Kubota R540 User manual

U.S.A. :KUBOTATRACTORCORPORATION
1000 KubotaDrive,Grapevine,TX 76051
Telephone: 888 - 4 KUBOTA
Canada :KUBOTACANADALTD.
5900  14 thAvenue,Markham,Ontario,L 3 S 4 K 4 ,Canada
Telephone:(
905 ) 294 - 7477
France :KUBOTAEUROPES.A.S
19 - 25 ,RueJulesVercruysse,Z.I.BP 88 , 95101 ArɡenteuilCedex,France
Telephone:(
33 ) 1 - 3426 - 3434
Italy :KUBOTAEUROPES.A.SItalyBranch
ViaGrandi,
29  20068 PeschieraBorrome(MI)Italy
Telephone:(
39 ) 02 - 51650377
Germany :KUBOTABAUMASCHINENGmbH
Steinhauserstr,
100 , 66482 ZweibruckenRheinlandpfalzGermany
Telephone:(
49 ) 6332 - 4870100
U.K. :KUBOTA(U.K.)LTD.
DormerRoad,Thame,Oxfordshire,OX
9  3 UN,U.K.
Telephone:(
44 ) 1844 - 214500
Australia :KUBOTAAUSTRALIAPTYLTD.
25 - 29 PermasWay,Truɡanina,VIC 3029 ,Australia
Telephone:(
61 )- 3 - 9394 - 4400
Malaysia :KUBOTAMALAYSIASDN.BHD.
Lot
766 ,JalanSubanɡ 4 ,offPersiaranSubanɡSunɡaiPenaɡaIndustrialPark,
47500 SubanɡJaya
Telephone:(
60 )- 3 - 7890 - 3533
Philippines :KUBOTAPHILIPPINES,INC.
232 QuirinoHiɡhway,Baesa,QuezonCity 1106 ,Philippines
Telephone:(
63 ) 2 - 422 - 3500
Taiwan :SHINTAIWANAGRICULTURALMACHINERYCO.,LTD.
16 ,Fenɡpinɡ 2 ndRd,TaliaoShianɡKaohsiunɡ 83107 ,TaiwanR.O.C.
Telephone:(
886 ) 7 - 702 - 2333
Thailand :SIAMKUBOTACORPORATIONCO.,LTD.
101 / 19 - 24 Moo 20 ,NavanakornIndustrialEstate,TambonKhlonɡnuenɡ,AmphurKhlonɡluanɡ,
Pathumthani
12120 ,THAILAND
Telephone:(
66 ) 2 - 909 - 0300
Japan :KUBOTACorporation
Farm&IndustrialMachineryInternationalOperationsHeadquarters
2 - 47 ,Shikitsuhiɡashi 1 -chome,Naniwa-ku,Osaka,Japan 556 - 8601
AZ. C. 2-2. -. K English (Australia)
Code No. R5533-8130-2
MODEL R540
1BBABBKAP0460
1BBABBKAP0450
2101-0939
©KUBOTA Corporation 2020 READ AND SAVE THIS MANUAL
OPERATOR'S MANUAL
R540
KUBOTA
WHEEL LOADER

2010-0857
ABBREVIATION LIST
Abbreviations Definitions
API
ASTM
DIN
EN
FOPS
HST
ISO
JIS
MIL
ROPS
rpm
rps
SAE
SMV
American Petroleum Institute
American Society for Testing and Materials, USA
Deutsches Institut für Normung, GERMANY
(German Institute for Standardization)
European Standard
Falling Objects Protective Structures
Hydrostatic Transmission
International Organization for Standaridization
Japanese Industry Standard
Militaly Standard
Roll-Over Protective Structures
Revolutions Per Minute
Revolutions Per Second
Society of Automotive Engineers, USA
Slow Moving Vehicle
R540
English (Australia)

UNIVERSAL SYMBOLS
As a guide to the operation of your machine, various universal symbols have been utilized on the instruments
and controls. The symbols are shown below with an indication of their meaning.
Safety Alert Symbol
Engine Oil-Pressure
Battery Charging Condition
Diesel Preheat/Glow Plugs
Water separator fill-up
Horn
Engine Warning
Wiper/washer
Coolant Temperature
HST Temperature
HST Oil-Pressure
Diesel Fuel
Hydraulic Oil
Low Travel Speed
High Travel Speed
Parking Brake
Neutral
Travel Forward
Travel Backward
Lock
Unlock
Hydraulic lock indicator
Auxiliary port indicator
Auxiliary hold indicator
Read the Operating instructions
Diesel Particulate Filter regeneration
Parked Diesel Particulate Filter Regeneration
Diesel Particulate Filter Regeneration Inhibit
Parked Regeneration switch
Bucket Up
Bucket Down
Bucket Tilt
Bucket Dump
Bucket Float
Working Light
High-beam
Low-beam
Hazard Switch
Hazard / Turn Signal
Clearance Light
Rotary Beacon
Differential Lock
Display Selector
User Setting
Set Clock
Service Interval
Brake fluid warning indicator
Air cleaner warning indicator

FOREWORD
Thank you for the purchase of a Kubota product.
Before using this product, read this manual carefully and use the product correctly.
After reading, keep the manual in a safe and easy-to-access place for future
reference. Note that product specifications are subject to change without prior
notice. The product delivered to you may differ slightly from the product described
in the manual.
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
Indicates that equipment or property damage could result if
instructions are not followed.
Gives helpful information.
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 assemble or use this unit.
