WORKSHOP MANUAL
TRACTOR
M105S
KiSC issued 03, 2007 A
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of M105S. It is divided into
three parts, “General", “Mechanism” and “Servicing”.
■ General
Information on the tractor identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
■ Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine / Tractor Mechanism Workshop Manual (Code No. 9789701872 / 97897-18200) for the one which has not been described to this workshop
manual.
■ Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
December 2004
© KUBOTA Corporation 2004
KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER
: Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING
: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
: Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT
: Indicates that equipment or property damage could result if instructions are not
followed.
■ NOTE
: Gives helpful information.
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground, and set
the parking brake.
• Lower the implement to the ground.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
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KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Never start the engine while standing on ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
2
KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
3
KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
SAFETY DECALS
The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on
the machine, replace it. The decal part number is listed in the parts list.
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KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
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KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
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KiSC issued 03, 2007 A
SAFETY INSTRUCTIONS
M105S, WSM
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KiSC issued 03, 2007 A
SPECIFICATIONS
M105S, WSM
SPECIFICATIONS
M105S
Model
4WD
Model
V3800-DI-TI
Type
Vertical, water-cooled, 4-cycle diesel engine
No. of cylinder
4
Total displacement
3769
Net power
78.3 kW (105 HP)* / 2600 min−1 (rpm)
PTO power *1 (factory
observed)
69.4 kW (93 HP)*1 / 2600 min−1 (rpm)
Maximum torque
355 N·m (36.2 kgf·m, 261.8 ft-lbs) / 1400 to 1600 min−1 (rpm)
Battery
12 V, RC, 160 min, CCA 900 A
Diesel fuel No.1 [below −10 °C (14 °F), Diesel fuel No.2-D [above −10 °C (14 °F)]
Fuel
Fuel tank
175 L (46.2 U.S.gals, 38.5 lmp.gals)
Engine crankcase
Dimensions
10.7 L (11.3 U.S.qts, 9.4 lmp.qts)
Engine coolant
9.1 L (9.6 U.S.qts, 8.0 lmp.qts)
Overall length
4120 mm (162.2 in.)
Overall width (Minimum tread)
2010 mm (79.1 in.)
Overall height
2680 mm (105.5 in.)
Wheel base
2435 mm (95.9 in.)
Tread
Front
1565 to 1675 mm (61.6 to 65.9 in.)
Rear
1505 to 1865 mm (59.3 to 73.4 in.)
Minimum ground clearance
435 mm (17.1 in.) (drawbar bracket)
Weight *2
3920 kg (8642 lbs)
Standard
tire size *3
Front
340 / 85R24 (13.6R24)
Rear
460 / 85R34 (18.4R34)
Clutch
Traveling
system
Multiple wet disc hydraulic
Steering
Full hydraulic power steering
Transmission
Brake
Hydraulic shuttle shift, fully synchronized main shift, 32F / 32R, If equip creep gear 48F / 48R
Travelling
Wet type multiple discs (hydraulic)
Parking
Wet type multiple discs (mechanical)
Differential
Bevel gears with differential lock (Front, Rear)
Hydraulic control system
Pump capacity
Position, draft and mix control
65.0 L/min. (17.2 U.S.gals./min., 14.3 lmp.gals./min.)
Three point hitch
Hydraulic
system
Max. lifting
force
At lifting point *4
24 in. behind
lifting point *4
Category II
2700 kg (5952 lbs) at lower link end with link horizontal
4000 kg (8818 lbs) with 2 assist cylinder
2100 kg (4630 lbs) at 610 mm (24 in.) behind lifting point
3400 kg (7490 lbs) with 2 assist cylinder
19.6 MPa (200 kgf/cm2, 2847 psi)
System pressure
Independent clutch
PTO system
(230.0 cu.in.)
100 × 120 mm (3.9 x 4.7 in.)
Bore and stroke
Engine
cm3
Live PTO
Wet type, multiple discs
Direction of
turning
Clockwise, viewed from tractor rear
PTO speed
540 min-1 (rpm) at 2205 engine min-1(rpm)
540 min-1 (rpm) at 1519 engine min-1(rpm)
Traction system
Swing drawbar, adjustable in direction
NOTE : * Manufacture's estimate.
*1 The company reserves the right to change the specifications without notice.
*2 W/O cast iron disks for rear wheels.
*3 Cast iron disks available for wheels.
*4 At lower link end with links horizontal.
W10281170
8
KiSC issued 03, 2007 A
TRAVELING SPEEDS
M105S, WSM
TRAVELING SPEEDS
(At rated engine rpm)
Model
M105S
Tire size (Rear)
460 / 85R34 (18.4R34)
Dual Speed : Hi
Dual Speed : Lo
km/h (mph)
km/h (mph)
1
0.36 (0.22)
0.30 (0.19)
2
0.46 (0.29)
0.38 (0.24)
3
0.57 (0.35)
0.47 (0.29)
4
0.72 (0.45)
0.60 (0.37)
1
0.92 (0.57)
0.76 (0.47)
2
1.18 (0.73)
0.97 (0.60)
3
1.45 (0.90)
1.20 (0.75)
4
1.84 (1.14)
1.52 (0.94)
1
2.02 (1.26)
1.67 (1.04)
2
2.57 (1.60)
2.13 (1.32)
3
3.17 (1.97)
2.62 (1.63)
4
4.02 (2.50)
3.33 (2.07)
1
5.15 (3.20)
4.26 (2.65)
2
6.56 (4.08)
5.42 (3.37)
3
8.08 (5.02)
6.68 (4.15)
4
10.27 (6.38)
8.49 (5.28)
1
7.05 (4.38)
5.83 (3.62)
2
8.98 (5.58)
7.43 (4.62)
3
11.06 (6.87)
9.15 (5.69)
4
14.06 (8.74)
11.63 (7.22)
1
17.99 (11.18)
14.87 (9.24)
2
22.92 (14.24)
18.94 (11.77)
3
28.22 (17.54)
14.50 (14.50)
4
38.64 (24.00)*
The company reserves the right to change the specifications without notice.
* At maximum engine rpm.
29.66 (18.43)
Shuttle shift
lever
Range gear shift
lever
CREEP
(option)
Forward
L:
H
Main gear shift
lever
W1035065
9
KiSC issued 03, 2007 A
TRAVELING SPEEDS
M105S, WSM
(At rated engine rpm)
Model
M105S
Tire size (Rear)
460 / 85R34 (18.4R34)
Dual Speed : Hi
Dual Speed : Lo
km/h (mph)
km/h (mph)
1
0.36 (0.22)
0.30 (0.19)
2
0.46 (0.29)
0.38 (0.24)
3
0.57 (0.35)
0.47 (0.29)
4
0.73 (0.45)
0.60 (0.37)
1
0.93 (0.58)
0.77 (0.48)
2
1.19 (0.74)
0.98 (0.61)
3
1.46 (0.91)
1.21 (0.75)
4
1.86 (1.16)
1.53 (0.95)
1
2.04 (1.27)
1.68 (1.04)
2
2.59 (1.61)
2.14 (1.33)
3
3.19 (1.98)
2.64 (1.64)
4
4.06 (2.52)
3.36 (2.09)
1
5.19 (3.22)
4.29 (2.67)
2
6.61 (4.11)
5.47 (3.40)
3
8.15 (5.06)
6.74 (4.19)
4
10.36 (6.44)
8.56 (5.32)
1
7.11 (4.42)
5.88 (3.65)
2
9.06 (5.63)
7.49 (4.65)
3
11.16 (6.93)
9.22 (5.73)
4
14.18 (8.81)
11.73 (7.29)
1
18.15 (11.28)
15.00 (9.32)
2
23.11 (14.36)
19.11 (11.87)
3
28.47 (17.69)
23.53 (14.62)
4
38.97 (24.21)*
The company reserves the right to change the specifications without notice.
* At maximum engine rpm.
29.92 (18.59)
Shuttle shift
lever
Range gear shift
lever
CREEP
(option)
Reverse
L:
H
Main gear shift
lever
W1033594
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KiSC issued 03, 2007 A
DIMENSIONS
M105S, WSM
DIMENSIONS
11
KiSC issued 03, 2007 A
G
GENERAL
KiSC issued 03, 2007 A
GENERAL
CONTENTS
1. TRACTOR IDENTIFICATION ......................................................................... G-1
2. GENERAL PRECAUTIONS ............................................................................ G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3
[1] WIRING...................................................................................................... G-3
[2] BATTERY................................................................................................... G-5
[3] FUSE.......................................................................................................... G-5
[4] CONNECTOR ............................................................................................ G-6
[5] HANDLING OF CIRCUIT TESTER......................................................... G-7
4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-8
5. TIGHTENING TORQUES ............................................................................. G-10
[1] GENERAL USE SCREWS, BOLT AND NUTS ................................... G-10
[2] STUD BOLTS.......................................................................................... G-10
[3] HYDRAULIC FITTINGS .......................................................................... G-11
6. MAINTENANCE ............................................................................................. G-12
7. CHECK AND MAINTENANCE ..................................................................... G-14
[1] DAILY CHECK ........................................................................................ G-14
[2] CHECK POINT OF INITIAL 50 HOURS ............................................. G-15
[3] CHECK POINTS OF EVERY 50 HOURS ........................................... G-18
[4] CHECK POINTS OF EVERY 100 HOURS ......................................... G-19
[5] CHECK POINTS OF EVERY 200 HOURS ......................................... G-25
[6] CHECK POINTS OF EVERY 300 HOURS ......................................... G-29
[7] CHECK POINTS OF EVERY 400 HOURS ......................................... G-30
[8] CHECK POINTS OF EVERY 600 HOURS ......................................... G-30
[9] CHECK POINTS OF EVERY 800 HOURS ......................................... G-33
[10]CHECK POINTS OF EVERY 1 YEAR ................................................ G-33
[11]CHECK POINTS OF EVERY 2 YEARS.............................................. G-34
[12]OTHERS .................................................................................................. G-38
8. SPECIAL TOOLS .......................................................................................... G-43
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-43
[2] SPECIAL TOOLS FOR TRACTOR....................................................... G-60
9. TIRES............................................................................................................. G-74
[1] TYPE OF TIRES .................................................................................... G-74
[2] TREAD ADJUSTMENT........................................................................... G-74
(1) Front Wheel ....................................................................................... G-74
(2) Rear Wheel ........................................................................................ G-76
[3] WHEEL HUB........................................................................................... G-77
[4] TIRE PRESSURE ................................................................................... G-77
[5] TIRE LIQUID INJECTION ...................................................................... G-78
10. IMPLEMENT LIMITATIONS.......................................................................... G-82
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
1. TRACTOR IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine serial number, tractor serial number and hour meter reading.
(1) Tractor Identification Plate
(2) Tractor Serial Number
(3) CABIN Identification Plate
(CABIN Serial Number)
(4) Engine Serial Number
W1010602
G-1
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
2. GENERAL PRECAUTIONS
• During disassembly, carefully arrange removed parts in a clean
area to prevent confusion later. Screws, bolts and nuts should be
installed in their original position to prevent reassembly errors.
• When special tools are required, use KUBOTA genuine special
tools. Special tools which are not frequently used should be
made according to the drawings provided.
• Before disassembling or servicing electrical wires, always
disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain machine performance and to assure safety.
• Gaskets and O-rings must be replaced during reassembly. Apply
grease to new O-rings or oil seals before assembling. See the
figure left side.
• When reassembling external snap rings or internal snap rings,
they must be positioned so that sharp edge faces against the
direction from which a force is applied. See the figure left side.
• When inserting spring pins, their splits must face the direction
from which a force is applied. See the figure left side.
• To prevent damage to the hydraulic system, use only specified
fluid or equivalent.
(1)
(2)
(3)
(4)
(5)
Grease
Force
Sharp Edge
Axial Force
Rotating Movement
(A) External Snap Ring
(B) Internal Snap Ring
W1010904
G-2
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS
AND WIRING
To ensure safety and prevent damage to the machine and
surrounding equipment, heed the following precautions in handling
electrical parts and wiring.
■ IMPORTANT
• Check electrical wiring for damage and loosened
connection every year. To this end, educate the customer to
do his or her own check and at the same time recommend
the dealer to perform periodic check for a fee.
• Do not attempt to modify or remodel any electrical parts and
wiring.
• When removing the battery cables, disconnect the negative
cable first. When installing the battery cables, connect the
positive cable first.
(1) Negative Terminal
(2) Positive Terminal
W1011114
[1] WIRING
• Securely tighten wiring terminals.
(1) Correct
(Securely Tighten)
(2) Incorrect
(Loosening Leads to Faulty Contact)
W1011216
• Do not let wiring contact dangerous part.
(1) Dangerous Part
(2) Wiring (Incorrect)
(3) Wiring (Correct)
(4) Dangerous Part
W1011313
• Repair or change torn or aged wiring immediately.
(1) Aged
(2) Torn
(3) Insulating Vinyl Tape
W1012292
G-3
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
• Securely insert grommet.
(1) Grommet
(A) Correct
(B) Incorrect
W1011388
• Securely clamp, being careful not to damage wiring.
(1) Clamp
• Wind Clamp Spirally
(2) Wire Harness
(3) Clamp
(4) Welding Dent
W1011458
• Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
(1) Wiring
(2) Clamp
(A) Correct
(B) Incorrect
W1011587
• In installing a part, take care not to get wiring caught by it.
(1) Wiring
(A) Incorrect
W1011670
G-4
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
• After installing wiring, check protection of terminals and clamped
condition of wiring, only connect battery.
(1) Cover
• Securely Install Cover
W1011735
[2] BATTERY
• Take care not to confuse positive and negative terminal posts.
• When removing battery cables, disconnect negative cable first.
When installing battery cables, check for polarity and connect
positive cable first.
• Do not install any battery with capacity other than is specified
(Ah).
• After connecting cables to battery terminal posts, apply high
temperature grease to them and securely install terminal covers
on them.
• Do not allow dirt and dust to collect on battery.
CAUTION
• Take care not to let battery liquid spill on your skin and
clothes. If contaminated, wash it off with water immediately.
• Before recharging the battery, remove it from the machine.
• Before recharging, remove cell caps.
• Do recharging in a well-ventilated place where there is no
open flame nearby, as hydrogen gas and oxygen are formed.
W1011816
[3] FUSE
• Use fuses with specified capacity.
Neither too large or small capacity fuse is acceptable.
• Never use steel or copper wire in place of fuse.
• Do not install working light, radio set, etc. on machine which is not
provided with reserve power supply.
• Do not install accessories if fuse capacity of reserve power
supply is exceeded.
(1) Fuse
(2) Slow Blow Fuse
W1012092
G-5
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[4] CONNECTOR
• For connector with lock, push lock to separate.
(A) Push
W1012211
• In separating connectors, do not pull wire harnesses.
• Hold connector bodies to separate.
(A) Correct
(B) Incorrect
W1012272
• Use sandpaper to remove rust from terminals.
• Repair deformed terminal. Make certain there is no terminal
being exposed or displaced.
(1) Exposed Terminal
(2) Deformed Terminal
(3) Sandpaper
(4) Rust
W1012346
• Make certain that there is no female connector being too open.
(A) Correct
(B) Incorrect
W1012430
G-6
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
• Make certain plastic cover is large enough to cover whole
connector.
(1) Cover
(A) Correct
(B) Incorrect
W1012519
[5] HANDLING OF CIRCUIT TESTER
• Use tester correctly following manual provided with tester.
• Check for polarity and range.
W1012684
G-7
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
4. LUBRICANTS, FUEL AND COOLANT
Capacity
Place
1
2
M105S
175 L
46.2 U.S.gals
38.5 lmp.gals
Fuel tank
Engine block
radiator
9.1 L
9.6 U.S.qts
8.0 lmp.qts
Reserve tank
1.1 L
1.2 U.S.qts
1.0 lmp.qts
Coolant
Lubricants, fuel and coolant
No. 2-D diesel fuel
No. 1-D diesel fuel if temperature is
below -10 °C (14 °F)
Fresh clean water with anti-freeze
3
Engine crankcase
10.7 L
11.3 U.S.qts
9.4 lmp.qts
Engine oil: API service classification
CD, CE or CF
Below 0 °C (32 °F) :
SAE10W, 10W-30 or 10W-40
0 to 25 °C (32 to 77 °F):
SAE20, 10W-30 or 10W-40
Above 25 °C (77 °F):
SAE30, 10W-30 or 10W-40
4
Transmission case
60 L
63.4 U.S.qts
52.8 lmp.qts
KUBOTA UDT or KUBOTA SUPER
UDT fluid*
5
Front differential case oil
7.0 L
7.4 U.S.qts
6.2 lmp.qts
6
7
3.5 L
3.7 U.S.qts
3.1 lmp.qts
Front axle gear case oil
0.3 L
0.32 U.S.qts
0.26 lmp.qts
Brake system
(Reservoir and lines)
Air conditioner compressor
8
50 to 70 cm3
0.053 to 0.074 U.S.qts
0.044 to 0.062 Imp.qts
Refrigerant
1.1 kg
2.43 lbs
KUBOTA UDT or KUBOTA SUPER
UDT fluid or SAE80, 90 gear oil
KUBOTA UDT or SUPER UDT fluid*
or Turbine oil 32 (see below)
[regular type, multipurpose straight
mineral oil
Mobile DTE Oil #32
TEXACO Regal Oil #32
CHEVRON-GST Oil #32
TERESSO Oil #32]
Never use automotive brake oil.
Compressor oil:
DENSO Suniso
ND-OIL8 <**PAG OIL>
Refrigerant R-134a
* KUBOTA original transmission hydraulic fluid.
** PAG : Polyalkyleneglycol (Synthetic oil)
G-8
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Greasing
Place
9
No. of greasing point
Top link
2
Lift rod (Upper right, lower
right, lower left)
3
Front axle gear case support
2
Front axle support
2
Steering joint shaft
1
Battery terminal
2
Capacity
Until grease
overflow
Type of grease
Multipurpose
type grease
A small amount
■ NOTE
• Engine Oil : Oil used in the engine should have an American Petroleum Institute (API) service classification
and Proper SAE Engine Oil according to the ambient temperature as shown above.
• With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use
of a low-sulfur fuel on on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel,
it is advisable to employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals.
• Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
O : Recommendable X : Not Recommendable
Lubricating oil class
Fuel
Low-sulfur
High-sulfur
CF
❍
❍
CF-4
❍
X
CG-4
❍
X
Remark
TBN greater or equal 10
• Transmission Oil : The oil used to lubricate the transmission is also used as hydraulic fluid. To insure
proper operation of the hydraulic system and complete lubrication of the transmission, it is important that
a multi-grade transmission fluid be used in this system. We recommend the use of KUBOTA SUPER UDT
fluid for optimum protection and performance.
Do not mix different brands together.
• Indicated capacity of water and oil are manufacture's estimate.
G-9
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
5. TIGHTENING TORQUES
[1] GENERAL USE SCREWS, BOLT AND NUTS
Screws, bolt and nuts whose tightening torque are not specified in this Workshop Manual should be tightened
according to the table below.
Indication on top of
bolt
No-grade or 4T
Material of bolt
Material of opponent
part
Unit
Diameter
M6
(6 mm, 0.24 in.)
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
M14
(14 mm, 0.55 in.)
M16
(16 mm, 0.63 in.)
M18
(18 mm, 0.71 in.)
M20
(20 mm, 0.79 in.)
7T
SS400, S20C
Ordinariness
N·m
kgf·m ft-lbs
7.85
to
9.31
17.7
to
20.5
39.3
to
45.1
62.8
to
72.5
108
to
125
167
to
191
246
to
284
334
to
392
0.80
to
0.95
1.8
to
2.1
4.0
to
4.6
6.4
to
7.4
11.0
to
12.8
17.0
to
19.5
25.0
to
29.0
34.0
to
40.0
5.79
to
6.87
13.1
to
15.1
29.0
to
33.2
46.3
to
53.5
79.6
to
92.5
123
to
141
181
to
209
246
to
289
9T
SCr435,
SCM435
S43C, S48C
Aluminum
Ordinariness
Aluminum
Aluminum
N·m
kgf·m
ft-lbs
N·m
kgf·m
ft-lbs
N·m
kgf·m ft-lbs
7.85
to
8.82
16.7
to
19.6
31.4
to
34.3
0.80
to
0.90
1.7
to
2.0
3.2
to
3.5
5.79
to
6.50
12.3
to
14.4
23.2
to
25.3
–
–
–
5.79
to
6.50
13.1
to
15.1
29.0
to
32.5
46.3
to
53.5
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
7.24
to
8.31
17.4
to
20.2
35.5
to
41.2
57.2
to
66.5
91.2
to
108
145
to
166
203
to
235
272
to
318
0.80
to
0.90
1.8
to
2.1
4.0
to
4.5
6.4
to
7.4
–
1.00
to
1.15
2.4
to
2.8
4.9
to
5.7
7.9
to
9.2
12.6
to
15.0
20.0
to
23.0
28.0
to
32.5
37.5
to
44.0
7.85
to
8.82
17.7
to
20.5
39.3
to
44.1
62.8
to
72.5
–
9.81
to
11.2
23.6
to
27.4
48.1
to
55.8
77.5
to
90.1
124
to
147
197
to
225
275
to
318
368
to
431
–
–
–
N·m
kgf·m
ft-lbs
12.3
to
14.2
29.5
to
34.3
60.9
to
70.6
103
to
117
167
to
196
260
to
304
344
to
402
491
to
568
1.25
to
1.45
3.0
to
3.5
6.2
to
7.2
10.5
to
12.0
17.0
to
20.0
26.5
to
31.0
35.0
to
41.0
50.0
to
58.0
9.05
to
10.5
21.7
to
25.3
44.9
to
52.1
76.0
to
86.8
123
to
144
192
to
224
254
to
296
362
to
419
W1034542
[2] STUD BOLTS
Material of opponet
part
Unit
Diameter
M8
(8 mm, 0.31 in.)
M10
(10 mm, 0.39 in.)
M12
(12 mm, 0.47 in.)
Ordinariness
N·m
11.8
to
15.6
24.6
to
31.3
29.5
to
49.0
kgf·m ft-lbs
1.2
to
1.6
2.5
to
3.2
3.0
to
5.0
8.68
to
11.5
18.1
to
23.1
21.7
to
36.1
Aluminum
N·m
kgf·m
ft-lbs
8.82
to
11.8
19.7
to
25.4
0.90
to
1.2
2.0
to
2.6
6.51
to
8.67
14.5
to
18.8
31.4
3.2
23.1
W1048139
G-10
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[3] HYDRAULIC FITTINGS
■ Hydraulic Hose Fittings
Hose size
Thread size
02
03
04
05
06
Tightening torque
N·m
kgf·m
ft-lbs
1/8
13.7 to 15.7
1.4 to 1.6
10.1 to 11.6
1/4
22.6 to 27.5
2.3 to 2.8
16.6 to 20.3
3/8
45.1 to 53.0
4.6 to 5.4
33.3 to 39.0
W1014711
■ Hydraulic Pipe Cap Nuts
Tightening torque
Pipe size
N·m
kgf·m
ft-lbs
φ4 × t1.0
19.6 to 29.4
2.0 to 3.0
14.5 to 21.7
φ6 × t1.0
24.5 to 34.3
2.5 to 3.5
18.1 to 25.3
φ8 × t1.0
29.4 to 39.2
3.0 to 4.0
21.7 to 28.9
φ10 × t1.0
39.2 to 49.0
4.0 to 5.0
28.9 to 36.1
φ12 × t1.5
49.0 to 68.6
5.0 to 7.0
36.1 to 50.6
φ15 × t1.6
107.9 to 117.7
11.0 to 12.0
79.6 to 86.8
φ18 × t1.6
107.9 to 117.7
11.0 to 12.0
79.6 to 86.8
W1014848
■ Adaptors, Elbows and Nipples
Items
POA-PF
(Nipple with O-ring)
POB-PF
(Elbow with O-ring
and no nut)
Adaptor (NPT)
Thread size
Tightening torque
N·m
kgf·m
ft-lbs
PF 1/8
44.1 to 53.9
4.5 to 5.5
32.5 to 39.8
PF 1/4
73.5 to 83.4
7.5 to 8.5
54.2 to 61.5
PF 3/8
93.2 to 103.0
9.5 to 10.5
68.7 to 75.9
PF 1/2
112.8 to 122.6
11.5 to 12.5
83.2 to 90.4
PF 1/8
22.6 to 26.5
2.3 to 2.7
16.6 to 19.5
PF 1/4
35.3 to 43.1
3.6 to 4.4
26.0 to 31.8
PF 3/8
53.9 to 63.7
5.5 to 6.5
39.8 to 47.0
PF 1/2
73.5 to 83.4
7.5 to 8.5
54.2 to 61.5
PF 1/8
9.8 to 14.7
1.0 to 1.5
7.2 to 10.8
PF 1/4
29.4 to 34.3
3.0 to 3.5
21.7 to 25.3
PF 3/8
49.0 to 68.6
5.0 to 7.0
36.2 to 50.6
PF 1/2
68.6 to 88.3
7.0 to 9.0
50.6 to 65.1
W1015484
G-11
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
6. MAINTENANCE
Period
No.
Indication on hour meter
50
Item
Since then Impor
every
-tant
100 150 200 250 300 350 400 450 500 550 600
Reference
page
1
Engine start system
Check
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
50 hrs
G-18
2
Wheel bolt torque
Check
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
✩
50 hrs
G-19
3
Battery condition
Check
4
Greasing
5
Fan belt
Adjust
6
Brake pedal
Adjust
7
Parking brake lever
8
Air cleaner
element
[Double type]
Primary
element
Secondary
element
✩
✩
✩
✩
✩
✩
100 hrs
✩
✩
✩
✩
✩
✩
100 hrs
G-24
✩
✩
✩
✩
✩
✩
100 hrs
G-21
✩
✩
✩
✩
✩
✩
100 hrs
G-21
Adjust
✩
✩
✩
✩
✩
✩
100 hrs
G-23
Clean
✩
✩
✩
✩
✩
✩
G-19
100 hrs
*1
G-20
Replace
1 year
*2
G-33
Replace
1 year
G-33
✩
100 hrs
G-21
✩
Check
9
Fuel line
10
Hydraulic oil filter
Replace
11
Toe-in
12
Fuel tank water
✩
✩
✩
✩
Replace
13
*4
2 years
G-36
✩
✩
✩
200 hrs
G-17
Adjust
✩
✩
✩
200 hrs
G-26
Drain
✩
✩
✩
200 hrs
G-26
Check
✩
✩
✩
200 hrs
G-25
2 years
G-36
200 hrs
G-25
2 years
G-36
★
Power steering oil line
Replace
✩
Check
✩
✩
14
Radiator hose and clamp
15
Engine oil
Check
300 hrs
G-15
16
Water separator
Clean
✩
400 hrs
G-30
17
Fuel filter
Replace
✩
400 hrs
G-30
18
Engine oil filter
Replace
★
✩
600 hrs
G-15
19
Transmission fluid
Change
★
✩
600 hrs
G-16
20
Front differential case oil
Change
★
✩
600 hrs
G-17
21
Front axle gear case oil
Change
★
✩
600 hrs
G-18
22
King-pin pivot
Adjust
✩
600 hrs
G-32
23
Brake oil
Change
✩
600 hrs
G-31
24
Front axle pivot
Adjust
✩
600 hrs
G-31
25
Engine valve clearance
Adjust
800 hrs
1-S13
26
Cooling system
Flush
2 years
G-34
27
Coolant
Change
2 years
G-34
28
Parking brake cable
Replace
2 years
G-37
29
Brake hose
Replace
2 years
G-37
Replace
★
✩
✩
W1035769
G-12
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Period
No.
Indication on hour meter
50
Item
Since then Impor
every
-tant
100 150 200 250 300 350 400 450 500 550 600
Reference
page
30
Master cylinder kit
Replace
2 years
5-S11
31
Equalizer kit
Replace
2 years
5-S11
32
Brake seal 1 and 2
Replace
2 years
5-S16
33
Fuel system
Bleed
G-38
34
Brake system
Bleed
G-39
35
Clutch housing water
Drain
Service as required
G-38
36
Fuse
Replace
G-41
37
Light bulb
Replace
G-39
W1033488
Additional Items for CABIN Type
Period
No.
Indication on hour meter
50
Item
Since then Impor
every
-tant
100 150 200 250 300 350 400 450 500 550 600
Reference
page
1
Inner air filter
Clean
✩
✩
✩
200 hrs
G-27
2
Fresh air filter
Clean
✩
✩
✩
200 hrs
G-28
3
Air conditioner condenser
Clean
✩
✩
✩
200 hrs
G-28
4
Air conditioner drive belt
Adjust
✩
✩
✩
200 hrs
G-29
5
Air conditioner pipes and
hoses
Check
1 year
G-32
6
CAB isolation cushion
Check
1 year
7
Washer liquid
Add
8
Refrigerant (gas)
Check
Service as required
G-32
G-40
G-42
■ IMPORTANT
•
•
•
•
•
The jobs indicated by “★” must be doen after the first 50 hours of operation.
*1 : Air cleaner should be cleaned more often in dusty condition than in normal conditions.
*2 : Every year or every 6 times of cleaning.
*3 : Replace only if necessary.
*4 : When the battery is used for less than 100 hours per year, check the battery condition by reading the indicator annually.
W1036925
G-13
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
7. CHECK AND MAINTENANCE
CAUTION
• Be sure to check and service the tractor on a flat place with engine shut off, the parking brake on and chock
the wheels.
[1] DAILY CHECK
To prevent trouble from occurring, it is important to know the condition of the tractor. Check the following items
before starting.
Checking
• Check areas where previous trouble was experienced.
• Walk around the tractor.
1. Check the tire pressure, and check for wear and damage.
2. Check for oil and water leak.
3. Check the engine oil level.
4. Check the transmission fluid level.
5. Check the coolant level.
6. Check the brake oil level.
7. Check the washer liquid level.
8. Check the water separator.
9. Check air cleaner evacuator valve (when used in a dusty place).
10.Check the condition of seat belt.
11.Check and clean the radiator screen and grill.
12.Check and clean the air conditioner condenser screen, and intercooler screen.
13.Check the nuts of tires are tight.
14.Check the number plate or SMV emblem for damage and replace as necessary if equipped.
15.Care of danger, warning and caution labels.
16.Clean around the exhaust manifold and the muffler of the engine.
•
1.
2.
3.
4.
5.
While sitting in the operator's seat.
Check the throttle pedal, brake pedal and clutch pedal.
Check the throttle lever and shuttle lever.
Check the parking brake.
Check the steering wheel.
Check the seat belt.
•
1.
2.
3.
Turning the key switch.
Check the performance of the easy checker lights.
Check the head lights, turn signal lights, hazard lights and other light equipment. Clean if necessary.
Check the performance of the meters and gauges.
•
1.
2.
3.
Starting the engine.
Check to see that the lights on the easy checker go off.
Check the color of the exhaust gas.
Check the brakes for proper operation.
G-14
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[2] CHECK POINTS OF INITIAL 50 HOURS
Changing Engine Oil
CAUTION
• Before changing oil, be sure to stop the engine.
• Allow engine to cool down sufficiently, oil can be hot and
can burn.
1. To drain the used oil, remove the drain plugs (1) at the bottom of
the engine and drain the oil completely into the oil pan.
All the used oil can be drained out easily when the engine is still
warm.
2. After draining reinstall the drain plugs (1).
3. Fill with the new oil up to the upper notch on the dipstick.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
Engine Oil
Capacity
(1) Drain Plug
(2) Oil Inlet Plug
(3) Dipstick
10.7 L
11.3 U.S.qts
9.4 Imp.qts
(A) Oil level is acceptable within this
range.
W1039461
Replacing Engine Oil Filter
CAUTION
• Be sure to stop the engine before changing oil filter
cartridge.
• Allow engine to cool down sufficiently, oil can be hot and
can burn.
1. Remove the oil filter (1).
2. Put a film of clean engine oil on rubber seal of new filter.
3. Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
4. After the new filter has been replaced, the engine oil normally
decreases a little. Make sure that the engine oil does not leak
through the seal and be sure to check the oil level on the dipstick.
Then, replenish the engine oil up to the prescribed level.
■ IMPORTANT
• To prevent serious damage to the engine, use only a
KUBOTA genuine filter.
(1) Engine Oil Filter
W1040148
G-15
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Changing Transmission Fluid
•
1.
2.
3.
4.
CAUTION
Allow engine to cool down sufficiently, oil can be hot and
can burn.
To drain the used oil, remove the drain plug (1) at the bottom of
the transmission case and drain the oil completely into the oil
pan.
After draining reinstall the drain plug.
Fill with the new KUBOTA SUPER UDT fluid up to the upper
notch on the dipstick (2).
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
After running the engine for a few minutes, stop it and check the
oil level again; add oil to prescribed level.
Transmission fluid
(1) Drain Plug
(2) Dipstick
(3) Oil Inlet
Capacity
60.0 L
63.4 U.S.qts
52.8 Imp.qts
(A) Oil level is acceptable within the
range.
W1040339
G-16
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Replacing Hydraulic Oil Filter
•
1.
2.
3.
4.
5.
■
•
(1)
(2)
(3)
(4)
CAUTION
Allow engine to cool down sufficiently, oil can be hot and
can burn.
