Ventrac 4520Z User manual

Service Manual
4520Z
Serial Numbers 01001–05664
09.40001Rev 00 Original Instructions (EN)

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Ventrac by Venture Products Inc.®
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: Page 2 4520Z
09.40001Rev 00

Revision History
Revision Date Description
4520Z :
09.40001Rev 00

Preface
The purpose of this publication is to provide a trained service technician with the
information for troubleshooting, testing, and repair of the Ventrac 4520 series
machines.
Refer to the Operator’s Manuals for operating, maintenance, and adjustment
instructions. Refer to the Part’s Manual for specific part information. Additional copies
of the Operator’s and Part’s manuals are available at www.Ventrac.com under
resources.
Venture Products Inc.® and Ventrac reserve the right to change the product
specifications or this publication without notice.
DANGER
This symbol indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. This signal word is limited to the most
extreme cases.
WARNING
This symbol indicates a potentially hazardous situation which, if not avoided
could result in death or serious injury.
CAUTION
This symbol indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury and/or property damage. It may also be
used to alert against unsafe practices.
IMPORTANT
The important notice will give the important instructions which must be
followed to prevent damage to equipment.
Note: A note will give the general information about the correct operation,
maintenance, service, testing, or repair of the machine.
Preface: Page 4 4520Z
09.40001Rev 00

Service Procedure Icons
The following icons appear throughout this service manual to bring attention to
specific important details of a service procedure.
Critical Process is used to highlight:
• installing safety equipment (shields, guards, seat belts, brakes and R.O.P.S.
components) that may have been removed
• dimensions or settings that must be maintained for proper machine operation
• a specific fastener tightening sequence
• component orientation that may not be obvious
Critical Torque
This icon is used to highlight an assembly torque requirement that is different
than what is recommended in the Standard Torque Tables; refer to Torque
Specifications, page 2–4.
Fluid Specifications is used to highlight fluid specifications and capacities that
are less common, and may not appear on the machine service decal or in the
machine Operator’s Manual
Note: Refer to the service decal on the machine and the machine Operator’s Manual
for commonly used fluid specifications and capacities.
Safety and Instructional Decals
There are many safety and instruction decals affixed to the Ventrac 4520. If any
decals become illegible or damaged, install a new decal. Decal part numbers are
listed in the Parts Manual. Order replacement decals from an Authorized Ventrac
Dealer.
4520Z Preface:
09.40001Rev 00

Table of Contents
Preface ............................................................................................................................................ 4
Chapter 1: General Safety Instructions .............................................................................. 1–1
Before Operating the Machine Safety............................................................................. 1–2
While Operating the Machine Safety............................................................................... 1–3
Maintenance and Service Safety ..................................................................................... 1–4
Jacking Instructions............................................................................................................. 1–6
Raising the Front of the Machine ................................................................................. 1–6
Raising the Rear of the Machine .................................................................................. 1–8
Chapter 2: Specifications ....................................................................................................... 2–1
4520Z Specifications........................................................................................................... 2–2
Fluid Capacities and Specifications............................................................................. 2–2
4520Z Engine Specifications......................................................................................... 2–3
Hydraulic System ............................................................................................................. 2–3
Torque Specifications.......................................................................................................... 2–4
Fastener Identification .................................................................................................... 2–4
Fasteners with a Locking Feature.................................................................................... 2–5
Calculating the Torque Values When Using a Drive-Adapter Wrench ................ 2–5
Standard Torque Specifications Table for SAE J429 Grade 2 Steel
Fasteners........................................................................................................................... 2–7
Standard Torque Specifications Table for SAE J429 Grade 5 Steel
Fasteners........................................................................................................................... 2–8
Standard Torque Specifications Table for SAE J429 Grade 8 Steel
Fasteners........................................................................................................................... 2–9
Standard Torque Specifications Table for ASTM F593 Stainless Steel Hex
Cap Screw ....................................................................................................................... 2–10
Standard Torque Specifications Table for Metric Class 8.8 Steel Fasteners... 2–12
Standard Torque Specifications Table for Metric Class 10.9 Steel
Fasteners......................................................................................................................... 2–13
Standard Torque Specifications Table for Metric A2–70 or A4–70 Stainless
Steel Fasteners .............................................................................................................. 2–14
Shop Supplies..................................................................................................................... 2–15
Special Tools ....................................................................................................................... 2–18
Chapter 3: Troubleshooting ................................................................................................... 3–1
GEARS – The Systematic Approach to Defining, Diagnosing and Solving
Problems................................................................................................................................ 3–2
General Hydraulic System Problems .............................................................................. 3–3
General Electrical System Problems............................................................................... 3–6
General Engine Problems.................................................................................................. 3–8
Chapter 4: Engine.................................................................................................................... 4–1
General Engine Information .............................................................................................. 4–2
4520 Operator’s Manual................................................................................................. 4–2
Kubota Service Manuals ................................................................................................ 4–2
Engine Service and Repairs.............................................................................................. 4–3
Air Cleaner System.......................................................................................................... 4–3
4520Z Removing and Installing the Air Cleaner System............................................ 4–4
Exhaust System ............................................................................................................... 4–5
4520Z Removing the Exhaust System ........................................................................... 4–6
4520Z Installing the Exhaust System.............................................................................. 4–7
Fuel System ...................................................................................................................... 4–8
Checking the Fuel Lines and Connections .................................................................... 4–9
Priming the Fuel System .................................................................................................. 4–10
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09.40001Rev 00