SAFETY FIRST
DANGER :
WARNING:
CAUTION:
IMPORTANT:
NOTE:

CONTENTS
SAFE OPERATION......................................................................................................................7
SERVICING OF THE WHEEL LOADER ...................................................................................25
DEALER SERVICE............................................................................................................................................. 25
1. Warranty policy .......................................................................................................................................... 25
2. Procedure for scrapping the wheel loader................................................................................................. 26
SPECIFICATIONS......................................................................................................................27
SPECIFICATION TABLE..................................................................................................................................... 27
MACHINE PARTS......................................................................................................................29
DESCRIPTION OF MACHINE PARTS ............................................................................................................... 29
INSTRUMENT PANEL AND CONTROLS.................................................................................31
SWITCHES ......................................................................................................................................................... 31
CONTROL PEDALS AND LEVERS ................................................................................................................... 32
INSTRUMENT PANEL ........................................................................................................................................ 33
CHECKS BEFORE STARTING THE MACHINE .......................................................................34
DAILY CHECK ITEMS ........................................................................................................................................ 34
CHECKS FOR THE SWITCHES ........................................................................................................................ 34
1. Parking brake switch ................................................................................................................................. 34
2. Starter switch............................................................................................................................................. 34
3. Horn switch................................................................................................................................................ 35
4. Multi function switch .................................................................................................................................. 35
4.1 Turn signal blinking ............................................................................................................................ 35
4.2 High-low beam changing.................................................................................................................... 35
5. Headlight switch ........................................................................................................................................ 35
6. Working light switch................................................................................................................................... 36
7. Hazard light switch .................................................................................................................................... 36
8. Attachment unlock switch .......................................................................................................................... 36
9. Diesel particulate filter (DPF) switch.......................................................................................................... 36
10. Differential lock switch ............................................................................................................................. 37
11. Hydraulic lock switch................................................................................................................................ 37
12. AUX port enable switch ........................................................................................................................... 37
13. AUX port variable switch ......................................................................................................................... 38
14. AUX hold switch ...................................................................................................................................... 38
15. Float switch.............................................................................................................................................. 38
16. Display selector switch ............................................................................................................................ 39
16.1 Setting the clock............................................................................................................................... 39
CHECKS FOR THE INDICATORS ..................................................................................................................... 40
1. Battery charge indicator............................................................................................................................. 40
2. Engine oil pressure warning indicator........................................................................................................ 41
3. Grow plug indicator.................................................................................................................................... 41
4. Water separator filled-up indicator............................................................................................................. 41
5. LCD for normal operation .......................................................................................................................... 42
5.1 Fuel gauge ......................................................................................................................................... 42
5.1.1 How to use the fuel level audible indication switch.................................................................... 42
5.2 Coolant temperature gauge ............................................................................................................... 43
5.3 Hour meter ......................................................................................................................................... 43
5.4 Engine tachometer ............................................................................................................................. 43
6. LCD for warning......................................................................................................................................... 43
6.1 Engine oil pressure warning indicator ................................................................................................ 43
6.2 Battery charge indicator ..................................................................................................................... 43
7. Warning indicator....................................................................................................................................... 44
7.1 Overheat warning............................................................................................................................... 44
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CHECKS FOR THE SAFETY LEVERS AND THE APPLIANCE ........................................................................ 45
1. Safety key start system ............................................................................................................................. 45
2. Lift arm support.......................................................................................................................................... 45
2.1 Installing the lift arm support .............................................................................................................. 45
3. Steering frame lock.................................................................................................................................... 46
3.1 Attaching the steering frame lock....................................................................................................... 46
CABIN TYPE MACHINE ..................................................................................................................................... 47
1. Front wiper / washer system [Cabin type only].......................................................................................... 47
2. Rear wiper / washer system [Cabin type only] .......................................................................................... 47
3. Interior lamp [Cabin type only]................................................................................................................... 47
4. Opening and closing the cabin door [Cabin type only] .............................................................................. 47
5. Opening and closing the side cabin window [Cabin type only].................................................................. 48
6. Emergency hammer [Cabin type only] ...................................................................................................... 48
7. Sun visor [Cabin type only]........................................................................................................................ 49
CHECKS FOR THE AIR CONDITIONER ........................................................................................................... 49
1. Air flow of the air conditioner [Cabin type only] ......................................................................................... 49
1.1 Recirculation / fresh air selection lever [Cabin type only]................................................................... 49
1.2 How to change the filter of air conditioner [Cabin type only] .............................................................. 50
2. Air control vent [Cabin type only]............................................................................................................... 50
3. Control panel [Cabin type only] ................................................................................................................. 51
3.1 Air conditioner switch and indicator light [Cabin type only] ................................................................ 51
3.2 Temperature control dial [Cabin type only]......................................................................................... 51
3.3 Blower switch [Cabin type only] ......................................................................................................... 51
3.4 Operating the control panel [Cabin type only] .................................................................................... 51
OPERATION OF THE ENGINE .................................................................................................53
PRECAUTIONS FOR OPERATING THE ENGINE............................................................................................. 53
EXHAUST AFTERTREATMENT DEVICES........................................................................................................ 53
1. Diesel oxidation catalyst and diesel particulate filter (DPF) muffler........................................................... 53
2. Handling points for DPF regeneration ....................................................................................................... 54
3. DPF regeneration process......................................................................................................................... 54
3.1 Operating procedure for Auto Regeneration Mode ............................................................................ 55
3.1.1 Regeneration operating procedure for Auto Regeneration Mode.............................................. 55
3.1.2 PM warning level and required procedures for Auto Regeneration Mode ................................. 56
3.2 Operating the machine for Parked Regeneration Mode..................................................................... 57
3.3 Operating procedure for Inhibit Mode ................................................................................................ 58
3.3.1 Regeneration operating procedure for Inhibit Mode .................................................................. 58
3.3.2 PM warning level and required procedures for Inhibit Mode ..................................................... 59