Remove the two oil filters (1).
Clean off metal filings with clean rags at the magnetic filters (2).
Put a film of clean transmission oil on rubber seal of new filters.
Tighten the filter quickly until it contacts the mounting surface.
Tighten filter by hand an additional 1/2 turn only.
After the new filter has been replaced, the transmission fluid level
with decrease a little. Make sure that the transmission fluid does
not leak through the seal, and check the fluid level.
Top up if necessary.
IMPORTANT
To prevent serious damage to the hydraulic system, use
only a KUBOTA genuine filter.
Hydraulic Oil Filter
Magnetic Filter
Dipstick
Oil Inlet
(A) Oil level is acceptable within the
range.
W1040732
Changing Front Differential Case Oil
1. To drain the used oil, remove the drain and filling plug (1), (2) at
the front differential case and drain the oil completely into the oil
pan.
2. After draining reinstall the drain plug (1).
3. Remove the oil level check plug (3).
4. Fill with the new oil up to the lower rim of check plug port.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
5. After filling reinstall the filling plug (2) and check plugs (3).
Front differential case oil
(1) Drain Plug
(2) Filling Plug
Capacity
7.0 L
7.4 U.S.qts
6.2 Imp.qts
(3) Check Plug
W1041009
G-17
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Changing Front Axle Gear Case Oil
1. To drain the used oil, remove the right and left drain plugs (2) and
filling plugs (1) at the front axle gear case and drain the oil
completely into the oil pan.
2. After draining reinstall the drain plugs (2).
3. Fill with the new oil up to the filling plug port.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
4. After filling reinstall the filling plugs (1).
Front Axle Gear Case
Oil
Capacity
(1) Filling Plug
3.5 L
3.7 U.S.qts
3.1 Imp.qts
for each side
(2) Drain Plug
W1041387
[3] CHECK POINTS OF EVERY 50 HOURS
Checking Engine Start System
•
•
■
1.
2.
■
1.
2.
3.
4.
5.
6.
■
1.
2.
3.
4.
5.
CAUTION
Do not allow anyone near the tractor while testing.
If the tractor does not pass the test, do not operate the
tractor.
Preparation before testing.
Place all control levers in the “NEUTRAL” position.
Set the parking brake and stop the engine.
Test : Switch for the main gear shift lever.
Sit on operator's seat.
Shift the main gear shift lever (1) to the desired position.
Depress the clutch pedal fully.
Disengage the PTO clutch control lever (3).
Turn the key to “START” position.
The engine must not crank.
Test : Switch for the PTO clutch control lever.
Sit on operator's seat.
Engage the PTO clutch control lever (3).
Depress the clutch pedal (2) fully.
Turn the key to “START” position.
The engine must not crank.
(1) Main Gear Shift Lever
(2) Clutch Pedal
(3) PTO Clutch Control Lever
W1041704
G-18
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Checking Wheel Mounting Nuts Tightening Torque
•
•
•
1.
CAUTION
Never operate tractor with a loose rim, wheel, or axle.
Any time bolts and nuts are loosened, retighten to specified
torque.
Check all bolts and nuts frequently and keep them tight.
Check the wheel mounting nuts regularly especially when new.
If there are loosened, tighten as follows.
Tightening torque
Front rim and disc
mounting nut
Front wheel mounting nut
260 to 303 N·m
26.5 to 31.0 kgf·m
192 to 224 ft-lbs
Rear rim and disc
mounting nut
260 to 303 N·m
26.5 to 31.0 kgf·m
192 to 224 ft-lbs
Rear wheel mounting nut
343 to 401 N·m
35.0 to 41.0 kgf·m
254 to 297 ft-lbs
(1) Front Wheel Mounting Nut
(2) Front Rim and Disc Mounting Nut
(3) Rear Rim and Disc Mounting Nut
(4) Rear Wheel Mounting Nut
W1042230
[4] CHECK POINTS OF EVERY 100 HOURS
Checking Battery Condition
•
•
•
1.
2.
■
CAUTION
Keep electrolyte away from eyes, hands and clothes. If you
are spattered with it, wash it away completely with water
immediately and get medical attention.
Keep open sparks and flames away from the battery at all
times. Hydrogen gas mixed with oxygen becomes very
explosive.
Wear eye protection and rubber gloves when working
around battery.
The factory installed battery is of non-refillable type. If the
indicator (2) turns white, do not charge the battery but replace it
with new one.
Clean the battery surface with a clean cloth.
Keep the terminals clean and coated with petroleum jelly.
How to read the indicator
Check the battery condition by reading the indicator.
State of indicator display
Green
Specific gravity of electrolyte and quality of electrolyte
are both in good condition.
Black
Needs charging battery.
White
Needs changing battery.
(1) Battery
(2) Indicator
W1042636
G-19
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Directions for Storage
•
•
•
•
•
CAUTION
When connecting the battery, do not reverse the polarities.
Connection with reverse polarities will cause spark and
troubles to the battery and electrical system in the tractor.
When disconnecting the cable from the battery, start with
the negative terminal first.
When connecting the cable to the battery, start with the
positive terminal first.
Reversing the steps may cause shortcircuiting, should a
metallic tool touch the terminals.
When storing the tractor for long periods of time, remove the
battery from the tractor and store in a cool, dry place.
W1042912
Cleaning Air Cleaner Element4
1. Remove the air cleaner cover (4) and primary element (2).
2. Clean the primary element if:
• When dry dust adheres to the element, blow compressed air from
the inside turning the element. Pressure of compressed air must
be under 205 kPa (2.1 kgf/cm2, 30 psi).
3. When replacing the air cleaner primary element (2), replace the
secondary element (1) as well :
Once a year or after every six times of cleaning, whichever
comes first.
■ IMPORTANT
• The air cleaner uses a dry element, never apply oil.
• Do not run the engine with filter element removed.
• Be sure to refit the dust cup with the arrow ↑ (on the rear of
cup) upright. If the dust cup is improperly fitted, evacuator
valve will not function and dust will adhere to the element.
• Do not touch the secondary element except in cases where
replacing is required.
■ Evacuator Valve
Open evacuator valve once a week under ordinary conditions or
daily when used in a dusty place to get rid of large particles of dust
and dirt.
(1) Secondary (Safety) Element
(2) Primary Element
(3) Evacuator Valve
(4) Cover
W1043169
G-20
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Checking Fuel Line
1. Check to see that all lines and hose clamps are tight and not
damaged.
2. If hoses and clamps are found worn or damaged, replace or
repair them at once.
■ NOTE
• If the fuel line is removed, be sure to properly bleed the fuel
system.
Refer to “Bleeding Fuel System”. (See page G-38.)
(1) Fuel Line
(2) Clamp Band
W1043622
Adjusting Fan Belt Tension
CAUTION
Be sure to stop the engine before checking belt tension.
Stop the engine and remove the key.
Apply moderate thumb pressure to belt between pulleys.
If tension is incorrect, loosen the alternator mounting bolts and,
using a lever placed between the alternator and the engine block,
pull the alternator out until the deflection of the belt falls within
acceptable limits.
4. Replace fan belt if it is damaged.
•
1.
2.
3.
Belt tension
Factory spec.
(1) Bolt
10 to 12 mm
0.39 to 0.47 in.
A : Check the belt tension
B : To tighten
W1043886
Adjusting Brake Pedal
1) Brake Pedal Free Travel
CAUTION
• When checking, parking the tractor on flat ground, and stop
the engine.
1. Measure the free travel by depressing the brake pedals.
2. Slightly depress the brake pedals and measure free travel at the
top of pedal stroke.
3. If the measurement is not within the factory specifications, adjust
the free travel by the push rod (2).
4. After adjustment, tighten the lock nut firmly.
■ IMPORTANT
• Keep the free travel in the right and left brake pedals equal.
Brake pedal free travel
(1) Brake Pedal
(2) Push Rod
Factory spec.
7 to 14 mm
0.28 to 0.55 in.
A : Free Travel
W1044283
G-21
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
2) Brake Pedal Stroke and Difference between Right and Left
Pedal Strokes
CAUTION
• When checking, park the tractor on flat ground, and stop the
engine.
1. Disengage the brake pedal lock.
2. Step on either side brake pedal and measure the level difference
(pedal stroke) between right and left pedals.
3. Do the same for the other side.
4. If the pedal stroke exceeds the factory specification, check the air
bleeding, master cylinder, equalizer or brake case.
Brake pedal stroke
Factory spec.
Less than 100 mm
3.9 in.
Difference between left
and right brake pedal
stroke
Factory spec.
0 to 5 mm
0 to 0.20 in.
(1) Brake Pedal LH
(2) Brake Pedal RH
(3) Brake Pedal Lock
A : Pedal Stroke
W1044545
3) Equalizer Working Level
1. Gently step on both the right and left pedals at once with your
both feet. Step on the right pedal all the way (the left pedal rises).
Measure the level difference between the two pedals.
2. Next step on the left pedal all the way and measure the level
difference.
3. If the measurement is not within the factory specification, check
the equalizer (3).
Level difference
between two pedals
(1) Brake Pedal
(2) Master Cylinder
Factory spec.
Less than 10 mm
0.4 in.
(3) Equalizer
W1045198
G-22
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Adjusting Parking Brake Lever Free Play
1. Release the parking brake lever.
2. Pull the parking brake lever with a force of 30 kg (66.2 lbs) for
checking the free play and check the number of notches (A).
3. If the number of notches is not within the factory specifications,
loosen the lock nuts (1) and adjust the length of the parking brake
wire (2).
4. After adjustment, tighten the lock nuts firmly.
Parking brake lever
travel
(number of notches)
Factory spec.
2 notches
■ IMPORTANT
• After adjustment, check the parking brake performance
according to steps 1 to 5.
1. Set the parking brake lever to the 7th notch.
2. Start the engine and set at the idling speed.
3. Shift the travelling speed to the maximum speed range.
4. Release the clutch pedal slowly, and check that the engine
is stopped.
5. If the engine is not stopped, check the parking brake pad
and brake plate. (See page 5-S17 to S18.)
(1)
(2)
(3)
(4)
Parking Brake Lever
Parking Brake Wire
Notches
Lock Nut
A : Pull
B : Release
W1045376
G-23
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Lubricating Grease Fittings
1. Apply a small amount of multipurpose grease to following points:
2. If you operated the machine in extremely wet and muddy
condition, lubricate grease fittings more often.
(1) Grease Fitting (Front Axle Support)
(Front, Rear)
(2) Grease Fitting (Front Wheel Case
Support) (RH, LH)
(3) Grease Fitting (Top Link)
(4)
(5)
(6)
(7)
Grease Fitting (Top Link Bracket)
Grease Fitting (Lifting Rod)
Grease Fitting (Steering Joint Shaft)
Grease Fitting (Battery Terminal)
W1045953
G-24
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[5] CHECK POINTS OF EVERY 200 HOURS
Changing Hydraulic Oil Filter
1. See page G-17.
W1046442
Checking Radiator Hose and Hose Clamp
Check to see if radiator hoses are properly fixed every 200 hours
of operation or six months, whichever comes first.
1. If hose clamps are loose or water leaks, tighten bands securely.
2. Replace hoses and tighten hose clamps securely, if radiator
hoses are swollen, hardened or cracked. Replace hoses and
hose clamps every 2 years or earlier if checked and found that
hoses are swollen, hardened or cracked.
■ Precaution at Overheating
Take the following actions in the event the coolant temperature
be nearly or more than the boiling point, what is called
“Overheating”.
1. Stop the machine operation in a safe place and keep the engine
unloaded idling.
2. Don't stop the engine suddenly, but stop it after about 5 minutes
of unloaded idling.
3. Keep yourself well away from the machine for further 10 minutes
or while the steam blown out.
4. Checking that there gets no danger such as burn, get rid of the
causes of overheating according to the manual, see
“Troubleshooting” section, and then, start again the engine.
(1) Radiator Hose
(2) Clamp
W1046500
Checking Power Steering Oil Line
1. Check to see that all line and hose clamps are tight and not
damaged.
2. If hoses and clamps are found worn or damaged, replace or
repair them at once.
(1) Power Steering Hose
W1046795
G-25
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Draining Fuel Tank Water
1. Remove the drain cover (2) at the bottom of right side fuel tank
(1) to left sediments, impurities and water out of the tank.
2. Finally attach the drain cover (2) on the fuel tank (1).
(When reassembling)
• Be sure to fix the O-ring (3) is in position on the drain cover (2).
Tightening torque
Drain cover mounting
screw
23.6 to 27.4 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
■ IMPORTANT
• If the fuel contains poor qualities with much water in it, drain
the fuel tank at shorter intervals.
• Drain the fuel before operating the tractor after a long period
of storage.
(1) Fuel Tank
(2) Drain Cover
(3) O-ring
(4) Screw
W1046897
Adjusting Toe-in
1. Park tractor on a flat place.
2. Turn steering wheel so that front wheels are in the straight ahead
position.
3. Lower the implement, lock the park brake and stop the engine.
4. Measure distance between tire beads at front of tire, hub height.
5. Measure distance between tire beads at rear of tire, hub height.
6. Front distance should be shorter than rear distance.
7. If not, adjust tie-rod length.
Toe-in (b-a)
Factory spec.
2.0 to 8.0 mm
0.08 to 0.31 in.
■
1.
2.
3.
Toe-in Adjustment
Detach the snap ring (1).
Loosen the tie-rod joint lock nut (3).
Turn the tie-rod joint (2) to adjust the rod length until the proper
toe-in measurement is obtained.
4. Retighten the tie-rod joint lock nut (3).
5. Attach the snap ring (1) of the tie-rod joint.
Tightening torque
Tie-rod joint lock nut
(1) Snap Ring
(2) Tie-rod Joint
(3) Tie-rod Joint Lock Nut
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
(a) Wheel-to-wheel distance at front
(b) Wheel-to-wheel distance at rear
(c) Front
W1047149
G-26
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Cleaning Inner Air Filter
1. Remove the inner air filter, and blow air the direction opposite to
the filter's normal air flow. Pressure of compressed air must be
under 205 kPa (2.1 kgf/cm2, 30 psi).
■ How to attach and detach the push-rivet assy.
• Detaching procedure
To remove the push rivet of the indoor air filter, hold the rivet
around its head (3), apply a phillips screwdriver to the recess (A)
and turn the rivet counterclockwise.
• Attaching procedure
To fix the push rivet in the indoor air filter, put the rivet end in the
filter and push on the rivet head (3) all the way.
(1) Inner Filter
(2) Push-rivet
(3) Rivet Head
(A) Recess
(B) Push
W1047808
G-27
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Cleaning Fresh Air Filter
1. Remove the knob bolts (3) and pull out filter (1).
■ NOTE
• Do not hit the filter. If the filter becomes deformed, dust may
enter into the air-conditioner, which may cause damage and
malfunction.
• Do not use gasoline, thinner or similar chemicals to clean
the filter as damage to the filter may occur.
• It may also cause an unpleasant odor in the CABIN when the
system is used next.
■ Cleaning the air filter
• Normal use
Blow air from the opposite direction to the filter's normal air flow.
Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2,
30 psi)
• If the filter is very dirty
Dip the filter in lukewarm water with mild dish washing detergent.
Move it up and down as well as left and right to loosen dirt. Rinse
the filter with clean water and let it air-dry.
■ IMPORTANT
• Do not hit the filter. If the filter becomes deformed, dust may
enter into the air-conditioner, which may cause damage and
malfunction.
• Do not use gasoline, thinner or similar chemicals to clean
the filter as damage to the filter may occur.
• If may also cause an unpleasant odor in the CAB when the
system is used next.
(1) Fresh Air Filter
(2) Cover
(3) Knob Bolt
A : Air Inner Port
B : Air Conditioner Airflow
W1048208
Cleaning Air Conditioner Condenser
1. Check the air conditioner condenser (1).
2. If dust and dirt, wash off all dirt and dust from the condenser (1)
with a soft brush, use care not to damage or bend the fins.
(1) Air Conditioner Condenser
W1048552
G-28
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Sliding Air Conditioner Condenser
•
1.
2.
3.
■
•
(1)
(2)
(3)
(4)
CAUTION
The condenser and receiver become hot while the air
conditioner is running. Before checking or cleaning them,
wait long enough until they cool down.
Release the air conditioner hoses off the hook.
Loosen the wing nut.
Hold the handle, slide the air conditioner condenser assembly
toward yourself.
IMPORTANT
Do not hold the air conditioner receive or the air conditioner
pipes when sliding out the condenser for cleaning.
Condenser
Receiver
Handle
Wing Nut
(5) Air Conditioner Hose
(6) Hook
A : PULL
W1048917
Adjusting Air Conditioner Belt Tension
•
1.
2.
3.
4.
CAUTION
Be sure to stop the engine before checking air conditioner
belt tension.
Stop the engine and remove the key.
Apply 98 N (10 kgf, 22 lbs) pressure to the belt between the
pulleys.
If tension is incorrect, adjust the belt tension.
If belt is damaged, replace it.
Air conditioner belt
tension
(1) Adjusting Bolt
Factory spec.
A deflection of between
10 to 12 mm (0.39 to 0.47
in.) when the belt is
pressed in the middle of
the span
A : Deflection
W1049284
[6] CHECK POINTS OF EVERY 300 HOURS
Changing Engine Oil
1. See page G-15.
W1049642
G-29
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[7] CHECK POINTS OF EVERY 400 HOURS
Cleaning Water Separator
1. Close the fuel cock (1).
2. Unscrew the retainer ring (2) and remove the cup (3), and rinse
the inside with kerosene.
3. Take out the element and dip it in the kerosene to rinse.
4. After cleaning, reassemble the water separator, keeping out dust
and dirt.
5. Bleed the fuel system. (See page G-38.)
(1)
(2)
(3)
(4)
(5)
Fuel Cock
Retainer Ring
Cup
O-ring
Element
(6) Spring
(7) Red Float
A : CLOSE
W1049718
Replacing Fuel Filter
1. Remove the fuel filter (1).
2. Put a film of clean fuel on rubber seal of new filter.
3. Tighten the filter until it contacts the mounting surface. Tighten
filter by hand an additional 1/2 turn only.
4. Bleed the fuel system.
Refer to “Bleeding Fuel System”. (See page G-38.)
(1) Fuel Filter
W1050132
[8] CHECK POINTS OF EVERY 600 HOURS
Replacing Engine Oil Filter
1. See page G-15.
W1050294
Changing Transmission Fluid
1. See page G-16.
W1050340
Changing Front Differential Case Oil
1. See page G-17.
W1050385
Changing Front Axle Gear Case Oil
1. See page G-18.
W1050430
G-30
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Changing Brake Oil
•
■
•
•
•
1.
2.
3.
CAUTION
Be sure to check and service the tractor on a flat place with
engine shut off and applying the parking brake on.
IMPORTANT
Be sure to use the recommended brake oil. (See page G-8.)
When refilling brake oil, use the same quality of oil as the
one already in the reservoir. Adding an oil of different make
or type can cause trouble, and thus must be avoided.
While changing brake oil, make sure to keep enough brake
oil in the reservoir.
Remove the brake reservoir cap (1), and fill with oil up to the
MAX. level.
After installing the vinyl pipes (3) to the bleeder (2), loosen the
bleeder a half turn.
Move the brake pedal up and down. Repeat this motion until
fresh oil overflows.
(1) Brake Reservoir Cap
(2) Air Bleeder (on Brake Case)
(3) Vinyl Pipe
A : MAX Level
B : MIN Level
W1050507
Adjusting Front Axle Pivot
1. Jack up the tractor body, then loosen the lock nut (2).
2. Measure the adjusting screw tightening torque.
3. If tightening torque is not within the factory specifications, adjust
the adjusting screw (1).
4. After adjustment, tighten the lock nut firmly.
Front axle adjusting screw
19.6 to 29.4 N·m
2.0 to 3.0 kgf·m
14.5 to 21.7 ft-lbs
Lock nut
98.1 to 147.1 N·m
10.0 to 15.0 kgf·m
72.3 to 108.5 ft-lbs
Tightening torque
(1) Adjusting Screw
(2) Lock Nut
W1050914
G-31
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Adjusting King-pin Pivot
1. Jack up the tractor, then loosen the lock nut (2).
2. Measure the adjusting screw tightening torque.
3. If tightening torque is not within the factory specifications, adjust
the adjusting screw (1).
4. After adjustment, tighten the lock nut (2) firmly.
Adjusting screw
4.9 to 9.8 N·m
0.5 to 1.0 kgf·m
3.62 to 7.24 ft-lbs
Lock nut
98.1 to 147.0 N·m
10.0 to 15.0 kgf·m
72.4 to 108.4 ft-lbs
Tightening torque
(1) Screw
(2) Lock Nut
W1051354
Checking Air Conditioner Pipes and Hoses
1. Check to see that all lines and hose clamps are tight and not
damaged.
2. If hoses and clamps are found worn or damaged, replace or
repair them at once.
(1) A/C Hose
(2) Heater Hose
W1051760
Checking Cabin Isolation Cushion
1. Check the cushions (1) for any breakage or fatigue.
2. Replace them if they have deteriorated.
(1) Cushion
W1052027
G-32
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[9] CHECK POINT OF EVERY 800 HOURS
Adjusting Engine Valve Clearance
1. See page 1-S13.
W1052150
[10] CHECK POINT OF EVERY 1 YEAR
Replacing Air Cleaner Primary and Secondary Element
1. Refer to "Cleaning Air Cleaner Element"
(See page G-20.)
W1052222
G-33
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[11] CHECK POINTS OF EVERY 2 YEARS
Flush Cooling System and Changing Coolant
CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (1) and remove
radiator cap (2). The radiator cap (2) must be removed to
completely drain the coolant.
3. Fill with clean water and cooling system cleaner.
4. Follow directions of the cleaner instruction.
5. After flushing, fill with clean water and anti-freeze until the coolant
level is just below the port.
6. Fill with clean water and anti-freeze up to the upper line of
recovery tank (3).
7. Install the radiator cap (2) securely.
8. Start and operate the engine for few minutes.
9. Stop the engine. Check coolant level and add coolant if
necessary.
Coolant
Capacity
9.1 L
9.6 U.S.qts
8.0 Imp.qts
■
•
•
•
IMPORTANT
Do not start engine without coolant.
Use clean, fresh water and anti-freeze to fill the radiator.
When the anti-freeze is mixed with water, the anti-freeze
mixing ratio must be less than 50 %.
• Securely tighten radiator cap (2). If the cap is loose or
improperly fitted, water may lead out and the engine could
overheat.
■ NOTE
• On cabin type machines, fresh water circulates through the
heater. This means that one more liter or so of fresh water
is required.
In changing fresh water, pour fresh water up to the filter port
of the recovery tank. Turn ON the heater (shift the
temperature control lever toward WARM), and run the
engine for a while in order to warm fresh water. Then stop
the engine.
When fresh water has cooled down, some of the fresh water
in the recovery tank is sucked. Now the recovery tank is
appropriately filled with fresh water.
(1) Radiator Hose
(2) Radiator Cap
(3) Recovery Tank
W1052302
G-34
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Flush Cooling System and Changing Coolant (Continued)
■ Anti-Freeze
CAUTION
• When using antifreeze, put on some protection such as
rubber gloves (Antifreeze contains position).
• If should drink antifreeze, throw up at once and take medical
attention.
• When antifreeze comes in contact with the skin or clothing,
wash it off immediately.
• Do not mix different types of Antifreeze.
The mixture can produce chemical reaction causing harmful
substances.
• Antifreeze is extremely flammable and explosive under
certain conditions. Keep fire and children away from
antifreeze.
• When draining fluids from the engine, place some container
underneath the engine body.
• Do not pour waste onto the grounds, down a drain, or into
any water source.
• Also, observe the relevant environmental protection
regulations when disposing of antifreeze.
If it freezes, coolant can damage the cylinders and radiator. If the
ambient temperature falls below 0 °C or before a long-term storage,
let out cooling water completely, or mix fresh water with long-life
coolant and fill the radiator and reserve tank with the mixture.
1. Long-life coolant (hereafter LLC) comes in several types. Use
ethylene glycol (EG) type for this engine.
2. Before employing LLC-mixed cooling water, fill the radiator with
fresh water and empty it again.
Repeat this procedure 2 or 3 times to clean up the inside.
3. Mixing the LLC
Put the LLC in cooling water in the percentage (%) for a target
temperature. When mixing, stir it up well, and then fill into the
radiator.
4. The procedure for the mixing of water and antifreeze differs
according to the make of the antifreeze and the ambient
temperature. Refer to SAE J1034 standard, more specifically
also to SAE J814c.
■ IMPORTANT
• When the antifreeze is mixed with water, the antifreeze
mixing ratio must be less than 50 %.
Freeze Point
Boiling Point*
°C
°C
40
−24
106
50
−37
108
Vol % Anti-freeze
*At 1.013 x 1000000 Pa (760 mmHg) pressure (atmospheric).
A higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
W1052897
G-35
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
5. Adding the LLC
(1) Add only water if the mixture reduces in amount by
evaporation.
(2) If there is a mixture leak, add the LLC of the same
manufacture and type in the same mixture percentage.
*Never add any long-life coolant of different manufacture.
(Different brands may have different additive components, and
the engine may fail to perform as specified.)
6. When the LLC is mixed, do not employ any radiator cleaning
agent. The LLC contains anticorrosive agent. If mixed with the
cleaning agent, sludge may build up, adversely affecting the
engine parts.
7. Kubota's genuine long-life coolant has a service life of 2 years.
Be sure to change the coolant every 2 years.
■ NOTE
• The above data represents industry standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add water
only to keep the antifreeze mixing ratio less than 50 %. In
case of leakage, add antifreeze and water in the specified
mixing ratio before filling in to the radiator.
W1053945
Replacing Radiator Hose (Water Pipes)
1. Replace the hoses and clamps.
Refer to “Checking Radiator Hose and Hose Clamp”.
(See page G-25.)
W1054349
Replacing Fuel Hose
1. Replace the fuel hose and clamps, if necessary.
Refer to “Checking Fuel Line”.
(See page G-21.)
W1054573
Replacing Power Steering Hose
1. Replace the hoses and clamps, if necessary.
Refer to “Checking Power Steering Oil Line”.
(See page G-25.)
W1054527
G-36
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Replacing Brake Hose
1. Replace the brake hoses (1).
2. After replacing the hoses, bleed an air from brake system. (See
page G-39.)
(1) Brake Hose
W1054709
Replacing Parking Brake Cable
1. Replace the parking brake cable (3).
Refer to “Adjusting Parking Brake Lever Free Play”
(See page G-23.)
(1) Parking Brake Lever
(2) Lock Nut
(3) Parking Brake Cable
(4) Parking Brake Camshaft
W1054811
Replacing Master Cylinder Kit and Equalizer Kit
1. Refer to “Removing Master Cylinder and Equalizer”.
(See page 5-S11.)
W1055146
Replacing Brake Seal 1 and 2
1. Refer to “Brake Case”.
(See page 5-S16.)
W1055100
G-37
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[12] OTHERS
Bleeding Fuel System
Air must be removed:
1. When the fuel filter or lines are removed.
2. When water is drained from water separator.
3. When tank is completely empty.
4. After the tractor has not been used for a long period of time.
■ Bleeding procedure is as follows:
1. Fill the fuel tank with fuel, and open the fuel cock (1).
2. Pump the fuel pump knob (2) located on the top of the fuel filter.
The fuel pump knob will pump easily at first and with added
resistance as air is purged from the system. To make sure air is
completely purged, pinch the fuel overflow hose (3) with fingers,
if a pulsation is felt when the knob is pumped, then, no air
remains.
3. Set the hand throttle lever at the maximum speed position, turn
the key switch to start the engine, and then reset the throttle lever
at the mid speed (around 1500 rpm) position.
If engine doesn't start, try it several times at 30 second intervals.
4. Accelerate the engine to remove the small portion of air left in the
fuel system.
5. If air still remains and the engine stops, repeat the above steps.
■ IMPORTANT
• Do not hold key switch at engine start position for more than
10 seconds continuously. If more engine cranking is
needed, try again after 30 seconds.
(1) Fuel Cock
(2) Fuel Pump Knob
(3) Fuel Overflow Hose
A:
B:
C:
D:
Close
Open
Up
Down
W1055254
Draining Clutch Housing Water
1. The tractor is equipped with drain plug (1) under the clutch
housing.
2. After operating in rain, snow or tractor has been washed, water
may get into the clutch housing.
3. Remove the drain plug (1) and drain the water, then install the
plug (1) again.
(1) Drain Plug (Water)
W1055587
G-38
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Bleeding Brake System
■ NOTE
• While bleeding, make sure to keep enough brake oil in the
brake oil reservoir.
1. Disconnect the brake pipes (1) from the master cylinder.
2. Move the brake pedal up and down by hand. At this time, when
raising the pedal, close the master cylinder outlet by a finger, and
when lowering, release the finger.
Repeat this operation several times. (Prepare and oil can.)
3. After bleeding the master cylinder, install the front brake pipes.
4. After installing the vinyl pipe (3) to the bleeder (2) loosen the
bleeder two turns.
5. Move the brake pedal up and down.
Repeat this motion until air bubble in brake oil disappears.
After bleeding, tighten the bleeders firmly.
Tightening torque
Brake pipe nut
16.0 to 24.0 N·m
1.6 to 2.5 kgf·m
11.8 to 17.7 ft-lbs
(Reference : Importance of Bleeding)
• If the air mixes in the brake hydraulic circuit, poor or no braking
force is obtained due to compress the air even when the brake
pedal is pressed.
Accordingly whenever the hydraulic brake system is
disassembled, be sure to bleed after reassembling.
(1) Brake Pipe
(2) Bleeder (on Brake Case)
(3) Vinyl Pipe
W1055717
Replacing Light Bulb
1. Head lights.
Take the bulb out of the light body and replcwith a new one.
2. Other lights
Detach the lens and replace the bulb.
Light
Head Lights
Capacity
60 / 55 W
Tail Light
10 W
Turn Signal / Hazard Light (Front)
21 W
Turn Signal / Hazard Light (Rear)
21 W
Brake Stop Light
21 W
Instrument Panel Light
3.4 W
Work Light
55 W
Dome Light (Room Lamp)
10 W
Sidemarker Light
10 W
Number Plate Light
10 W
W1056015
G-39
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Lubricating Points Cabin
1. Apply oil to the door hinges (1) and the rear window hinges (2).
(1) Door Hinge
(2) Rear Window Hinge
W1056309
Adding Washer Liquid
1. Add a proper amount of automobile washer liquid when it is
necessary.
Washer liquid tank
Capacity
1.3 L
1.4 U.S.qts
1.1 Imp.qts
(1) Washer Liquid Tank
W1056398
G-40
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Replacing Fuse
1. The tractor electrical system is protected from potential damage
by fuses.
A blown fuse indicates that there is an overload or short
somewhere in the electrical system.
2. If any of the fuses should blow, replace with a new one of the
same capacity.
■ IMPORTANT
• Before replacing a blown fuse, determine why the fuse blew
and make any necessary repairs. Failure to follow this
procedure may result in serious damage to the tractor
electrical system. Refer to troubleshooting section of this
manual for specific information dealing with electrical
problems.
Fuse No.
Capacity (Ampere)
Protected circuit
(1)
15 A
Flasher (Hazard)
(2)
15 A
Stop Lamp, Dome Light
(3)
20 A
Head Light, Horn
(4)
25 A
Aircon (Fan motor)
(5)
5A
Aircon (Compressor)
(6)
25 A
Beacon
(7)
25 A
Auxiliary Power
(8)
–
–
(9)
5A
Heater Relay
(10)
5A
Starter Relay
(11)
5A
Key Stop Solenoid
(12)
10 A
Meter Panel
(13)
10 A
Turn Signal
(14)
5A
Radio
(15)
5A
Aircon (Control)
(16)
15 A
Wiper
(17)
15 A
Work Light (Rear)
(18)
15 A
Work Light (Front)
(19)
15 A
Cigarette Lighter
(20)
10 A
Transmission Control
(21)
60 A
Deforgger (If equipped),
Auxiliary Power, Compressor
(22)
30 A
Aircon (Fan motor)
(23)
30 A
Main Key
(24)
120 A
Starter
(25)
120 A
Air Heater
(26)
60 A
Flusher, Stop Lamp, Dome Light
(27)
50 A
Head Light, Work Light
[A] Fuse Box
W1056680
G-41
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Checking the Amount of Refrigerant (Gas)
1. A shortage of refrigerant impairs the air conditioner performance.
Check the following points. If it is indicated that the amount of
refrigerant is extremely low. Do to inspect and charge.
■ Checking procedure
1. Run the air-conditioner in the following conditions.
• Engine speed:
About 1500 rpm
• Temperature control dial: Maximum cooling position (leftmost)
• Blower switch:
Highest blow (HI)
• Air-conditioner switch:
ON
2. Look into the sight glass to see if the refrigerant is flowing through
its circuit.
(Reference)
(A) Proper
: Little or no air bubbles in the refrigerant flow.
(B) Low
: Lots of air bubbles in the refrigerant flow (air bubbles or foam
passing continuously).
(C) Overfull or no refrigerant
: Colorless and transparent
(1) Sight Glass
(A) Proper
(B) Low
(C) Overfull or no refrigerant
W1057923
G-42
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
8. SPECIAL TOOLS
[1] SPECIAL TOOLS FOR ENGINE
Special Use Puller Set
Code No.: 07916-09032
Application: Use exclusively for pulling out bearing, gears and other
parts with ease.