Removing and Installing the Fuel Tank......................................................................... 4–11
Removing the Fuel Pump ................................................................................................ 4–13
Installing the Fuel Pump................................................................................................... 4–14
Engine Cooling System ................................................................................................ 4–15
4520Z Removing the Radiator........................................................................................ 4–16
4520Z Installing the Radiator .......................................................................................... 4–17
Engine............................................................................................................................... 4–17
Chapter 5: Hydraulic System ................................................................................................ 5–1
General Information............................................................................................................. 5–2
4520 Operator’s Manual and Accessory Installation Instructions ........................ 5–2
Towing the 4520 ............................................................................................................... 5–2
Relieving Pressure from the Hydraulic System ........................................................ 5–2
Remote Filtering the Hydraulic System ...................................................................... 5–3
Testing the Static Implement Pressure ....................................................................... 5–5
Testing the Hydrostatic Drive System Under Load .................................................. 5–5
Testing the Steering Valve P-Port Bypass ................................................................. 5–6
Adjusting the Hydraulic Pump Tow Valve................................................................... 5–7
Hydraulic Hoses ................................................................................................................... 5–9
Installing the Hydraulic Hoses and Tubes (O-Ring Face Seal)........................... 5–10
Installing the Hydraulic Fittings (SAE Straight Thread O-Ring Fittings)............ 5–12
Hydraulic Schematic ......................................................................................................... 5–16
Hydraulic Flow Diagrams ................................................................................................. 5–17
Drive Circuit..................................................................................................................... 5–17
Implement Circuit ........................................................................................................... 5–18
Service and Repairs.......................................................................................................... 5–19
General Precautions for Removing and Installing Hydraulic System
Components.................................................................................................................... 5–19
Removing the Front Hydraulic Motor ........................................................................ 5–21
Installing the Front Hydraulic Motor........................................................................... 5–22
Removing the Rear Hydraulic Motor ......................................................................... 5–22
Installing the Rear Hydraulic Motor............................................................................ 5–23
Removing the Hydraulic Pump ................................................................................... 5–24
Installing the Hydraulic Pump ..................................................................................... 5–26
Removing the SDLA Spool Valve............................................................................... 5–27
Installing the SDLA Spool Valve................................................................................. 5–27
Replacing the SDLA Spool Valve Float Detent....................................................... 5–28
Removing and Installing the Hydraulic Cooler Fan................................................ 5–29
Removing and Installing the Steering Valve ............................................................ 5–30
Removing the Steering Cylinder................................................................................. 5–32
Installing the Steering Cylinder................................................................................... 5–33
Removing the Lift Cylinder........................................................................................... 5–33
Installing the Lift Cylinder............................................................................................. 5–34
Removing the 3–Point Hitch Spool Valve................................................................. 5–35
Installing the 3–Point Hitch Spool Valve ................................................................... 5–35
Removing the 3–Point Hitch Lift Cylinder................................................................. 5–36
Installing the 3–Point Hitch Lift Cylinder................................................................... 5–37
Removing and Installing the Hydraulic Fluid Reservoir ........................................ 5–38
Chapter 6: Electrical System................................................................................................. 6–1
General Information............................................................................................................. 6–3
4520 Operator’s Manual and Accessory Installation Instructions ........................ 6–3
Kubota Engine Electrical Components ....................................................................... 6–3
Amperage Draw Chart .................................................................................................... 6–4
Electrical Drawings .............................................................................................................. 6–5
4520Z Preface:
09.40001Rev 00