4. Tips on diesel particulate filter (DPF) regeneration ................................................................................... 60
STARTING THE ENGINE ................................................................................................................................... 60
1. Checkpoints after starting the engine ........................................................................................................ 61
STARTING THE ENGINE UNDER COLD CONDITIONS................................................................................... 61
STOPPING THE ENGINE................................................................................................................................... 61
1. Engine stop knob....................................................................................................................................... 62
STARTING THE ENGINE WITH AN AUXILIARY BATTERY .............................................................................. 62
OPERATION OF THE MACHINE ..............................................................................................63
PRECAUTIONS FOR OPERATING THE MACHINE.......................................................................................... 63
GUIDE FOR THE OPERATOR ........................................................................................................................... 63
WORKING IN THE VICINITY OF OVERHEAD POWER LINES ........................................................................ 63
RUNNING-IN OF THE MACHINE....................................................................................................................... 63
STARTING OF THE MACHINE .......................................................................................................................... 64
1. Precautions for starting the machine ......................................................................................................... 64
2. Adjusting the operator's seat ..................................................................................................................... 64
3. How to use the seat belt ............................................................................................................................ 65
4. Adjusting the tilt steering ........................................................................................................................... 65
TRAVELING WITH MACHINE ............................................................................................................................ 65
1. Starting to travel with machine .................................................................................................................. 65
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R540

2. Accelerator pedal....................................................................................................................................... 66
3. Inching and brake pedal ............................................................................................................................ 66
4. Neutral switch ............................................................................................................................................ 67
5. Direction switch ......................................................................................................................................... 67
6. Speed control switch ................................................................................................................................. 68
7. Precautions for turning the machine.......................................................................................................... 68
8. Rule to decelerate on a slope.................................................................................................................... 69
9. Precautions for traveling on rough roads................................................................................................... 69
10. Precautions for traveling on snow ........................................................................................................... 69
STOPPING THE MACHINE................................................................................................................................ 69
OPERATING THE LIFT ARM.............................................................................................................................. 70
OPERATING THE BUCKET ............................................................................................................................... 70
AUXILIARY PORT OPERATION ........................................................................................................................ 72
1. Selecting the action modes ....................................................................................................................... 72
2. Handling the AUX port............................................................................................................................... 73
3. Setting the maximum flow volume............................................................................................................. 74
RELEASING THE PRESSURE TRAPPED IN THE HYDRAULIC SYSTEM ...................................................... 77
QUICK COUPLER .............................................................................................................................................. 77
1. Attaching the attachments to the quick coupler......................................................................................... 77
2. Detaching the attachments from the quick coupler ................................................................................... 80
CONNECTING AND DISCONNECTING THE HYDRAULIC HOSE................................................................... 80
HOW TO USE THE INCHING AND BRAKE PEDAL.......................................................................................... 81
1. Operating the inching and brake pedal...................................................................................................... 81
2. Using the inching and brake pedal according to the job............................................................................ 82
TYPICAL JOBS USING A WHEEL LOADER ..................................................................................................... 83
1. Digging and loading job ............................................................................................................................. 83
1.1 Loading a sand pile ............................................................................................................................ 83
1.2 Digging and loading from flat ground ................................................................................................. 84
2. Refilling...................................................................................................................................................... 84
3. Leveling the ground ................................................................................................................................... 84
4. Loading method onto a truck ..................................................................................................................... 85
4.1 Loading onto a truck by cross loading method................................................................................... 85
4.2 Loading onto a truck by V-shift loading method ................................................................................. 85
TRANSPORTING BY TRUCK ...................................................................................................86
LOADING THE MACHINE ON AND FROM A TRUCK....................................................................................... 86
PRECAUTIONS FOR TRANSPORTING............................................................................................................ 86
LIFTING THE MACHINE............................................................................................................88
PRECAUTIONS FOR LIFTING THE MACHINE................................................................................................. 88
HANDLING THE WHEEL LOADER IN COLD WEATHER .......................................................89
PREPARATION FOR OPERATION OF THE MACHINE IN COLD WEATHER .................................................. 89
TAKING CARE OF MACHINE AFTER OPERATION IN COLD WEATHER ....................................................... 89
MAINTENANCE.........................................................................................................................90
PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 90
MAINTENANCE INTERVALS ............................................................................................................................. 92
PERIODIC SERVICE .................................................................................................................95
OPENING AND CLOSING OF COVERS............................................................................................................ 95
1. Precautions for opening and closing the covers........................................................................................ 95
2. Opening and closing the engine cover ...................................................................................................... 95
3. Opening the side cover.............................................................................................................................. 95
DAILY CHECK .................................................................................................................................................... 96
1. Checking and replenishing the engine oil.................................................................................................. 96
2. Checking and replenishing the hydraulic oil .............................................................................................. 97
3. Checking and replenishing the fuel ........................................................................................................... 98
4. Checking and replenishing the coolant...................................................................................................... 99
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5. Checking and refilling the oil in the brake fluid reservoir ......................................................................... 100
6. Applying the grease to the grease fittings ............................................................................................... 100
7. Checking the pressure and wear of tire and the wheel nuts.................................................................... 102
8. Checking and cleaning the radiator and the oil cooler............................................................................. 102
9. Checking the steering.............................................................................................................................. 102
10. Checking the gear locked parking brake ............................................................................................... 103
11. Checking the disc brake......................................................................................................................... 103
12. Checking and cleaning the engine and the electrical wiring.................................................................. 103
13. Checking the fan belt............................................................................................................................. 103
14. Washing the whole machine.................................................................................................................. 103
15. Draining the water separator ................................................................................................................. 103
16. Cleaning the evacuator valve ................................................................................................................ 104
17. Checking the dust indicator ................................................................................................................... 104
18. Checking the diesel particulate filter (DPF) muffler ............................................................................... 105
19. Checking the washer liquid [Cabin type only]........................................................................................ 105
20. Checking and tightening the loose bolts and the nuts ........................................................................... 105
21. Checking the electrical wiring for short-circuits and loose terminals ..................................................... 105