W10240500
Piston Ring Compressor
Code No.: 07909-32111
Application: Use exclusively for pushing in the piston with piston
rings into the cylinder.
W10241000
Piston Ring Tool
Code No.: 07909-32121
Application: Use exclusively for removing or installing the piston ring
with ease.
W10241500
Diesel Engine Compression Tester
Code No.: 07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F)
07909-31271 (I)
07909-31211 (E and F) 07909-31281 (J)
07909-31231 (H)
Application: Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1)
(2)
(3)
(4)
(5)
(6)
Gauge
L Joint
Adaptor A
Adaptor B
Adaptor C
Adaptor E
(7)
(8)
(9)
(10)
(11)
Adaptor F
Adaptor G
Adaptor H
Adaptor I
Adaptor J
W10242000
G-43
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Oil Pressure Tester
Code No.: 07916-32032
Application: Use to measure lubricating oil pressure.
(1)
(2)
(3)
(4)
Gauge
Cable
Threaded Joint
Adaptor 1
(5)
(6)
(7)
(8)
Adaptor 2
Adaptor 3
Adaptor 4
Adaptor 5
W10243180
Adaptor 7
Code No.: 07916-32591
Application: Use to measure lubricating oil pressure.
W1030102
Valve Seat Cutter
Code No.: 07909-33102
Application: Use to reseat valves.
Angle:
0.785 rad (45°)
0.262 rad (15°)
Diameter: 28.6 mm (1.126 in.)
31.6 mm (1.244 in.)
35.0 mm (1.378 in.)
38.0 mm (1.496 in.)
41.3 mm (1.626 in.)
50.8 mm (2.000 in.)
W10244580
Connecting Rod Alignment Tool
Code No.: 07909-31661
Application: Use to check the connecting rod alignment.
Applicable: Connecting rod big end I.D.
range
30 to 75 mm (1.18 to 2.95 in.) dia.
Connecting rod length
65 to 300 mm (2.56 to 11.81 in.)
W10245830
G-44
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Nozzle Tester
Code No.: 07909-31361
Application: Use to check the fuel injection pressure and spray
pattern of nozzle.
Measuring : 0 to 50 MPa
range
(0 to 500 kgf/cm2, 0 to 7000 psi)
W10246530
Plastigage
Code No.: 07909-30241
Application: Use to check the oil clearance between crankshaft and
bearing, etc..
Measuring: Green .... 0.025 to 0.076 mm (0.001 to 0.003 in.)
range
Red ....... 0.051 to 0.152 mm (0.002 to 0.006 in.)
Blue ....... 0.102 to 0.229 mm (0.004 to 0.009 in.)
W10247190
Red Check
Code No.: 07909-31371
Application: Use to check cracks on cylinder head, cylinder block,
etc..
W10249090
Radiator Tester
Code No.: 07909-31551
Application: Use to check of radiator cap pressure, and leaks from
cooling system.
W1024532
G-45
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
■ NOTE
• The following special tools are not provided, so make them referring to the figure.
Small End Bushing Replacing Tool
Application: Use to press out and to press fit the small end bushing.
[Press out]
A
157 mm (6.1811 in.)
B
14.5 mm (0.571 in.)
C
120 mm (4.7244 in.)
D
30.0 mm dia. (1.1811 in. dia.)
E
32.95 mm dia. (1.2972 in. dia.)
F
20 mm dia. (0.7874 in. dia.)
a
6.3 μm (250 μin.)
b
6.3 μm (250 μin.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
[Press fit]
A
157 mm (6.1811 in.)
B
14.5 mm (0.571 in.)
C
120 mm (4.7244 in.)
D
30.0 mm dia. (1.1811 in. dia.)
E
42.000 mm dia. (1.6535 in. dia.)
F
20 mm dia. (0.7874 in. dia.)
a
6.3 μm (250 μin.)
b
6.3 μm (250 μin.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
W1031485
G-46
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Idle Gear Bushing Replacing Tool
Application: Use to press out and to press fit the bushing.
1. For idle gear bushing
A
196 mm (7.7165 in.)
B
37.5 mm (1.476 in.)
C
150 mm (5.9055 in.)
D
44.95 mm dia. (1.7697 in. dia.)
E
48.075 to 48.100 mm dia. (1.8927 to 1.8937 in. dia.)
F
20 mm dia. (0.7874 in. dia.)
a
6.3 μm (250 μin.)
b
6.3 μm (250 μin.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
W10440400
Gear Case Oil Seal Replacing Tool
Application: Use to press fit the oil seal.
A
148.8 mm (5.8582 in.)
B
50 mm (1.9685 in.)
C
18.8 mm (0.7401 in.)
D
13.7 to 13.9 mm (0.5394 to 0.5472 in.)
E
11 mm (0.433 in.)
F
18 mm dia. (0.7087 in. dia.)
G
38 mm dia. (1.4961 in. dia.)
H
45 mm dia. (1.7716 in. dia.)
I
57.9 to 58.1 mm dia. (2.2795 to 2.2874 in. dia.)
J
79.5 mm dia. (3.1299 in. dia.)
K
87 mm dia. (3.452 in. dia.)
L
12 mm (0.4724 in.)
M
40 mm (1.5748 in.)
N
120 mm (4.7244 in.)
W1041529
G-47
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
A
20 mm dia. (0.79 in. dia.)
B
11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.)
C
6.5 to 6.6 mm dia. (0.256 to 0.259 in. dia.)
D
225 mm (8.86 in.)
E
70 mm (2.76 in.)
F
45 mm (1.77 in.)
G
25 mm dia. (0.98 in. dia.)
H
5 mm (0.197 in.)
I
6.7 to 7.0 mm dia. (0.263 to 0.275 in. dia.)
J
20 mm dia. (0.787 in. dia.)
K
12.5 to 12.8 mm dia. (0.492 to 0.504 in. dia.)
L
8.9 to 9.1 mm (0.350 to 0.358 in.)
C1
Chamfer 1.0 mm (0.039 in.)
C2
Chamfer 2.0 mm (0.079 in.)
C0.3
Chamfer 0.3 mm (0.012 in.)
W1045889
Auxiliary Socket for Fixing Crankshaft Sleeve
Application: Use to fix the crankshaft sleeve of the diesel engine.
A
Rmax = 12.5 S
B
94.5 to 95.0 mm dia. (3.7205 to 3.7402 in. dia.)
C
40 mm dia. (1.5748 in. dia.)
D
30 mm dia. (1.1811 in. dia.)
E
12 mm (0.4724 in.)
F
7.9 to 8.1 mm (0.3110 to 0.3189 in.)
G
20 mm (0.0787 in.)
H
130 mm dia. (5.1181 in. dia.)
I
99.4 to 99.6 mm dia. (3.9134 to 3.9213 in. dia.)
J
95.05 to 95.20 mm dia. (3.7421 to 3.7480 in. dia.)
K
3 mm dia. (0.1181 in.dia.)
L
15 mm (0.5905 in.)
M
10 mm (0.3937 in.)
N
90 mm (3.5433 in.)
O
115 mm (4.5275 in.)
P
16.9 to 17.1 mm (0.6654 to 0.6732 in.)
C1
Chamfer 1.0 mm (0.039 in.)
C3
Chamfer 3.0 mm (0.1181 in.)
C5
Chamfer 5.0 mm (0.1969 in.)
C0.2
Chamfer 0.2 mm (0.0079 in.)
C0.3
Chamfer 0.3 mm (0.0118 in.)
W1041815
G-48
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Balancer Bushing Replacing Tool 1 Assembly
Application: Use to press fit the bushing.
No.
1
name of Part
Q'ty
Remarks
Shaft
1
–
2
Piece 1
1
–
3
Piece 2
1
–
4
Bolt
2
M6 × P1.0
W1035596
Balancer Bushing Replacing Tool 1 Components Parts
1) Shaft
A
498 mm (19.61 in.)
B
318.8 to 319.2 mm (12.5726 to 12.5669 in.)
C
102.8 to 103.2 mm (4.0472 to 4.0630 in.)
D
60 mm (2.36 in.)
E
8 mm (0.31 in.)
F
5 mm (0.20 in.)
G
30 mm dia. (1.18 in. dia.)
H
65 mm dia. (2.56 in. dia.)
I
6 mm (0.24 in.)
J
Chamfer 1 mm (0.04 in.)
K
53 mm dia. (2.09 in. dia.)
L
54.7 to 54.9 mm dia. (2.1535 to 2.1614 in. dia.)
M
0.26 rad (15 °)
N
Chamfer 0.5 mm (0.02 in.)
O
41 mm dia. (1.61 in. dia.)
P
32 mm dia. (1.26 in. dia.)
Q
33.961 to 34.0 mm dia. (1.3370 to 1.3386 in. dia.)
R
18 mm dia. (0.71 in. dia.)
S
19.967 to 20.0 mm dia. (0.7861 to 0.7874 in. dia.)
U
3 mm (0.12 in.)
V
149.1 to 149.4 mm (5.8701 to 5.8819 in.)
W
365.1 to 365.4 mm (14.3740 to 14.3858 in.)
X
123 mm (4.84 in.)
Y
375 mm (14.76 in.)
Z
M6 × P1.0 depth 7 mm (0.28 in.)
a
Chamfer 2 mm (0.08 in.)
W1036035
G-49
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
2) Piece 1
A
Chamfer 0.1 mm (0.004 in.)
B
1 mm (0.04 in.)
C
Chamfer 1 mm (0.04 in.)
D
53.8 to 53.9 mm dia. (2.1181 to 2.1220 in. dia.)
E
20.02 to 20.041 mm dia. (0.7882 to 0.7890 in. dia.)
F
48 mm dia. (1.89 in. dia.)
G
49.934 to 49.94 mm dia. (1.9659 to 1.9661 in. dia.)
H
8 mm (0.31 in.)
I
2 mm (0.08 in.)
J
35 mm (1.38 in.)
K
5 mm (0.20 in.)
L
0.26 rad (15 °)
W1036402
3) Piece 2
A
Chamfer 0.1 mm (0.004 in.)
B
1 mm (0.04 in.)
C
Chamfer 1 mm (0.04 in.)
D
54.3 to 54.4 mm dia. (2.1378 to 2.1417 in. dia.)
E
34.025 to 34.05 mm dia. (1.3396 to 1.3406 in. dia.)
F
48.5 mm dia. (1.9094 in. dia.)
G
50.421 to 50.44 mm dia. (1.9851 to 1.9858 in. dia.)
H
8 mm (0.31 in.)
I
2 mm (0.08 in.)
J
35 mm (1.38 in.)
K
5 mm (0.20 in.)
L
0.26 rad (15 °)
W1036583
G-50
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Balancer Bushing Replacing Tool 2
Application: Use to press fit the bushing.
A
35 mm (1.38 in.)
B
33 mm (1.30 in.)
C
Chamfer 0.5 mm (0.02 in.)
D
1 mm (0.04 in.)
E
Chamfer 1 mm (0.04 in.)
F
40 mm dia. (1.57 in. dia.)
G
50.921 to 50.94 mm dia. (2.0048 to 2.0055 in. dia.)
H
54.8 to 54.9 mm dia. (2.1575 to 2.1614 in. dia.)
I
30 mm dia. (1.18 in. dia.)
J
49 mm dia. (1.93 in. dia.)
K
6 mm (0.24 in.)
L
125 mm (4.92 in.)
M
160 mm (6.30 in.)
N
3 mm (0.12 in.)
O
5 mm (0.20 in.)
P
0.26 rad (15 °)
W1036805
G-51
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Balancer Bushing Replacing Tools 3, 4, 5
Application: Use to press fit the bushing.
No.
Name of Part
Q'ty
1
Bracket
1
2
Flange Nut
1
3
Washer
1
4
Shaft
1
5
Piece 1
1
6
Clevis
1
7
Washer
1
8
Cotter Pin
1
9
Joint 1
1
10
Piece 2
1
11
Joint 2
1
12
Piece 3
1
[a] Tool 3
[b] Tool 4
[c] Tool 5
A : Section
W1037123
Balancer Bushing Replacing Tool Components Parts
1) Bracket
A
12 mm (0.47 in.)
B
50 mm (1.97 in.)
C
Chamfer 1 mm (0.04 in.)
D
80 mm (3.15 in.)
E
104 mm (4.09 in.)
F
22 mm (0.87 in.)
G
13 mm dia. (0.51 in. dia.)
W1037894
G-52
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
2) Shaft
A
44 mm dia. (1.73 in. dia.)
B
12 mm (0.47 in.)
C
Chamfer 1 mm (0.04 in.)
D
3 mm (0.12 in.)
E
3 mm (0.12 in.)
F
30 mm (1.18 in.)
G
38 mm (1.38 in.)
H
35 mm (1.38 in.)
I
M12 × P1.25
J
53 mm (2.09 in.)
K
4 mm (0.16 in.)
L
75 mm (2.95 in.)
M
57 mm (2.24 in.)
N
70 mm (2.76 in.)
O
19.5 mm (0.77 in.)
P
12 mm (0.47 in.)
Q
0.8 mm (0.03 in.)
R
6 mm (0.24 in.)
W1037691
3) Piece 1
A
26 mm (1.02 in.)
B
18 mm (0.71 in.)
C
16.5 to 17.0 mm (0.6496 to 0.6693 in.)
D
1.5 mm (0.06 in.)
E
54.0 to 54.2 mm dia. (2.1260 to 2.1339 in. dia.)
F
50.55 to 50.75 mm dia. (1.9902 to 1.9980 in. dia.)
G
16 mm (0.63 in.)
H
Chamfer 1 mm (0.04 in.)
I
8.5 mm dia. (0.33 in. dia.)
J
0.4 mm (0.0157 in.)
K
3 mm (0.12 in.)
L
19 mm (0.75 in.)
M
Chamfer 0.5 mm (0.02 in.)
N
36 mm (1.42 in.)
O
45 mm dia. (1.77 in. dia.)
P
0.78 rad (45 °)
Q
11.5 mm (0.45 in.)
W1038038
G-53
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
4) Joint 1
A
M12 × P1.25
B
Chamfer 1 mm (0.04 in.)
C
30 mm dia. (1.18 in. dia.)
D
13 mm dia. (0.51 in. dia.)
E
Chamfer 3 mm (0.12 in.)
F
3 mm (0.12 in.)
G
45 mm (1.77 in.)
H
75 mm (2.95 in.)
I
57 mm (2.24 in.)
J
85 mm (3.35 in.)
K
70 mm (2.76 in.)
L
178 mm (7.01 in.)
W1038382
5) Piece 2
A
26 mm (1.02 in.)
B
18 mm (0.71 in.)
C
16.5 to 17.0 mm (0.6496 to 0.6693 in.)
D
1.5 mm (0.06 in.)
E
53.5 to 53.7 mm dia. (2.1063 to 2.1142 in. dia.)
F
50.05 to 50.25 mm dia. (1.9705 to 1.9783 in. dia.)
G
16 mm (0.63 in.)
H
Chamfer 1 mm (0.04 in.)
I
8.5 mm dia. (0.33 in. dia.)
J
0.4 mm (0.0157 in.)
K
3 mm (0.12 in.)
L
19 mm (0.75 in.)
M
Chamfer 0.5 mm (0.02 in.)
N
36 mm (1.42 in.)
O
45 mm dia. (1.77 in. dia.)
P
0.78 rad (45 °)
Q
11.5 mm (0.45 in.)
W1038568
G-54
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
6) Joint 2
A
M12 × P1.25
B
Chamfer 1 mm (0.04 in.)
C
30 mm dia. (1.18 in. dia.)
D
13 mm dia. (0.51 in. dia.)
E
Chamfer 3 mm (0.12 in.)
F
3 mm (0.12 in.)
G
45 mm (1.77 in.)
H
75 mm (2.95 in.)
I
57 mm (2.24 in.)
J
85 mm (3.35 in.)
K
70 mm (2.76 in.)
L
394 mm (15.51 in.)
W1038747
7) Piece 3
A
26 mm (1.02 in.)
B
18 mm (0.71 in.)
C
16.5 to 17.0 mm (0.6496 to 0.6693 in.)
D
1.5 mm (0.06 in.)
E
53.0 to 53.2 mm dia. (2.0866 to 2.0945 in. dia.)
F
49.55 to 49.75 mm dia. (1.9508 to 1.9587 in. dia.)
G
16 mm (0.63 in.)
H
Chamfer 1 mm (0.04 in.)
I
8.5 mm dia. (0.33 in. dia.)
J
0.4 mm (0.0157 in.)
K
3 mm (0.12 in.)
L
19 mm (0.75 in.)
M
Chamfer 0.5 mm (0.02 in.)
N
36 mm (1.42 in.)
O
45 mm dia. (1.77 in. dia.)
P
0.78 rad (45 °)
Q
11.5 mm (0.45 in.)
W1038887
G-55
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Engine Stand
Application: Use to support engine.
A
480 mm (18.90 in.)
B
50 mm (1.97 in.)
C
108.5 mm (4.272 in.)
D
263 mm (10.35 in.)
E
12.5 mm (0.492 in.)
F
237.5 mm (9.350 in.)
G
142.5 mm (5.610 in.)
H
95 mm (3.74 in.)
I
4.14 mm dia. (0.55 in. dia.)
J
40 mm (1.57 in.)
K
210 mm (8.27 in.)
L
190 mm (7.48 in.)
M
100 mm (3.94 in.)
N
6 mm (0.24 in.)
O
6 mm (0.24 in.)
P
25 mm dia. (0.98 in. dia.)
C10
Chamfer 10 mm (0.394 in.)
W1033645
Flywheel Stopper (for SAE Flywheel and Housing)
Application: Use to loosen and tighten the flywheel screw.
A
140 mm (5.5 in.)
B
80 mm (3.15 in.)
C
49.3 mm (1.94 in.)
D
49.3 mm (1.94 in.)
E
23.8 mm (0.94 in.)
F
23.8 mm (0.94 in.)
G
11 mm dia. (0.43 in. dia.)
H
56.5 mm (2.22 in.)
I
56.5 mm (2.22 in.)
J
8 mm (0.31 in.)
W1048867
G-56
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Nozzle Adaptor for Measuring Cylinder Compression Pressure
Application: Use for measuring diesel engine compression pressure.
A
5 mm (0.1969 in.)
B
115.9 to 116.1 mm (4.5630 to 4.5709 in.)
C
105 mm (4.1339 in.)
U
19 mm dia. (0.7480 in. dia.)
D
4 mm dia., 4 mm depth (0.1575 in. dia., 0.1575 in. depth)
V
16 mm dia. (0.6299 in. dia.)
E
6 mm (0.2362 in.)
W
14 mm dia. (0.5512 in. dia.)
T
3 mm dia., 44.5 to 45 mm depth
(0.1181 in. dia., 1.7520 to 1.7717 in. depth)
F
5.3 mm (0.2087 in.)
X
0.524 rad (30°)
G
1.9 mm (0.0748 in.)
Y
10 mm (0.3937 in.)
H
3.5 mm (0.1378 in.)
Z
19 mm (0.7480 in.)
I
11.6 to 12.1 mm (0.4567 to 0.4764 in.)
a
14.94 to 15 mm dia. (0.5882 to 0.5906 in. dia.)
J
6 to 6.1 mm (0.2362 to 0.2402 in.)
b
55 mm (2.1654 in.)
K
13 mm dia. (0.5118 in. dia.)
c
66 mm (2.5984 in.)
L
11 mm (0.4331 in.)
d
100 to 100.1 mm (3.9370 to 3.9409 in.)
M
5/8-18UNF-2B
e
16.89 to 17 mm dia. (0.6650 to 0.6693 in. dia.)
N
14.0 to 14.011 mm dia. (0.5512 to 0.5516 in. dia.)
f
7.1 to 7.2 mm dia. (0.2795 to 0.2835 in. dia.)
O
3 mm dia. (0.1181 in. dia.)
g
20.3 to 20.5 mm (0.7992 to 0.8071 in.)
P
15 mm (0.5906 in.)
h
Q
44 mm (1.7323 in.)
C0.5
R
55 mm (2.1654 in.)
C1
Chamfer 1 mm (Chamfer 0.0394 in.)
S
22 mm (0.8661 in.)
C5
Chamfer 5 mm (Chamfer 0.1969 in.)
(1) Material SS400
(2) Material S43C-D
(3) Pin (05012-00408)
3 mm dia. (0.1181 in. dia.)
Chamfer 0.5 mm (Chamfer 0.0197 in.)
(4) O-ring (04811-00150)
G-57
(5) Arc welding
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Jig for Governor Connecting Rod
Application: Use for connecting the governor connecting rod to the
rack pin of the fuel injection pump assembly.
A
1 mm (0.0394 in.)
B
C0.2 mm (0.0079 in.)
C
C2 mm (0.0787 in.)
D
35 mm dia. (1.3780 in. dia.)
E
C1 mm (0.0394 in.)
F
C0.1 mm (0.0039 in.)
G
1 mm (0.0394 in.)
H
C0.2 mm (0.0079 in.)
I
R8 mm (0.3150 in. rad.)
J
1 mm (0.0394 in.)
K
1 mm (0.0394 in.)
L
C0.2 mm (0.0079 in.)
M
C0.2 mm (0.0079 in.)
N
29 mm (1.1417 in.)
O
6 mm (0.2362 in.)
P
10.7 mm (0.4213 in.)
Q
35 mm (1.3780 in.)
R
99.3 mm (3.9095 in.)
S
45.65 to 45.75 mm (1.7972 to 1.8012 in.)
T
145 mm (5.7087 in.)
U
16.15 to 16.35 mm (0.6358 to 0.6437 in.)
V
3 mm (0.1181 in.)
W
10 mm (0.3937 in.)
X
8 mm (0.3150 in.)
(1) Material: S45C-D
(2) Permanent Magnet φ 8 mm
(0.3150 in. dia.)
Thickness: 3 mm (0.1181 in.)
W1115114
Fuel Camshaft Lock Screw
For locking fuel camshaft.
A
M8 × Pitch 1.25
B
5 mm dia. (0.197 in. dia.)
C
4 mm (0.157 in.)
D
45 mm (1.772 in.)
E
10 mm (0.39 in.) : Conspicuously Painted
W1049757
G-58
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Injection Pump Gear Puller
Application : Use for removing the injection pump gear from injection
pump shaft.
A
50 mm (1.97 in.)
B
30 mm (1.18 in.)
C
20 mm (0.079 in.)
D
22 mm dia. (0.87 in. dia.)
E
19 mm (0.75 in.)
F
M22 × P1.5
G
M12 × P1.25
H
14 mm dia. (0.55 in. dia.)
(1) Bolt : M12 P1.25 × L
(110 mm (4.33 in.))
(2) Puller
W1050836
G-59
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[2] SPECIAL TOOLS FOR TRACTOR
Tie-rod End Lifter
Code No. : 07909-39051
Application : Use for removing the tie-rod end with ease.
W10264720
Steering Wheel Puller
Code No. : 07916-51090
Application : Use for removing the steering wheel without damaging
the steering shaft.
W10265330
Relief Valve Pressure Tester
Code No. : 07916-50045
Application : This allows easy measurement of relief set pressure.
(1)
(2)
(3)
(4)
(5)
Gauge (07916-50322)
Cable (07916-50331)
Threaded Joint (07916-50401)
Threaded Joint (07916-50341)
Adaptor B (M18 × P1.5)
(07916-50361)
(6) Adaptor C (PS3/8)
(07916-50371)
(7) Adaptor D (PT1/8) (07916-50381)
(8) Adaptor E (PS3/8) (07916-50392)
(9) Adaptor F (PF1/2) (07916-62601)
(10) Adaptor 58 (PT1/4)
(07916-52391)
W10267410
Flow Meter
Code No. : 07916-52791 (Flow Meter)
07916-52651 (Hydraulic Test Hose)
Application : This allows easy testing of hydraulic system.
(1) Flow Meter
(2) Hydraulic Test Hose
W10313180
G-60
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Adaptor Set for Flow Meter
Code No. : 07916-54031
Application : Use for testing the hydraulic system.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Adaptor 52
Adaptor 53
Adaptor 54
Adaptor 61
Adaptor 62
Adaptor 63
Adaptor 64
(8)
(9)
(10)
(11)
(12)
(13)
Adaptor 65
Adaptor 66
Adaptor 67
Adaptor 68
Adaptor 69
Hydraulic Adaptor 1
W10313960
Toe-in Gauge
Code No. : 07909-31681
Application : This allows easy measurement of toe-in for all machine
models.
W10266890
Injector CH3
Code No. : 07916-52501
Application : Use for injecting calcium chloride solution into, and
removing it from, rear tires.
W10265850
Brake Air Bleeder
Code No. : 07916-54001
Application : This allows easy air bleed of the hydraulic brake
system.
W10516480
G-61
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Relief Valve Setting Pressure Adaptor G
Code No. : 07916-52751
Application : This offers easy measurement of relief valve setting
pressure from the hydraulic coupler. This is available
with the relief valve setting pressure tester.
W10623960
Shuttle Clutch Compression Tool
Code No. : 07916-55031
Application : Use exclusively for pushing the thrust collar, remove
the external snap ring.
■ NOTE
• Replace the center guide (1) for shown in figure.
A
20 mm dia. (0.79 in. dia.)
B
11.5 mm dia. (0.45 in. dia.)
C
Chamfer 1 mm (0.04 in.)
D
6 mm (0.24 in.)
E
15 mm (0.59 in.)
F
20 mm (0.79 in.)
G
Weld all around
H
6 mm (0.24 in.)
I
M4 × 0.7
J
28 mm (1.1 in.)
K
8 mm (0.31 in.)
L
5 mm (0.2 in.)
M
64 mm dia. (2.52 in. dia.)
N
70.5 mm dia. (2.78 in. dia.)
O
73 mm dia. (2.87 in. dia.)
P
80 mm dia. (3.15 in. dia.)
Q
25 mm (0.98 in.)
R
35 mm (1.38 in.)
S
20 mm (0.79 in.)
T
M8 × 1.25
(1) Center Guide
W1020107
G-62
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Pressure Gauge 50
Code No. : 07916-52961
Application : This pressure gauge is used to measure the low oil
pressure.
W10518650
Pinion Locking Tool
Code No. : 07916-52311
Application : Use for preventing the shaft from turning when
removing the staking nut from the counter shaft and
spiral bevel pinion shaft.
W10445520
Clutch Tool B
Code No.: 07916-53041
Application: Use for mounting the clutch to the flywheel.
(1) Gauge Ring (No. 07916-53041)
(2) Center Bar (No. 07916-53041)
(3) Centering Guide (No. 07916-53041)
W10520300
Rear Axle Cover Puller
Code No. : 07916-51041
Application : Use for removing a rear axle cover from rear axle.
W1073259
G-63
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Rear Axle Nut Wrench 98
Code No. : 07916-52521
Application : Use for removing and installing a rear axle nut.
W1031880
Power Steering Adaptor
Code No. : 07916-54021
Application : Use for measuring the relief valve setting pressure for
power steering.
W10442870
Adaptor 56 (For Hydraulic Brake)
Code No. : 07916-52970
Application : Use for testing the hydraulic brake oil leakage.
W10523600
G-64
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
■ NOTE
• Special tools for R134a refrigerant air conditioning system introduced below are available from DENSO
CO.LTD..
Air Conditioner Service Tool
Code No. : DENSO.CO. 95048-00061
Application : Use for charging, testing or discharging the air
conditioning system.
W1013507
(1) Manifold Gauge
Assembly
(2) Charging Hose
(Red : HI)
(3) Charging Hose
(Blue : LO)
(4) Charging Hose (Green)
(5) Can Tap Valve
(6) T Joint
(7) Quick Coupler (HI)
(8) Quick Coupler (LO)
(9) Service Valve Packing
(10) Charging Hose Packing
(11) Tool Case
95048-10090
95948-10270
95948-10280
95948-10260
95048-10150
95048-10160
95048-10130
95048-10140
95906-10310
95906-10300
95949-10610
W1014733
Electric Gas Leak Tester
Code No. : DENSO.CO. 95146-00060
Application : Use for gas leak testing the air conditioning system.
W1013817
Vacuum Pump
Code No. : DENSO.CO. 95046-00040 (AC220V)
95046-00050 (AC240V)
Application : Use for evacuating the air conditioning system.
(1) Adaptor (for R134a)
(2) Vacuum Pump
W1013764
G-65
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Adaptor (for R134a)
Code No. : DENSO.CO. 95048-10190 (AC220V)
95048-10200 (AC240V)
Application : Use for evacuating the air conditioning system.
W1013888
■ NOTE
• The following special tools are not provided, so make them referring to the figure.
Draft Control Test Bar
Application: Use for checking the lift range and floating range of
hydraulic draft control.
A
1045 mm (41.14 in.)
B
1000 mm (29.37 in.)
C
20 mm dia. (0.79 in. dia.)
D
30 mm dia. (1.18 in. dia.)
E
90 mm (3.54 in.)
F
36.5 mm (1.44 in.) (Top link mounting hole)
G
30 mm (1.18 in.)
H
15 mm (0.59 in.)
I
26.0 mm dia. (1.02 in. dia.)
J
Weld all around
K
Weld all around
L
20 mm (0.79 in.)
W10625190
G-66
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Hydraulic Arm Shaft Bushing Press-Fitting Tool
Application : Use for replacing the hydraulic arm shaft bushings in
the hydraulic cylinder body.
Right
Left
A
64.75 to 64.95 mm
(2.5492 to 2.5571 in.)
69.75 to 69.95 mm
(2.7461 to 2.7539 in.)
B
17.5 to 18.5 mm
(0.6890 to 0.7283 in.)
13.5 to 14.5 mm
(0.5315 to 0.5709 in.)
C
60 mm (2.3622 in.)
D
32 mm (1.26 in.)
40 mm (1.5748 in.)
E
59.97 to 59.999 mm
(2.3610 to 2.3618 in.)
64.97 to 64.99 mm
(2.5579 to 2.5587 in.)
F
70 mm dia. (2.76 in. dia.)
G
40 mm dia. (1.57 in. dia.)
H
50 mm (1.97 in.)
I
10 mm (0.39 in.)
a
6.3 μm (250 μin.)
b
6.3 μm (250 μin.)
c
6.3 μm (250 μin.)
d
6.3 μm (250 μin.)
W10316550
Valve Adaptor
Application : Use for measuring the system pressure of shuttle
valve.
A
24 mm (0.94 in.)
B
27.7 mm (1.09 in.)
C
G1/4
D
11 mm (0.43 in.)
E
15 mm (0.59 in.)
F
40 mm (1.57 in.)
G
60 mm (2.36 in.)
H
15 mm (0.59 in.)
I
R1/8
J
4 mm dia. (0.15 in. dia.)
C1
Chamfer 1 mm (0.039 in.)
C2
Chamfer 2 mm (0.079 in.)
W1055758
G-67
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Cylinder Safety Valve Setting Pressure Adaptor
Application : Use for setting the safety valve to the nozzle tester to measure cracking pressure and check oil tightness
of the safety valves.
A
45 mm (1.77 in.)
N
10 mm dia. (0.39 in. dia.)
B
40 mm (1.58 in.)
O
7.5 mm dia. (0.3 in. dia.)
C
35 mm (13.8 in.)
P
1.05 rad (60 °)
D
23 to 23.3 mm (0.9055 to 0.9713 in.)
Q
3 mm dia. (1.18 in. dia.)
E
16 mm (0.63 in.)
R
36 mm (1.18 in.)
F
40 mm dia. (1.58 in. dia.)
S
60 mm (2.36 in.)
G
32.4 to 32.7 mm dia. (1.2756 to 1.2874 in. dia.)
T
5 mm (0.20 in.)
H
21 mm dia. (0.83 in. dia.)
U
10 mm (0.39 in.)
I
20 to 20.05 mm dia. (0.7874 to 0.7894 in. dia.)
V
M30 × 1.5
J
2.5 to 2.59 mm (0.0984 to 0.1097 in.)
W
0.52 rad (30 °)
K
0.79 rad (45 °)
X
8 mm dia. (0.32 in. dia.)
L
0.26 rad (15 °)
Y
19 mm (0.75 in.)
M
M12 × P1.5
Z
10 mm (0.39 in.)
G-68
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Stopper Magnet Clutch (For A/C Compressor)
Application: Use to loosen and tighten the magnet clutch mounting nut. (Use radius M)
A
125 mm (4.92 in.)
H
4.52 rad (120 °)
B
40 mm dia. (1.57 in. dia.)
I
Radius 27 mm (Radius 1.06 in.)
C
Radius 33 mm (Radius 1.30 in.)
J
Radius 50 mm (Radius 1.97 in.)
D
16 mm (0.63 in.)
K
Weld all around
E
120 mm dia. (4.72 in. dia.)
L
20 mm (0.78 in.)
F
12 mm dia. (0.47 in. dia.)
M
Radius 41 mm (Radius 1.61 in.)
G
3 × M8 × 1.25 All screws
G-69
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Stopper Bolt (for A/C Compressor)
Application: Use with the stopper magnet clutch.
A
12 mm (0.47 in.)
E
5.5 mm dia. (0.22 in. dia.)
B
35 mm (1.38 in.)
