Kybota LA1153 User manual

CONTENTS
ASSEMBLY INSTRUCTIONS ..................................................................................... 1
TO THE DEALER..................................................................................................... 1
SAFETY ................................................................................................................... 1
UNPACKING AND CHECKING PARTS .................................................................. 2
Unpacking Wooden Crate................................................................................................. 2
Checking Parts .................................................................................................................3
TRACTOR PREPARATION ..................................................................................... 4
Tool Box (CAB MODEL) ................................................................................................... 4
ASSEMBLY.............................................................................................................. 4
Main Frame....................................................................................................................... 4
Tool Box (CAB MODEL) ................................................................................................... 5
Control Valve .................................................................................................................... 5
Hydraulic Lines .................................................................................................................6
Controller and Cables.....................................................................................................10
Control Valve Cover........................................................................................................ 12
Self-Level Valve (if equipped)......................................................................................... 13
Controller and Cables.....................................................................................................15
Control Valve Cover........................................................................................................ 18
Accumulator (if equipped)............................................................................................... 18
Multi Coupler (if equipped).............................................................................................. 22
3rd Function (if equipped)...............................................................................................27
Controller section............................................................................................................ 30
Quick Hitch Frame and Bucket.......................................................................................34
Hydraulic Hoses.............................................................................................................. 35
PRE-OPERATION CHECK.................................................................................... 35
Lubrication ...................................................................................................................... 35
Transmission Fluid.......................................................................................................... 35
ESTIMATED ASSEMBLY TIME............................................................................. 36
TIGHTENING TORQUE OF BOLTS AND NUTS .................................................. 37
TEMPLATE FOR CONTROLLER CABLE ............................................................. 38

1ASSEMBLY INSTRUCTIONS
ASSEMBLY INSTRUCTIONS
TO THE DEALER
1. This manual contains procedures intended to assist
the dealer in unpacking and assembling the product
before delivering to the customer.
The customer's purchase is based on confidence in
both the product and your store. Observe the
procedures in this manual to assemble and adjust
equipment for your customer's safety and satisfaction.
When fully assembled, check function of each part and
feature.
2. The following safety alert symbol marks and
indications are found throughout this manual in steps
where particular attention is required so as to ensure
your safety and to avoid product damage. Observe
the instructions in these warnings where indicated.
SAFETY
To prevent accidents, read through the following items
before starting work, and always regard safety when
working. It is your responsibility to ensure your safety on
the job.
1. Preparations
(1) Select a work site which is level, has sufficient
space, and is not close to dangerous objects.
(2) Avoid poorly ventilated
rooms.
Asphyxiation from exhaust
fumes is always a possibility
that accompanies running an
engine.
(3) Working clothes which may
be pinched or caught in the
equipment must not be worn.
Loose clothing can cause
serious injury or death.
(4) Always wear a mask and
protective goggles during
work when dust or flying
debris may be thrown by
equipment.
2. Assembly and adjustments
(1) Before assembling
equipment, read the
assembly instructions for the
product to become familiar
with the equipment and
procedures.
(2) Use only adequate and
required equipment, tools
and instruments (e.g. torque
wrench, battery hydrometer
and etc.).
(3) Set the parking brake and
block wheels to prevent
machine (or tractor)
movement.
(4) Lower the attachment or
implement to the ground
before assembling or
adjusting equipment.
(5) Before working under
suspended or raised
equipment, support the
equipment or attachment
and utilize the valve lock to
prevent the machine from
falling or moving out of place.
(6) Keep fire from cigarettes,
matches or other ignition
sources away from fuel, oil,
antifreeze and other
flammable materials.
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, may result in minor or
moderate injury.
Indicates that equipment or
property damage could result if
instructions are not followed.
Gives helpful information

ASSEMBLY INSTRUCTIONS2
3. After assembly check
(1) Before operating or test driving the equipment,
read and understand the operator's manual.
(2) Once the equipment is fully
assembled, select a safe
place for a test run. Prevent
onlookers from approaching
the equipment.
To avoid personal injury or
death:
ADo not start engine or
operate levers from
anywhere other than the
seat.
To avoid personal injury:
ADo not bypass-start the
equipment. Short circuiting
the starter terminal runs the
risk that the equipment will
start operating or moving
unexpectedly.
UNPACKING AND CHECKING PARTS
BUnpacking Wooden Crate
1. Cutting metal bands (if two are banded together).
Metal bands hold the two crates together as one. Cut
these bands and separate the crates.
2. Unpacking the crates
(1) Hook a hoist to the 4 corners of the crate and raise
the hoist cable until taut.
This serves to prevent the upper part of the crate
from striking the loader when cut.
(2) Saw the crate as indicated in figure 1.
ASawing outside the indicated area may damage the
loader or accessory parts.
ABe sure that the crate is free of other obstructions (e.g.
nails, staples and etc.).
(3) Raise the upper part of the crate and remove from
the immediate area.
(4) Remove the remaining slats from the crate. These
are indicated by the oblique lines in
Figure 1...