22. Checking the lamps and the instruments .............................................................................................. 105
23. Testing the horn ..................................................................................................................................... 105
24. Checking the machine for leaks ............................................................................................................ 105
25. Checking and cleaning after operating in muddy areas ........................................................................ 105
SERVICE EVERY 50 HOURS .......................................................................................................................... 106
1. Checking the battery condition ................................................................................................................ 106
1.1 Charging the battery......................................................................................................................... 106
1.2 Storing the battery............................................................................................................................ 107
SERVICE EVERY 250 HOURS ........................................................................................................................ 107
1. Checking the fan belt tension .................................................................................................................. 107
2. Checking the radiator hoses and the clips............................................................................................... 108
3. Cleaning and checking the air cleaner element....................................................................................... 108
4. Checking the fuel line and the intake air line ........................................................................................... 109
5. Checking the wheel nuts ......................................................................................................................... 109
6. Cleaning the air cleaner element............................................................................................................. 109
7. Replacing the water separator filter element ........................................................................................... 110
8. Changing the engine oil........................................................................................................................... 110
9. Replacing the engine oil filter cartridge ....................................................................................................111
SERVICE EVERY 500 HOURS .........................................................................................................................111
1. Checking the end plate of center shaft .....................................................................................................111
2. Checking and replenishing the oil in the front and the rear axle differential case and the reduction
gear case................................................................................................................................................. 112
3. Replacing the return filter ........................................................................................................................ 112
4. Replacing the fuel filter ............................................................................................................................ 113
SERVICE EVERY 1000 HOURS ...................................................................................................................... 113
1. Changing the oil for the front and the rear axle differential case and the reduction gear case................ 113
2. Replacing the HST oil filter ...................................................................................................................... 114
3. Changing the hydraulic oil and the suction filter ...................................................................................... 115
4. Replacing the air cleaner element ........................................................................................................... 116
5. Adjusting the engine valve clearance ...................................................................................................... 116
SERVICE EVERY 1500 HOURS ...................................................................................................................... 116
1. Checking the injector ............................................................................................................................... 116
2. Replacing the oil separator element ........................................................................................................ 116
3. Checking the EGR cooler ........................................................................................................................ 117
SERVICE EVERY 2000 HOURS ...................................................................................................................... 117
1. Checking the alternator and the starter motor ......................................................................................... 117
SERVICE EVERY 3000 HOURS ...................................................................................................................... 117
1. Checking the EGR system ...................................................................................................................... 117
SERVICE EVERY 6000 HOURS ...................................................................................................................... 117
1. Cleaning the diesel particulate filter (DPF) .............................................................................................. 117
ANNUAL SERVICING....................................................................................................................................... 117
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R540

1. Checking the electrical leads and the terminals ...................................................................................... 117
2. Checking the exhaust manifold for cracks, gas, leakage, and mounting screw ...................................... 117
3. Checking the intake air line for air leaks.................................................................................................. 117
4. Checking the air-flow-sensor (AFS)......................................................................................................... 118
5. Checking the condition of diesel particulate filter (DPF) muffler.............................................................. 118
6. Checking the diesel particulate filter (DPF) differential pressure sensor and rubber piping for gas leak 118
7. Checking the diesel particulate filter (DPF) exhaust gas temperature sensor......................................... 118
8. Checking the EGR piping for gas leak..................................................................................................... 118
9. Checking the brake hose......................................................................................................................... 118
BIENNIAL SERVICING..................................................................................................................................... 118
1. Replacing the brake hose........................................................................................................................ 118
2. Changing the brake fluid.......................................................................................................................... 118
3. Replacing the rubber parts of master cylinder......................................................................................... 118
4. Replacing the fuel hoses and the clamps................................................................................................ 118
5. Changing the coolant............................................................................................................................... 118
6. Replacing the intake air line .................................................................................................................... 119
7. Replacing the rubber piping related oil separator.................................................................................... 119
8. Replacing the diesel particulate filter (DPF) differential pressure sensor rubber piping (front and back) 119
9. Replacing the suction pipe downstream the air-flow-sensor (AFS)......................................................... 119
10. Replacing the EGR cooler hose ............................................................................................................ 119
11. Replacing the radiator hoses (water pipes) ........................................................................................... 120
PERIODIC PARTS REPLACEMENT ................................................................................................................ 120
1. Replacing the air conditioner pipes and hoses [Cabin type only] ............................................................ 120
SERVICING AS REQUIRED............................................................................................................................. 120
1. Replacing and repairing the electrical system ......................................................................................... 120
1.1 Replacing the fuses.......................................................................................................................... 120
1.2 Replacing the slow blow fuses ......................................................................................................... 122
2. Draining the fuel filter by draining the water separator ............................................................................ 123
3. Bleeding the fuel system ......................................................................................................................... 123
SERVICE FOR TIRES ...................................................................................................................................... 124
1. Precautions for handling the tires ............................................................................................................ 124
2. Checking the tire pressure....................................................................................................................... 124
3. Changing the tires ................................................................................................................................... 124
4. Mounting the tires .................................................................................................................................... 125
5. Tire chains ............................................................................................................................................... 125
COMPLETION OF OPERATION AND STORING ...................................................................126
STORING THE MACHINE................................................................................................................................ 126
CAUTION WHEN WASHING THE MACHINE .................................................................................................. 126
RECOMMENDED OILS ...........................................................................................................127
RECOMMENDED OIL LIST.............................................................................................................................. 127
BIODIESEL FUEL (BDF) .................................................................................................................................. 129
TROUBLESHOOTING.............................................................................................................130
TROUBLESHOOTING OF THE ENGINE AND OTHER SYSTEMS................................................................. 130
LIST OF ERROR CODE NUMBERS ................................................................................................................ 132
APPENDIX ...............................................................................................................................137
SERVICE HOUR METER ................................................................................................................................. 137
INDEX.......................................................................................................................................138
R540
5

6
R540

SAFE OPERATION
Careful operation is your best insurance against an
accident.