F
6.5 mm dia. (0.26 in. dia.)
C
7 mm (0.28 in.)
G
0.52 rad (30 °)
D
0.4 mm (0.016 in.)
H
M8 × 1.25
W1065437
Hydraulic Brake Adaptor
Application : Use for measuring the braking pressure in brake case.
A
19 mm (0.74 in.)
B
21.4 mm (0.84 in.)
C
42 mm (1.65 in.)
D
25 mm (0.98 in.)
E
15 mm (0.59 in.)
F
3 mm (0.125 in.)
G
12.5 mm (0.49 in.)
H
PS 1/4
I
M12 x P1.0
J
5 mm dia. (0.20 in. dia.)
W1069991
G-70
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Hydraulic Cylinder Block Tool
Application : Use for separating a hydraulic cylinder block.
■ NOTE
• The sealing surface of the connecting parts must be welded.
A
75 mm (2.95 in.)
N
12 mm dia. (0.47 in. dia.)
B
24 mm (0.94 in.)
O
Radius 31 mm (1.22 in. radius)
C
60 mm (2.36 in.)
P
t3.2 mm (t0.126 in.)
D
6 mm (0.24 in.)
Q
4 mm (0.16 in.)
E
45 mm (1.77 in.)
R
72.8 mm (2.87 in.)
F
140 mm (5.51 in.)
S
130 mm (5.12 in.)
G
74 mm (2.91 in.)
T
50 mm (1.97 in.)
H
12 mm (0.47 in.)
U
62 mm (2.44 in.)
I
20 mm (0.79 in.)
J
1580 mm (62.2 in.)
a
26.0 mm dia. (1.02 in. dia.)
K
177 mm (6.97 in.)
b
Square steel tube 50 mm x 20 mm x t2.3 mm
(Square steel tube 1.97 in. x 0.79 in. x t0.09 in.)
L
65 mm (2.56 in.)
c
Square steel tube 75 mm × 40 mm × t2.3 mm
(Square steel tube 2.95 in. × 1.57 in. × t0.09 in.)
M
70 mm (2.76 in.)
G-71
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Front Axle Rocking Restrictor
A
120 mm (4.72 in.)
B
12 mm (0.72 in.)
C
M10 × P1.25
D
30 mm (1.18 in.)
E
M16 × P1.5
F
10 mm (0.39 in.)
G
20 mm (0.79 in.)
H
36 mm (1.42 in.)
I
64 mm (2.52 in.)
J
45 mm (1.77 in.)
K
20 mm (0.79 in.)
(1) Screw
M10 × P1.25 × L50 mm (2 in.)
(2) Screw
M16 × P1.5 × L50 mm (2 in.)
(3) Rocking Restrictor
W10545380
Hydraulic Clutch Spring Compressor
A
70 mm (2.76 in.)
B
67.5 mm (2.66 in.)
C
56 mm (2.20 in.)
D
10 mm (0.39 in.)
E
72 mm dia. (2.83 in. dia.)
F
76 mm dia. (2.99 in. dia.)
G
80 mm dia. (3.15 in. dia.)
H
85 mm dia. (3.35 in. dia.)
I
30 mm (1.18 in.)
J
26 mm (1.02 in.)
W1071025
Adaptor
Application : Use for testing the hydraulic pump flow.
A
PF 3/8 (for testing hose)
B
0.52 rad (30 °)
C
G 1/2
D
15 mm (0.59 in.)
E
18 mm (0.71 in.)
F
40 mm (1.57 in.)
G
HEX. 27 mm
W1071249
G-72
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Clutch Compression Tool
Application : Use exclusively for pushing the thrust collar to remove
the external snap ring.
A
60 mm (2.36 in.)
B
120 mm (4.72 in.)
C
M18 × P1.5 screw
D
45 mm (1.77 in.)
E
115 mm (4.53 in.)
F
12 mm (0.47 in.)
G
32.5 mm (1.28 in.)
H
65 mm (2.56 in.)
I
25 mm (0.98 in.)
J
110 mm dia. (4.33 in. dia.)
K
98 mm dia. (3.86 in. dia.)
L
90 mm dia. (3.54 in. dia.)
M
18 mm dia. (0.71 in. dia.)
N
12 mm (0.47 in.)
O
30 mm (1.18 in.)
P
35 mm (1.38 in.)
(1) Centering Guide
(2) Thrust Collar Holder
(3) Nut (M18 × P1.5)
W10532280
G-73
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
9. TIRES
[1] TYPE OF TIRES
■ IMPORTANT
• Do not use tires larger than specified
Type of Tire
Farm Tire
Front
340 / 85R24 (13.6R24)
Rear
460 / 85R34 (18.4R34)
W1019656
[2] TREAD ADJUSTMENT
CAUTION
• When working on slopes or when working with trailer, set the wheel tread as wide as practical for maximum
stability.
• Support tractor securely on stands before removing a wheel.
• Never operate tractor with a loose rim, wheel, or axle.
(1) Front Wheel
Adjusting Front Tread (with Four Wheel Drive)
Front tread width can be adjusted as shown with the standard
equipped tires.
To change the tread width.
1. Remove the wheel rim and disk mounting bolts.
2. Change the position of the rim and disk (right and left) to the
desired position, and tighten the bolts.
3. Adjust the toe-in. (See page G-26.)
■ IMPORTANT
• Always attach wheel as shown in the drawing.
• If not attached as illustrated, transmission parts may be
damaged.
• When re-fitting or adjusting a wheel, tighten the bolts to the
following torques then recheck after driving the tractor 200
m (200 yards) and thereafter according to service interval.
Refer to “Check Wheel Mounting Nuts Tightening Torques”.
(See page G-19.)
(1) Nut
W1056420
G-74
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Tractor
Tire sizes
M105S
340/85R24
(13.6R24)
1565 mm
(61.6 in.)
1675 mm
(66.9 in.)
A : Tread
■ NOTE
• Need to limit turning angle deponded on the tire size.
instructions.
Refer to the chart provided for additional
Front Wheel Steering Angle
1. Inflate the tires to the specified pressure.
2. Adjust turning angle with the stopper bolts table of the below.
3. The right side is similarly adjusted.
■ IMPORTANT
• Always check if tires contact with tractor or loader frame
assemblies.
(1) Stopper Bolt
B : Front
W1057295
Stopper Bolt (ex. LH stopper bolt)
Angle
0.52 rad (30 °) 0.58 rad (33 °) 0.65 rad (37 °) 0.73 rad (42 °) 0.79 rad (45 °) 0.87 rad (50 °)
Stopper
A : 5 mm (0.2 in.) Collar
G-75
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
(2) Rear Wheel
Adjusting Rear Tread
Rear tread width can be adjusted as shown with the standard
equipped tires.
To change the tread width.
1. Remove the wheel rim and / or disk mounting bolts.
2. Change the position of the rim and / or disk (right and left) to the
desired position, and tighten the bolts.
■ IMPORTANT
• Always attach tires as shown in the drawings.
• If not attached as illustrated, transmission parts may be
damaged.
• When re-fitting or adjusting a wheel, tighten the bolts to the
following torques then recheck after driving the tractor 200
m (200 yards) and thereafter according to service interval.
Refer to “Check Wheel Mounting Nuts Tightening Torques”.
(See page G-19.)
(1) Wheel Nut
(2) Rim Disc Nut
W1057789
[Steel disc]
460 / 85R34
(18.4R34)
1560 mm (61.4 in.)
1755 mm (69.1 in.)
1850 mm (72.8 in.)
1860 mm (73.2 in.)
460 / 85R34
(18.4R34)
1505 mm (59.3 in.)
1665 mm (65.6 in.)
1705 mm (67.1 in.)
1865 mm (73.4 in.)
(1) Rear Wheel Disc
(2) Rear Wheel Rim
[Cast iron disc]
A :Tread
G-76
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[3] WHEEL HUB
Screw circle diameter
(A)
Front wheel hub
Rear wheel hub
203.2 mm (8 in.)
203.2 mm (8 in.)
6
8
Number of screws
Screws
Hub pilot diameter (B)
M16 x P1.5
M16 x P1.5
152.4 mm (6 in.)
152.4 mm (6 in.)
W1043392
[4] TIRE PRESSURE
CAUTION
Do not attempt to mount a tire. This should be done by a qualified person with the proper equipment.
IMPORTANT
Do not use tires larger than specified.
When you intend to mount different size of tires from equipped ones, consult your distributor about front
drive gear ratio for detail.
• Excessive wear of tires may occur due to improper gear ratio.
•
■
•
•
Through the tire pressure is factory-set to the prescribed level, it
naturally drops slowly in the course of time. Thus, check it every day
and inflate as necessary.
To inflate the wheel tires, use an air compressor or hand pump.
■ Recommended Inflation Pressure
• Maintain the pressure shown below for normal use.
Tire sizes
Inflation pressure
Front
340 / 85R24 (13.6R24)
160 kPa (1.6 kgf/cm2, 23 psi)
Rear
460 / 85R34 (18.4R34)
140 kPa (1.4 kgf/cm2, 20 psi)
■ NOTE
• Maintain the maximum pressure in front tires, if using a front
loader of when equipped with a full load of front weights.
(A) Insufficient
(B) Standard
(C) Excessive
(D) Ground
W1027488
G-77
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
[5] TIRE LIQUID INJECTION
Auxiliary weights can be used to increase traction force for plowing in fields or clayey grounds.
Another way is to inject water or another liquid, such as a calcium chloride solution in the tires. Water must not be
used in winter since it freezes at 0 °C (32 °F). The calcium chloride solution will not freeze and moreover, affords
higher effect than water since its specific gravity is higher than that of water by about 20 %. Below is an explanation
of calcium chloride solution injection.
■ IMPORTANT
• Do not fill the front tires with liquid.
Preparation of Calcium Chloride Solution
CAUTION
• When making a calcium chloride solution, do not pour water
over calcium chloride since this results in chemical reaction
which will cause high temperature. Instead add a small
amount of calcium chloride to the water at a time until the
desired solution is achieved.
Freezing temp.
Weight of CaCl2 to be dissolved in 100 L (26.5
U.S.gals, 22.0 lmp.gals) of water
−5 °C (23 °F)
12 kg (26.4 lbs)
−10 °C (14 °F)
21 kg (46.3 lbs)
−15 °C (5 °F)
28 kg (61.7 lbs)
−20 °C (−4 °F)
34 kg (75.0 lbs)
−25 °C (−13 °F)
40 kg (88.2 lbs)
−33 °C (−22 °F)
44 kg (97.0 lbs)
−35 °C (−31 °F)
49 kg (108 lbs)
−40 °C (−40 °F)
52 kg (114.6 lbs)
−45 °C (−49 °F)
56 kg (123.5 lbs)
−50 °C (−58 °F)
61 kg (134.5 lbs)
(a) Water
(b) CaCl2 (Calcium Chloride)
W1033083
G-78
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Attaching Injector
1. Lift the rear tires off the ground.
2. Turn the tire so that the air valve is at the top.
3. Remove the air valve, and attach the injector (Code No. 0791652501).
(1) Injector
(2) Hose
W1033331
G-79
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Injection
CAUTION
• When a calcium chloride solution is used, cool it before
pouring it into the tire.
• Do not fill tires with water or solution more than 75 % of full
capacity (to the valve stem level).
• To avoid damage of transmission, do not use rear wheel
weights and liquid ballast at the same time.
The following four ways can be used to inject water or a calcium
chloride solution into tires.
1. Gravity injection (Fig. 1)
2. Pump injection (Fig. 2)
3. Pressure tank injection (Fig. 3)
4. Injection directly from tap (only when water is being used).
■ NOTE
• Once injection is completed, reset the air valve, and pump
air into the tire to the specified pressure.
Weight of calcium chloride solution filling 75 % of full capacity of
a tire.
Tire sizes
460 / 85R34 (18.4R34)
Slush free at −10 °C (14 °F)
Solid at −30 °C (−22 °F )
[Approx. 1 kg (2 lbs.) CaCl2 per 4 L
(1 gal.) of water]
417 kg (920 lbs)
Slush free at −24 °C (−11 °F)
Solid at −47 °C (−53 °F )
[Approx. 1.5 kg (3.5 lbs.) CaCl2 per 4
L (1 gal.) of water]
457 kg (1007 lbs)
Slush free at −47 °C (−53 °F)
Solid at −52 °C (−62 °F )
[Approx. 2.25 kg (5 lbs.) CaCl2 per 4 L
(1 gal.) of water]
490 kg (1081 lbs)
(1)
(2)
(3)
(4)
(5)
Pump
Pressure Tank
Compressor
Air
Water
(A) Correct : 75 %
Air compresses like a cushion
(B) Incorrect : 100 % full water can not
be compressed
W1033435
G-80
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
Draining Water or Solution
1. Lift the rear tires off the ground.
2. Turn the tire so that the air valve is at the bottom.
3. Remove the air valve, and drain liquid (liquid can only be drained
to the level of the valve and liquid under that level remains
inside).
4. To drain liquid completely, use the injector (1) (Code No. 0791652501), and direct compressed air into the tire to force out the
liquid through the injector's vent (3).
(1) Injector
(2) Hose
(3) Vent
A : Compressed Air
W1045167
G-81
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
10. IMPLEMENT LIMITATIONS
The KUBOTA Tractor has been thoroughly tested for proper performance with implements sold or approved by
KUBOTA. Use with implements which are not sold or approved by KUBOTA and which exceed the maximum
specifications listed below, or which are otherwise unfit for use with the KUBOTA Tractor may result in malfunctions
or failures of the tractor, damage to other property and injury to the operator or others. [Any malfunctions or failures
of the tractor resulting from use with improper implements are not covered by the warranty.]
Tread (max. width)
Front
without spacer
with spacer
1675 mm
(65.9 in.)
2035 mm
(80.1 in.)
Operating condition
Rear
2110 mm
(83.1 in.)
Implement weight : W1
Max. drawbar Load : W2
As in the following list
(Shown on the next page)
800 kg (1764 lbs)
IMPORTANT
Tractor with front
spacer option is not
approved for use
with front loader.
Lower link max.
lifting capacity : W0
2700 kg
(5952 lbs)
Trailer loading weight : W3
Without trailer brake
With trailer brake
3000 kg (6614 lbs)
13000 kg (28660 lbs)
Lower link end max. loading weight.............W0
Implement weight........................................The implement's weight which can be put on the lower link : W1
Max. drawbar load.......................................W2
Trailer loading weight..................................The max. loading weight for trailer (without trailer's weight) : W3
■ NOTE
• Implement size may vary depending on soil operating conditions.
G-82
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
No.
Implement
1
Slurry Tank
2
Trailer
Rotary-Cutter
(3P type)
Rotary-Cutter
(Drawbar
type)
3
4
5
Mower
Disc Mower
(Drawbar
type)
Remarks
M105S
Max. Tank Capacity
5000 L (1321 U.S.gals, 1100 Imp.gals)
Max. Load Capacity
6000 kg (13200 lbs)
Max. Load Capacity
7000 kg (15400 lbs)
Max. Drawbar Load
1500 kg (3300 lbs)
Max. Cutting Width
3200 mm (126 in.)
Max. Weight
800 kg (1764 lbs)
Max. Cutting Width
6096 mm (240 in.)
Max. Cutting Width
3962 mm (156 in.)
Flail Mower
(Heavy)
Max. Cutting Width
4267 mm (168 in.)
Max. Weight
1360 kg (3000 lbs)
Sickle Bar
Max. Cutting Width
3050 mm (120 in.)
Mid
Max. TankRear 3P
capacity
Drawbar
Sprayer
Rotary Tiller
1000 L (264 U.S.gals, 220 Imp.gals)
1000 L (264 U.S.gals, 220 Imp.gals)
5500 L (1453 U.S.gals, 1210 Imp.gals)
Max. Tilling Width
2700 mm (108 in.)
Max. Weight
1200 kg (2645 lbs)
14 in. x 5
16 in. x 4
18 in. x 4
20 in. x 3
22 in. x 2
24 in. x 1
Max. Size
6
Bottom Plow
Max.
Weight
3P Type
900 kg (1980 lbs)
Max. Size
7
Discharrow
3P Type
24 in. x 28
Max. Harrowing Width
3300 mm (130 in.)
Max. Weight
900 kg (1980 lbs)
Drawbar Type Max. Harrowing Width
8
Disc Plow
9
Sub Soiler
4300 mm (168 in.)
Max. Size
28 in. x 4
Max. Weight
900 kg (1980 lbs)
Numbers of Cultivating
Tines
Cultivating Depth
550 mm (22 in.)
Max. Width
10
Cultivator
3
5490 mm (216 in.)
Number of Rows
6
Max. Weight
900 kg (1980 lbs)
W1012736
G-83
KiSC issued 03, 2007 A
G GENERAL
M105S, WSM
No.
Implement
11
Front Blade *1, *2
12
Rear Blade
Remarks
M105S
Max. Cutting Width
2600 mm (102 in.)
Max. Oil Pressure
19.6 MPa (200 kgf/cm2, 2842 psi)
Max. Cutting Width
2600 mm (102 in.)
Max. Oil Pressure
19.6 MPa (200 kgf/cm2, 2842 psi)
Max. Lifting Capacity
13
Front Loader *1, *2
14
Box Blade
15
Snow Blade
1300 kg (2866 lbs)
Max. Oil Pressure
(extra hydro kit)
20.5 MPa (210 kgf/cm2, 2975 psi)
Max. Cutting Width
2430 mm (96 in.)
Max. Weight
800 kg (1760 lbs)
Max. Width
2600 mm (102 in.)
Max. Weight
800 kg (1760 lbs)
■ NOTE
• Implement size may very depending on soil operating conditions.
*1 Must remove front weight with this implement.
*2 Need subframe.
W1043839
G-84
KiSC issued 03, 2007 A
1
ENGINE
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. FEATURE ...................................................................................................... 1-M1
2. ENGINE BODY ............................................................................................. 1-M2
[1] CYLINDER BLOCK................................................................................. 1-M2
[2] HALF-FLOATING HEAD COVER .......................................................... 1-M2
[3] CYLINDER HEAD ................................................................................... 1-M3
[4] CENTER DIRECT INJECTION SYSTEM (E-CDIS)............................. 1-M3
[5] PISTON.................................................................................................... 1-M4
[6] BUILT-IN DYNAMIC BALANCER .......................................................... 1-M4
3. LUBRICATING SYSTEM .............................................................................. 1-M5
[1] OIL COOLER .......................................................................................... 1-M5
4. COOLING SYSTEM ...................................................................................... 1-M6
[1] THERMOSTAT ........................................................................................ 1-M6
[2] BOTTOM BYPASS SYSTEM................................................................. 1-M7
5. FUEL SYSTEM ............................................................................................. 1-M8
[1] GOVERNOR ............................................................................................ 1-M8
[2] 2-STAGE DI NOZZLE .......................................................................... 1-M11
[3] INJECTION PUMP WITH F.S.P.......................................................... 1-M12
[4] AUTOMATIC TIMER............................................................................. 1-M13
6. INTAKE SYSTEM ....................................................................................... 1-M14
[1] INTAKE AIR HEATER.......................................................................... 1-M14
7. TURBOCHARGER SYSTEM ...................................................................... 1-M15
[1] BOOST COMPENSATOR .................................................................... 1-M15
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
1. FEATURE
The V3 series DI engine is the vertical type 4-cycle
diesel engine featuring the advanced performances
shown below.
This is a small sized, high power and environment
conscious engine, which employs the four valve system,
two inlet valves with double ports, and two exhaust
valves with the new E-CDIS. Thus, this engine achieves
high combustion efficiency and complies with various
regulations of exhaust gas.
Based upon the conventional model, Kubota
developed a unique governor system and various new
mechanisms which reduces exhaust emission, noise and
vibration and realize durability and high torque.
W1012646
1-M1
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
2. ENGINE BODY
[1] CYLINDER BLOCK
This engine employs separate type crankcases - the
crankcase 1 (1) with combustion part and the crankcase
2 (2) which supports the crankcase 1 (1) and reduces
noise.
Since it is a hanger type, you can easily assemble /
disassemble it. The cylinder is a linerless type which
enables good cooling operation, less strain and good
abrasion resistance.
(1) Crankcase 1
(2) Crankcase 2
(3) Oil Pan
W1012734
[2] HALF-FLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 0.5 mm (0.02 in.) or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover
(2) Cylinder Head Cover
W1012841
1-M2
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
[3] CYLINDER HEAD
This engine employs four valve system, the cylinder
head is provided with double intake passenge in order to
ensure appropriate air suction and give an optimum
swirl.
(1) Intake
(2) Exhaust
W1012934
[4] CENTER DIRECT INJECTION SYSTEM (E-CDIS)
V3 series DI engine adopts the Center Direct Injection
System (E-CDIS), in which the injection nozzle is
positioned upright at the center of the cylinder.
This system serves to inject fuel directly at the center
of the cylinder. By so doing, injected fuel and suction air
can be mixed more uniformly, leading to more stable,
higher combustion performance. In other words, cleaner
emission, higher power output, lower fuel consumption,
lower operating noise and higher start-up performance
have been achieved.
(1) Exhaust Valves
(2) Piston
(3) Injection Nozzle
(4) Intake Valves
W1013037
1-M3
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
V3 series DI engine has two intake valves and two
exhaust valves per each cylinder.
The rocker arm (1) contacts a bridge arm (2) instead
of the valves stem tip.
The bridge arm then contacts both intake valves or
bath exhaust valves and causes two valves to open
simultaneously.
(1) Rocker Arm
(2) Bridge Arm
W1013140
[5] PISTON
Piston's skirt is coated with molybdenum disulfide*,
which reduces the piston slap noise and thus the entire
operating noise.
*Molybdenum disulfide (MoS2)
The molybdenum disulfied serves as a solid lubricant,
like a Graphite or Teflon. This material helps resist metal
wears even with little lube oil.
(1) Molybdenum Disulfide
W1013276
[6] BUILT-IN DYNAMIC BALANCER
Engine are sure to vibrate by piston's reciprocation.
Theoretically, three-cylinder engines are much less
prone to cause vibration than four-cylinder ones (second
inertia, etc.). However, any engine has many moving
parts in addition to its pistons and cannot be completely
free from vibration.
The four cylinder engine is fitted with balance weight
on crankcase to absorb the second inertia mentioned
above and reduce vibration.
W1013386
1-M4
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
3. LUBRICATING SYSTEM
[1] OIL COOLER
V3 series engine has a water-cooled oil cooler that
not only cools hot oil, but also warms the cool engine oil
shortly after start up.
As shown in the figure, the oil flows inside the
connected cooler plate, whereas coolant is kept
circulating outside the cooler plate, thereby cooling down
or warming the oil.
(A) Oil Inlet Port
(B) Oil Outlet Port
(a) Coolant Inlet Port
(b) Coolant Outlet Port
W1013462
1-M5
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
4. COOLING SYSTEM
[1] THERMOSTAT
Conventional
thermostatically-controlled
valves
(outlet water temperature control type) open against the
flow of coolant. In this design, the pressure (steam
pressure + water pump's discharge pressure) affects the
open/close performance of such valve. In other words,
the valve may be delayed in opening at a preset opening
temperature opening suddenly, above the preset
temperature. This is called the overshoot phenomenon.
The overshoot problem invites the undershoot
phenomenon too. Too much water cooled by the radiator
flows through the water passage, which suddenly closes
the valve below the thermostat's preset valve closing
temperature.
A repeated cycle of such overshoot and undershoot
phenomena is called the water temperature hunting.
This hunting problem may adversely affect the cooling
system parts, and also the engine and its related
components.
To cope with this trouble, the V3 series engine is
equipped with the flow control thermostat. The valve has
a notch to control the coolant flowrate smoothly in small
steps.
(1)
(2)
(3)
(4)
Coolant Temperature
Time
Overshoot
Notch
(A)
(B)
(C)
(D)
(E)
(F)
Valve Lift Versus
Flowrate
At Short Valve Lift
At Medium Valve Lift
At High Valve Lift
Valve Lift
W1013613
1-M6
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
[2] BOTTOM BYPASS SYSTEM
Bottom bypass system is introduced in V3 Series for
improving the cooling performance of the radiator.
While the temperature of coolant in the engine is low,
the thermostat is held closed and the coolant is allowed
to flow through the bypass pipe and to circulate in the
engine.
When the temperature exceeds the thermostat valve
opening level, the thermostat fully opens itself to prevent
the hot coolant from flowing through the bypass into the
engine.
In this way, the radiator can increase its cooling
performance.
(1) Thermostat
(A) Thermostat Closed
(B) Thermostat Open
W1013839
1-M7
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
5. FUEL SYSTEM
[1] GOVERNOR
The engine employs the separated fuel injection
pump in combination with Kubota's own small multifunction mechanical governor, which enables more
dependability.
It also employs the torque limiting mechanism to
control the maximum peak torque so that it complies with
the regulations of exhaust gas.
This mechanism maintains engine speed at a
constant level even under fluctuating loads, provides
stable idling and regulates maximum engine speed by
controlling the fuel injection rate.
This engine uses a mechanical governor that controls
the fuel injection rate at all speed ranges (from idling to
maximum speed) by utilizing the balance between the
flyweight's centrifugal force and spring tension.
A governor shaft for monitoring engine speed is
independent of the injection pump shaft and rotates at
twice the speed of conventional types, providing better
response to load fluctuation and delivering greater
engine output.
W1013982
■ At Start
The stop solenoid (energized-to-run type) is powered
to release the stop lever.
As no centrifugal force is applied to flyweight (1), low
tension of start spring (2) permits control rack to move
the starting position, supplying the amount of fuel
required to start the engine.
(1) Flyweight
(2) Start Spring
W1014056
1-M8
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
■ At Idling
Turn the speed control lever (3) clockwise to idle the
engine. It tensions the governor spring (4) to pull the fork
lever 2 (5).
When the fork lever 2 is pulled, it moves the torque
spring pin (6) and the fork lever 1 (7) in the direction of
the arrow A to restrain the weight. In combination with
the start spring tension, it is balanced with the centrifugal
force of flywheel weight to keep idling.
(1)
(2)
(3)
(4)
Flyweight
Start Spring
Speed Control Lever
Governor Spring
(5) Fork Lever 2
(6) Spring Pin
(7) Fork Lever 1
W1014143
■ At rated speed with full load and overload
As the speed control lever is changed from the middle
speed to high speed, the governor spring tension
increases to compress the torque spring and move the
fork lever 1 in the direction of the arrow A.
The fork lever 2 moves until it reaches the output
limiting bolt to keep rated rotation and rated output.
When the engine is overloaded, the engine rotating
speed decreases and the centrifugal force of flywheel
weight decreases. Then the torque spring moves the
fork lever 1 in the direction of arrow A.
The control rack moves in the direction that increases
fuel supply to increase the output. It is balanced with the
centrifugal force of the flywheel weight to produce lowspeed output (torque output).
(1) No-load Maximum Rotation
(2) Output Limiting Bolt
(3) Torque Limiting Bolt
(4) Idling Adjusting Bolt
W1014385
1-M9
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
■ To stop engine
When the stop solenoid is turned off, the spring
tension of the solenoid is released, the rod extrudes and
the stop lever moves the control rack in the direction of
the arrow B which stops the engine.
To stop the engine manually, move the external stop
lever to the left.
W1014625
1-M10
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
[2] 2-STAGE DI NOZZLE
Exhaust and noise regulations are becoming
increasingly strict, particularly in regard to the reduction
of NOx (nitrogen oxides) and particulates.
The two-spring nozzle holder has been developed to
reduce NOx (nitrogen oxides) and particulates from
direct injection diesel engine exhaust.
■ Features
The two-spring nozzle holder limits needle valve lift at
initial valve opening to throttle the injection quantity.
Main injection occurs when the in-line pressure has
increased sufficiently to move the needle valve through
its full lift.
This gives the following features.
• Improved engine stability at low and intermediate
speeds.
• Decreased engine hunting and surge.
• Decreased noise at idling.
• Decreased idling speed because of improved engine
stability.
• Stabilized fuel injection characteristics from the
injection pump and nozzle system, and easier
matching of governor characteristics to engine
demand.
(1) Nozzle Holder Body
(7) Second Spring
(2) 1st Stage Injection Pressure
(8) Pre-lift Adjusting Spring Seat
Adjusting Shim
(9) Chip-packing
(3) First Spring
(10) Max-lift Adjusting Washer
(4) Pressure Pin
(11) Retaining Nut
(5) Spring Seat
(12) Nozzle
(6) 2nd Stage Injection Pressure
Adjusting Shim
W1014767
1-M11
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
A-B : First Spring's Set
Force
B-C-D : Combined Force of
First and Second
Springs
P1 : First Opening
Pressure
P2 : Second Opening
Pressure
L : Full Needle Valve Lift
I : Needle Valve Pre-lift
X1 : Cam Angle (°)
Y1 : Injection Rate (mm3/°)
X2 : Needle Valve Lift (mm)
Y2 : In-line Pressure
W1015118
■ First opening pressure
The force of the high pressure fuel delivered by the injection pump acts to push the needle valve up. When this
force exceeds the set force of the first spring, the nozzle's needle valve pushes the first pushrod up and the valve
opens. (First opening pressure is represented by point E in the bottom left hand figure, and point A in the above
figure.)
■ Second opening pressure
When the first pushrod has been lifted through the pre-lift, it contacts the second pushrod. As the set force of the
second spring is acting on the second pushrod, the combined forces of both the first spring and the second spring then
act on the needle valve, which will not lift unless these forces are overcome.
[3] INJECTION PUMP WITH F.S.P.
The fuel injection pump with F.S.P. (Fine Spill Port)
mechanism is equipped with two functions: speed timer
function and injection rate control function.
The former function works like this. As the rpm is low,
the injection timing gets delayed. This helps cut down on
NOx and operating noise.
The latter function serves to keep down the initial
injection rate and keep up the later injection rate, which
cuts down on NOx and PM as well.
(1) Fine Spill Port (F.S.P.)
(2) Leaking Fuel at Initial Fuel
Pressure-Feed Stage
(3) Plunger Chamber
(4)
(5)
(6)
(7)
Main Port
F.S.P. Stroke
Cylinder
Plunger
W1015443
1-M12
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
[4] AUTOMATIC TIMER
The fuel camshaft is equipped with an automatic timer
(Bosch SCDM type), which is designed to adjust the
injection timing according to the engine speed and to
obtain the best combustion efficiency.
(Never disassemble the timer.)
(1)
(2)
(3)
(4)
Timing Flange
Flyweight
Large Cam
Small Cam
(5) Flange
(6) Spring-loaded Screws
(7) Pin
W1015595
1-M13
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
6. INTAKE SYSTEM
[1] INTAKE AIR HEATER
The intake air heater is introduced in order to further
improve the starting performance and to reduce the
white smoke at cold starting.
The intake air heater is mounted on the intake
manifold. In this new construction, there is no need to
arrange any glow plug on the cylinder head. This means
that a multi-valve design can be implemented and that
the starting performance and serviceability are
enhanced.
W1015732
1-M14
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
7. TURBOCHARGER SYSTEM
[1] BOOST COMPENSATOR
The boost compensator is controlled by the boost
pressure of the turbocharger, which reduces transient
smoke caused by oversupply of fuel when the engine
starts and accelerates.
When the boost pressure is lower than working
pressure of the boost actuator (1), it prevents oversupply
of fuel to reduce transient smoke.
When the boost pressure is higher than working
pressure of the boost actuator (1), it controls the supply
of fuel to the equivalent of maximum power / rated speed
output.
The boost compensator adjusting screws (2) are set
and tamper-proof capped in factory, so never take off the
tamper-proof cap and readjust the screws.