3ASSEMBLY INSTRUCTIONS
BChecking Parts
Remove all loader components. Referring to the illustration, ensure that all components have been included.
AThe valve kit and front guard kit are not included with the loader and must be ordered separately.
(1) Quick hitch
(2) Boom assembly
(3) Main frame LH
(4) Main frame RH
(5) Parts box
(6) Front guard kit [M1871]
(7 to 12) Valve kit
[M1822 (ROPS MODEL)]
[M1825 (CAB MODEL)]
[M1322 (M7040SU)]
[M1332 (M7040SUH)]
(7) Control valve assembly [M1822, M1825, M1322, M1332]
(8) Control lever stand assembly [M1822, M1825, M1322, M1332]
(9) Return line tube [M1822, M1825, M1332]
(10) Return line hose [M1322]
(11) Hose 6 [M1822, M1825, M1322, M1332]
(12) Hose 5 [M1822, M1825, M1322, M1332]
(13) Connector stay assy [M1822, M1825, M1322, M1332]

ASSEMBLY INSTRUCTIONS4
TRACTOR PREPARATION
1. Locate the tractor on a firm level surface.
Lower the implement to the ground, set the parking
brake and stop the engine.
2. Set the front tread as follows.
ASetting the tread wider than recommended may cause
premature failure of the front axle components due to
excessive stress.
3. For better stability, set the rear tread as follows
depending on the requirements of the work being
done.
BTool Box (CAB MODEL)
1. Remove the tool box and stays from the tractor.
ASSEMBLY
ADo not tighten any bolts firmly until most components
are attached to the tractor.
ABefore finally tightening all mounting hardware, start
the engine and apply down pressure to the bucket until
the loader takes the tractor weight off the front wheels
- do not lift the wheels off the ground. Make sure that
the mounting pins can be rotated easily.
Torque all bolts and nuts in this position.
ATo avoid damage to hoses, adjust all connections to
route hoses away from sharp edges.
AAssemble on a hard surface, preferably concrete.
BMain Frame
1. Install the main frames to the clutch housing and the
front axle as shown.
Tightening torque: 367.8 N-m
(37.5 kgf-m, 271.2 ft-lbs)
AWhile setting up the main frame, keep the air-
conditioner and power-steering hoses in their
positions.
AIf any of them is unavoidably dislocated, return it in its
original position with the main frame in place.
Otherwise such hose may come in the way of the fan.
Front Tread
2WD 4WD
M5040
M6040
M7040
M7040SU
M7040SUH
1420 mm (55.9 in.) 1520 mm (59.8 in.)
Rear Tread
M5040
M6040
M7040
M7040SU
M7040SUH
1520 mm (59.8 in.) or more
(1) Main frame
(2) 16-M20 x 60 bolts
16-M20 spring lock washers
16-3/4 hardened plain washers
(1) Main frame
(2) Hoses

5ASSEMBLY INSTRUCTIONS
AMain frame must be hoisted vertically as shown to
avoid contact with the fuel tank.
BTool Box (CAB MODEL)
1. Attach the tool box stay to the main frame LH using
bolts, nuts and collars.
2. Attach the tool box to the stay using the original
fasteners.
AWhen installing the accumulator, be sure to remove
the collars then attach the accumulator stay and tool
box stay with the original bolts and nuts.
BControl Valve
1. Attach the valve stay support on the tractor.
[M1822 (ROPS MODEL)]
[M1825 (CAB MODEL)]
(1) Main frame
(2) Fuel tank
(1) Tool box stay
(2) Tool box
(3) 2-Collars
(4) 2-M10 x 80 bolts
2-M10 nuts
(1) Accumulator stay
(2) Tool box stay
(3) 2-M10 x 80 bolts
(4) 2-M10 nuts
(1) Valve stay support
(2) 3-M12 x 75 bolts
(1) Valve stay support (2) 2-M12 x 40 bolts