Read and understand the Safe operation section
carefully, before operating the wheel loader.
All operators, no matter how much experience they
may have had, should read this and other related
manuals before operating the machine or any
attachment. It is the owner's obligation to instruct all
operators in safe operation.
PRECAUTIONS BEFORE
OPERATING THE WHEEL
LOADER
1. General precautions
Know your equipment and its limitations. Read and
understand this entire manual before starting and
operating the machine.
• If using an attachment on the machine, read the
attachment operator's manual to ensure the safe
operating procedures.
• Pay special attention to the safety labels on the
machine and the attachments.
• Do not start or operate an unsafe machine. Before
working the machine, be sure that any unsafe
condition has been satisfactorily remedied. Check
brakes, steering, and attachment controls before
moving. Consult a proper maintenance authority if
any malfunctioning part of the system is observed.
Be sure all safety appliances are in the right place
and in good operating condition.
• Wear and use safety gear such as non-slip safety
shoes or boots, safety glasses, and safety hardhats
as appropriate for the job. Do not operate or work
around the machine, when wearing loose, bulky
clothing.
• Never operate the machine or any equipment while
under the influence of alcohol or other drugs, or
while fatigued.
• Before allowing other people to use your machine,
give instruction to the operator on safe and correct
use of the machine and make sure that the operator
reads and understands the Operator's Manual for
the machine.
• Inspect your seat belt daily for signs of fraying,
wear or other weakness that could endanger your
safety.
• Do not use the loader bucket or an attachment to lift
or carry a person.
• Do not use the bucket or any other working
attachment of the machine for crane work.
Otherwise, the machine may lose its balance and
overturn.
• Use the following precautions when changing the
attachment.
1. Position the machine and attachment on level
ground.
2. Make sure that no persons are in the immediate
vicinity of the machine.
3. When actuating the machine to change the
front attachment:
a. Lower the bucket and attachment to the
ground.
b. Actuate the parking brake switch.
c. Stop the engine (for machines with
mechanical quick coupler).
d. Release the hydraulic pressure in the
hydraulic system by operating the
appropriate control levers (for machines
with mechanical quick coupler).
4. After changing the front attachment, make sure
that the installed attachment is securely
attached to the quick coupler.
• To mount a fire extinguisher, use the space above
the fender on the side of the operator's seat.
• Carry out the following procedure when lifting the
machine.
1. Attach the steering-frame-lock.
(1) Snap pin (2) Steering frame lock
2. Use the locations indicated by marks in the
diagram to lift the machine.
SAFE OPERATION
R540
7

(1) Diagram to lift machine
3. Pass a nylon sling or chain through the lugs
and lift as shown in the following diagram.
Use only a nylon sling or chain that is capable
of holding the weight of the machine.
(1) Lugs (both sides) (A) 3.8 m
(B) 4.0 m
(C) 1.5 m
2. Precautions of ROPS and FOPS
Know your equipment and its limitations. Read and
understand this entire manual before starting and
operating the machine with the ROPS and FOPS.
• For your safety, KUBOTA installs a ROPS (roll-
over-protective-structure) and a FOPS (falling-
objects-protective-structure) with a seat belt.
Always use the seat belt when the machine is
equipped with canopy or cab.
OSHA regulations and SAE standard require the
ROPS and FOPS on wheel loaders, bulldozers,
truck type loaders, graders, and scrapers.
(1) ROPS and FOPS
• Never modify structural members of ROPS by
welding, drilling, bending, grinding, or cutting
because modifying may weaken the structure. If
any component is damaged, replace it. Do not
attempt repairs. If ROPS is loosened or removed
for any reason, reinstall all parts correctly. Tighten
mounting bolts to proper torque.
• Do not install any ballast, including water, and
calcium chloride that is added into the tires, that
exceed the specified maximum weight shown under
“MAXIMUM GROSS MACHINE WEIGHT” space on
the ROPS label.
SAFE OPERATION
8
R540

PRECAUTIONS FOR THE AXLE
SUSPENSION
Improper handling of the machine damages the axle
suspension! To protect the axle suspension from
excessive wear, observe the following instructions.
• Only use KUBOTA-approved tire sizes.
• Observe the tire pressure table.
(See Checking the tire pressure on page 124)
• Check tire pressure before commencing day-to-day
operations.
• Do not use any liquids in the tires.
• Replace excessively worn tires with new tires
before commencing operations.
• Only use identical wheels and tires with the same
degree of wear on the same axle.
• Never exceed the specified max. load capacity.