(1) Boost Actuator
(2) Boost Compensator Adjusting
Screw
W1015897
1-M15
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................1-S1
SERVICING SPECIFICATIONS ....................................................................1-S5
TIGHTENING TORQUES ............................................................................1-S11
CHECKING, DISASSEMBLING AND SERVICING....................................1-S12
[1] CHECKING AND ADJUSTING .............................................................1-S12
(1) Engine Body......................................................................................1-S12
(2) Lubricating System ...........................................................................1-S14
(3) Cooling System.................................................................................1-S15
(4) Fuel System ......................................................................................1-S17
[2] DISASSEMBLING AND ASSEMBLING................................................1-S19
(1) Separating Front Axle Support as a Unit ..........................................1-S19
(2) Separating Engine from Clutch Housing...........................................1-S23
(3) Removing External Components ......................................................1-S25
(4) Turbocharger ....................................................................................1-S26
(5) Cylinder Head and Valves ................................................................1-S28
(6) Thermostat........................................................................................1-S32
(7) Injection Pump Unit...........................................................................1-S33
(8) Water Pump and Oil Cooler ..............................................................1-S45
(9) Gear Case.........................................................................................1-S46
(10)Piston and Connecting Rod ..............................................................1-S48
(11)Flywheel and Crankshaft ..................................................................1-S52
[3] SERVICING ............................................................................................1-S55
(1) Cylinder Head ...................................................................................1-S55
(2) Idle Gear and Camshaft....................................................................1-S61
(3) Piston and Connecting Rod ..............................................................1-S65
(4) Crankshaft.........................................................................................1-S68
(5) Cylinder .............................................................................................1-S72
(6) Oil Pump ...........................................................................................1-S73
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
1. TROUBLESHOOTING
Symptom
Probable Cause
Engine Does Not Start No fuel
(Starter Does Not
Run)
Reference
Page
Solution
Replenish fuel
G-8
Air in the fuel system
Vent air
G-38
Water in the fuel system
Change fuel and
repair or replace fuel
system
Fuel pipe clogged
Clean
G-21
Fuel filter clogged
Replace
G-30
Excessively high viscosity of fuel or engine oil at
low temperature
Use specified fuel
or engine oil
G-8
Fuel with low cetane number
Use specified
fuel
G-8
Fuel leak due to loose injection pipe retaining nut
Tighten retaining nut
1-S28
Incorrect injection timing
Adjust
1-S17
Injection nozzle clogged
Repair or replace
1-S18, 28
Injection pump malfunctioning
Repair or replace
1-S17, 33 to
36
Seizure of crankshaft, camshaft, piston, cylinder
or bearing
Repair or replace
–
Compression leak from cylinder
Replace head gasket,
tighten cylinder head
screw and nozzle
holder
Improper valve timing
Correct or replace
timing gear
Piston ring and cylinder worn
Replace
Excessive valve clearance
Adjust
1-S13
Stop solenoid malfunctioning
Replace
9-S19
Battery discharged
Charge
9-S10
Starter malfunctioning
Repair or replace
Key switch malfunctioning
Replace
Wiring disconnected
Connect
G-8, 26
1-S28 to 31
1-S46
1-S66, 72
9-S17, 43
–
–
W1014322
1-S1
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Symptom
Engine Revolution Is
Not Smooth
Probable Cause
Solution
Reference
Page
Fuel filter clogged or dirty
Replace
G-30
Air cleaner clogged
Clean or replace
G-20
Fuel leak due to loose injection pipe retaining nut
Tighten retaining nut
1-S28
Injection pump malfunctioning
Repair or replace
1-S17, 33 to
36
Incorrect nozzle opening pressure
Repair or replace
1-S18, 28
Injection nozzle stuck or clogged
Repair or replace
1-S18, 28
Governor malfunctioning
Repair
Bearing worn out
Replace
–
Turbocharger shaft bent
Replace
1-S26
Turbocharger fin or other part damaged due to
foreign matters
Replace
1-S26
Excessive engine oil
Reduce to specified
level
G-15
Piston ring and cylinder worn or stuck
Repair or replace
Incorrect injection timing
Adjust
1-S17
Oil Leak into Exhaust
Pipe or Suction Pipe
Waste oil pipe clogged or deformed
Repair or replace
1-S26
Piston ring seal faulty
Replace the
turbocharger
assembly
1-S26
Either Black or Dark
Gray Exhaust Gas Is
Observed
Overload
Lessen the load
Low grade fuel used
Use specified fuel
G-8
Fuel filter clogged
Replace
G-30
Air cleaner clogged
Clean or replace
G-20
Deficient nozzle injection
Repair or replace
nozzle
1-S18, 28
Either White or Blue
Exhaust Gas Is
Observed
1-S37 to 41
1-S66, 72
–
W1010692
1-S2
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Symptom
Deficient Output
Probable Cause
Reference
Page
Solution
Incorrect injection timing
Adjust
Engine's moving parts seem to be seizing
Repair or replace
–
Injection pump malfunctioning
Repair or replace
1-S17, 33 to
36
Deficient nozzle injection
Repair or replace
nozzle
1-18, 28
Compression leak
Check the
compression pressure
and repair
Gas leak from exhaust system
Repair or replace
1-S26
Air leak from compressor discharge side
Repair or replace
1-S27
Air cleaner dirty or clogged
Clean or replace
G-20
Compressor wheel turning heavily
Replace the
turbocharger
assembly
1-S27
Piston ring's gap facing the same direction
Shift ring gap direction
1-S50
Oil ring worn or stuck
Replace
1-S51, 66
Piston ring groove worn
Replace piston
1-S51, 66
Valve stem and valve guide worn
Replace
1-S57
Crankshaft bearing, and crank pin bearing worn
Replace
1-S68 to 71
Oil leaking due to defective seals or packing
Replace
–
Injection pump's plunger worn
Repair or replace
1-S17, 33 to
36
Deficient nozzle injection
Repair or replace
nozzle
1-S18, 28
Injection pump broken
Replace
1-S18, 33 to
36
Water Mixed into
Lubricant Oil
Head gasket defective
Replace
1-S30, 31
Cylinder block or cylinder head flawed
Replace
1-S55
Low Oil Pressure
Engine oil insufficient
Replenish
Oil strainer clogged
Clean
1-S48
Relief valve stuck with dirt
Clean
1-S46
Relief valve spring weaken or broken
Replace
1-S46
Excessive oil clearance of crankshaft bearing
Replace
1-S71
Excessive oil clearance of crankpin bearing
Replace
1-S49, 69
Excessive oil clearance of rocker arm
Replace
1-S59
Oil passage clogged
Clean
Different type of oil
Use specified type of
oil
Oil pump defective
Repair or replace
Excessive Lubricant
Oil Consumption
Fuel Mixed into
Lubricant Oil
1-S17
1-S28 to 31
G-8, 15
–
G-8, 15
1-S73
W1010765
1-S3
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Symptom
High Oil Pressure
Engine Overheated
Probable Cause
Solution
Reference
Page
Different type of oil
Use specified type of
oil
G-8
Relief valve defective
Replace
Engine oil insufficient
Replenish
Fan belt broken or elongated
Replace or adjust
1-S15
Coolant insufficient
Replenish
G-34
Radiator net and radiator fin clogged with dust
Clean
Inside of radiator corroded
Clean or replace
G-34
Coolant flow route corroded
Clean or replace
G-34
Radiator cap defective
Replace
1-S16
Overload running
Reduce the load
Head gasket defective
Replace
Incorrect injection timing
Adjust
Unsuitable fuel used
Use specified fuel
1-S46
G-8, 15
–
–
1-S30, 31
1-S17
G-8
W1010838
1-S4
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item
Cylinder Head Surface
Factory Specification
Allowable Limit
–
0.05 mm
0.0020 in.
0.72 to 0.90 mm
0.0283 to 0.0354 in.
–
3.47 MPa /
250 min−1 (rpm)
35.4 kgf/cm2 /
250 min−1 (rpm)
503 psi /
250 min−1 (rpm)
2.56 MPa /
250 min−1 (rpm)
26.1 kgf/cm2 /
250 min−1 (rpm)
371 psi /
250 min−1 (rpm)
–
10 % or less
Intake
1.6 to 2.0 mm
0.0630 to 0.0790 in.
–
Exhaust
2.3 to 2.6 mm
0.0906 to 0.1024 in.
–
Intake
1.047 rad
60 °
–
Exhaust
0.785 rad
45 °
–
Intake
1.047 rad
60 °
–
Exhaust
0.785 rad
45 °
–
Intake
0.6 to 0.8 mm
0.0236 to 0.0315 in.
1.2 mm
0.0472 in.
Exhaust
0.85 to 1.05 mm
0.0335 to 0.0413 in.
1.2 mm
0.0472 in.
Clearance
(Intake)
0.055 to 0.085 mm
0.0022 to 0.0033 in.
0.1 mm
0.0039 in.
Valve Stem O.D.
(Intake)
6.960 to 6.975 mm
0.2740 to 0.2746 in.
–
Valve Guide I.D.
(Intake)
7.030 to 7.045 mm
0.2768 to 0.2774 in.
–
Clearance
(Exhaust)
0.055 to 0.085 mm
0.0022 to 0.0033 in.
0.1 mm
0.0039 in.
Valve Stem O.D.
(Exhaust)
6.960 to 6.975 mm
0.2740 to 0.2746 in.
–
Valve Guide I.D.
(Exhaust)
7.030 to 7.045 mm
0.2768 to 0.2774 in.
–
0.23 to 0.27 mm
0.0091 to 0.0106 in.
–
Flatness
Top Clearance
Compression Pressure
Variance Among Cylinders
Valve Seat Width
Valve Seat Angle
Valve Face Angle
Valve Recessing
Valve Stem to Valve Guide
Valve Clearance (Cold)
W1013874
1-S5
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Item
Intake Valve Timing
Exhaust Valve Timing
Valve Spring
Setting Load / Setting Length
Factory Specification
Allowable Limit
Open
0.24 rad (14 °)
before T.D.C.
–
Close
0.61 rad (36 °)
after B.D.C.
–
Open
0.785 rad (45 °)
before B.D.C.
–
Close
0.29 rad (17 °)
after T.D.C.
–
Intake
35.1 to 35.6 mm
1.3819 to 1.4016 in.
34.6 mm
1.3622 in.
Exhaust
35.1 to 35.6 mm
1.3819 to 1.4016 in.
34.6 mm
1.3622 in.
Intake
63.547 N / 31.5 mm
6.48 kgf / 31.5 mm
14.256 lbs / 1.2401 in.
45.864 N / 31.5 mm
4.68 kgf / 31.5 mm
10.296 lbs / 1.2401
in.
Exhaust
63.547 N / 31.5 mm
6.48 kgf / 31.5 mm
14.256 lbs / 1.2401 in.
45.864 N / 31.5 mm
4.68 kgf / 31.5 mm
10.296 lbs / 1.2401
in.
–
1.0 mm
0.039 in.
Oil Clearance
0.016 to 0.045 mm
0.00063 to 0.00177 in.
0.15 mm
0.0059 in.
Rocker Arm Shaft
O.D.
15.973 to 15.984 mm
0.6289 to 0.6293 in.
–
Rocker Arm I.D. for
Shaft
16.000 to 16.018 mm
0.6299 to 0.6306 in.
–
Clearance
0.018 to 0.042 mm
0.0007 to 0.0017 in.
0.15 mm
0.0059 in.
Valve Arm Bridge
(I.D.)
9.050 to 9.065 mm
0.3563 to 0.3569 in.
–
Valve Arm Bridge
Shaft
(O.D.)
9.023 to 9.032 mm
0.3552 to 0.3556 in.
–
Tilt (Valve Spring)
Rocker Arm Shaft to Rocker Arm
Valve Arm Bridge and Valve Arm Bridge
Shaft
Push Rod
Alignment
–
0.25 mm
0.0098 in.
Tappet to Tappet Guide
Clearance
0.020 to 0.062 mm
0.0008 to 0.0024 in.
0.07 mm
0.0028 in.
Tappet Guide Bore
(I.D.)
24.000 to 24.021 mm
0.9449 to 0.9457 in.
–
Tappet
(O.D.)
23.959 to 23.980 mm
0.9433 to 0.9441 in.
–
0.07 to 0.22 mm
0.0028 to 0.0087 in.
0.3 mm
0.0118 in.
–
0.01 mm
0.0004 in.
Camshaft
Side Clearance
Alignment
W1013874
1-S6
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Item
Cam Height
Camshaft
Timing Gear
Idle Gear Shaft 1, 2 to Idle Gear 1, 2
Bushing
Factory Specification
Allowable Limit
Intake
37.63 mm
1.4815 in.
37.13 mm
1.4618 in.
Exhaust
38.96 mm
1.5338 in.
38.46 mm
1.5141 in.
Oil Clearance
0.050 to 0.091 mm
0.00197 to 0.00358 in.
0.15 mm
0.0059 in.
Camshaft Journal
(O.D.)
45.934 to 45.950 mm
1.8084 to 1.8091 in.
–
Camshaft Bearing
(I.D.)
46.000 to 46.025 mm
1.8110 to 1.8120 in.
–
Idle Gear 1 to
Crank Gear
(Backlash)
0.049 to 0.193 mm
0.0019 to 0.0076 in.
0.22 mm
0.0087 in.
Idle Gear 1 to Cam
Gear
(Backlash)
0.049 to 0.189 mm
0.0019 to 0.0074 in.
0.22 mm
0.0087 in.
Idle Gear 1 to Idle
Gear 2
(Backlash)
0.044 to 0.185 mm
0.0017 to 0.0073 in.
0.22 mm
0.0087 in.
Idle Gear 2 to
Injection Pump
Gear
(Backlash)
0.044 to 0.177 mm
0.0017 to 0.0070 in.
0.22 mm
0.0087 in.
Cam Gear to
Balancer Gear 1
(Backlash)
0.047 to 0.182 mm
0.0018 to 0.0072 in.
0.22 mm
0.0087 in.
Idle Gear 1 to
Balancer Gear 2
(Backlash)
0.044 to 0.183 mm
0.0017 to 0.0072 in.
0.22 mm
0.0087 in.
Oil Clearance
0.050 to 0.091 mm
0.0020 to 0.0036 in.
0.10 mm
0.0039 in.
Idle Gear 1, 2
Bushing
(I.D.)
45.025 to 45.050 mm
1.7726 to 1.7736 in.
–
Idle Gear 1, 2 Shaft
(O.D.)
44.959 to 44.975 mm
1.7700 to 1.7707 in.
–
Idle Gear
Side Clearance
0.15 to 0.30 mm
0.0059 to 0.0118 in.
0.9 mm
0.0354 in.
Balancer Shaft
Side Clearance
0.07 to 0.22 mm
0.0028 to 0.0087 in.
0.3 mm
0.0118 in.
Balancer Shaft
Alignment
–
0.02 mm
0.0008 in.
W1017654
1-S7
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Item
Balancer Shaft
Factory Specification
Allowable Limit
Oil Clearance
0.070 to 0.159 mm
0.0028 to 0.0063 in.
0.2 mm
0.0079 in.
Balancer Shaft
Journal
(O.D.)
50.92 to 50.94 mm
2.0047 to 2.0055 in.
–
Balancer Bearing
(I.D.)
51.01 to 51.08 mm
2.0083 to 2.0110 in.
–
30.000 to 30.013 mm
1.1811 to 1.1816 in.
30.05 mm
1.1831 in.
Piston Pin Bore
I.D.
Compression Ring 1 to Ring Groove
Clearance
0.05 to 0.09 mm
0.0020 to 0.0035 in.
0.15 mm
0.0059 in.
Compression Ring 2 to Ring Groove
Clearance
0.093 to 0.120 mm
0.0037 to 0.0047 in.
0.20 mm
0.0079 in.
Oil Ring to Ring Groove
Clearance
0.02 to 0.06 mm
0.0008 to 0.0023 in.
0.15 mm
0.0059 in.
Piston Ring Gap
Compression Ring
1
0.30 to 0.45 mm
0.0118 to 0.0177 in.
1.25 mm
0.0492 in.
Compression Ring
2
0.30 to 0.45 mm
0.0118 to 0.0177 in.
1.25 mm
0.0492 in.
Oil Ring
0.25 to 0.45 mm
0.0098 to 0.0177 in.
1.25 mm
0.0492 in.
Connecting Rod
Alignment
–
0.05 mm
0.0059 in.
Piston Pin to Small End Bushing
Clearance
0.020 to 0.040 mm
0.0008 to 0.0016 in.
0.15 mm
0.0020 in.
Piston Pin
(O.D.)
30.006 to 30.011 mm
1.1813 to 1.1815 in.
–
Small End Bushing
(I.D.)
30.031 to 30.046 mm
1.1823 to 1.1829 in.
–
0.15 to 0.31 mm
0.0059 to 0.0122 in.
0.50 mm
0.0197 in.
–
0.02 mm
0.00079 in.
Crankshaft
Side Clearance
Alignment
Crankshaft Journal
O.D.
74.977 to 74.990 mm
2.9518 to 2.9524 in.
–
Crankshaft Journal to Crankshaft Bearing
Oil Clearance
0.018 to 0.062 mm
0.0007 to 0.0024 in.
0.20 mm
0.0079 in.
Crank Pin
O.D.
52.977 to 52.990 mm
2.0857 to 2.0862 in.
–
Crank Pin to Pin Bearing
Oil Clearance
0.018 to 0.051 mm
0.0007 to 0.0020 in.
0.20 mm
0.0079 in.
Cylinder Bore
I.D.
100.000 to 100.022 mm
3.9370 to 3.9379 in.
100.15 mm
3.9429 in.
Cylinder Bore
(Oversize)
I.D.
100.500 to 100.522 mm
3.9567 to 3.9576 in.
100.65 mm
3.9626 in.
W1018346
1-S8
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
LUBRICATING SYSTEM
Item
Factory Specification
Allowable Limit
–
49 kPa
0.5 kgf/cm2
7 psi
At Rated Speed
196 to 392 kPa
2.0 to 4.0 kgf/cm2
28 to 57 psi
147.1 kPa
1.5 kgf/cm2
21.3 psi
Engine Oil Pressure Switch
Working Pressure
39.2 to 58.8 kPa
0.4 to 0.6 kgf/cm2
5.6 to 8.4 psi
–
Inner Rotor to Outer Rotor
Clearance
0.04 to 0.16 mm
0.0016 to 0.0063 in.
0.3 mm
0.0118 in.
Outer Rotor to Pump Body
Clearance
0.100 to 0.184 mm
0.0039 to 0.0072 in.
0.3 mm
0.0118 in.
Rotor to Cover
Clearance
0.025 to 0.075 mm
0.0010 to 0.0030 in.
0.225 mm
0.0089 in.
Relief Valve
Working Pressure
885 kPa
9.04 kgf/cm2
129 psi
–
Engine Oil Pressure
At Idle Speed
W1019038
COOLING SYSTEM
Item
Thermostat
Factory Specification
Allowable Limit
Valve Opening
Temperature
74.5 to 78.5 °C
166.1 to 173.3 °F
–
Valve Opening
Temperature
(Opened
Completely)
90 °C
194 °F
–
Water tightness at
specified pressure
137 kPa
1.4 kgf/cm2
20 psi
–
Radiator Water
Tightness
Radiator Cap
Air Leakage
10 seconds or more
88 → 59 kPa
0.9 → 0.6 kgf/cm2
13 → 9 psi
–
Fan Belt
Tension
10 to 12 mm / 98 N
10 to 12 mm / 10 kgf
0.394 to 0.472 in. /
22.1 lbs
–
W1019384
1-S9
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
FUEL SYSTEM
Item
Factory Specification
Allowable Limit
0.12 to 0.16 rad
(7 to 9 °)
before T.D.C.
–
Injection Pressure
(1st stage)
18.63 to 19.61 MPa
190 to 200 kgf/cm2
2702 to 2845 psi
–
Injection Pressure
(2nd stage)
23.54 to 24.52 MPa
240 to 250 kgf/cm2
3414 to 3556 psi
–
When the pressure is
16.67 MPa
(170 kgf/cm2, 2418 psi),
the valve seat must be
fuel tightness
–
Injection Timing
Fuel Injection Nozzle
Valve Seat
Tightness
W1023036
1-S10
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
3. TIGHTENING TORQUES
Tightening torque of screws, bolts and nuts on the table below are especially specified.
(For general screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
6.9 to 11.3
0.7 to 1.15
5.1 to 8.32
*Cylinder head screw
98.1 to 107.9
10.0 to 11.0
72.3 to 79.6
*Connecting rod screw
78.5 to 83.4
8.0 to 8.5
57.9 to 61.5
*Flywheel screw
98.1 to 107.9
10.0 to 11.0
72.3 to 79.6
*Crankshaft screw
255.1 to 274.7
26.0 to 28.0
188.1 to 202.5
*Main bearing case screw
137.3 to 147.1
14.0 to 15.0
101.3 to 108.5
Rocker arm bracket screw
49.0 to 55.9
5.0 to 5.7
36.2 to 41.2
Nozzle holder clamp nut
17.7 to 20.6
1.8 to 2.1
13.0 to 15.2
Injection pipe retaining nut
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1
9.8 to 11.3
1.0 to 1.15
7.23 to 8.32
Oil switch taper screw
14.7 to 19.6
1.5 to 2.0
10.8 to 14.5
Oil cooler joint screw
39.2 to 44.1
4.0 to 4.5
28.9 to 32.5
Oil pump cover screw
7.9 to 9.3
0.80 to 0.95
5.8 to 6.9
Engine and clutch housing mounting screw, nut
(standard type)
124 to 147
12.6 to 15.0
91.2 to 108
Engine and clutch housing mounting nut (wide type)
167 to 196
17.0 to 20.0
123 to 144
Engine and clutch housing mounting stud bolt
38.2 to 45.1
3.9 to 4.6
28.2 to 33.3
Starter's terminal B mounting nut
9.8 to 11.8
1.0 to 1.2
7.2 to 8.7
Intake air heater terminal nut
3.4 to 5.4
0.35 to 0.55
2.53 to 3.98
Injection pump gear mounting nut
73.6 to 83.4
7.5 to 8.5
54.2 to 61.5
Injection pump unit mounting nut
17.7 to 20.6
1.8 to 2.1
13.0 to 15.2
Gear case cover
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Relief valve retaining screw
68.6 to 78.4
7.0 to 8.0
50.6 to 57.9
Idle gear mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Plate mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Camshaft set screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Flywheel housing mounting screw
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Crankcase 2 mounting screw
49.0 to 55.9
5.0 to 5.7
36.2 to 41.2
Injection pump mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Injection pump mounting nut
17.7 to 20.6
1.8 to 2.1
13.0 to 15.2
Governor weight mounting nut
62.8 to 72.6
6.4 to 7.4
46.3 to 53.5
Fuel camshaft stopper mounting screw
7.9 to 9.3
0.80 to 0.95
5.8 to 6.9
Governor housing mounting screw
9.8 to 11.3
1.0 to 1.15
7.23 to 8.32
Anti-rotation nut
2.8 to 4.0
0.29 to 0.41
2.1 to 3.0
Cylinder head cover screw
Overflow pipe assembly retaining screw
■ NOTE
• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
W1012736
1-S11
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. After warming up the engine, stop it and remove the air cleaner,
the muffler, high pressure pipes, cylinder head cover, overflow
pipe, all nozzle holders and all nozzle gaskets.
2. Install a compression tester (Code No: 07909-30207) and nozzle
adaptor for diesel engines to nozzle holder hole.
3. After making sure that the speed control lever is set at the stop
position (Non-injection), run the engine at 200 to 300 min-1 (rpm)
with the starter.
4. Read the maximum pressure. Measure the pressure more than
twice.
5. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the nozzle hole and
measure the compression pressure again.
6. If the compression pressure increase after applying oil, check the
cylinder wall and piston rings.
7. If the compression pressure is still less than the allowable limit,
check the top clearance, valve and cylinder head.
■ NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
Factory spec.
3.47 MPa / 250 min-1 (rpm)
35.4 kgf/cm2 / 250 min-1 (rpm)
503 psi / 250 min-1 (rpm)
Allowable limit
2.56 MPa / 250 min-1 (rpm)
26.1 kgf/cm2 / 250 min-1 (rpm)
371 psi / 250 min-1 (rpm)
Compression pressure
Nozzle holder clamp nut
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
Overflow pipe assembly
retaining screw
9.8 to 11.3 N·m
1.0 to 1.15 kgf·m
7.23 to 8.32 ft-lbs
Cylinder head cover screw
6.9 to 11.3 N·m
0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
Injection pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Tightening torque
W1024650
1-S12
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Checking Valve Clearance
■ IMPORTANT
• Valve clearance must be checked and adjusted when engine
is cold.
1. Remove the high pressure pipes and the head cover.
2. Align the 1TC mark of flywheel and the convex of flywheel
housing timing windows so that the first piston (gear case side)
comes to the compression top dead center.
3. Before adjusting the valve clearance, adjust the bridge evenly to
the valves stem.
4. Loosen the lock nut (2) and adjust with screw (1).
5. Slightly push the rocker arm by your fingers and screw in the
adjusting screw slowly until you feel the screw touch the top of
valve stem, then tighten the lock nut.
6. Loosen the lock nut (4) of adjusting screw (3) (push rod side) and
insert the thickness gauge between the rocker arm and the
bridge head. Set the adjusting screw to the specified value, then
tighten the lock nut.
Valve clearance
0.23 to 0.27 mm
0.0091 to 0.0106 in.
Factory spec.
■ NOTE
• After adjusting, tighten the lock nut (4) securely.
Valve arrangement
Adjustment cylinder
Location of piston
When No.1 piston is compression
top dead center
IN.
EX.
1st
✩
✩
2nd
✩
✩
3rd
4th
1st
When No.1 piston is overlap
position
3rd
✩
4th
✩
✩
Cylinder head cover screw
6.9 to 11.3 N·m
0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
Injection pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Tightening torque
(1) Adjusting Screw
(2) Lock Nut
✩
2nd
(3) Adjusting Screw
(4) Lock Nut
W1025407
1-S13
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(2) Lubricating System
Engine Oil Pressure
1. Remove the oil switch and set a pressure tester (Code No.
07916-32031).
2. Start the engine. After warming up, measure the oil pressure of
both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
• Engine oil insufficient.
• Oil pump defective.
• Oil strainer clogged.
• Oil filter cartridge clogged.
• Oil gallery clogged.
• Excessive oil clearance of bearing.
• Foreign matter in the relief valve.
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
At idle
speed
Engine oil pressure
At rated
speed
Tightening torque
Allowable
limit
49 kPa
0.5 kgf/cm2
7 psi
Factory
spec.
196 to 392 kPa
2.0 to 4.0 kgf/cm2
28 to 57 psi
Allowable
limit
147.1 kPa
1.5 kgf/cm2
21.3 psi
Oil switch taper screw
14.7 to 19.6 N·m
1.5 to 2.0 kgf·m
10.8 to 14.5 ft-lbs
W1026718
1-S14
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(3) Cooling System
Fan Belt Tension
1. Press the fan belt between alternator and crank pulley at force of
98 N (10 kgf, 22 lbs).
Check if the fan belt deflection is 10 to 12 mm (0.394 to 0.472 in.).
2. If the deflection is not within the factory specifications, loosen the
alternator mounting screws and relocate the alternator to adjust.
Deflection (A)
Factory spec.
10 to 12 mm
0.394 to 0.472 in.
(A) Deflection
W1027655
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt is damaged, replace it.
3. Check if the fan belt is worn and sunk in the pulley groove.
4. If the fan belt is nearly worn out and deeply sunk in the pulley
groove, replace it.
(A) Good
(B) Bad
W1027790
Thermostat Valve Opening Temperature
1. Push down the thermostat valve and insert a string between the
valve and the valve seat.
2. Place the thermostat and a thermostat in a container with water
and gradually heat the water.
3. Hold the string to suspend the thermostat in the water. When the
water temperature rises, the thermostat valve will open, allowing
it to fall down from the string.
Read the temperature at this moment on the thermometer.
4. Continue heating the water and read the temperature when the
valve has risen by about 8 mm (0.315 in.).
5. If the measurement is not acceptable, replace the thermostat.
Thermostat’s valve
opening temperature
Factory spec.
74.5 to 78.5 °C
166.1 to 173.3 °F
Temperature at which
thermostat completely
opens
Factory spec.
90 °C
194 °F
W1027990
1-S15
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester.
Increase water pressure to the specified pressure of 137 kPa (1.4
kgf/cm2, 20 psi).
3. Check the radiator for water leaks.
4. When water leakage is excessive, replace the radiator. If water
leakage is caused by a small pinhole, correct the radiator with
radiator cement.
W1028218
Radiator Cap Air Leakage
1. Set a radiator tester on the radiator cap.
2. Set a radiator tester.
Apply the specified pressure of 88 kPa (0.9 kgf/cm2, 13 psi).
3. Check if the pressure drop to less than 59 kPa (0.6 kgf/cm2, 9 psi)
in 10 seconds.
4. If the pressure is less than the factory specification, replace it.
W1028342
1-S16
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(4) Fuel System
Injection Timing
1. Make sure of matching the injection timing align mark (1) of the
injection pump unit and the plate (gearcase), as shown in the
illustration.
2. Remove the injection pipes.
3. Remove the stop solenoid.
4. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (2) for
No.1 cylinder.
5. After the fuel fills up to the hole of the delivery valve holder for
No.1 cylinder, turn back (clockwise) the flywheel around 1.57 rad
(90 °).
6. Turn the flywheel counterclockwise to set at around 1.35 rad (20
°) before T.D.C..
7. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
8. Check to see the degree on flywheel.
The flywheel has mark “1TC”, “10” and “20” for the crank angle
before the top dead center of No. 1 piston.
9. If the injection timing is not within the specification, rotate the
injection pump unit to adjust the injection timing.
■ IMPORTANT
• When installing the injection pump unit to the engine body,
follow the correct procedure.
See the “Injection Pump Unit”.
Injection timing
Factory spec.
0.12 to 0.16 rad (7 ° to 9 °)
before T.D.C.
Injection pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Injection pump unit
mounting nut
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
Tightening torque
(1) Injection Timing Align Mark
(2) Delivery Valve Holder
(a) Injection Timing Advanced
(b) Injection Timing Delayed
W1028613
Injection Pump Test
1. Remove the injection pump unit.
(Refer to “Injection Pump Unit”. (See page 1-S33 to 36.)
2. Check the injection pump on the test beach in Denso Service
shop.
W1029716
1-S17
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Fuel Injection Timer Test
1. Remove the injection pump unit.
(Refer to “Injection Pump Unit”. (See page 1-S33 to 36.)
2. Check the fuel injection timer on the test bench in Bosch service
shop.
W1029657
CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction the spray goes. If the spray from the nozzle directly contacts the human body, cells may be
destroyed and blood poisoning may be caused.
Checking Nozzle Injection Pressure
1. Set the injection nozzle to the nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the injection nozzle assembly or repair at Denso service
shop.
■ NOTE
• Injection nozzle gasket must be replaced when the injection
nozzle is removed for checking.
Injection pressure
Factory
spec.
1st
stage
18.63 to 19.61 MPa
190 to 200 kgf/cm2
2702 to 2845 psi
W1029881
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.
2. If the spraying condition is defective, replace the injection nozzle
assembly or repair at Denso service shop.
(a) Good
(b) Bad
W1030250
Valve Seat Tightness
1. Set the injection nozzle to a nozzle tester.
2. Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/cm2,
2418 psi) for 10 seconds.
3. If any fuel leak is found, replace the injection nozzle assembly or
repair at Denso service shop.
Valve seat tightness
Factory spec.
No fuel leak at
16.67 MPa
170 kgf/cm2
2418 psi
W1030380
1-S18
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Separating Front Axle Support as a Unit
Draining Coolant
•
1.
2.
3.
4.
CAUTION
Never remove the radiator cap until coolant temperature is
well below its boiling point. Then loosen cap slightly to the
stop to relieve any excess pressure before removing cap
completely.
Stop the engine and let cool down.
To drain the coolant, open the radiator drain plug (1). When
opening the drain plug set the hose to drain port (2).
Remove the radiator cap to completely drain the coolant.
After all coolant is drained, reinstall the radiator drain plug.
Coolant
Capacity
(1) Drain Plug
9.1 L
9.6 U.S.qts
8.0 Imp.qts
(2) Drain Port
W1030568
Draining Engine Oil
1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. Remove the drain plugs (1) to drain oil.
4. After draining, screw in the drain plugs (1).
(When reassembling)
• Fill the engine oil up to the upper line on the dipstick (3).
Engine Oil
Capacity
10.7 L
11.3 U.S.qts
9.4 Imp.qts
■ IMPORTANT
• Never mix two different type of oil.
• Use the proper SAE Engine Oil according to ambient
temperature.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
(1) Drain Plug
(2) Oil Inlet Plug
(3) Dipstick
(A) Oil level is acceptable within this
range.
W1030778
1-S19
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Muffler and Bonnet
1. Open the bonnet (1) and disconnect the battery (2) negative
terminal and head light 4P connector (7).
2. Remove the bonnet dampers (3) and close the bonnet (1).
3. Remove the bonnet hinge mounting screws (4) through the holes
(5) in the upper part of the bonnet.
4. Remove the bonnet (1) and muffler (6).
5. Remove the side cover (7) LH and RH.
■ IMPORTANT
• When disconnecting the battery cables, disconnect the
grounding cable first. When connecting, positive cable first.
(1)
(2)
(3)
(4)
Bonnet
Battery
Damper
Screw
(5)
(6)
(7)
(8)
Hole
Muffler
4P Connector
Side Cover
W1031264
Radiator Hoses, Air Cleaner Hoses and Oil Cooler Pipes
1. Remove the side panel LH (1) and side panel RH (2).
2. Disconnect the radiator hose (3).
3. Remove the shield weather strip (4) and radiator plate (5).
4. Remove the air cleaner hoses (6).
5. Disconnect the power steering turning hoses (7).
6. Remove the harness cover (8) and disconnect the battery cord
(9).
7. Disconnect oil cooler pipe (10) and oil cooler hose (11).
(When reassembling)
Starter's terminal B
mounting nut
9.8 to 11.8 N·m
1.0 to 1.2 kgf·m
7.2 to 8.7 ft-lbs
Power steering turning
hose retaining nut
22.6 to 27.0 N·m
2.2 to 2.8 kgf·m
16.2 to 19.9 ft-lbs
Oil cooler pipe nut
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.1 to 50.6 ft-lbs
Oil cooler hose retaining
nut
45.1 to 53.0 N·m
4.6 to 5.4 kgf·m
33.3 to 39.0 ft-lbs
Tightening torque
• Be sure to connect the power steering turning hoses to original
positions.