Electrical System Quick Checks....................................................................................... 6–6
Testing the Charging System ........................................................................................ 6–6
Checking the Operation of the Interlock Switches ................................................... 6–6
Electrical Component Testing ........................................................................................... 6–9
Fuses .................................................................................................................................. 6–9
Relays............................................................................................................................... 6–15
Tractor Control Module (TCM)........................................................................................ 6–19
Removing and Installing the TCM.............................................................................. 6–20
Tractor Control System (TCS) ........................................................................................ 6–21
Removing and Installing the TCS............................................................................... 6–22
Information Gauge Cluster .............................................................................................. 6–23
Programming the Gauge ................................................................................................. 6–24
Power Relay Module ......................................................................................................... 6–26
Fusible Link Harness......................................................................................................... 6–27
Testing the Fusible Link Harness ............................................................................... 6–27
Key Switch ........................................................................................................................... 6–28
Testing the Key Switch...................................................................................................... 6–29
Power Take Off (PTO) Enable Switch........................................................................... 6–29
Testing the Power Take Off (PTO) Switch.................................................................... 6–30
Seat Switch.......................................................................................................................... 6–31
Testing the Seat Switch ................................................................................................ 6–31
Headlight Switch ................................................................................................................ 6–32
Testing the Headlight Switch ........................................................................................... 6–33
Directional Signal Switch.................................................................................................. 6–33
Testing the Directional Signal Switch ............................................................................ 6–34
Hazard Flasher Switch...................................................................................................... 6–34
Testing the Hazard Flasher Switch ................................................................................ 6–35
Work Light Switch .............................................................................................................. 6–35
Testing the Work Light Switch......................................................................................... 6–36
Strobe Light Switch............................................................................................................ 6–36
Testing the Strobe Light Switch ...................................................................................... 6–37
Rear 12 Volt Switch ........................................................................................................... 6–37
Testing the Rear 12 Volt Switch...................................................................................... 6–38
Rear 12 Volt Momentary Switch ..................................................................................... 6–38
Testing the Rear 12 Volt Momentary Switch................................................................ 6–39
Parking Brake Switch........................................................................................................ 6–39
Testing the Parking Brake Switch................................................................................... 6–40
PTO Electric Clutch ........................................................................................................... 6–41
Testing the PTO Electric Clutch.................................................................................. 6–41
Warning Alarm .................................................................................................................... 6–43
Testing the Warning Alarm........................................................................................... 6–43
Neutral Switch..................................................................................................................... 6–44
Testing the Neutral Switch ............................................................................................... 6–45
Hydraulic Fluid Temperature Switches ......................................................................... 6–46
Testing the Front Motor Hydraulic Fluid Temperature Switch.............................. 6–46
Testing the Hydraulic Cooler Temperature Switch ................................................. 6–47
Hydraulic Cooler Fan ........................................................................................................ 6–49
Testing the Hydraulic Cooler Fan............................................................................... 6–49
Speed Sensor ..................................................................................................................... 6–51
Testing the Speed Sensor............................................................................................ 6–52
Adjusting the Speed Sensor........................................................................................ 6–53
RPM Sensor ........................................................................................................................ 6–54
Testing the RPM Sensor............................................................................................... 6–54
Preface: Page 8 4520Z
09.40001Rev 00

Adjusting the RPM Sensor........................................................................................... 6–55
Fuel Pump ........................................................................................................................... 6–56
Testing the Fuel Pump .................................................................................................. 6–56
Fuel Level Sender.............................................................................................................. 6–58
Testing the Fuel Level Sender .................................................................................... 6–58
Oil Pressure Switch ........................................................................................................... 6–60
Testing the Oil Pressure Switch.................................................................................. 6–60
Speed Direction Lift Auxiliary (SDLA) Control Lever (Optional) ............................. 6–62
Testing the SDLA Control Lever 12V Switches....................................................... 6–62
12 Volt Front and Rear Socket and Plug ...................................................................... 6–63
Battery .................................................................................................................................. 6–65
Battery Safety ................................................................................................................. 6–66
Cleaning the Battery and Terminals........................................................................... 6–66
Charging the Battery ..................................................................................................... 6–67
Storing the Battery ......................................................................................................... 6–67
Removing the Battery ................................................................................................... 6–68
Installing the Battery...................................................................................................... 6–68
Chapter 7: Chassis .................................................................................................................. 7–1
General Information............................................................................................................. 7–3
4520 Operator’s Manual and Accessory Installation Instructions ........................ 7–3
Adjustments........................................................................................................................... 7–4
Adjusting the PTO Belt Tension.................................................................................... 7–4
Adjusting the PTO Electric Clutch Air Gap................................................................. 7–4
Adjusting the Parking Brake .......................................................................................... 7–6
Adjusting Neutral.............................................................................................................. 7–7
Adjusting the Neutral Switch ........................................................................................ 7–9
Service and Repairs.......................................................................................................... 7–11
Removing and Installing the Wheels......................................................................... 7–11
Removing and Installing Outer Dual Wheels........................................................... 7–12
Removing and Installing the Hood............................................................................. 7–13
Removing and Installing the Grill ............................................................................... 7–14
Removing and Installing the Engine Covers ........................................................... 7–14
Removing and Installing the Hydraulic Pump Cover ............................................. 7–15
Removing and Installing the Right Hydraulic Pump Cover .................................. 7–16
Removing and Installing the Hydraulic Filter Access Cover ................................ 7–17
Removing and Installing the Lower Frame Cover.................................................. 7–18
Removing and Installing the Control Panel.............................................................. 7–19
Removing and Installing the Hydraulic Cooler Top Cover.................................... 7–20
Removing and Installing the Hydraulic Cooler Inner Cover................................. 7–21
Removing and Installing the SDLA Pivot Cover ..................................................... 7–22
Removing and Installing the Right Outer Seat Box Panel.................................... 7–23
Removing and Installing the Right Rear Seat Box Panel ..................................... 7–24
Removing and Installing the Fuel Tank Top Cover................................................. 7–25
Removing and Installing the Fuel Tank Inner Cover.............................................. 7–26
Removing and Installing the Left Outer Seat Box Panel ...................................... 7–27
Removing and Installing the Left Rear Seat Box Panel........................................ 7–28
Removing and Installing the Roll Bar ........................................................................ 7–29
Removing and Installing the Seat .............................................................................. 7–30
Removing and Installing the Seat Mount.................................................................. 7–31
Removing and Installing the Steering Wheel .......................................................... 7–32
Removing and Installing the Steering Valve Cover................................................ 7–33
Removing and Installing the Parking Brake Cover ................................................ 7–34
Removing the Dash....................................................................................................... 7–35
4520Z Preface:
09.40001Rev 00