• Only use KUBOTA-approved buckets, palette forks,
and fork arms.
PRECAUTIONS FOR
OPERATING THE MACHINE
• Get on and off safely when entering or leaving the
operator's cab. Face the machine. Always maintain
a three-point-contact with the steps and handrails.
Do not use control levers as handles.
Do not jump on or off the machine. Never try to get
on or off a moving machine.
• Do not start the engine or operate the control
elements from anywhere other than the operator's
seat.
• Before starting the engine, fasten the seat belt,
make sure that the direction switch is set in the
neutral position, the parking-brake-switch is
actuated and the bucket is lowered to the ground.
• Do not start the engine by shorting across starter
terminals.
• Watch where you are going at all times. Watch for
and avoid obstacles.
• Never permit passengers on the machine. Keep
bystanders away from the machine during
operation.
• When working around other machines, let the other
operators know what you are performing at all
times.
• Never allow anyone to get under or near the bucket
or attachment when it is raised.
• When raising the bucket or attachment, take extra
caution to prevent it from touching overhead wires
or other obstacles. Contact with wires may cause
fatal injuries.
• Keep away from the muffler while the engine is
running and immediately after it has stopped.
• Hazardous operation such as on dangerous terrain,
beyond the load capacity or contrary to the
intended use of the machine must be avoided as it
may cause the machine to tip over.
• Do not drive the machine close to edges of ditches
or banks which may collapse under the weight of
the machine, especially when the ground is loose or
wet.
• Slow down for turns, uneven terrain, and slopes to
avoid tipping over.
• When transporting a load, keep the loader bucket
as low as possible to avoid tipping over. Be
extremely careful when working on inclines.
• Operation on slopes can be dangerous. Rain, snow,
gravel soft ground, and so on will change the
ground conditions. Do not operate the machine in
questionable ground conditions. If operating on a
slope or ramp, always slow down, travel straight up,
and down the incline and not across. Keep the
bucket as low as possible. If you do not follow these
instructions, the machine can go out of control and
tip over.
• Avoid turning on a slope.
• Never perform digging or shoveling with the
machine in the articulated condition, or the machine
may tip over.
• Never dig or shovel at high speed. Digging or
shoveling at high speed can cause the machine to
lose stability and its rear wheels to lift off the
ground, which may lead to serious personal injury
or fatal accidents.
• Do not go up or down a 30 degrees or steeper hill.
Otherwise, the machine may skid sideways or turn
on its side. If the ground is ungraded or is soft, limit
the slope below 15 degrees.
• To avoid tipping over, do not operate the machine
on any site where the terrain cannot be
ascertained, such as ground covered with seeds or
snow and check for hidden projections, dips, road
shoulders, and so on beforehand, and take care not
to approach them during work.
• Be sure to ease off the accelerator at the end of
backfilling grooves, or areas at the edge of cliffs or
pond banks, or at the end of an ascent. Upon
removal of the external load, the machine speed
will automatically increase, reduce speed to avoid
entering grooves or tipping over.
• To avoid the machine slipping or tipping over, do
not operate the machine on ungraded or soft
terrain, such as land fills. Grade and compact the
site beforehand at all times.
• Avoid running the engine for a long time indoors.
When the engine must be run indoors, be sure to
open the windows and doors. Carbon monoxide
gas from exhaust is colorless, odorless and deadly.
• Check that no one is near the muffler exhaust
before starting the engine. If exposed to exhaust
fume, he or she may get burned or poisoned.
Check that there is no flammable objects, such as
dead leaves, sheets of paper, or pieces of cloth,
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attached to areas around the engine before starting
the engine.
• To avoid the danger of exhaust fume poisoning, do
not operate the engine, in a closed building without
proper ventilation. Carbon monoxide is odorless,
colorless, and deadly.
• Be especially careful when reversing and watch the
area behind the loader carefully before starting to
drive.
• When parking your machine if at all possible, park
on a firm, flat, and level surface. If not, park across
a slope. Set the parking brake, lower the
implements to the ground, remove the starter key
from the ignition, and lock the cab door if equipped
and chock the wheels.
• Do not get a load on the bucket at the position as
the following figure.
1. Safety for children
Serious accidents can occur if the operator does not
pay attention to children in the vicinity of the machine.
Children are unpredictable.
• Always keep an eye on children because they
change their location continuously.
• Make sure that no children are within the working
range of the machine.
• Be extremely cautious when children approach the
working area. Stop working, if necessary.
• Do not carry children on the machine.
• Do not allow children to operate the machine.
• Do not allow children to play around the machine.
PRECAUTIONS FOR
TRAVELING
• Before traveling on the public road, follow all local
and state-traffic-regulations.
•Traveling on the public road
Please note the following points:
– Raise the lift arm.
– Fully tilt the bucket.
– Lock the control lever and the auxiliary-port-
lever by pressing the control-lever-lock-knob
and the auxiliary-port-lever-lock-knob.
• When traveling on a public road, lock the bucket
and attachments securely so that they cannot
lower, even if any control lever is operated. Lift the
bucket about 40 cm above the ground and set it in
the proper position for travel, then lock the control
lever.
• First check the area around the machine, then
gradually increase the engine rpm and slowly move
the machine. Do not move the machine abruptly. To
move the machine on a steep slope, press the
accelerator pedal gradually while releasing the
inching and brake pedal so that the machine does
not move backwards.
• The steering wheel for this machine will not return
to the starting position after turning a bend. Be sure
to turn the wheel to the starting position by yourself.
• When operating the machine, obey all safety
signals and traffic signs.
• Use the brake when the machine begins to
accelerate by itself.