(1)
(2)
(3)
(4)
(5)
(6)
Side Panel LH
Side Panel RH
Radiator Hose
Shield Weather Strip
Radiator Plate
Air Cleaner Hose
(7)
(8)
(9)
(10)
(11)
Power Steering Turning Hose
Harness Cover
Battery Cord
Oil Cooler Pipe
Oil Cooler Hose
W1031544
1-S20
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Propeller Shaft
1. Slide the propeller shaft cover (3) after removing the screw (5).
2. Tap out the spring pins (2) and then slide the coupling (1) to the
rear.
(When reassembling)
• Apply grease to the splines of the propeller shaft (6) and the
pinion shaft.
• Tap in the spring pins (2) as shown in figure.
(1)
(2)
(3)
(4)
Coupling
Spring Pin
Propeller Shaft Cover
Spring Pin
(5) Screw
(6) Propeller Shaft
(7) Coupling
W1032390
Differential Lock Spring
1. Loosen the lock nut (1) and disconnect spring (2) from differential
lock lever (3).
(When reassembling)
• Be sure to fix the front edge of differential lock cable at the center
of thread.
(1) Lock Nut
(2) Spring
(3) Differential Lock Lever
(4) Differential Lock Cable
W1032951
1-S21
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Air Condenser and Compressor
■ Without discharging the refrigerant from system
1. Remove the air condenser slide stopper (1) and slide out the air
condenser (2).
2. Remove the compressor (3) with hoses.
(When reassembling)
• Take care not to damage the air condenser fin.
• After reassembling the compressor, be sure to adjust the air
conditioner belt tension.
(Refer to “Adjusting Air Conditioner Belt Tension” : See page G29.)
■ With discharge the refrigerant from system
1. Refer to “Discharge the Refrigerant” (See page 10-S19).
(When reassembling)
• Charge the refrigerator to the air conditioner system, refer to
“Charging the Refrigerant”. (See page 10-S21.)
2. Disconnect the low pressure hose (5) and high pressure hose (4)
from compressor (3).
3. Disconnect the high pressure hose (6) from receiver.
(When reassembling)
• Apply compressor oil (DENSO CO. ND-OIL8) to the O-rings and
take care not to damage them.
High pressure hose
retaining nut
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 ft-lbs
Low pressure hose
mounting screw
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 ft-lbs
Tightening torque
(1) Condenser Slide Stopper
(2) Condenser
(3) Compressor
(4) High Pressure Hose
(5) Low Pressure Hose
(6) High Pressure Hose
W1033120
Front Axle Support as a Unit
1. Check the front axle and clutch housing case are securely
mounted on the disassembling stands.
2. Install the front axle rocking restrictor (1) (See page G-72) to the
front axle bracket.
3. Separate the front axle support as a unit after removing the front
axle support mounting screws.
(When reassembling)
Tightening torque
Front axle support
mounting screw
(M14, UBS)
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
(1) Front Axle Rocking Restrictor
W1033876
1-S22
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(2) Separating Engine from Clutch Housing
Fuel Pipe, Accelerator Cable, Heater Hose and Wire Harness
1. Disconnect the fuel pipe (1) from injection pump.
2. Disconnect the overflow hose (2).
3. Disconnect the accelerator cable (3) from injection pump.
4. Disconnect the heater hoses (4) from engine.
5. Disconnect the all connections (relaies, sensors, switches,
starter motor and starter motor) of engine wire harness.
(When reassembling)
• Be sure to connect the heater hoses to original positions.
(1) Fuel Pipe
(2) Overflow Hose
(3) Accelerator Cable
(4) Heater Hoses
(5) Wire Harness
W1034113
Steering Joint, Hose, Meter Cable, Oil Cooler Pipe and Hose
1. Remove the steering joint (1).
2. Disconnect the meter cable (2) from the engine.
3. Disconnect the delivery hose (3), oil cooler hose (4).
4. Remove the oil cooler pipe (5).
(When reassembling)
Tightening torque
(1) Steering Joint
(2) Meter Cable
(3) Delivery Hose
Delivery hose retaining nut
22.6 to 27.6 N·m
2.2 to 2.8 kgf·m
16.2 to 19.9 ft-lbs
Oil cooler pipe nut
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.1 to 50.6 ft-lbs
Oil cooler hose retaining
45.1 to 53.0 N·m
4.6 to 5.4 kgf·m
33.3 to 39.0 ft-lbs
(4) Oil Cooler Hose
(5) Oil Cooler Pipe
W1034340
Brake Oil Tank
1. Remove the brake oil tank (1) from the bonnet support (3).
2. Remove the stay (2).
3. Disconnect the tank air bleeder hoses (5).
4. Remove the muffler pipe support (4) and bonnet support (3).
(1) Brake Oil Tank
(2) Stay
(3) Bonnet Support
(4) Muffler Pipe Support
(5) Air Bleeder Hose
W1034721
1-S23
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Separating Engine from Clutch Housing
1. Remove the floor mat (1) and panel cover (2).
2. Hoist the engine by hoist and chain.
3. Remove the engine mounting screws and nuts, and separate the
engine from the clutch housing.
(When reassembling)
• Apply molybdenum disulphide (Three Bond 1901 or equivalent)
to the splines of clutch disc boss.
• Apply liquid gasket (Three Bond 1141, 1211 or equivalent) to joint
face of the engine and clutch housing.
Tightening torque
(1) Floor Mat
(2) Panel Cover
Engine and clutch housing
mounting screw, nut
(standard type)
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 ft-lbs
Engine and clutch housing
mounting nut (wide type)
167 to 196 N·m
17.0 to 20.0 kgf·m
123 to 144 ft-lbs
Engine and clutch housing
mounting stud bolt
38.2 to 45.1 N·m
3.9 to 4.6 kgf·m
28.2 to 33.3 ft-lbs
a : Standard Type Nut (7T)
b : Wide Type Nut (9T)
W1035075
1-S24
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(3) Removing External Components
External Components
1. Remove the damper disc (1).
2. Remove the all radiator hoses (2).
3. Remove the muffler (3).
4. Remove the steering controller (4).
5. Remove the fan (5) and fan belt (6).
6. Remove the alternator (7).
7. Remove the starter (8).
(When reassembling)
• Confirm that the pilot bearing (9) is surely assembled to the
flywheel.
• Direct the shorter end of the dumper disc boss toward the
flywheel.
• Apply molybdenum disulphide (Three Bond 1901 or equivalent)
to the pilot bearing (9) and damper disc (1) boss.
■ IMPORTANT
• Align the center of damper disc and flywheel by inserting the
clutch center tool (Code No. 07916-53041).
Tightening torque
(1)
(2)
(3)
(4)
(5)
Damper Disc
Radiator Hose
Muffler
Steering Controller
Fan
Dumper disc mounting
screw
(6)
(7)
(8)
(9)
(10)
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
Fan Belt
Alternator
Starter
Pilot Bearing
Clutch Center Tool
W1035529
1-S25
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(4) Turbocharger
•
■
•
•
•
CAUTION
While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the
turbocharger.
NOTE
When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other
foreign matter in the oil pipes.
When the turbocharger assembly has been replace, pour fresh engine oil through the oil filler port of the
turbocharger.
Before starting the engine, make sure that air cleaner is position.
Oil Pipe
1. Remove the joint screw (1) and clamp (2) and take off the pipe 1
(3).
2. Remove the bolts (4) and release the clamp (5).
3. Disconnect the oil pipe 2 (6) and pipe 4 (7).
(When reassembling)
• Pour fresh engine oil through the oil filler port of the turbocharger.
• Replace the gasket with new one.
• Be careful not to allow dust, dirt and other foreign matters in the
oil pipes.
■ NOTE
• Tape or plug all openings to prevent foreign matters from
damaging the oil cavities in the turbocharger.
(1)
(2)
(3)
(4)
Joint Screw
Clamp
Oil Pipe 1
Bolt
(5) Clamp
(6) Oil Pipe 2
(7) Oil Clamp 4
W1036602
1-S26
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Turbocharger
1. Remove the screw (1) and bolt (2).
2. Take off the turbocharger assembly (3).
(When reassembling)
• Replace the gasket with new one.
(1) Screw
(2) Bolt
(3) Turbocharger Assembly
W1036884
1-S27
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(5) Cylinder Head and Valves
Cylinder Head Cover and Nozzle Holder
1. Remove the injection pipes (1).
2. Remove the cylinder head cover (2).
3. Remove the overflow pipe (3).
4. Remove the nozzle holder clamps (4), nozzle holder assembly
(5) and nozzle gaskets.
(When reassembling)
• Check to see that the cylinder head cover gasket is not defective.
• Be sure to place the nozzle gaskets.
• Tighten the head cover mounting bolts to specified torque.
• Mount the check valve with the ↓ mark toward the tank.
Nozzle holder clamp nut
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
Overflow pipe assembly
retaining screw
9.8 to 11.3 N·m
1.0 to 1.15 kgf·m
7.23 to 8.32 ft-lbs
Cylinder head cover screw
6.9 to 11.3 N·m
0.7 to 1.15 kgf·m
5.1 to 8.32 ft-lbs
Injection pipe retaining nut
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
Tightening torque
(1) Injection Pipe
(2) Head Cover
(3) Overflow Pipe
(4) Nozzle Holder Clamps
(5) Nozzle Holder Assembly
W1037062
1-S28
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Rocker Arm and Push Rod
1. Remove the rocker arm (1) as a unit.
2. Remove the push rods (2).
3. Detach the bridge arm (4).
(When reassembling)
• When putting the push rods onto the tappets, check to see if their
ends are properly engaged with the grooves.
■ IMPORTANT
• After reassembling the rocker arm, be sure to adjust the
valve clearance.
Tightening torque
Rocker arm bracket screw
(1) Rocker Arm
(2) Push Rod
49.0 to 55.9 N·m
5.0 to 5.7 kgf·m
36.2 to 41.2 ft-lbs
(3) Tappet
(4) Bridge Arm
W1037771
Injection Nozzle Oil Seal (if necessary)
1. Remove the injection nozzle oil seal (1) from cylinder head cover
(2).
(When reassembling)
• When install the injection nozzle oil seal, use the new one.
(1) Injection Nozzle Oil Seal
(2) Cylinder Head Cover
W1038387
1-S29
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Cylinder Head and Tappet
1. Loosen the pipe band, and remove the water return pipe (1).
2. Disconnect the fuel pipe (3) first and then the fuel filter (2).
3. Remove the IN. / EX. Manifold.
4. Remove the cylinder head screw in the order of (18) to (1), and
remove the cylinder head.
5. Remove the cylinder head gasket.
6. Remove the tappets (4) from the crank case.
(When reassembling)
• Replace the head gasket with a new one.
• Before installing the tappets (4), apply engine oil thinly around
them.
• When mounting the gasket, set it to the knock pin hole. Take
care not to mount it reversely.
• The cylinder head should be free of scratches and dust.
• Take care for handling the gasket not to damage it.
• Install the cylinder head.
• Tighten the cylinder head screw gradually in the order of (1) to
(18) after applying engine oil.
• Be sure to adjust the valve clearance. See the “Valve
Clearance”.
• It is not necessary to retighten the cylinder head screw after
running the engine for 30 minutes.
■ IMPORTANT
• When replace the piston, piston pin bush, connecting rod or
crankpin bearing, select the cylinder head gasket thickness
to meet with the top clearance refer to the “Selecting
Cylinder Head Gasket”.
■ NOTE
• Mark the cylinder number to the tappets to prevent
interchanging.
Tightening torque
(1)
(2)
(3)
(4)
Return Pipe
Fuel Filter
Fuel Pipe
Tappet
Cylinder head mounting
screw
98.1 to 107.9 N·m
10.0 to 11.0 kgf·m
72.3 to 79.6 ft-lbs
A : Gear Case Side
B : Flywheel Side
W1038522
1-S30
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Selecting Cylinder Head Gasket
■ Replacing the Cylinder Head Gasket
1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket
(1) in advance.
2. Replace the same notch (a), (b) or (c) as the original cylinder
head gasket (1).
■ Selecting the Cylinder Head Gasket
• Select the cylinder head gasket (1) thickness to meet with the top
clearance when replacing the piston, piston pin bush, connecting
rod or crankpin bearing.
1. Measure the piston head's protrusion or recessing from the
crankcase cylinder face 4 spots per each piston (average of four
pistons) using the dial gauge as shown in figure.
2. Select the suitable cylinder head gasket refer to the table below.
Notch of
Cylinder
Head
Gasket
Thickness of cylinder
head gasket
Part Code
Piston Head's
protrusion or
recessing from the
level of crankcase
cylinder face.
(average of 4 pistons)
0.80 mm
0.0315 in.
1G514-03310
-0.07 to +0.049 mm
-0.0028 to +0.0019 in.
1.00 mm
0.0394 in.
0.90 mm
0.0354 in.
1G514-03600
+0.050 to +0.149 mm
+0.0020 to +0.0058 in.
1.05 mm
0.0413 in.
0.95 mm
0.0374 in.
1G514-03610
+0.150 to +0.20 mm
+0.0059 to +0.0078 in.
Before
tightening
After
tightening
2 notches
(a)
0.90 mm
0.0354 in.
1 notch
(b)
Without
notch (c)
(1)
(2)
(A)
(B)
Cylinder Head Gasket
Measuring Point
Gear Case Side
Flywheel Side
(a) 2 Notches
(b) 1 Notch
(c) Without Notch
W1039324
Valve
1. Remove the valve spring collets (1) after compressing the valve
spring (3) with the valve spring retainer (2).
(When reassembling)
• Install the valve spring with its small-pitch end downward (at the
head side).
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
(1)
(2)
(3)
(4)
(5)
(6)
Valve Spring Collet
Valve Spring Retainer
Valve Spring
Valve Stem Seal
Valve
Arm Bridge
(7) Large Pitch
(8) Smaller Pitch
(9) Install the spring with its smallerpitch end downward (at the head
side)
W1040057
1-S31
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(6) Thermostat
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove the
thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the
thermostat cover side of the gasket (2).
• Attach the thermostat with its hole facing toward the air suction
side.
(1) Thermostat Cover
(2) Thermostat Cover Gasket
(3) Thermostat Assembly
(4) Hole
W1040577
1-S32
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(7) Injection Pump Unit
Injection Pump Unit
(Removing the fuel injection pump unit)
1. Remove the lubricating oil pipe (1) for the automatic timer.
2. Detach the gear cover (2) for the fuel injection pump gear from
the gear case.
3. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.
■ IMPORTANT
• When the align mark (3) on the injection pump gear is
mashed with the idle gear 2 (4), it means that the piston of
the 4th cylinder is at the top dead center in the compression
stroke.
4. Put an temporarily align mark (5) on the engaged tooth of the idle
gear 2, using a white marking pen (6). This marking helps to
reassemble these gears in mesh later.
■ NOTE
• When the already existing align marks align with each other,
there is no need to put another align mark with white pen.
5. Remove the plugs (7) from the injection pump unit.
6. Tighten the fuel camshaft lock screw (8) at upper side until it
comes into contact with the fuel camshaft.
7. Tighten the fuel camshaft lock screw (8) at lower side until it
comes into contact with the fuel camshaft.
■ NOTE
• Never overtighten the fuel camshaft lock screws when they
have come into contact with the camshaft. Otherwise the
injection pump unit case itself may get damaged.
• Use of a socket set screw (dog point type) in recommended
for best results. (See page G-58.)
(1) Lubricating oil pipe for the automatic (7) Plug
timer
(8) Fuel Camshaft Lock Screw
(2) Gear Cover
(9) Governor Lubricating Oil Pipe
(3) Align Mark on the Injection Pump
Retaining Nut
Gear
(10) Injection Pump Unit Support
(4) Idle Gear 2
(11) Injection Pump Unit Mounting Nut
(5) Temporarily Align Mark
(6) White Marking Pen
W1040787
1-S33
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Injection Pump Unit (Continued)
(Removing the fuel injection pump unit)
1. Remove the injection pump gear mounting nut (9) and washer
(10).
2. Set the injection pump gear puller (11) (see page G-59) for the
injection pump gear (12).
3. Remove the injection pump gear (12) with the automatic timer
(13).
■ NOTE
• Never disassemble the automatic timer.
• Be careful not to drop the half-moon key (14) from the fuel
camshaft.
4. Disconnect the governor lubricating oil pipe retaining nut (15).
5. Remove the injection pump unit support (16).
6. Remove the injection pump unit mounting nuts (17) and detach
the injection pump unit (18).
(9)
(10)
(11)
(12)
(13)
(14)
Injection Pump Gear Mounting Nut
Washer
Injection Pump Gear Puller
Injection Pump Gear
Automatic Timer
Half-moon Key
(15) Governor Lubricating Oil Pipe
Retaining Nut
(16) Injection Pump Unit Support
(17) Injection Pump Unit Mounting Nut
(18) Injection Pump Unit
W1042187
1-S34
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Injection Pump Unit (Continued)
(Reassembling the fuel injection pump unit)
1. Place the piston of the 4th cylinder at the top dead center in the
compression stroke. Fix the flywheel with the flywheel stopper.
2. Place the injection pump gear with the automatic timer (1) back
into the gear case position.
Make sure aligning the align marks (2) of the injection pump gear
an the idle gear 2.
3. Install the injection pump unit (3) to the injection pump gear with
the automatic timer (1).
■ NOTE
• When installing the injection pump unit to the injection
pump gear, make sure that the half-moon key is fit in the key
way of injection pump gear.
4. Install the washer (4) and temporarily tighten the injection pump
gear mounting nut (5) by hand for not to drop the injection pump
gear from gear case.
5. Tighten the injection pump unit mounting nuts (6) to the specified
torque, aligning the injection timing marks (7).
6. Tighten the injection pump gear mounting nut to the specified
torque.
7. Unscrew the fuel camshaft lock screws (8) and install the plugs.
■ NOTE
• Never forget to unscrew the fuel camshaft lock screws,
otherwise the injection pump unit case itself may get
damaged.
(1) Injection Pump Gear with the
Automatic Timer
(2) Align Marks
(3) Injection Pump Unit
(4) Washer
(5) Injection Pump Gear Mounting Nut
W1043436
1-S35
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Injection Pump Unit (Continued)
(Reassembling the fuel injection pump unit)
1. Reconnect the governor lubricating oil pipe retaining nut (9).
2. Attach the gear cover (10).
3. Reconnect the lubricating pipe for the automatic timer (11).
4. Fix the injection pump unit support (12).
5. Remove the flywheel stopper.
6. Check the injection timing. (See page 1-S17.)
Tightening torque
(6)
(7)
(8)
(9)
Injection pump unit
mounting nut
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
Injection pump gear
mounting nut
83.0 to 98.0 N·m
8.5 to 10.0 kgf·m
61.5 to 72.3 ft-lbs
Governor lubricating oil
pipe retaining nut
14.7 to 24.5 N·m
1.5 to 2.5 kgf·m
10.9 to 18.1 ft-lbs
Injection Pump Unit Mounting Nut
Injection Timing Marks
Fuel Camshaft Lock Screw
Governor Lubricating Oil Pipe
Retaining Nut
(10) Gear Cover
(11) Lubricating Pipe for the Automatic
Timer
(12) Injection Pump Unit Support
W1044005
1-S36
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Governor Housing Assembly
1. Remove the injection pump unit from the engine. (See the
“Injection Pump Unit”.)
2. Remove the governor lubricating pipe (1).
3. Remove the stop solenoid (2).
4. Detach the sight cover (3) from the injection pump unit.
5. Unhook the start spring (4) from the rack pin (5) of injection pump
assembly.
6. Remove the nut (6).
■ NOTE
• Be careful not to drop the nut inside.
7. Slide off the governor connecting rod (7) from the rack pin of
injection pump assembly.
8. For convenient sake, temporarily hook the start spring on the
rack pin hole of the governor connecting rod.
9. Remove the governor housing mounting screws.
10.Detach the governor housing assembly (8) from the injection
pump unit.
(When reassembling)
• When reassembling the inside parts, put the oil on each inside
part slightly.
• After sliding on the governor connecting rod to the rack pin,
tighten the nut with the specified torque with using the jig for
keeping the governor connecting rod horizontal. (See the
Replacing Injection Pump Assembly.)
• After tightening the nut, hook the start spring on the rack pin.
• Check the movement of control rack of injection pump assembly
by the stop lever.
■ NOTE
• When installing the governor housing assembly to the
injection pump unit, be careful not to damage O-ring (9).
• When linking the governor connecting rod to the rack pin of
injection pump, use the jig for keeping the governor
connecting rod horizontal. Otherwise the control rack may
be stuck, and causes to be difficult to start the engine or
hunting of governor. (See the Replacing Injection Pump
Assembly).
Governor housing
mounting screw
9.8 to 11.3 N·m
1.00 to 1.15 kgf·m
7.23 to 8.32 ft-lbs
Anti-rotation nut
2.8 to 4.0 N·m
0.29 to 0.41 kgf·m
2.1 to 3.0 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
Governor Lubricating Pipe
Stop Solenoid
Sight Cover
Start Spring
Rack Pin
(6)
(7)
(8)
(9)
Anti-rotation Nut
Governor Connecting Rod
Governor Housing Assembly
O-ring
W1044674
1-S37
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Governor Fork Lever Assembly
1. Pull off the governor fork lever shaft (1) with the extra screw (Dia.:
4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2).
2. Unhook the governor spring (3) at the governor fork lever (4)
side.
3. Remove the governor fork lever assembly from the governor
housing (5).
(When reassembling)
• After reassembling the governor housing assembly, check the
movement of the governor fork lever assembly, the speed control
lever and the stop lever.
■ NOTE
• When assembling the inside parts, put the oil on each inside
part slightly.
• Be careful not to deform the start spring.
(1) Governor Fork Lever Shaft
(2) Extra Screw
(Dia. : 4 mm, Pitch : 0.7 mm,
Length : more than 25 mm)
(3) Governor Spring
(4) Governor Fork Lever
(5) Governor Housing
W1045973
1-S38
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Governor Lever
1. Remove the speed control lever (1) and the return spring (2).
2. Remove the governor lever assembly (3) from the governor
housing.
3. Remove the start spring (4) and the stop spring (5).
(1) Speed Control Lever
(2) Return Spring
(3) Governor Lever Assembly
(4) Start Spring
(5) Stop Spring
W1046875
Stop Lever
1. Remove the stop lever (1) and the return spring (2).
2. Remove the stop lever shaft (3).
(1) Stop Lever
(2) Return Spring
(3) Stop Lever Shaft
W1047173
1-S39
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Fuel Camshaft and Governor Weight
1. Separate the governor housing assembly from the injection
pump unit. (See the “Injection Pump Unit”.)
2. Remove the governor sleeve (1).
3. Remove the injection pump assembly (2).
4. Remove the fuel camshaft lock screws.
5. Fix the fuel camshaft with open end wrench (3), and remove the
governor weight mounting nut and the governor weight (4).
6. Loosen the fuel camshaft stopper mounting screws and remove
the fuel camshaft stopper (5).
7. Pull out the fuel camshaft (6) and bearings (7) together.
8. After removing the bearing's cir-clip (8), press out the bearings.
■ NOTE
• Do not use the fuel camshaft lock bolts, when removing the
governor weight mounting nut. Otherwise, the lock bolts or
injection pump housing might get damage.
(When reassembling)
• Press the bearings into the fuel camshaft.
• Set the cir-clip at the gear side's bearing.
• Install the fuel camshaft and bearings to the injection pump
housing.
• Attach the fuel camshaft stopper and tighten the fuel camshaft
stopper mounting screws with the specified torque.
• Attach the governor weight to the fuel camshaft and tighten the
governor weight mounting nut with specified torque.
Injection pump mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Injection pump mounting
nut
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
Governor Sleeve
Injection Pump Assembly
Open End Wrench (22 mm)
Governor Weight
Fuel Camshaft Stopper
(6)
(7)
(8)
(9)
Fuel Camshaft
Bearing
Cir-clip
Key Way of Fuel Camshaft
W1047498
1-S40
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Fuel Camshaft and Governor Weight (Continued)
(When reassembling)
• Fix the fuel camshaft with lock bolts as the key way of fuel
camshaft (9) is upward.
• Install the injection pump assembly to the injection pump
housing.
• Attach the O-ring and the cover and tighten the cover mounting
screws.
• Install the governor sleeve to the fuel camshaft.
• Check the movement of the governor sleeve.
■ NOTE
• Be careful not to damage the O-ring.
• Be careful the direction of the governor sleeve.
• When reassembling the inside parts, put the oil on each
inside part slightly.
Fuel camshaft stopper
mounting screw
7.9 to 9.3 N·m
0.80 to 0.95 kgf·m
5.8 to 6.9 ft-lbs
Governor weight mounting
nut
62.8 to 72.6 N·m
6.4 to 7.4 kgf·m
46.3 to 53.5 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
Governor Sleeve
Injection Pump Assembly
Open End Wrench (22 mm)
Governor Weight
Fuel Camshaft Stopper
(6)
(7)
(8)
(9)
Fuel Camshaft
Bearing
Cir-clip
Key Way of Fuel Camshaft
W1048682
1-S41
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Replacing Injection Pump Assembly (If necessary)
• The injection pump can be replaced with the crankshaft in
whatever position.
1. Disconnect all injection pipes (1).
2. Disconnect the fuel pipe (2) and fuel overflow pipe (10).
3. Disconnect the connector (3) from the stop solenoid. Then
remove the stop solenoid (4).
4. Detach the sight cover (5) from the injection pump unit.
5. Unhook the starter spring (6), and remove the control rod nut (8).
6. Just loosen the injection pump assembly mounting screws and
nuts like the figure, which the injection pump assembly keeps
tilted.
7. Slide off the governor connecting rod (7) from the rock pin of
injection pump assembly.
8. Remove the injection pump mounting screws and nuts, and take
out the injection pump assembly (9).
■ NOTE
• Be careful not to drop the anti-rotation nut (8).
• Be careful not to deform the start spring.
• When taking out the injection pump assembly, be careful not
to hit it against the governor connecting rod.
(When reassembling)
• Install the new injection pump according to the installing
procedure.
(1)
(2)
(3)
(4)
(5)
Injection Pipe
Fuel Pipe
Connector
Stop Solenoid
Sight Cover
(6)
(7)
(8)
(9)
(10)
Starter Spring
Governor Connecting Rod
Anti-rotation Nut
Injection Pump
Fuel Overflow Pipe
W1049309
1-S42
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Installing Procedure of Injection Pump Assembly
1. Install the injection pump assembly (1) in the unit (2), and tighten
the mounting screws and nuts like the figure, which the injection
pump assembly (1) keeps tilted.
2. Hook the governor connecting rod (4) to the rack pin of the
injection pump assembly (1).
3. Tighten the mounting screws and nuts with the specified torque,
not to slide off the governor connecting rod (4) from the rack pin.
4. Place the service jig (3) in the stop solenoid mounting hole of the
fuel injection pump unit.
5. Make sure the permanent magnet at the tip of the service jig is
attracted to the governor connecting rod (4). To do this, turn the
jig a little clockwise and counterclockwise and look into the fuel
injection pump unit sight hole to see if the governor connecting
rod (4) moves right and left accordingly.
6. Slightly tighten the anti-rotation nut of the governor connecting
rod.
7. Holding down the service jig (3) by hand, tighten up the antirotation nut (5) to the specified torque.
8. Hook the start spring (6) to the rack pin (7).
(1)
(2)
(3)
(4)
Fuel Injection Pump Assembly
Fuel Injection Pump Unit
Service Jig
Governor Connecting Rod
(5) Anti-rotation Nut
(6) Start Spring
(7) Rack Pin
W1050085
1-S43
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Installing Procedure (Continued)
1. Move the stop lever (1) and visually check to see if the fuel
injection pump control rack comes smoothly back to the start
position by the counter force of the start spring.
2. If the control rack fails to move back smoothly, remove the start
spring and the anti-rotation nut, take the above steps from 2 of
the former page again.
3. Finally fit the sight cover and the stop solenoid back into place.
Tightening torque
Anti-rotation nut
2.8 to 4.0 N·m
0.29 to 0.41 kgf·m
2.1 to 3.0 ft-lbs
Injection pump mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Injection pump mounting
nut
17.7 to 20.6 N·m
1.8 to 2.1 kgf·m
13.0 to 15.2 ft-lbs
(1) Stop Lever
(2) Sliding Point between the Governor
Fork Lever and the Governor
Connecting Rod
W1050946
Fan Drive Pulley
1. Set the stopper to the flywheel.
2. Remove the crankshaft screw (1).
3. Draw out the fan drive pulley (2).
(When reassembling)
Tightening torque
(1) Crankshaft Screw
Crankshaft screw
255.0 to 274.6 N·m
26.0 to 28.0 kgf·m
188.1 to 202.5 ft-lbs
(2) Fan Drive Pulley
W1051452
1-S44
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(8) Water Pump and Oil Cooler
Water Pump
1. Remove the pipe band and the water pipe (1).
2. Remove the water pump (2).
(When reassembling)
• When mounting the water pump, take care not to forget mounting
the O-ring and not to let it out of position.
(1) Water Pipe
(2) Water Pump
W1051675
Oil Cooler
1. Remove the water pipe (1).
2. Remove the oil filter cartridge (2) and the oil cooler joint screw
(3).
3. Remove the oil cooler (4).
Tightening torque
(1) Water Pipe
(2) Oil Filter Cartridge
Oil cooler joint screw
39.2 to 44.1 N·m
4.0 to 4.5 kgf·m
28.9 to 32.5 ft-lbs
(3) Oil Cooler Joint Screw
(4) Oil Cooler
W1051821
1-S45
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(9) Gear Case
Gear Case Cover
1. Remove the gear case cover.
(When reassembling)
• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.
• Carefully apply the adhesive evenly. (Refer to the figure on the
left)
■ NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
• Apply a liquid gasket (Three Bond 1217D) to the gear case
cover.
Tightening torque
Gear case cover mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
(1) Liquid Gasket
W1052038
Relief Valve
1. Remove the relief valve retaining screw (1).
2. Remove the relief valve (2), the spring (3) and the packing (4).
Tightening torque
Relief valve retaining
screw
(1) Relief Valve Retaining Screw
(2) Relief Valve
68.6 to 78.4 N·m
7.0 to 8.0 kgf·m
50.6 to 57.9 ft-lbs
(3) Spring
(4) Packing
W1052893
Idle Gear 1 and Idle Gear 2
1. Remove the idle gear mounting screw (1).
2. Draw out the idle gear (2) and (3).
(When reassembling)
• When install the idle gear (2) and (3), be sure to place the 4th
cylinder piston at the top dead center in compression then, align
all mating marks on each gear to assemble the timing gears, set
the idle gear last.
Tightening torque
Idle gear mounting screw
(1) Idle Gear Mounting Screw
(2) Idle Gear 1
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
(3) Idle Gear 2
W1053095
1-S46
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Camshaft and Balancer Shaft
1. Remove the camshaft set screws and draw out the camshaft (1).
2. Remove the balancer shaft 1 set screws and draw out the
balancer shaft 1 (2).
3. Remove the balancer shaft 2 set screws and draw out the
balancer shaft 2 (6).
(When reassembling)
• When install the balancer shaft 1 and 2, be sure to place the 4th
cylinder piston at the top dead center in compression then, align
all mating marks on each gear to assemble the timing gears, set
the idle gear last.
Camshaft set screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Balancer shaft set screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Tightening torque
(1) Camshaft
(2) Balancer Shaft 1
(3) Idle Gear 1
(4) Crank Gear
(5) Idle Gear 2
(6) Balancer Shaft 2
W1053305
Plate (Gear Case)
1. Remove the three plate mounting screws. Detach the plate (1).
(When reassembling)
• Apply Three Bond 1217D adhesive or equivalent over the
shaded zones on both sides of the gasket that will be sandwiched
between the crankcase and plate.
• Be sure to fix the O-rings (4).
Tightening torque
(1) Plate
(2) Gasket
Plate mounting screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
(3) Liquid Gasket
(4) O-ring
W1053809
1-S47
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(10) Piston and Connecting Rod
Oil Pan and Oil Strainer
1. Unscrew the oil pan mounting screws and remove the oil pan (1).
2. Unscrew the oil strainer mounting screw, and remove the oil
strainer (2).
(When reassembling)
• Install the oil strainer, using care not to damage the O-ring.
• Apply liquid gasket (Three Bond 1217D) to the oil pan as shown
in the figure.
• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.
• Carefully apply the adhesive evenly.
■ NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
• To avoid uneven tightening, tighten mounting screws in
diagonal order from the center.
• After cleaning the oil strainer, install it.
• Attach the oil pan with its central drain plug facing toward
the air suction side.
(1) Oil Pan
(2) Oil Strainer
(3) Liquid Gasket
W1054035
1-S48
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Connecting Rod Cap
1. Remove the connecting rod screws (1) from connecting rod cap.
2. Remove the connecting rod caps.
(When reassembling)
• Align the marks (a) with each other. (Face the marks toward the
injection pump.)
• Apply engine oil to the connecting rod screws and lightly screw it
in by hand, then tighten it to the specified torque.
If the connecting rod screw won't be screwed in smoothly, clean
the threads.
If the connecting rod screw is still hard to screw in, replace it.
• When using the existing crank pin bearing again, put tally marks
on the crank pin bearing and the connecting rod in order to keep
their positioning.
• Fit the crank pin bearing in place : its centrally groove side toward
the connecting rod, and the non-grooved side toward the cap.