ASSEMBLY INSTRUCTIONS6
2. Fit the valve stay assembly to the valve stay support.
BHydraulic Lines
CThe tractor's hydraulic power take-off comes in
two different types. Check the hydraulic power
take-off of the tractor in question and take its
specified assembling procedure.
1. [Type 1]
Remove the plugs from the tractor's pump port, power
beyond port and tank port.
Connect the loader adapters to these ports.
ABe sure to hand the above two removed plugs (power
beyond port and pump port) to the customer and to ask
him/her to store them in a safe place. These two plugs
must be back into position when the loader and its
component parts have been detached.
AHolding the hydraulic block, tighten up the adapter.
Apply oil on the O-ring and the backup ring.
AMake sure to disconnect the loader adapters (inlet (4)
and power beyond (5)) and apply the plugs, removed
in step 1 above, to the tractor's pump port and power
beyond port when the loader and its component parts
have been detached.
The pump will be damaged if the engine is started with
cap nuts mounted on the adapters (inlet (4) and power
beyond (5)).
Tightening torque : 122 N-m
(12.3 kgf-m, 88.5 ft-lbs)
2. [Type 2]
Remove the U pipe and tank port plug.
Connect the loader adapters to the tank port.
(1) Valve stay
(2) 4-M10 x 110 hex. bolts
(3) 4-M10 spring lock washers
(1) Tank port
(2) Power beyond port
(3) Pump port
(1) Assy adapter 1
(2) Tee, swivel run 7/8
(3) Cap, nut#10, 7/8-14 jic37deg
(4) Adapter assy inlet
(5) Adapter assy power beyond
(6) Pump line port
(7) Power beyond port
(1) Tank port plug
(2) U pipe

7ASSEMBLY INSTRUCTIONS
AThe following adaptor is used for Type 1, not for Type
2.
3. Connect the pump line hose as shown.
4. Connect the pump line hose to the valve.
AIndicate that equipment or property damage could
result if instructions are not followed.
5. Connect the power beyond line hose as shown.
(1) Assy adapter 1
(2) Tee, swivel run 7/8
(3) Cap, nut#10, 7/8-14 jic37deg
(4) Pump line port
(5) Power beyond port
(1) Adapter assy inlet
(2) Adapter assy power beyond
(1) Pump line hose with sleeve (hose 6, 630 mm (24.8 in.))
(1) Pump line hose with sleeve (hose 6, 630 mm (24.8 in.))
(2) Valve port marked with an orange dot (Pump line)
(1) Power beyond line hose with sleeve
[ROPS MODEL] (hose 5, 500 mm (19.7 in.))
[CAB MODEL] (hose 5, 450 mm (17.7 in.))

ASSEMBLY INSTRUCTIONS8
6. Connect the power beyond line hose to the valve.
AIndicate that equipment or property damage could
result if instructions are not followed.
[Except M7040SU, M7040SUH]
[M7040SU, M7040SUH]
AIf the loader operates slowly up and down while
operating the tractor, turn off the tractor immediately.
Check connecting pump line hose and power beyond
line hose to verify that it is installed correctly to the
control valve.
ATo verify the hoses, the power beyond line hose
should be installed to the green colored port and the
pump line should be installed to the orange colored
port of the valve.
AIf the pump line hose and power beyond line hose are
installed incorrectly, the tractor hydraulic pump may
experience malfunction.
7. [M5040, M6040, M7040, M7040SUH]
Connect the return line tube.
(1) Power beyond line hose with sleeve
[ROPS MODEL] (hose 5, 500 mm (19.7 in.))
[CAB MODEL] (hose 5, 450 mm (17.7 in.))
(2) Valve port marked with a green dot (Power beyond line)
(1) Pump line hose with sleeve
(2) Power beyond line hose with sleeve
(1) Return line tube
(1) Return line tube

9ASSEMBLY INSTRUCTIONS
8. [M7040SU]
Connect the return line hose.
9. Fit the connector assembly stay to the main frame.
10.Connect the hoses between the connector assembly
stay and the valve.
(1) Return line hose
(2) Tee, swivel run 7/8
(1) 2-M10 x 45 bolts
(2) Connector assy stay
(1) Hydraulic hose (Red)
(2) Hydraulic hose (Blue)
(3) Hydraulic hose (Yellow)
(4) Hydraulic hose (White)
(A) Use the holes.
(1) Hydraulic hose (Red 500 mm (19.7 in.))
(2) Hydraulic hose
[ROPS MODEL] (Blue 500 mm (19.7 in.))
[CAB MODEL] (Blue 510 mm (20.1 in.))
(3) Hydraulic hose (Yellow 560 mm (22.0 in.))
(4) Hydraulic hose
[ROPS MODEL] (White 455 mm (17.9 in.))
[CAB MODEL] (White 435 mm (17.1 in.))

