresh Air Selection Lever [Cabin Type Only]
53
How to Change the Filter of Air Conditioner [Cabin Type Only]
54
Air Control Vent [Cabin Type Only]
54
Control Panel [Cabin Type Only]
55
Air Conditioner Switch and Indicator Light [Cabin Type Only]
55
Blower Switch [Cabin Type Only]
55
Operating the Control Panel [Cabin Type Only]
55
Temperature Control Dial [Cabin Type Only]
55
Operation of the Engine
57
Precautions for Operating the Engine
57
Exhaust Aftertreatment Devices
57
Diesel Oxidation Catalyst and Diesel Particulate Filter (DPF) Muffler
57
Handling Points for DPF Regeneration
58
DPF Regeneration Process
58
Operating Procedure for Auto Regeneration Mode
59
Regeneration Operating Procedure for Auto Regeneration Mode
59
PM Warning Level and Required Procedures for Auto Regeneration Mode
60
Operating the Machine for Parked Regeneration Mode
61
Operating Procedure for Inhibit Mode
62
Regeneration Operating Procedure for Inhibit Mode
62
PM Warning Level and Required Procedures for Inhibit Mode
63
Tips on Diesel Particulate Filter (DPF) Regeneration
64
Starting the Engine
64
Checkpoints after Starting the Engine
65
Starting the Engine under Cold Conditions
65
Stopping the Engine
65
Engine Stop Knob
66
Starting the Engine with an Auxiliary Battery
66
Operation of the Machine
67
Precautions for Operating the Machine
67
Guide for the Operator
67
Working in the Vicinity of Overhead Power Lines
67
Running-In of the Machine
67
Starting of the Machine
68
Precautions for Starting the Machine
68
Adjusting the Operator's Seat
68
How to Use the Seat Belt
69
Adjusting the Tilt Steering
69
Traveling with Machine
69
Starting to Travel with Machine
69
Accelerator Pedal
70
Inching and Brake Pedal
70
Neutral Switch
71
Direction Switch
71
Speed Control Switch
72
Precautions for Turning the Machine
72
Rule to Decelerate on a Slope
73
Precautions for Traveling on Rough Roads
73
Precautions for Traveling on Snow
73
Stopping the Machine
73
Operating the Lift Arm
74
Operating the Bucket
74
Auxiliary Port Operation
76
Selecting the Action Modes
76
Handling the aux Port
77
Setting the Maximum Flow Volume
78
Releasing the Pressure Trapped in the Hydraulic System
81
Quick Coupler
81
Attaching the Attachments to the Quick Coupler
81
Detaching the Attachments from the Quick Coupler
84
Connecting and Disconnecting the Hydraulic Hose
84
How to Use the Inching and Brake Pedal
85
Operating the Inching and Brake Pedal
85
Using the Inching and Brake Pedal According to the Job
86
Typical Jobs Using Awheel Loader
87
Digging and Loading Job
87
Loading a Sand Pile
87
Digging and Loading from Flat Ground
88
Refilling
88
Leveling the Ground
88
Loading Method Onto a Truck
89
Loading Onto a Truck by Cross Loading Method
89
Loading Onto a Truck by V-Shift Loading Method
89
Transporting by Truck
90
Loading the Machine on and from a Truck
90
Precautions for Transporting
90
Lifting the Machine
92
Precautions for Lifting the Machine
92
Handling the Wheel Loader in Cold Weather
93
Preparation for Operation of the Machine in Cold Weather
93
Taking Care of Machine after Operation in Cold Weather
93
Maintenance
94
Precautions for Maintenance
94
Maintenance Intervals
96
Periodic Service
99
Opening and Closing of Covers
99
Precautions for Opening and Closing the Covers
99
Opening and Closing the Engine Cover
99
Opening the Side Cover
99
Daily Check
100
Checking and Replenishing the Engine Oil
100
Checking and Replenishing the Hydraulic Oil
101
Checking and Replenishing the Fuel
102
Checking and Replenishing the Coolant
103
Checking and Refilling the Oil in the Brake Fluid Reservoir
104
Applying the Grease to the Grease Fittings
104
Checking the Pressure and Wear of Tire and the Wheel Nuts
106
Checking and Cleaning the Radiator and the Oil Cooler
106
Checking the Steering
106
Checking the Gear Locked Parking Brake
107
Checking the Disc Brake
107
Checking and Cleaning the Engine and the Electrical Wiring
107
Checking the Fan Belt
107
Washing the Whole Machine
107