Tightening torque
Connecting rod screw
(1) Connecting Rod Screw
78.5 to 83.4 N·m
8.0 to 8.5 kgf·m
57.9 to 61.5 ft-lbs
(a) Mark
W1054832
1-S49
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Piston
1. Completely clean carbon in the cylinders.
2. Turn the flywheel and set a piston to the top dead center.
3. Pull out the piston upward by lightly tapping it from the bottom of
the crankcase with the grip of a hammer.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine
oil to the cylinder.
• When inserting the piston into the cylinder, face the mark (3) on
the connecting rod to the injection pump.
■ IMPORTANT
• Do not change the combination of cylinder and piston.
Make sure of the position of each piston by marking. For
example, mark “1” on the No. 1 position.
• When inserting the piston into the cylinder, place the gap of
each piston ring like the figure.
• Carefully insert the pistons using a piston ring compressor
(1). Otherwise, their chrome-plated section of piston rings
may be scratched, causing trouble inside the liner.
• When inserting the piston in place, be careful not to get the
molybdenum disulfide coating torn off its skirt. This coating
is useful in minimizing the clearance with the cylinder liner.
Just after the piston pin has been press-fitted, in particular,
the piston is still hot and the coating is easy to peel off. Wait
until the piston cools down.
(1) Piston Ring Compressor
(2) Molybdenum Disulfide Coating in
Piston Skirt
(3) Mark
(a) 0.79 rad (45 °)
(A)
(B)
(C)
(D)
(E)
Top Ring Gap
Second Ring Gap
Oil Ring Gap
Piston Pin Hole
Injection Pump Side
W1055159
1-S50
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (1), and separate the connecting rod (7)
from the piston (2).
(When reassembling)
• Be sure to fix the crankpin bearing and the connecting rod are
same I.D. colors.
• When installing the ring, assemble the rings so that the
manufacture's mark (12) near the gap faces the top of the piston.
• When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin.
• When installing the piston pin, immerse the piston in 80 °C (176
°F) oil for 10 to 15 minutes and insert the piston pin to the piston.
• Assemble the piston to the connecting rod with the ↑ mark (8)
and the connecting rod numbering mark (9) facing same side.
• The end faces of the oil ring are plated with hard chrome. In
putting the piston into the cylinder, be careful not to get the oil ring
scratched by the cylinder. Use the piston ring fitter to tighten up
the oil ring. If the ring’s planting is scratched, it may get stuck on
the cylinder wall, causing a serious trouble.
■ IMPORTANT
• Mark the same number on the connecting rod and the piston
so as not to change the combination.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Piston Pin
Piston
Piston Pin Snap Pin
Compression Ring 1
Compression Ring 2
Oil Ring
Connecting Rod
Mark (↑)
Numbering Mark
(10) Expander Joint
(11) Oil Ring Gap
(12) Manufacture's Mark
(A) Connecting Rod ID Color : Blue
or without Color
(B) Crankpin Bearing ID Color : Blue
or without Color
W1055741
1-S51
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(11) Flywheel and Crankshaft
Flywheel
1. Install the stopper to the flywheel so that the flywheel does not
turn.
■ NOTE
• Do not use an impact wench. Serious damage will occur.
2. Detach the flywheel screws.
3. Remove the flywheel.
(When reassembling)
• Apply engine oil to the flywheel screws.
• Before fitting the flywheel and the crankshaft together, wipe oil,
dust and other foreign substances off their mating faces.
• The flywheel and the crankshaft are fitting together in just one
position. Make sure they are tightly fit and drive the bolts.
Tightening torque
98.1 to 107.9 N·m
10.0 to 11.0 kgf·m
72.3 to 79.6 ft-lbs
Flywheel screw
W1056461
Flywheel Housing
1. Remove the flywheel housing.
(When reassembling)
• Apply liquid gasket (Three Bond 1217D or equipment) to flywheel
housing.
• Confirm that the liquid gasket coating surface is free of water,
dust and oil in order to maintain sealing effect.
• Be careful not to get a damage to the oil seal when installing the
flywheel housing to the crankshaft.
• Be careful not to place the oil seal tilted.
• Tighten the flywheel housing mounting screws with even force on
the diagonal line.
■ NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
Tightening torque
(1) Flywheel Housing
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Flywheel housing
mounting screw
(2) Oil Seal
W1056964
1-S52
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Crankcase 1 and Crankcase 2
1. Remove the crankcase 2 (2) from the crankcase 1.
(When reassembling)
■ IMPORTANT
• Make sure the crankcase 1 and 2 are clean.
• Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
• Apply liquid gasket (Three Bond 1217D) to the crankcase 2
as shown in the figure.
• Match the crankcase 1 and 2, referring to the flywheel housing's
contoured face.
• Temporarily tighten the crankcase 2 mounting screws loosely.
• For aligning the crankcase 1 and 2, set the flywheel housing as a
jig temporarily, and tighten the flywheel housing mounting
screws. Possible gap between crankcase 1 and 2 must be 0.05
mm (0.0020 in.) or smaller.
• After aligning the crankcase 1 and 2, tighten the crankcase 2
mounting screws to the specified torque on the diagonal line.
• Tighten the flywheel housing mounting screws. (See “The
Flywheel Housing”).
■ NOTE
• When mounting the adhesive-applied parts, take care to fit
them to the mating parts.
• Assemble the adhesive-applied parts within ten minutes.
Crankcase 2 mounting
screw
49.0 to 55.9 N·m
5.0 to 5.7 kgf·m
36.2 to 41.2 ft-lbs
Flywheel housing
mounting screw
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Tightening torque
(1) Liquid Gasket
(2) Crankcase 2
(3) Crankcase 1
(4) Flywheel Housing
(5) Gap to be Smaller than 0.05 mm
(0.0020 in.)
W1057247
1-S53
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Crankshaft
1. Remove the main bearing case.
2. Remove the crankshaft.
(When reassembling)
• Reassemble the main bearing case having the same number as
the one engraved on the crankcase, and set the casting mark “F
/ W SIDE” on the main bearing case facing towards the flywheel
side.
• Reassemble the thrust bearing (2), with the oil groove facing
outside, into both side of the fourth main bearing case (3).
• Apply oil to the main bearing case screws and tighten them to the
specified torque.
Tightening torque
(1) F / W SIDE Mark
(2) Thrust Bearing
Main bearing case screw
137.3 to 147.1 N·m
14.0 to 15.0 kgf·m
101.3 to 108.5 ft-lbs
(3) 4th Main Bearing Case
W1057882
1-S54
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
[3] SERVICING
(1) Cylinder Head
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head's four sides (A), (B),
(C) and (D) and two diagonal (E) and (F) as shown in the figure.
Measure the clearance with a feeler gauge.
3. If the measurement exceeds the allowable limit, correct it with a
surface grinder.
■ IMPORTANT
• Be sure to check the valve recessing after correcting.
Cylinder head surface
flatness
Allowable limit
0.05 mm
0.0020 in.
W1058703
Cylinder Head Flaw
1. Prepare an air spray red check (Code No. 07909-31371).
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid
(2) Detergent
(3) White Developer
W1058902
1-S55
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Valve Recessing
1. Clean the cylinder head, the valve face and seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
If it still exceeds the allowable limit after replacing the valve,
replace the cylinder head.
Valve recessing
(1) Cylinder Head Surface
Factory
spec.
Intake
valve
(recessing)
0.6 to 0.8 mm
0.0236 to 0.0315 in.
Factory
spec.
Exhaust
valve
(recessing)
0.85 to 1.05 mm
0.0335 to 0.0413 in.
Allowable
limit
(recessing)
1.2 mm
0.0472 in.
(A) Recessing
(B) Protrusion
W1059101
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its seat
with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply oil,
then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
■ IMPORTANT
• When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
(1) Correct
(2) Incorrect
(3) Incorrect
W1059556
1-S56
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. of the cylinder head at the most
wear part as shown in the figure below with a small hole gauge.
And calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the valves.
If it still exceeds the allowable limit, replace the valve guide.
Clearance between valve
stem and guide
Factory
spec.
Intake
valve
0.055 to 0.085 mm
0.0022 to 0.0033 in.
Exhaust
valve
0.055 to 0.085 mm
0.0022 to 0.0033 in.
Allowable limit
Valve stem O.D.
Factory
spec.
Valve guide I.D.
Factory
spec.
0.1 mm
0.0039 in.
Intake
valve
6.960 to 6.975 mm
0.2740 to 0.2746 in.
Exhaust
valve
6.960 to 6.975 mm
0.2740 to 0.2746 in.
Intake
valve
7.030 to 7.045 mm
0.2768 to 0.2774 in.
Exhaust
valve
7.030 to 7.045 mm
0.2768 to 0.2774 in.
W1060229
Replacing Valve Guide
(When removing)
1. Using a valve guide replacing tool, press out the used valve
guide.
(When installing)
1. Clean a new valve guide, and apply engine oil to it.
2. Using a valve guide replacing tool, press in a new valve guide
until it is flush with the cylinder head as shown in the figure.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
■ IMPORTANT
• Do not hit the valve guide with a hammer, etc. during
replacement.
(A) When removing
(B) When installing
W1060680
1-S57
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Correcting Valve and Valve Seat
■ NOTE
• Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
• After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 1.047 rad (60 °) (intake
valve) or 0.785 rad (45 °) (exhaust valve) seat cutter (Code No.
07909-33102).
2. Resurface the seat surface with a 0.523 rad (30 °) valve seat
cutter to intake valve seat and with a 0.262 rad (15 °) valve seat
cutter to exhaust valve seat so that the width is close to specified
valve seat width (2.12 mm, 0.0835 in.).
3. After resurfacing the seat, inspect for even valve seating, apply a
thin film of compound between the valve face and valve seat, and
fit them with valve lapping tool.
4. Check the valve seating with prussian blue. The valve seating
surface should show good contact all the way around.
(a)
(b)
(c)
(d)
(e)
Identical Dimensions
Valve Seat Width
0.523 rad (15 °) or 0.262 rad (15 °)
0.262 rad (15 °) or 0.523 rad (30 °)
0.785 rad (45 °) or 1.047 rad (60 °)
(A) Check Contact
(B) Correct Seat Width
(C) Check Contact
W1060921
Free Length and Tilt of Valve Spring
1. Measure the free length (A) with vernier calipers. If the
measurement is less than the allowable limit, replace it.
2. Put the spring on a surface plate, place a square on the side of
the spring, and check to see if the entire side is contact with the
square. Rotate the spring and measure the maximum (B). If the
measurement exceeds the allowable limit, replace.
3. Check the entire surface of the spring for scratches. Replace it,
if any.
Factory
spec.
Free length (A)
Allowable
limit
Tilt (B)
Intake
valve
35.1 to 35.6 mm
1.3819 to 1.4016 in.
Exhaust
valve
35.1 to 35.6 mm
1.3819 to 1.4016 in.
Intake
valve
34.6 mm
1.3622 in.
Exhaust
valve
34.6 mm
1.3622 in.
Allowable limit
1.0 mm
0.039 in.
W1061991
1-S58
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
Factory
spec.
Setting load / Setting
length
Allowable
limit
Intake
valve
63.547 N / 31.5 mm
6.48 kgf / 31.5 mm
14.256 lbs. / 1.2401 in.
Exhaust
valve
63.547 N / 31.5 mm
6.48 kgf / 31.5 mm
14.256 lbs. / 1.2401 in.
Intake
valve
45.864 N / 31.5 mm
4.68 kgf / 31.5 mm
10.296 lbs. / 1.2401 in.
Exhaust
valve
45.864 N / 31.5 mm
4.68 kgf / 31.5 mm
10.296 lbs. / 1.2401 in.
W1062321
Oil Clearance between Rocker Arm Shaft and Bearing
1. Measure the rocker arm bearing I.D. with an inside micrometer.
2. Measure the rocker arm shaft O.D. with an outside micrometer,
and then calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the rocker
arm and measure the oil clearance again. If it still exceeds the
allowable limit, replace also the rocker arm shaft.
Factory spec.
0.016 to 0.045 mm
0.00063 to 0.00177 in.
Allowable limit
0.15 mm
0.0059 in.
Rocker arm shaft O.D.
Factory spec.
15.973 to 15.984 mm
0.6289 to 0.6293 in.
Rocker arm I.D. for shaft
Factory spec.
16.000 to 16.018 mm
0.6299 to 0.6306 in.
Oil clearance of rocker
arm shaft and bearing
W1062503
Push Rod Alignment
1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
Push rod alignment
Allowable limit
0.25 mm
0.0098 in.
W1062712
1-S59
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Oil Clearance between Tappet and Tappet Guide Bore
1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder gauge,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
Oil clearance between
tappet and tappet guide
bore
Factory spec.
0.020 to 0.062 mm
0.0008 to 0.0024 in.
Allowable limit
0.07 mm
0.0028 in.
Tappet O.D.
Factory spec.
23.959 to 23.980 mm
0.9433 to 0.9441 in.
Tappet guide bore I.D.
Factory spec.
24.000 to 24.021 mm
0.9449 to 0.9457 in.
W1062838
1-S60
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(2) Idle Gear and Camshaft
Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance isn't proper, replace the gear.
Factory spec.
0.049 to 0.193 mm
0.0019 to 0.0076 in.
Allowable limit
0.22 mm
0.0087 in.
Factory spec.
0.049 to 0.189 mm
0.0019 to 0.0074 in.
Allowable limit
0.22 mm
0.0087 in.
Factory spec.
0.044 to 0.185 mm
0.0017 to 0.0073 in.
Allowable limit
0.22 mm
0.0087 in.
Backlash between idle
gear 2 and injection
pump gear
Factory spec.
0.044 to 0.177 mm
0.0017 to 0.0070 in.
Allowable limit
0.22 mm
0.0087 in.
Backlash between cam
gear and balancer gear
1
Factory spec.
0.047 to 0.182 mm
0.0018 to 0.0072 in.
Allowable limit
0.22 mm
0.0087 in.
Backlash between idle
gear 1 and balancer
gear 2
Factory spec.
0.044 to 0.183 mm
0.0017 to 0.0072 in.
Allowable limit
0.22 mm
0.0087 in.
Backlash between crank
gear and idle gear 1
Backlash between idle
gear 1 and cam gear
Backlash between idle
gear 1and idle gear 2
W1063044
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
Factory spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
Allowable limit
0.9 mm
0.0354 in.
Idle gear side clearance
W1063644
1-S61
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the
camshaft stopper.
Factory spec.
0.07 to 0.22 mm
0.0028 to 0.0087 in.
Allowable limit
0.30 mm
0.0118 in.
End play of camshaft
W1063804
Camshaft Alignment
1. Support the camshaft with V block on the surface plate and set a
dial indicator with its tip on the intermediate journal at right angle.
2. Rotate the camshaft on the V blocks and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
camshaft.
Camshaft alignment
Allowable limit
0.01 mm
0.00039 in.
W1064033
Cam Height
1. Measure the height of the cam at its highest point with an outside
micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
Factory
spec.
Intake and exhaust cam
height
Allowable
limit
Intake
valve
37.63 mm
1.4815 in.
Exhaust
valve
38.96 mm
1.5338 in.
Intake
valve
37.13 mm
1.4618 in.
Exhaust
valve
38.46 mm
1.5141 in.
W1064167
1-S62
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Oil Clearance of Camshaft Journal
1. Measure the camshaft journal O.D. with an outside micrometer.
2. Measure the cylinder block bore I.D. for camshaft with an inside
micrometer.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
Factory spec.
0.050 to 0.091 mm
0.00197 to 0.00358 in.
Allowable limit
0.15 mm
0.0059 in.
Camshaft journal O.D.
Factory spec.
45.934 to 45.950 mm
1.8084 to 1.8091 in.
Camshaft bearing I.D.
Factory spec.
46.000 to 46.025 mm
1.8110 to 1.8120 in.
Oil clearance of
camshaft journal
W1064350
Oil Clearance between Idle Gear Shaft 1, 2 and Idle Gear 1, 2
Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
bushing.
Factory spec.
0.050 to 0.091 mm
0.0020 to 0.0036 in.
Allowable limit
0.10 mm
0.0039 in.
Idle gear 1, 2 bushing
I.D.
Factory spec.
45.025 to 45.050 mm
1.7726 to 1.7736 in.
Idle gear 1, 2 shaft O.D.
Factory spec.
44.959 to 44.975 mm
1.7700 to 1.7707 in.
Clearance between idle
gear 1, 2 shaft and idle
gear 1, 2 bushing
W1064798
1-S63
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Replacing Idle Gear Bushing
(When removing)
1. Using an idle gear bushing replacing tool, press out the used
bushing.
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Using an idle gear bushing replacing tool, press in a new bushing
(service parts) to the specified dimension. (See figure.)
(A) When removing
(B) When installing
W1064996
Balancer-shaft Side Clearance
1. Set a dial indicator with tip on the balancer shaft.
2. Measure the side clearance by moving the balancer shaft to the
front and rear.
3. If the measurement exceeds the allowable limit, replace the
balancer shaft.
End play of balancer
shaft
Factory spec.
0.070 to 0.220 mm
0.0028 to 0.0087 in.
Allowable limit
0.3 mm
0.0118 in.
W1065170
Balancer-shaft Alignment
1. Support the balancer shaft with V blocks on the surface plate and
set a dial indicator with its tip on the intermediate journal at high
angle.
2. Rotate the balancer shaft on the V block and get the
misalignment (half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
balancer shaft.
Balancer shaft
alignment
Allowable limit
0.02 mm
0.0008 in.
W1065323
1-S64
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Oil Clearance of Balancer-shaft Journal
1. Measure the balancer shaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. (A), (B) for balancer shaft
with an inside micrometer.
3. If the clearance exceeds the allowable limit, replace the balancer
shaft.
Factory spec.
0.070 to 0.159 mm
0.0028 to 0.0063 in.
Allowable limit
0.2 mm
0.0079 in.
Balancer-shaft journal
O.D.
Factory spec.
50.92 to 50.94 mm
2.0047 to 2.0055 in.
Balancer-shaft bearing
I.D. (A), (B)
Factory spec.
51.01 to 51.08 mm
2.0083 to 2.0110 in.
Oil clearance of
balancer-shaft journal
(A), (B)Balancer-shaft Bearing I.D.
W1065449
(3) Piston and Connecting Rod
Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
2. If the measurement exceeds the allowable limit, replace the
piston.
Factory spec.
30.000 to 30.013 mm
1.1811 to 1.1816 in.
Allowable limit
30.05 mm
1.1831 in.
Piston pin bore I.D.
W1066065
1-S65
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Clearance between Piston Ring and Groove
1. Remove carbon from the ring grooves.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance exceeds allowable limit, replace the ring since
compression leak and oil shortage result.
4. If the clearance still exceeds the allowable limit after replacing the
ring, replace the piston.
Factory spec.
Allowable limit
Top ring
0.05 to 0.09 mm
0.0020 to 0.0035 in.
Second ring
0.093 to 0.120 mm
0.0037 to 0.0047 in.
Oil ring
0.020 to 0.060 mm
0.0008 to 0.0023 in.
Top ring
0.15 mm
0.0059 in.
Second ring
0.20 mm
0.0079 in.
Oil ring
0.15 mm
0.0059 in.
W1066194
Piston Ring Gap
1. Insert the piston ring into the lower part of the liner (the least worn
out part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. If the gap exceeds the allowable limit, replace the piston ring.
Factory spec.
0.30 to 0.45 mm
0.0118 to 0.0177 in.
Allowable limit
1.25 mm
0.0492 in.
Factory spec.
0.25 to 0.45 mm
0.0098 to 0.0177 in.
Allowable limit
1.25 mm
0.0492 in.
Top ring and second ring
Oil ring
W1066469
1-S66
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the O.D. of the piston pin where it contacts the bushing
with an outside micrometer.
2. Measure the I.D. of the piston pin bushing at the connecting rod
small end with a cylinder gauge.
Calculate the oil clearance.
3. If the clearance exceeds the allowable limit, replace the bushing.
If it still exceeds the allowable limit, replace the piston pin.
Oil clearance between
piston pin and small end
bushing
Factory spec.
0.020 to 0.040 mm
0.0008 to 0.0016 in.
Allowable limit
0.15 mm
0.0059 in.
Piston pin O.D.
Factory spec.
30.006 to 30.011 mm
1.1813 to 1.1815 in.
Small end bushing I.D.
Factory spec.
30.031 to 30.046 mm
1.1823 to 1.1829 in.
W1066948
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing replacing
tool.
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil to
them.
2. Insert a new bushing onto the tool and press-fit it with a press so
that the seam (1) of bushing position as shown in the figure, until
it is flash with the connecting rod.
(1) Seam
(A) When Removing
(B) When Installing
(C) 0.26 rad (15 °)
W1067145
1-S67
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Connecting Rod Alignment
■ NOTE
• Since the I.D. of the connecting rod small end bushing is the
basis of this check, check the bushing for wear beforehand.
1. Remove the piston pin in the connecting rod.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool
(Code No. 07909-31661).
4. Put a gauge over the piston pin, and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate, measure
the space between the pin of the gauge and the face plate.
6. If the measurement exceeds the allowable limit, replace the
connecting rod.
Connecting rod
alignment
Allowable limit
0.05 mm
0.0020 in.
W1067334
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the front
and rear.
3. If the measurement exceeds the allowable limit, replace the
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the table
and figure.
Crankshaft side
clearance
Factory spec.
0.15 to 0.31 mm
0.0059 to 0.0122 in.
Allowable limit
0.50 mm
0.0197 in.
(Reference)
• Oversize dimensions of crankshaft journal
Oversize
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
29.20 to 29.25 mm
1.1496 to 1.1515 in.
29.40 to 29.45 mm
1.1574 to 1.1594 in.
Dimension B
169.1 to 169.15 mm
6.6575 to 6.6594 in.
169.2 to 169.25 mm
6.6614 to 6.6634 in.
Dimension C
2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius
2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇
W1067652
1-S68
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Crankshaft Alignment
1. Support the crankshaft with V block on the surface plate and set
a dial indicator with its tip on the intermediate journal at right
angle.
2. Rotate the crankshaft on the V block and get the misalignment
(half of the measurement).
3. If the misalignment exceeds the allowable limit, replace the
crankshaft.
Crankshaft alignment
Allowable limit
0.02 mm
0.00079 in.
W1068435
Oil Clearance between Crankpin and Crankpin Bearing
1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage (Code No. 07909-30241) on the center
of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get the
oil clearance.
5. If the oil clearance exceeds the allowable limit, replace the
crankpin bearing.
6. If the same size bearing is useless because of the crankpin wear,
replace it with an undersize one referring to the table and figure.
■ NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod
screws are tightened.
Crankpin O.D.
Factory spec.
52.977 to 52.990 mm
2.0857 to 2.0862 in.
Oil clearance between
crankpin and crankpin
bearing
Factory spec.
0.018 to 0.051 mm
0.0007 to 0.0020 in.
Allowable limit
0.20 mm
0.0079 in.
W1068647
1-S69
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Oil Clearance between Crankpin and Crankpin Bearing
(Continued)
■ IMPORTANT
• STD size crankpin bearing.
To replace it with a specific STD service part, make sure the
crankpin bearing has the same ID color as the connecting
rod.
ID Color
Connecting rod
Large-end in. dia.
Blue
56.01 to 56.02 mm
2.2051 to 2.2055 in.
Without
color
56.00 to 56.01 mm
2.2047 to 2.2051 in.
Crankpin bearing
Class
Part code
Center wall thick
L
1C020-22311
1.496 to 1.501 mm
0.0589 to 0.0591 in.
S
1C020-22331
1.491 to 1.496 mm
0.0587 to 0.0589 in.
(Reference)
• Undersize dimensions of crankpin
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius
2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius
*Dimension B
1.0 to 1.5 mm relief
0.0394 to 0.0591 in. relief
1.0 to 1.5 mm relief
0.0394 to 0.0591 in. relief
Dimension C
52.777 to 52.790 mm dia.
2.0778 to 2.0783 in. dia.
52.577 to 52.590 mm dia.
2.0700 to 2.0705 in. dia.
Undersize
(0.8-S)
The crankpin must be fine-finished to higher than ∇∇∇∇.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.
(1) ID Color
(2) Center Wall Thick
(3) Crankpin Bearing
W1069506
1-S70
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing
1. Clean the crankshaft journal and crankshaft bearing.
2. Put a strip of press gauge (Code No.: 07909-30241) on the
center of the journal.
■ IMPORTANT
• Never insert the press gauge into the oil hole of the journal.
3. Install the main bearing case and tighten the screws to the
specified torque, and remove the cases again.
4. Measure the amount of the flattening with the scale and get the
oil clearance.
5. If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
Crankshaft journal O.D.
Factory spec.
74.977 to 74.990 mm
2.9518 to 2.9524 in.
Oil clearance between
crankshaft journal and
crankshaft bearing
Factory spec.
0.018 to 0.062 mm
0.0007 to 0.0024 in.
Allowable limit
0.20 mm
0.0079 in.
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm
0.008 in.
0.4 mm
0.016 in.
Dimension A
2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius
2.8 to 3.2 mm radius
0.1102 to 0.1260 in. radius
*Dimension B
1.0 to 1.5 mm relief
0.0394 to 0.0591 in. relief
1.0 to 1.5 mm relief
0.0394 to 0.0591 in. relief
Dimension C
74.777 to 74.790 mm dia.
2.9440 to 2.9445 in. dia.
74.577 to 74.590 mm dia.
2.9361 to 2.9366 in. dia.
Undersize
(0.8-S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.0394 to 0.0591 in.) relief.
W1070101
Replacing Crankshaft Sleeve
1. Remove the used crankshaft sleeve (1) using a special-use puller
set (Code No.: 07916-09032).
2. Set the sleeve guide (4) to the crankshaft (2).
3. Heat a new sleeve to a temperature between 150 to 200 °C (302
to 392 °F), and fix the sleeve to the crankshaft as shown in figure.
4. Press fit the sleeve using the auxiliary socket for pushing (3).
■ NOTE
• Mount the sleeve with its largely chamfered surface facing
outward.
(1) Crankshaft Sleeve
(2) Crankshaft
(3) Auxiliary Socket for Pushing
(4) Sleeve Guide
W1070594
1-S71
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.’s.
2. Get the difference (Maximum wear) between the maximum and
the minimum I.D.’s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to “Correcting Cylinder”.)
4. Visually check the cylinder wall for scratches. If deep scratches
are found, the cylinder should be bored. (Refer to “Correcting
Cylinder”.)
Factory spec.
100.000 to 100.022 mm
3.9370 to 3.9379 in.
Allowable limit
100.15 mm
3.9429 in.
Cylinder Bore I.D.
A : Top
B : Middle
C : Bottom (Skirt)
(a) Right-angled to Piston Pin
(b) Piston Pin Direction
W1069784
Correcting Cylinder (Oversize +0.5 mm)
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
Cylinder Bore I.D. (2)
Factory spec.
100.500 to 100.522 mm
3.9567 to 3.9576 in.
Maximum wear
Allowable limit
100.65 mm
3.9626 in.
Finishing
Horn to 1.2 to 2.0 mm μR max.
∇∇∇∇
(0.000047 to 0.000079 in. μR max.)
2. Replace the piston and piston rings with oversize (0.5 mm) ones.
■ NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction)
(2) Oversize Cylinder I.D.
W1070275
1-S72
KiSC issued 03, 2007 A
ENGINE
M105S, WSM
(6) Oil Pump
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and the
outer rotor with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
Clearance between
inner rotor and outer
rotor
Factory spec.
0.04 to 0.16 mm
0.0016 to 0.0063 in.
Allowable limit
0.3 mm
0.0118 in.
W1071602
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
2. If the clearance exceeds the allowable limit, replace the oil pump
rotor assembly.
Clearance between
outer rotor and pump
body
Factory spec.
0.100 to 0.184 mm
0.0039 to 0.0072 in.
Allowable limit
0.3 mm
0.0118 in.
W1071741
Clearance between Rotor and Cover
1. Put a strip of plastigage (Code No. 07909-30241) onto the rotor
face with grease.
2. Install the cover and tighten the screws with the specified torque.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
4. If the clearance exceeds the allowable limit, replace oil pump
rotor assembly and the cover.
Clearance between rotor
and cover
Tightening torque
Factory spec.
0.025 to 0.075 mm
0.0010 to 0.0030 in.
Allowable limit
0.225 mm
0.0089 in.
Oil pump cover screw
7.9 to 9.3 N·m
0.80 to 0.95 kgf·m
5.8 to 6.9 ft-lbs
W1071866
1-S73
KiSC issued 03, 2007 A
2
CLUTCH
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. TRAVELING CLUTCH .................................................................................. 2-M1
[1] STRUCTURE ........................................................................................... 2-M1
[2] OIL FLOW ............................................................................................... 2-M2
2. PTO CLUTCH ............................................................................................... 2-M3
[1] STRUCTURE ........................................................................................... 2-M3
[2] OIL FLOW ............................................................................................... 2-M4
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
1. TRAVELING CLUTCH
[1] STRUCTURE
(1) Clutch Pedal
(2) Clutch Cable
(3) Hydraulic Shuttle Valve
(4) Return Spring
(5) Reverse Side Clutch
(6) Forward Side Clutch
(7) Damper Disc
The damper disc (7) helps ease the shock load when engaging the shuttle clutch.
The hydraulic shuttle clutch, which switches forward and reverse running, function as the travelling clutch. When
the clutch pedal (1) is depressed, the clutch spool of shuttle valve (3) moves via the clutch cable (2).
As for the oil, it does not flow to both the forward side (6) and reverse side (5) of the clutch pack, the clutch pack
enters the state of “Disengaged” and power is not transmitted.
2-M1
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
[2] OIL FLOW
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Shuttle Valve
Regulator Valve
Shuttle Lever
Clutch Pedal
Forward Clutch
Reverse Clutch
Spool
(A) From Pump
(B) To PTO Clutch
(C) To Power Steering
W1012813
The oil from regulator valve (2) flows into the shuttle valve (1).
When the shuttle lever (3) shift to the forward or reverse, the oil flows to the forward or reverse clutch (5), (6).
During the oil is feeding in the clutch pack, depress the clutch pedal (4).
The feeding oil returns to the tank through the spool (7), and the clutch becomes at “Disengage” condition.
2-M2
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
2. PTO CLUTCH
[1] STRUCTURE
The PTO shift lever (1) and the PTO clutch valve (3)
are connected by the PTO shift cable (2) as shown in the
figure.
When the PTO shift lever (1) is moved to the B side,
the PTO clutch valve (3) is set at “Engaged” position.
Then the oil flows to clutch pack (4) through the clutch
valve (3), and the clutch pack (4) is engaged and the
PTO drive shaft (5) and PTO shaft (6) rotate. When the
shift lever is moved to the A side, the PTO clutch is set at
“Disengaged” position.
(1)
(2)
(3)
(4)
(5)
(6)
PTO Shift Lever
PTO Shift Cable
PTO Clutch Valve
Clutch Pack
PTO Drive Shaft
PTO Shaft
A : Disengage
B : Engage
W1013041
2-M3
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
[2] OIL FLOW
The oil from the regulator valve (5) flows to the PTO
valve built into the pump base (6).
When the PTO lever (7) is at the “Disengaged”
position, the oil flows is stopped by the PTO clutch valve
(1), When the PTO lever (7) is at the “Engaged”
position, the oil flows through the PTO clutch valve (1) to
the modulating valve (4) and PTO clutch pack (2) to
engage it.
(1)
(2)
(3)
(4)
PTO Clutch Valve
PTO Clutch Pack
Relief Valve
Modulating Valve
(5) Regulator Valve
(6) Pump Base
(7) PTO Lever
W1013258
2-M4
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................2-S1
SERVICING SPECIFICATION .......................................................................2-S2
TIGHTENING TORQUES ..............................................................................2-S3
CHECKING, DISASSEMBLING AND SERVICING......................................2-S4
[1] CHECKING AND ADJUSTING ...............................................................2-S4
(1) Traveling Clutch ..................................................................................2-S4
(2) PTO Clutch .........................................................................................2-S6
[2] DISASSEMBLING AND ASSEMBLING..................................................2-S7
(1) Removing Damper Disc ......................................................................2-S7
(2) Removing Shuttle Clutch Valve ........................................................2-S13
(3) Removing PTO Clutch Valve ............................................................2-S14
(4) PTO Clutch Pack ..............................................................................2-S16
[3] SERVICING ............................................................................................2-S22
(1) Damper Disc .....................................................................................2-S22
(2) PTO Clutch .......................................................................................2-S22
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
1. TROUBLESHOOTING
TRAVELING CLUTCH
Symptom
Shuttle Clutch Slip
Probable Cause
Reference
Page
Solution
Operating pressure is low
Adjust
8-S11
Shuttle clutch valve malfunctioning
Replace
2-S13
Clutch disc or steel plate excessively worn
Replace
3-S38
Deformation of piston or steel plate
Replace
3-S38
Shuttle Clutch
Operating Pressure
Is Low
Transmission oil improper or insufficient
Replenish or change
Relief valve malfunctioning
Adjust or replace
8-S11
Shuttle Clutch Drags
Return spring weaken or broken
Replace
3-S21
Modulating valve malfunctioning
Replace
–
Deformation of piston or steel plate
Replace
3-S38
Shuttle linkage defective or deformed
Adjust or replace
3-S6
Tractor Does Not
Keep in Neutral
G-8
W1013580
PTO CLUTCH
PTO Clutch Slip
Operating pressure is low
Adjust
8-S12
PTO clutch valve malfunctioning
Repair or replace
2-S15
Clutch disc or steel plate excessively worn
Replace
2-S23
Deformation of piston or return spring
Replace
2-S23
PTO Shaft Does Not
Rotate
PTO clutch malfunctioning
Repair or replace
2-S22
PTO propeller shaft coupling disengaged
Engage
PTO Clutch
Operating Pressure
Is Low
Transmission oil improper or insufficient
Replenish or change
Relief valve malfunctioning
Adjust or replace
8-S12
PTO Clutch Drags
Brake plate excessively worn
Replace
2-S22
Return spring weaken or broken
Replace
2-S22
Modulating valve malfunctioning
Repair or replace
2-S20
Deformation of plate or steel plate
Replace
2-S23
–
G-8
W1013718
2-S1
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
2. SERVICING SPECIFICATION
TRAVELING CLUTCH
Item
Clutch Pedal
Damper Disc Boss to Gear Shaft
Factory Specification
Allowable Limit
Free Travel
Below 15 mm
0.59 in.