Installing the Dash ......................................................................................................... 7–36
Removing the Weight Transfer Assembly................................................................ 7–37
Installing the Weight Transfer Assembly .................................................................. 7–38
Removing the Parking Brake Lever........................................................................... 7–39
Installing the Parking Brake Lever ............................................................................. 7–40
Removing the Parking Brake Band ........................................................................... 7–40
Installing the Parking Brake Band.............................................................................. 7–41
Removing the Parking Brake Drum ........................................................................... 7–41
Installing the Parking Brake Drum ............................................................................. 7–42
Removing the High / Low Shift Cable........................................................................ 7–43
Installing the High / Low Shift Cable.......................................................................... 7–43
Removing the Rear Weight Mount............................................................................. 7–44
Installing the Rear Weight Mount .............................................................................. 7–44
Removing the 3–Point Hitch........................................................................................ 7–45
Installing the 3–Point Hitch .......................................................................................... 7–45
Removing the Front / Rear Connector Link ............................................................. 7–46
Installing the Front / Rear Connector Link................................................................ 7–46
Removing the Connector Link Mount........................................................................ 7–47
Installing the Connector Link Mount .......................................................................... 7–47
Removing the Center Pivot.......................................................................................... 7–48
Installing the Center Pivot ............................................................................................ 7–49
Removing the Front Hitch Arms ................................................................................. 7–50
Installing the Front Hitch Arms.................................................................................... 7–50
Removing the PTO Idler Pulley .................................................................................. 7–51
Installing the PTO Idler Pulley..................................................................................... 7–51
Chapter 8: Axles....................................................................................................................... 8–1
General Information............................................................................................................. 8–2
4520 Operator’s Manual and Accessory Installation Instructions ........................ 8–2
Axle Assemblies................................................................................................................... 8–3
Service and Repairs............................................................................................................ 8–4
Removing the Front Axle Assembly ............................................................................ 8–4
Installing the Front Axle Assembly............................................................................... 8–5
Removing the Rear Axle Assembly ............................................................................. 8–6
Installing the Rear Axle Assembly ............................................................................... 8–8
Removing and Installing Front Axle Housing Assemblies...................................... 8–8
Removing and Installing Rear Axle Housing Assemblies ...................................... 8–9
Removing and Installing Axle Shafts......................................................................... 8–10
Axle Bearing Replacement .......................................................................................... 8–11
Axle Seal Replacement ................................................................................................ 8–12
Changing Rear Transaxle Fluid.................................................................................. 8–12
Chapter 9: Appendix A............................................................................................................ 9–1
Wiring Diagram Reference Key (Serial # 01001–02172) ........................................... 9–2
Wiring Diagram — Rear Harness (Serial # 01001–02172).................................... 9–3
Wiring Diagram — Front Harness (Serial # 01001–02172)................................... 9–4
Wiring Diagram — Engine Harness (Serial # 01001–02172)................................ 9–5
Wiring Diagram Reference Key (Serial # 02173–05664) ........................................... 9–6
Wiring Diagram — Rear Harness (Serial # 02173–05664).................................... 9–7
Wiring Diagram — Front Harness (Serial # 02173–05664)................................... 9–8
Wiring Diagram — Engine Harness (Serial # 02173–05664)................................ 9–9
Hydraulic Schematic ......................................................................................................... 9–10
Preface: Page 10 4520Z
09.40001Rev 00