ASSEMBLY INSTRUCTIONS10
BController and Cables
CExcept M7040SUH
1. Remove the cover cap of the tractor.
2. Fit the controller stay 2 in position.
[M1822 (ROPS MODEL)]
[M1825 (CAB MODEL)]
3. Fix the controller assembly stay 1 to the controller stay
2.
4. Pass the wire cable in the specified route.
[M1822 (ROPS MODEL)]
[M1825 (CAB MODEL)]
(1) Remove the mat.
(2) Pass the cable through the opening.
(3) Make a cut in the mat so that the cable can pass
through the slit.
AFor the cutting position, refer to the pattern sheet on
last page.
AKeep the wire cable hidden with the sleeve. Pass the
sleeve down through the bottom of the hole.
(1) Cover cap
(1) Controller stay 2 (2) 2-M10 x 40 bolts
(1) Controller stay 2 (2) 2-M10 x 70 bolts
2-M10 Spring lock washer
(1) Controller stay 2
(2) Controller assy stay 1
(3) 2-M8 x 18 bolts
(1) 3-Assy cable with sleeve

11ASSEMBLY INSTRUCTIONS
5. Install the control lever.
[M1822 (ROPS MODEL)]
Install the lever pointing straight to the traveling direction.
[M1825 (CAB MODEL)]
CM7040SUH
[M1332]
1. Fit the controller stay in position.
2. Fix the controller assy to the controller stay and follow
the step 6 below.
CAll models
6. Set the lock lever on the cable controller to the neutral
position.
AControl lever should be neutral and be locked with lock
lever.
[Except M7040SUH]
(A) "FRONT"
(B) "SIDE"
(A) "FRONT"
(B) "SIDE"
(1) Controller assy
(2) Controller stay
(3) 2-M10 x 30 bolts
(4) 3-M8 x 30 bolts
(5) 3-M8 nuts
(6) 3-Spring washers
(7) Fender
(1) Lock lever (A) "LOCK"
(B) "UNLOCK"

ASSEMBLY INSTRUCTIONS12
[M7040SUH]
7. Install one lock nut to each cable end. Then route the
cable ends through the valve stay.
AThe cable with blue tape is for boom section and the
cable with red tape is for bucket section.
8. Install the other lock nuts to the cable ends and adjust
the location of lock nuts so that the cable end hole
aligns with the spool hole. Then tighten the lock nuts.
9. Loosen the M6 lock nuts of the cable ends. Turn the
cable ends and spools so that the direction of the pins
is horizontal. Then retighten the M6 lock nuts.
10.Connect the cable to the spools with pins.
11.Attach the lever cover in place.
[M1822 (ROPS MODEL)]
[M1825 (CAB MODEL)]
BControl Valve Cover
1. Attach the valve cover to the valve stay.
(1) Lock lever (A) "LOCK"
(B) "UNLOCK"
(1) Controller cable
(2) Boom section
(3) Bucket section
(4) Lock nuts
(5) M6 lock nuts
(6) 2-Pins
2-Snap pins
2-Plain washers
(1) Lever cover (2) 2-M8 flange bolts
(1) Lever cover (2) 2-M8 flange bolts
(1) Valve cover (2) 3-M8 bolts

13ASSEMBLY INSTRUCTIONS
[M1332]
2. Apply the label included in valve kit.
BSelf-Level Valve (if equipped)
1. Put the stud bolt in the valve stay support.
[M1858 (ROPS MODEL)]
[M1859 (CAB MODEL)]
2. Temporarily assemble the valve stay to the valve stay
support.
3. Attach the self-level valve assy to the valve stay.
(1) Label (Part No. 7J417-5643-1)
(1) Valve stay support
(2) 3-M12 x 75 bolts
(3) 2-Stud bolts
(1) Valve stay support
(2) 2-M12 x 40 bolts
(3) 2-Stud bolts
(1) Valve stay
(2) 2-Stud bolts
(3) 2-M10 x 110 hex. bolts
(4) 2-M10 spring lock washers
(1) Self-level valve assy
(2) 2-M10 nuts
2-M10 spring lock washers
(3) M10 x 60 hex. bolt