Draining the Water Separator
107
Cleaning the Evacuator Valve
108
Checking the Dust Indicator
108
Checking the Diesel Particulate Filter (DPF) Muffler
109
Checking the Washer Liquid [Cabin Type Only]
109
Checking and Tightening the Loose Bolts and the Nuts
109
Checking the Electrical Wiring for Short-Circuits and Loose Terminals
109
Checking the Lamps and the Instruments
109
Testing the Horn
109
Checking the Machine for Leaks
109
Checking and Cleaning after Operating in Muddy Areas
109
Service Every 50 Hours
110
Checking the Battery Condition
110
Charging the Battery
110
Storing the Battery
111
Service Every 250 Hours
111
Checking the Fan Belt Tension
111
Checking the Radiator Hoses and the Clips
112
Cleaning and Checking the Air Cleaner Element
112
Checking the Fuel Line and the Intake Air Line
113
Checking the Wheel Nuts
113
Cleaning the Air Cleaner Element
113
Replacing the Water Separator Filter Element
114
Changing the Engine Oil
114
Replacing the Engine Oil Filter Cartridge
115
Service Every 500 Hours
115
Checking the End Plate of Center Shaft
115
Checking and Replenishing the Oil in the Front and the Rear Axle Differential Case and the Reduction Gear Case
116
Replacing the Return Filter
116
Replacing the Fuel Filter
117
Service Every 1000 Hours
117
Changing the Oil for the Front and the Rear Axle Differential Case and the Reduction Gear Case
117
Replacing the HST Oil Filter
118
Changing the Hydraulic Oil and the Suction Filter
119
Replacing the Air Cleaner Element
120
Adjusting the Engine Valve Clearance
120
Service Every 1500 Hours
120
Checking the Injector
120
Replacing the Oil Separator Element
120
Checking the EGR Cooler
121
Service Every 2000 Hours
121
Checking the Alternator and the Starter Motor
121
Service Every 3000 Hours
121
Checking the EGR System
121
Service Every 6000 Hours
121
Cleaning the Diesel Particulate Filter (DPF)
121
Annual Servicing
121
Checking the Electrical Leads and the Terminals
121
Checking the Exhaust Manifold for Cracks, Gas, Leakage, and Mounting Screw
121
Checking the Air-Flow-Sensor (AFS)
122
Checking the Condition of Diesel Particulate Filter (DPF) Muffler
122
Checking the Diesel Particulate Filter (DPF) Differential Pressure Sensor and Rubber Piping for Gas Leak
122
Checking the Diesel Particulate Filter (DPF) Exhaust Gas Temperature Sensor
122
Checking the EGR Piping for Gas Leak
122
Checking the Brake Hose
122
Biennial Servicing
122
Changing the Brake Fluid
122
Replacing the Brake Hose
122
Replacing the Rubber Parts of Master Cylinder
122
Replacing the Diesel Particulate Filter (DPF) Differential Pressure Sensor Rubber Piping (Front and Back)
123
Replacing the EGR Cooler Hose
123
Replacing the Intake Air Line
123
Replacing the Rubber Piping Related Oil Separator
123
Replacing the Suction Pipe Downstream the Air-Flow-Sensor (AFS)
123
Replacing the Radiator Hoses (Water Pipes)
124
Periodic Parts Replacement
124
Replacing the Air Conditioner Pipes and Hoses [Cabin Type Only]
124
Servicing as Required
124
Replacing and Repairing the Electrical System
124
Replacing the Fuses
124
Replacing the Slow Blow Fuses
126
Bleeding the Fuel System
127
Draining the Fuel Filter by Draining the Water Separator
127
Service for Tires
128
Changing the Tires
128
Checking the Tire Pressure
128
Precautions for Handling the Tires
128
Mounting the Tires
129
Tire Chains
129
Completion of Operation and Storing
130
Storing the Machine
130
Caution When Washing the Machine
130
Recommended Oils
131
Recommended Oil List
131
Biodiesel Fuel (Bdf)
133
Troubleshooting
134
Troubleshooting of the Engine and Other Systems
134
List of Error Code Numbers
136
Appendix
141
Service Hour Meter
141
Index
142
4
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Kubota R540 Specifications
General
Operating Weight
9171 lbs (4160 kg)
Bucket Capacity
0.8 cu. yd (0.6 m3)
Horsepower
51.0 hp (38.0 kW)
Lift Capacity
1, 950 kg
Lift Capacity at Full Height
1, 950 kg
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