• If the engine should stall on a slope, apply the
brake to hold the machine in a present position and
then set the parking brake switch to the parking
position, lower the bucket to the ground to prepare
for the next start.
• When operating over an obstacle such as a rock,
cross slowly at a right angle. Trying to cross over
obstacle diagonally or at high speed may tip the
machine over.
• If there is the risk of the machine slipping
excessively on frozen ground, install chains on the
front wheels. For operation on snow, install the
chains on both front and rear wheels or change into
winter tires.
• Do not turn sharply at high speed, or the machine
may tip over.
• Steering effort will increase if the engine stops. Do
not stop the engine during travel.
• If a tire has blown, the machine may slip or turn
over. If a tire blows, do not brake or steer hard,
brake slowly to stop the machine gradually.
1. Operating the engine at
overheating
Take the proper actions in this section in the event
which the coolant temperature increases too much.
The condition which the coolant temperature increases
too much is called “Overheating”.
1. Park the machine in a safe place and keep the
engine unloaded idling.
2. Do not stop the engine suddenly, but stop it after
about 5 minutes of unloaded idling.
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3. Keep yourself well away from the machine for a
further 10 minutes or while the steam blows out.
4. When there is no longer any danger of scalding, try
to find the cause of overheating according to the
manual, see TROUBLESHOOTING OF THE
ENGINE AND OTHER SYSTEMS on page 130 and
then start again the engine.
PRECAUTIONS AFTER
OPERATION OF THE WHEEL
LOADER
• When getting off the machine, always stop the
engine, follow the following procedure.
1. Set the parking brake.
2. Lower the bucket and attachment to the ground.
3. Release the hydraulic pressure in the hydraulic
system by operating the control levers.
(For details, see RELEASING THE PRESSURE
TRAPPED IN THE HYDRAULIC SYSTEM on
page 77)
4. Remove the key.
If the machine has to be parked on a slope, be sure
to block the wheels securely.
(1) Wheel chock
• All equipment left unattended at night adjacent to a
highway in normal use, or adjacent to construction
areas where work is in progress, shall have
appropriate lights or reflectors, or barricades
equipped with appropriate lights or reflectors to
identify the location of the equipment.
• For storage, be sure not to cover the machine until
after all the heated parts have cooled down.
• Before storing the machine for long periods of time,
do the following.
1. Set the parking brake.
2. Stop the engine.
3. Lower the bucket and attachments to the
ground.
4. Release the hydraulic pressure in the hydraulic
system by operating the control levers.
5. Remove the key.
PRECAUTIONS FOR SAFELY
LOADING AND TRANSPORTING
THE MACHINE
• When loading or unloading the machine on or from
a truck or trailer, be sure to use strong ramps.
Never use wet lumber, etc...
• Keep the ramps at an angle such that the machine
cannot slip. Never try to change direction while on
the ramps.
Angle of ramps 10 degrees to 15 degrees
• When loading or unloading the machine on or from
a truck, keep the bucket about 40 cm up from the
ground and reverse the machine at low speed to
load it, or advance it at the same speed to unload it.
• It is dangerous to alter the direction once already
on the ramps. If direction needs correction, bring
the machine down off the ramps first and make the
directional correction.
• If you operate a steering handle while the machine
is loaded or unloaded, the machine may move at an
angle. Be sure to stop the machine before using
another control.
While loading or unloading the machine, block the
truck wheels and apply the truck parking brake. If
necessary, place a support under the truck bed
behind the rear wheels to prevent the truck front
from lifting.
• After loading the machine on the truck bed, perform
the following.
1. Check to see that the center of gravity of the
machine aligns with that of the truck bed.
2. Secure the steering frame lock on the machine.
3. Set the parking brake.
4. Stop the engine.
5. Lower the bucket and attachment to the truck
bed.
6. Release the hydraulic pressure in the hydraulic
system by operating the control levers.
7. Remove the key.
8. Block the wheels of the machine.
9. Secure the machine with chains or belts.
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• While traveling with the machine loaded, do not
start with a jerk, stop suddenly or turn sharply on
curves so as to prevent the machine from shifting
on the truck bed.
PRECAUTIONS FOR
SERVICING THE MACHINE
SAFELY
• Before checking, adjusting, or cleaning the machine
parts, or leaving the machine, follow the following
items.
1. Set the parking brake.
2. Stop the engine.
3. Lower the bucket and attachment to the ground.
4. Release the hydraulic pressure in the hydraulic
system by operating the control levers.
(For details, see RELEASING THE PRESSURE
TRAPPED IN THE HYDRAULIC SYSTEM on
page 77)
5. Remove the key.
• Never be under the machine while it is being lifted
with only the bucket. If servicing or checking
underneath, support it firmly with strong jackstands.
• Secure the articulated steering with the steering
frame lock.
• Keep clear of articulation area when servicing.
• When checking or servicing the electrical system,
disconnect the battery cables.
• It is dangerous to drain oil or coolant and to replace
the filter just after stopping the engine. Wait for the
engine to cool.
• Do not allow an unauthorized person to service or
maintain the machine. Do not perform any work or
equipment that is not authorized. Do not try to do
any repairs that you do not understand. Follow the
maintenance and service procedures.
• Service or check the machine after it has
completely cooled off. Do not touch the muffler and
the radiator until they have cooled off.
• When you drive the connecting pins in or out, guard
against injury from flying pieces of metal. Use eye
or face protection.
• Safety covers, shields, and guards may not be
modified or removed.