ASSEMBLY INSTRUCTIONS14
4. Connect the pump line hose and tank hose.
AIndicate that equipment or property damage could
result if instructions are not followed.
[View from the top of the valve]
5. Connect the power beyond hose.
AIndicate that equipment or property damage could
result if instructions are not followed.
AIf the loader operates slowly up and down while
operating the tractor, turn off the tractor immediately.
Check connecting pump line hose and power beyond
line hose to verify that it is installed correctly to the
control valve.
ATo verify the hoses, the power beyond line hose
should be installed to the green colored port and also
the pump line should be installed to the orange colored
port of the valve.
AIf the pump line hose and power beyond line hose are
installed incorrectly, the tractor hydraulic pump may
experience malfunction.
(1) Pump line hose with sleeve (hose 6) (A) Tractor side
[ROPS MODEL] (580 mm (22.8 in.))
[CAB MODEL] (500 mm (19.7 in.))
(2) Hydraulic tank hose with sleeve
[ROPS MODEL] (345 mm (13.6 in.))
[CAB MODEL] (320 mm (12.6 in.))
(3) Valve port marked with an orange dot (Pump line)
(4) Valve port (Tank)
(1) Power beyond line hose with sleeve (hose 5)
[ROPS MODEL] (730 mm (28.4 in.))
[CAB MODEL] (670 mm (26.4 in.))
(2) Valve port marked with a green dot (Power beyond line)

15ASSEMBLY INSTRUCTIONS
6. Connect the hose between the valve and the coupler.
BController and Cables
1. Remove the cover cap of the tractor.
2. Fit the controller stay 2 in position.
[M1858 (ROPS MODEL)]
[M1859 (CAB MODEL)]
(1) Hydraulic hose
[ROPS MODEL] (Red 420 mm (16.5 in.))
[CAB MODEL] (Red 465 mm (18.3 in.))
(2) Hydraulic hose (Blue 400 mm (15.7 in.))
(3) Hydraulic hose
[ROPS MODEL] (Yellow 500 mm (19.7 in.))
[CAB MODEL] (Yellow 520 mm (20.5 in.))
(4) Hydraulic hose
[ROPS MODEL] (White 455 mm (17.9 in.))
[CAB MODEL] (White 485 mm (19.1 in.))
(1) Cover cap
(1) Controller stay 2 (2) 2-M10 x 40 bolts
(1) Controller stay 2 (2) 2-M10 x 70 bolts
2-M10 spring lock washer

ASSEMBLY INSTRUCTIONS16
3. Fix the controller assembly stay 1 to the controller stay
2.
4. Pass the wire cable in the specified route.
[M1858 (ROPS MODEL)]
AKeep the wire cable hidden with the sleeve. Pass the
sleeve down through the bottom of the hole.
5. Install the control lever.
[M1858 (ROPS MODEL)]
Install the lever pointing straight to the traveling direction.
[M1859 (CAB MODEL)]
(1) Controller stay 2
(2) Controller assy stay 1
(3) 2-M8 x 18 bolts
(1) 3-Assy cable with sleeve
(A) "FRONT"
(B) "SIDE"
(A) "FRONT"
(B) "SIDE"

17ASSEMBLY INSTRUCTIONS
6. Set the lock lever on the cable controller to the neutral
position.
AControl lever should be neutral and be locked with lock
lever.
7. Install one lock nut to each cable end. Then route the
cable ends through the valve stay.
AThe cable with blue tape is for boom section and the
cable with red tape is for bucket section and the cable
with gray tape is for switch section.
AConnect the switch section, keeping the self-level on/
off lever downward.
ACheck the spool position at first. It must be same
length like other spools.
8. Install the other lock nuts to the cable ends and adjust
the location of lock nuts so that the cable end hole
aligns with the spool hole. Then tighten the lock nuts.
9. Loosen the M6 lock nuts of the cable ends. Turn the
cable ends and spools so that the direction of the pins
is horizontal. Then retighten the M6 lock nuts.
10.Connect the cable to the spools with pins.
11.Attach the lever cover in place.
AThe self-level adjustment procedure is referred to in
the operator's manual.
(1) Lock lever (A) "LOCK"
(B) "UNLOCK"
(A) For switch section
(B) Same length (30 mm (1.2 in.))
(1) Controller cable
(2) Boom section
(3) Bucket section
(4) Switch section
(5) 6-Lock nuts
(6) 3-M6 lock nuts
(7) 3-Pins
3-Snap pins
(1) Lever cover
(2) 2-M8 flange bolts