• Always stop the engine before refueling. Keep
away from sparks and naked flames, while
refueling. Avoid fuel spills and overfilling the fuel
tank. Always refuel from properly grounded fuel
tank or system. Keep first aid kit and fire
extinguisher nearby at all times.
(1) Fuel tank cap
(2) Starter key
(3) Tank cap cover
• 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
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required so that the fluid level is between the
“UPPER” and “LOWER” levels.
• A battery, especially when charging, will give off
hydrogen and oxygen gases that are very
explosive. Keep away from sparks and naked
flames at all times. To avoid sparks from an
accidental short circuit, always disconnect the
battery ground cable first and always reconnect the
ground cable last.
(See STARTING THE ENGINE WITH AN
AUXILIARY BATTERY on page 62)
(1) Battery
• Never remove the engine/hydraulic oil plug or the
radiator cap right after the engine has been
stopped, or oil or hot water may gush out. Wait for
the water or oil to cool, loosen the engine/hydraulic
oil plug or radiator cap just a little to release
pressure, and then check the level. Releasing
pressure is especially important for opening the
radiator cap.
(1) Radiator cap
• Leaking hydraulic fluid has enough pressure to
penetrate the skin and cause serious injuries.
Leakages from pin holes can be totally invisible. Do
not use the bare hand for checking on possible
leakages. Always use a piece of wood or
cardboard. It is strongly recommended to use a
face mask or eye protection. Should injuries occur
with leaking hydraulic fluid, contact a doctor
immediately. This fluid can cause gangrene or
serious allergic reactions.
(1) Cardboard
(2) Hydraulic line
(3) Magnifying glass
•Towing in case of problems
If the machine breaks down and requires towing,
please contact your nearest KUBOTA dealer. In
case of an emergency, carry out the following
procedure.
1. Preparation of towing
a. To release the negative brake, loosen the 2
bolts on the rear axle cover and remove the
spacer.
b. Tighten both bolts by hand until both are in
contact the internal pusher plate. After
tightening both bolts, alternatively, for a
quarter of turn on each side, with a wrench
until they are completely tightened.
c. Remove the caps of the 2 high pressure
relief valves that are located at the top and
bottom of the pump. Loosen the M8 nuts
and tighten the adjust bolts by 6 turns.
Be careful never to loosen the M8 nuts too
much.
2. Towing
a. Make sure the foot brake is ready.
b. The towing speed should be less than the
following value.
Towing speed 1 km/h
c. Do not perform the towing over long
distance.
NOTE :
– When towing backward, pull the machine
using the towing pin.
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(1) Bolt
(2) Spacer
(3) Rear axle cover
(4) Towing pin
(A) Front
(B) Rear
• Do not install any tires on the rims yourself because
serious or fatal accidents could happen. Have the
tires mounted by your KUBOTA dealer.
• Use a face mask or eye protection to protect the
eyes and respiratory system against dust and other
foreign particles.
• Refuse such as old oil, fuel, hydraulic fluid, coolant,
and batteries comes under the category of toxic
waste and can be a hazard to the environment,
people, and animals.
• Undertake disposal in an appropriate way,
according to legally prescribed pollution control and
safety regulations.
• If you have questions about the correct disposal or
storage of refuse and toxic waste, contact your
KUBOTA dealer or a local waste management
contractor.
• Do not open high-pressure fuel system. High-
pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect nor 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.
• To avoid hazardous high voltage, turn the key
switch to the [STOP] position if it is necessary to
check to repair the computer, harness, or
connectors.
• During diesel particulate filter (hereinafter called
DPF) regenerating operations, exhaust gases and
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exhaust filter components reach temperatures hot
enough to burn people, or ignite or melt common
materials.
• Keep the wheel loader away from people, animals,
or structures which may be susceptible to harm or
damage from hot exhaust gases.
• To prevent fires, keep the DPF muffler and its
surroundings clear of anything flammable and keep
clean at all times.
• During regeneration, white exhaust gas may be
visible. Do not allow regeneration in a non-
ventilated space.
• During regeneration, do not leave the wheel loader.
•Fire prevention
Wheel loader and some attachments equip
components that are at high temperatures under
normal operating conditions. The primary source of
high temperatures is the engine and exhaust
system.
The electrical system, if damaged or incorrectly
maintained, can be a source of arcing or sparks.
The following fire prevention guidelines will help to
keep your equipment up and running efficiently and
keep the risk of fire to a minimum.
– Blow off all accumulated debris near hot
engine-exhaust-components such as
turbocharger and exhaust manifold as well as
EGR tube, exhaust pipes, and muffler more
frequently when working in severe conditions.
– Clean out all accumulated flammable debris
such as leaves, straw, pine needles, branches,
bark, small wood chips, and any other
combustible materials from inside the machine
belly pans or lower unit structures as well as
from area in proximity to the engine.
– Inspect the exhaust system daily for any signs
of leakage. Check for broken pipes and muffler
and also for loose or missing bolts, nuts and
clamps. If any exhaust leaks or fractured parts
are found, repairs must be completed prior to
operation.
– Examine the electrical wiring and connectors
frequently for damage. Repair any wires that
are loose or frayed before operating the
machine. Clean all electrical connections and
tighten all electrical connections as necessary.
– Inspect the exhaust system daily for any signs
of leakage. Check for broken pipes and muffler
and also for loose or missing bolts, nuts, and
clamps. If you find any exhaust leaks or
fractured parts, please take machine to your
dealer for repairs.
– Always keep a multipurpose fire extinguisher on
or near the machine. Be familiar with the
operation of the fire extinguisher.
– Do not park the machine anywhere there are
combustible materials such as dried grass and
straw.
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SAFETY LABELS
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