–
Total Stroke
150 to 155 mm
5.9 to 6.1 in.
–
–
2.0 mm
0.079 in.
Backlash
(Displacement
Around Disc Edge)
W1013874
PTO CLUTCH
PTO Clutch Disc
Thickness
1.70 to 1.90 mm
0.067 to 0.075 in.
1.55 mm
0.061 in.
Brake Ring
Thickness
4.4 to 4.6 mm
0.173 to 0.181 in.
4.2 mm
0.165 in.
Return Plate
Thickness
2.92 to 3.05 mm
0.115 to 0.120 in.
2.5 mm
0.098 in.
Driven Plate
Flatness
1.54 to 1.56 mm
0.060 to 0.061 in.
1.1 mm
0.043 in.
PTO Piston
Thickness
–
0.15 mm
0.006 in.
PTO Return Plate
Thickness
1.15 to 1.25 mm
0.045 to 0.075 in.
1.10 mm
0.043 in.
Return Spring
Tension
245.18 N/23.1 mm
25.0 kgf/23.1 mm
180.83 lbs/0.909 in.
225.56 N/23.1 mm
23.0 kgf/ 3.1 mm
166.36 lbs/0.909
in.
W1013973
2-S2
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10)
Item
N·m
kgf·m
ft-lbs
High pressure hose retaining nut
11.8 to 14.7
1.2 to 1.5
8.7 to 10.8
Low pressure hose mounting nut
7.8 to 11.8
0.8 to 1.2
5.8 to 8.7
Power steering turning delivery hose retaining nut
22.6 to 27.6
2.2 to 2.8
16.2 to 19.9
Oil cooler pipe nut
49.0 to 68.6
5.0 to 7.0
36.1 to 50.6
Oil cooler hose retaining nut
45.1 to 53.0
4.6 to 5.4
33.3 to 39.0
Engine and clutch housing mounting screw, nut
124 to 147
12.6 to 15.0
91.2 to 108
Engine and clutch housing mounting stud bolt
38.2 to 45.1
3.9 to 4.6
28.2 to 33.3
Damper disc mounting screw
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
HI-LO pipe retaining nut
29.4 to 39.2
3.0 to 4.0
21.7 to 28.9
Delivery pipe retaining nut
49.0 to 65.6
5.0 to 7.0
36.1 to 50.6
Shuttle valve mounting screw
23.0 to 27.5
2.4 to 2.8
17.4 to 20.2
PTO pipe retaining nut
29.4 to 39.2
3.0 to 4.0
21.7 to 28.9
107.9 to 117.7
11.0 to 12.0
79.6 to 86.8
Pump base mounting nut
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Hydraulic pump mounting nut
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
Rear wheel mounting nut
343 to 401
35.0 to 41.0
254 to 297
Tank stay mounting screw
196.1 to 225.6
20.0 to 23.0
144.7 to 166.4
Transmission case and clutch housing mounting screw
and nut (M12, grade 7 screw)
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Hydraulic cylinder assembly mounting screw and nut
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Rear axle case mounting screw
124 to 147
12.0 to 15.0
91.2 to 108.5
PTO clutch support mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Rear cover mounting screw
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Delivery pipe 1 and 2 retaining nut
W1012736
2-S3
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Traveling Clutch
Clutch Pedal Stroke
1. Stop the engine and remove the key.
2. Screw the lock nuts (1), (2) to the threaded end of cable as shown
in figure.
3. Measure the clutch pedal stroke A.
4. If the measurement is not within the factory specifications, adjust
with stopper bolt (3).
Total stroke A
Factory spec.
150 to 155 mm
5.9 to 6.1 in.
■ NOTE
• Be sure to fix the coil spring (4) in original direction when
hooking the coil spring as shown in figure.
(1) Lock Nut
(2) Lock Nut
(3) Stopper Bolt
(4) Coil Spring
W1012478
2-S4
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Clutch Pedal Free Travel
■ NOTE
• Before checking the clutch pedal free travel A, be sure to
adjust the pedal stroke.
1. Measure the clutch pedal free travel.
2. If adjustment is needed, loosen the lock nuts (1) and adjust the
cable length within acceptable limits.
3. Retighten the lock nut (1).
Proper clutch pedal free
travel A
(1) Lock Nut
Factory spec.
Below 15 mm
0.59 in.
A : Clutch Pedal Free Travel
W1012725
2-S5
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
(2) PTO Clutch
PTO Clutch Lever Movement
1. Stop the engine and remove the key.
2. Check the PTO clutch lever (1) on the “Engage” and
“Disengage” position of PTO clutch lever guide.
3. If the adjustment is needed, loosen the lock nuts (3) and adjust
the clutch control cable (2) length.
4. Retighten the lock nuts (3) firmly.
■ IMPORTANT
• Do not connect the universal joint of the implement to the
tractor PTO shaft while testing.
■ NOTE
• The clutch control cable (2) is fixed at center of the screw
with lock nut (3) at PTO clutch lever side.
• Install the clutch control cable (2) with PTO valve lever (5)
pulled C by 3 to 5 mm (0.12 to 0.20 in.).
• The movement of PTO lever is adjusted with lock nut (4) of
the clutch control cable at the valve side.
(1)
(2)
(3)
(4)
(5)
PTO Clutch Lever
Clutch Control Cable
Lock Nut
Lock Nut
PTO Valve Lever
A : Engage
B : Disengage
C : Pull
W1013155
• Refer to checking “PTO Clutch Valve” in “8.HYDRAULIC SYSTEM” section.
2-S6
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Removing Damper Disc
Draining Coolant
•
1.
2.
3.
4.
CAUTION
Never remove the radiator cap until coolant temperature is
well below its boiling point. Then loosen cap slightly to the
stop to relieve any excess pressure before removing cap
completely.
Stop the engine and let cool down.
To drain the coolant, open the radiator drain plug (1). When
opening the drain plug set the hose to drain port (2).
Remove the radiator cap to completely drain the coolant.
After all coolant is drained, reinstall the radiator drain plug.
Coolant
(1) Drain Plug
9.1 L
9.6 U.S.qts
8.0 Imp.qts
Capacity
(2) Drain Port
W1013823
Muffler and Bonnet
1. Open the bonnet (1) and disconnect the battery (2) negative
terminal and head light 4P connector (7).
2. Remove the bonnet dampers (3) and close the bonnet (1).
3. Remove the bonnet hinge mounting screws (4) through the holes
(5) in the upper part of the bonnet.
4. Remove the bonnet (1) and muffler (6).
5. Remove the side cover (7) LH and RH.
■ IMPORTANT
• When disconnecting the battery cords, disconnect the
grounding cord first. When connecting, positive cord first.
(1)
(2)
(3)
(4)
Bonnet
Battery
Damper
Screw
(5)
(6)
(7)
(8)
Hole
Muffler
4P Connector
Side Cover
W1014062
2-S7
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Propeller Shaft
1. Remove the clutch housing under cover (1).
2. Tap out the spring pin (2) and then slide the coupling (3) to the
front.
(When reassembling)
• Apply grease to the splines of coupling (3).
• Be sure to assembling the coupling after assemble the engine
and clutch housing case.
• Tap in the spring pins (2) as shown in figure.
• Apply liquid gasket (Three Bond 1208D, 1206D or equivalent) to
joint face of under cover and clutch housing case.
(1) Under Cover
(2) Spring Pin
(3) Coupling
(4) Propeller Shaft
(5) Propeller Shaft Cover
W1019942
Differential Lock Spring
1. Loosen the lock nut (1) and disconnect spring (2) from differential
lock lever (3).
(When reassembling)
• Be sure to fix the front edge of differential lock cable at the center
of thread.
(1) Lock Nut
(2) Spring
(3) Differential Lock Lever
(4) Differential Lock Cable
W1020099
2-S8
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Air Cleaner Hoses and Cooler Pipes
1. Remove the side panel LH (1) and side panel RH (2).
2. Remove the shield weather strip (3) and radiator plate (4).
3. Remove the air cleaner hoses (5).
4. Disconnect the oil cooler pipe (6) and hose (7).
(1)
(2)
(3)
(4)
Side Panel LH
Side Panel RH
Shield Weather Strip
Radiator Plate
(5) Air Cleaner Hose
(6) Oil Cooler Pipe
(7) Oil Cooler Hose
W1014586
2-S9
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Air Condenser and Compressor
■ Without discharging the refrigerant from system
1. Remove the air condenser slide stopper (1) and slide out the air
condenser (2).
2. Remove the compressor (3) with hoses.
(When reassembling)
• Take care not to damage the air condenser fin.
• After reassembling the compressor, be sure to adjust the air
conditioner belt tension.
(Refer to “Adjusting Air Conditioner Belt Tension” : See page G29.)
■ With discharge the refrigerant from system
1. Refer to “Discharge the Refrigerant” (See page 10-S19).
(When reassembling)
• Charge the refrigerator to the air conditioner system, refer to
“Charging the Refrigerant”. (See page 10-S21.)
2. Disconnect the low pressure hose (5) and high pressure hose (4)
from compressor (3).
3. Disconnect the high pressure hose (6) from receiver.
(When reassembling)
• Apply compressor oil (DENSO CO. ND-OIL8) to the O-rings and
take care not to damage them.
High pressure hose
retaining nut
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 ft-lbs
Low pressure hose
mounting screw
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 ft-lbs
Tightening torque
(1) Condenser Slide Stopper
(2) Condenser
(3) Compressor
(4) High Pressure Hose
(5) Low Pressure Hose
(6) High Pressure Hose
W1014957
Steering Joint, Hose, Meter Cable, Oil Cooler Pipe and Hose
1. Remove the steering joint (1).
2. Disconnect the meter cable (2) from the engine.
3. Disconnect the delivery hose (3), oil cooler hose (4).
4. Remove the oil cooler pipe (5).
(When reassembling)
Tightening torque
(1) Steering Joint
(2) Meter Cable
(3) Delivery Hose
Delivery hose retaining nut
22.6 to 27.6 N·m
2.2 to 2.8 kgf·m
16.2 to 19.9 ft-lbs
Oil cooler pipe nut
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.1 to 50.6 ft-lbs
Oil cooler hose retaining
45.1 to 53.0 N·m
4.6 to 5.4 kgf·m
33.3 to 39.0 ft-lbs
(4) Oil Cooler Hose
(5) Oil Cooler Pipe
W1015254
2-S10
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Brake Oil Tank
1. Remove the brake oil tank (1) from the bonnet support (3).
2. Remove the stay (2).
3. Disconnect the tank air bleeder hoses (5).
4. Remove the muffler pipe support (4) and bonnet support (3).
(1) Brake Oil Tank
(2) Stay
(3) Bonnet Support
(4) Muffler Pipe Support
(5) Air Bleeder Hose
W1015435
Fuel Pipe, Accelerator Cable, Heater Hose and Wire Harness
1. Disconnect the fuel pipe (1) from injection pump.
2. Disconnect the overflow hose (2).
3. Disconnect the accelerator cable (3) from injection pump.
4. Disconnect the heater hoses (4) from engine.
5. Disconnect the all connections (relaies, sensors, switches,
starter motor and starter motor) of engine wire harness.
(When reassembling)
• Be sure to connect the heater hoses to original positions.
(1) Fuel Pipe
(2) Overflow Hose
(3) Accelerator Cable
(4) Heater Hoses
(5) Wire Harness
W1015548
2-S11
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Separating Engine from Clutch Housing
1. Check the engine and clutch housing case are securely mounted
on the disassembling stands.
2. Install the front axle rocking restrictor (1) (See page G-72) to the
front axle bracket.
3. Remove the floor mat (2) and panel cover (3).
4. Remove the engine mounting screws and nuts, and separate the
engine from the clutch housing.
(When reassembling)
• Apply molybdenum disulphide (Three Bond 1901 or equivalent)
to the splines of damper disc boss.
• Apply liquid gasket (Three Bond 1141, 1211 or equivalent) to joint
face of the engine and clutch housing.
Engine and clutch housing
mounting screw, nut
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 ft-lbs
Engine and clutch housing
mounting stud bolt
38.2 to 45.1 N·m
3.9 to 4.6 kgf·m
28.2 to 33.3 ft-lbs
Tightening torque
(1) Front Axle Rocking Restrictor
(2) Floor Mat
(3) Panel Cover
W1015695
2-S12
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Damper Disc
1. Remove the damper disc (1).
(When reassembling)
• Confirm that the bearing (2) is surely assembled to the flywheel.
• Direct the shorter end of the damper disc boss toward the
flywheel.
• Apply molybdenum disulphide (Three Bond 1901 or equivalent)
to the shaft A.
■ IMPORTANT
• Align the center of damper disc and flywheel by inserting the
clutch center tool (3) (Code No. 07916-53041).
Tightening torque
(1) Damper Disc
(2) Bearing
Damper disc mounting
screw
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
(3) Clutch Center Tool
W1016312
(2) Removing Shuttle Clutch Valve
Shuttle Clutch Valve
1. Remove the floor mat (1) and inspection plate (2).
2. Remove the shuttle valve (3).
(When reassembling)
Tightening torque
(1) Floor Mat
(2) Inspection Plate
(3) Shuttle Valve
HI-LO pipe retaining nut
29.4 to 39.2 N·m
3.0 to 4.0 kgf·m
21.7 to 28.9 ft-lbs
Delivery pipe retaining nut
49.0 to 65.6 N·m
5.0 to 7.0 kgf·m
36.1 to 50.6 ft-lbs
Shuttle valve mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
(4) Delivery Pipe
(5) HI-LO Pipe
W1016768
2-S13
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
(3) Removing PTO Clutch Valve
Gear Pump and Pump Base Assembly
1. Remove the seat (1) and floor cover (2).
2. Remove the floor mat (3) and inspection plate under the floor
mat.
3. Remove the delivery pipe 1 (4) and delivery pipe 2 (5).
4. Remove the lowering speed adjustment rod (6).
5. Disconnect the parking brake cable (7).
6. Disconnect the PTO clutch cable (8).
7. Disconnect the suction pipes (11).
8. Remove the pump base (9) with gear pump.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of transmission case and valve assembly.
• Replace the oil pipes (10) with new ones.
• Be sure to check the PTO clutch lever movement. (See page 2S6.)
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Delivery pipe 1 and 2
retaining nut
107.9 to 117.7 N·m
11.0 to 12.0 kgf·m
79.6 to 86.8 ft-lbs
PTO pipe retaining nut
29.4 to 39.2 N·m
3.0 to 4.0 kgf·m
21.7 to 28.9 ft-lbs
Pump base mounting nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Seat
Floor Cover
Floor Mat
Delivery Pipe 1
Delivery Pipe 2
Lowering Speed Adjusting Rod
(7)
(8)
(9)
(10)
(11)
(12)
Parking Brake Cable
PTO Clutch Cable
Pump Base
Oil Pipe
Suction Pipe
PTO Pipe
W1017134
2-S14
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
PTO Valve
1. Remove the both hydraulic pumps (1).
2. Remove the cap (2) and internal snap ring (3).
3. Remove the spring pin (4) and then tap out the pin (5).
4. Remove the all gears.
5. Remove the external snap ring (6) and PTO valve lever (7).
6. Remove the oil seal (8) and external snap ring (9).
7. Remove the spring stopper screw (10) and tap out the PTO rotary
valve (11).
(When reassembling)
Tightening torque
Hydraulic pump mounting
nut
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 46.2 ft-lbs
• Hook the return spring (12) of the rotary valve to the spring
stopper screw (10).
• Apply transmission fluid to PTO rotary valve (11) and bearings.
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of hydraulic pump and pump base (13).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Hydraulic Pump
Cap
Internal Snap Ring
Spring Pin
Pin
External Snap Ring
PTO Valve Lever
(8)
(9)
(10)
(11)
(12)
(13)
Oil Seal
External Snap Ring
Spring Stopper Screw
PTO Rotary Valve
Return Spring
Pump Base
W1018889
2-S15
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
(4) PTO Clutch Pack
Draining Transmission Fluid
1. Place an oil pan underneath the transmission case.
2. Remove the drain plugs (1).
3. Drain the transmission fluid.
4. Reinstall the drain plugs (1).
(When reassembling)
• Fill up from filling port after removing the filling plug until reaching
the gauge.
• After running the engine for few minutes, stop it and check the
fluid level again, add the fluid to prescribed level if it is not correct
level.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other fluids
may damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-8.)
• Do not mix difference brands oil together.
Transmission fluid
60.0 L
63.4 U.S.qts
52.8 Imp.qts
Capacity
(1) Drain Plug
W1020481
Draining Fuel
1. Place oil pans under the right side fuel tank.
2. Remove the drain cover (2) at the bottom of side fuel tank (1).
3. Drain the fuel.
4. Reinstall the drain cover (2) on the fuel tank (1).
(When reassembling)
• Be sure to fix the O-ring (3) is in position on the drain cover (2).
Fuel Tank
(1) Fuel Tank
(2) Drain Cover
175 L
46.2 U.S.gals
38.5 Imp.gals
Capacity
(3) O-ring
(4) Screw
W1021162
Separating Cabin from Tractor Body
1. See “10. CABIN” (Page 10-S35).
2. Check the clutch housing case and transmission case are
securely mounted on the disassembling stands.
3. Remove the rear wheels.
(When reassembling)
Tightening torque
Rear wheel mounting nut
343 to 401 N·m
35 to 41 kgf·m
254 to 294 ft-lbs
W1021412
2-S16
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Fuel Tank and Auxiliary Step
1. Remove the auxiliary steps (1), (2).
2. Disconnect the 2P connector fuel tank unit (3).
3. Disconnect the fuel tank connector hose between left and right
side fuel tanks.
4. Remove the fuel tank bands (4).
5. Remove the fuel tank (5), (6) and fuel tank stay (7).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
Auxiliary Step RH
Auxiliary Step LH
2P Connector
Fuel Tank Band
Tank stay mounting screw
196.1 to 225.6 N·m
20.0 to 23.0 kgf·m
144.7 to 166.4 ft-lbs
(5) Fuel Tank RH
(6) Fuel Tank LH
(7) Fuel Tank Stay
W1021590
Gear Pump and Pump Base
1. Remove the suction pipes (1).
2. Remove the delivery pipes (2).
3. Remove the PTO pipe (3).
4. Remove the pump base with gear pumps.
(When reassembling)
• Replace the oil pipes with new ones and apply oil to them.
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of pump base and transmission case.
Tightening torque
(1) Suction Pipe
(2) Delivery Pipe
(3) PTO Pipe
Delivery pipe 1 and 2
retaining nut
107.9 to 117.7 N·m
11.0 to 12.0 kgf·m
79.6 to 86.8 ft-lbs
PTO pipe retaining nut
29.4 to 39.2 N·m
3.0 to 4.0 kgf·m
21.7 to 28.9 ft-lbs
Pump base mounting nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
(4) Pump Base
(5) Oil Pipe
W1021905
2-S17
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Separating Transmission Case
1. Remove the dual speed HI clutch pipe (4) and LO clutch pipe (5).
2. Remove the resonator pipe (9).
3. Remove the parking brake cable stay (6).
4. Remove the delivery pipe (8).
5. Remove the lubrication pipe (7).
6. Remove the transmission case mounting screws and nuts.
7. Separate the transmission case from the mid case (2).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of transmission case and mid case.
Tightening torque
(1)
(2)
(3)
(4)
(5)
Transmission case and
mid case mounting screw
and nut
Mid Case
Transmission Case
Nut
HI Clutch Pipe
LO Clutch Pipe
(6)
(7)
(8)
(9)
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Parking Brake Cable Stay
Lubrication Pipe
Delivery Pipe
Resonator Pipe
W1022354
Dismounting Hydraulic Cylinder Assembly
1. Remove the hydraulic cylinder assembly mounting screws and
nut.
Support the hydraulic cylinder assembly (1) with nylon lift strap
and hoist, and then remove it.
2. Dismounting the hydraulic cylinder assembly from transmission.
(When reassembling)
• Change the hydraulic cylinder gasket to new one.
Tightening torque
Hydraulic cylinder
assembly mounting screw
and nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
(1) Hydraulic Cylinder Assembly
W1022741
2-S18
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Rear Axle Case and Parking Brake Case
1. Remove the rear axle case mounting screws and nuts.
2. Support the rear axle case with nylon lift strap and hoist.
3. Separate the rear axle case from transmission case.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of the rear axle case and transmission case, after
eliminate the water, oil and stuck liquid gasket.
Tightening torque
Rear axle case mounting
screw
124 to 147 N·m
12.0 to 15.0 kgf·m
91.2 to 108.5 ft-lbs
W1023029
Rear Cover Assembly
1. Remove the rear cover and PTO drive shaft as a unit.
(When reassembling)
Tightening torque
Rear cover mounting
screw
77.5 to 90.1 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 ft-lbs
W1023232
2-S19
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
PTO Clutch Assembly
1. Remove the bearing retainer (1).
2. Remove the coupling (2) with bearing.
3. Remove the internal snap ring (3).
4. Tap out the PTO clutch shaft (4) to the front and remove the PTO
clutch assembly (5).
5. Remove the PTO clutch support (8).
(When reassembling)
Tightening torque
PTO clutch support
mounting screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
■
•
•
•
IMPORTANT
Replace the seal rings to new ones.
Apply transmission fluid to the seal rings.
When reassembling the PTO clutch assembly (5), direct the
projection part of brake ring (6) to left side in view of the
back.
• Confirm the moving of the piston smoothly when pressure
air at 0.29 to 0.39 MPa (3 to 4 kgf/cm2, 42 to 57 psi) is sent to
clutch pack.
(1)
(2)
(3)
(4)
Bearing Retainer
Coupling
Internal Snap Ring
PTO Clutch Shaft
(5)
(6)
(7)
(8)
PTO Clutch Assembly
Brake Ring
PTO Modulate Valve
PTO Clutch Support
W1023361
2-S20
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Clutch Hub and Clutch Discs
1. Remove the internal snap ring (3) with the clutch compression
tool (12).
2. Take out the plate assembly (4), clutch disc (5), drive plate (7),
return plate (8), return spring (2), piston (6) and brake (1).
(When reassembling)
• Apply transmission fluid to the pistons (11).
• Apply transmission fluid to the discs (5).
(1)
(2)
(3)
(4)
(5)
(6)
Brake Ring
Return Spring
Internal Snap Ring
Plate Assembly
Clutch Disc
Piston
(7)
(8)
(9)
(10)
(11)
(12)
Drive Plate
Return Plate
Clutch Case
Seal Ring
Piston Ring
Compression Tool
W1029591
2-S21
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
[3] SERVICING
(1) Damper Disc
Backlash between Damper Disc Boss and Shaft
1. Mount the damper disc to the input shaft.
2. Hold the shaft so that it does not turn.
3. Rotate disc lightly and measure the displacement around the disc
edge.
4. If the measurement exceeds the allowable limit, replace the
damper disc.
Displacement around
disc edge
Allowable limit
2.0 mm
0.079 in.
W1030042
(2) PTO Clutch
Wear of PTO Clutch Disc, Brake Ring, Return Plate and Driven
Plate
1. Measure the thickness of PTO clutch discs (1), brake ring (2),
return plate (3) and driven plate (4) with vernier calipers.
2. If the thickness is less than the allowable limit, replace it.
Factory spec.
1.7 to 1.9 mm
0.067 to 0.075 in.
Allowable limit
1.55 mm
0.061 in.
Factory spec.
4.4 to 4.6 mm
0.173 to 0.181 in.
Allowable limit
4.2 mm
0.165 in.
Factory spec.
2.92 to 3.05 mm
0.115 to 0.120 in.
Allowable limit
2.5 mm
0.098 in.
Factory spec.
1.54 to 1.56 mm
0.060 to 0.061 in.
Allowable limit
1.1 mm
0.043 in.
Thickness of clutch disc
Thickness of brake ring
Thickness of return plate
Thickness of driven
plate
(1) Clutch Disc
(2) Brake Ring
(3) Return Plate
(4) Driven Plate
W1030468
2-S22
KiSC issued 03, 2007 A
CLUTCH
M105S, WSM
Flatness of PTO Piston, Return Plate and Plate Assembly
1. Plate the PTO piston (1), return plate (2) and plate assembly (3)
on a surface plate.
2. Insert a thickness gauge (allowable limit size) underneath it at
least four points.
3. If the gauge can be inserted, replace it.
Flatness of PTO piston
Allowable limit
0.15 mm
0.006 in.
Flatness of PTO return
plate
Allowable limit
0.30 mm
0.012 in.
Flatness of PTO plate
assembly
Allowable limit
0.30 mm
0.012 in.
(1) Piston
(2) Return Plate
(3) Plate Assembly
W1030969
Pressure Spring Tension
1. Place the spring on the spring tester and compress it to 23.1 mm
(0.909 in.).
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
Factory spec.
245.18 N / 23.1 mm
25.0 kgf / 23.1 mm
180.83 lbs / 0.909 in.
Allowable limit
225.56 N / 23.1 mm
23.0 kgf / 23.1 mm
166.36 lbs / 0.909 in.
Spring setting load /
Setting length
(1) Return Spring
W1031235
2-S23
KiSC issued 03, 2007 A
3
TRANSMISSION
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 3-M1
2. GEAR SHIFT MECHANISM......................................................................... 3-M2
[1] SELECTING THE TRAVELING SPEED ............................................... 3-M2
[2] MAIN GEAR SHIFT LEVER.................................................................. 3-M3
[3] SWING SHIFT......................................................................................... 3-M5
[4] DUAL SPEED ......................................................................................... 3-M8
3. POWER TRAIN FOR TRAVELING GEAR................................................. 3-M9
[1] SHUTTLE SHIFT SECTION .................................................................. 3-M9
[2] MAIN GEAR SHIFT AND SWING SHIFT (LO-HI) SECTION ......... 3-M10
[3] DUAL SPEED SECTION ..................................................................... 3-M11
[4] RANGE GEAR SHIFT SECTION........................................................ 3-M11
[5] FOUR-WHEEL DRIVE SECTION ........................................................ 3-M12
4. POWER TRAIN FOR PTO SYSTEM ....................................................... 3-M13
[1] PTO GEAR SECTION.......................................................................... 3-M13
KiSC issued 03, 2007 A
M105S, WSM
TRANSMISSION
1. STRUCTURE
(1)
(2)
(8)
(9)
(7)
(6)
(4)
(5)
(3)
3TMACAK3P001A
(1) Shuttle Shift Section
(2) Main Gear Shift Section
(3) Range Gear Shift Section
(4) Four Wheel Drive Section
3-M1
(5) PTO Gear Section
(6) PTO Clutch Section
(7) Hydraulic Pump Drive Gear
(8) Swing Shift (HI-LO)
(9) Dual Speed Section (HI-LO)
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
2. GEAR SHIFT MECHANISM
[1] SELECTING THE TRAVELING SPEED
(1)
(2)
(3)
(4)
(5)
(6)
Hydraulic Shuttle Shift Lever
Main Gear Shift Lever
Range Gear Shift Lever
Pilot Lamp (LOW)
Pilot Lamp (HIGH)
Creep Lever (Option)
A:
F:
N:
R:
L:
H:
PUSH
FORWARD
NEUTRAL POSITION
REVERSE
LOW
HIGH
W1012674
By combinating the main gear shift lever (2), range gear shift lever (3), swing shift switch and the hydraulic shuttle
shift lever (1), forward speeds and reverse speeds in the table below are obtained.
Without creep
32 forward speed
32 reverse speed
With creep
48 forward speed
48 reverse speed
3-M2
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[2] MAIN GEAR SHIFT LEVER
■ Main Gear Shift Lever Linkage
1. 8 speed can be selected by the main gear shift lever
(1) and all speeds are fully synchronized to shift
without stopping.
2. The main shift rod 1 (4), link arm (5) and main shift rod
2 (6) are connected from main shift lever (1) to shaft
(2) of the main speed change cam which is moved the
shift fork rod and fork.
3. The select cable (7) is connected from the main gear
shift lever (1) to select lever (3) which is selected the
movement of the 1st-2nd shift fork or 3rd-4th shift
fork.
4. When the main gear shift lever (1) is moved to the left
(3rd-4th speed range side) on the NEUTRAL
position, the select lever (3) is pulled by select cable
(7), and when the main gear shift lever (1) is moved
to the right (1st-2nd speed range side), the select
lever (3) is pushed.
5. When the main gear shift lever (1) is moved at the 1st
or 3rd speed range position, shaft (2) is rotated
clockwise, when the main gear shift lever (1) is moves
at the 2nd or 4th speed range position, shaft (2) is
rotated counter-clockwise.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Main Gear Shift Lever
Shaft
Select Lever
Main Shift Rod 1
Link Arm
Main Shift Rod 2
Select Cable
A : PUSH
N : NEUTRAL POSITION
W1012970
3-M3
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
■ Shift Fork Rod and Fork
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
3rd-4th Shift Fork Rod
1st-2nd Shift Fork Rod
Shaft
3rd-4th Shift Fork
Interlock Ball
Detent Ball
Safety Switch
Spring
Cam
Select Lever
Select Arm
Positioning Screw
Ball
W1013349
1. Interlock balls (5) restrain the movement of the 1st-2nd shift fork rod and 3rd-4th shift fork rod at the same time.
As a result, double engagement of the gear is prevented.
2. Detent ball prevents the self disengagement of the gears.
3-M4
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[3] SWING SHIFT
■ Operation Method
1. The swing shift is a method which the HI and LO
speed range is changing by using the electric and
hydraulic device combination.
2. The main gear shift lever is in Neutral position during
the engine is running.
Move the lever against the left side face, and the
speed changes each time between the rabbit lamp-HI
(2) and turtle lamp-LO (3).
Be sure to use the clutch while shifting.
3. The lamp (2), (3) indicate that the shift is change
between HI speed range (2) and LO speed range (3).
4. The buzzer sounds when the shifting has occurred
with both the lamps (2), (3) off.
5. When moving the main gear shift lever (5) against the
left side at “Neutral”, the swing shift switch (4) is
turned each time between rabbit (HI) and turtle (LO).
Battery current flows from swing shift switch (4) to
solenoid valve (6) or (7), then solenoid valve is
actuated.
6. As for buzzer, the HI or LO monitor switch is turned
ON according to the movement of the HI-LO shift rod,
battery current flows from swing shift switch to buzzer
relay through the monitor switch.
Buzzer relay is actuated, battery current flows to
buzzer.
(1)
(2)
(3)
(4)
(5)
Main Gear Shift Lever
Rabbit Lamp-HI
Turtle Lamp-LO
Swing Shift Switch
Main Shift Lever
(6)
(7)
(8)
(9)
LO Solenoid Valve
HI Solenoid Valve
Buzzer Relay
Buzzer
W1013666
3-M5
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
■ Electrical Device
(1)
(2)
(3)
(4)
Swing Shift Switch
LO Solenoid Valve
HI Solenoid Valve
LO Motion Switch
(5) HI Motion Switch
(6) Buzzer Relay
(7) Buzzer
A : To Meter Panel (10A Fuse)
B : To OPC Unit
3-M6
C : To Meter Panel
(Swing Shift HI)
D : To Meter Panel
(Swing Shift LO)
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
■ Hydraulic Device
1. The shift fork rod (1) is used as a double acting piston.
2. The shift fork rod (1) is moved to the right or left by
switching the solenoid valve (2), (3) and flowing oil
into A chamber (4) or B chamber (5).
3. The HI or LO speed is charged by the shift fork (6)
with the shift fork rod (1).
(1)
(2)
(3)
(4)
Shift Fork Rod
LO Solenoid Valve
HI Solenoid Valve
A Chamber
(5) B Chamber
(6) Shift Fork
(a) Oil from the Regulator
Valve
W1014355
3-M7
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[4] DUAL SPEED
■ Dual Speed
Model M105S has dual speed device as a standard
equipment.
The dual speed device consists of the HI-LO clutch,
located in the mid case, and the clutch valve that controls
the HI-LO clutch.
The dual speed shift switch (1) can be operated when
the tractor is travelling without using the clutch (Tractor
travel speed change by about 17 %). LO speed and HI
speed change at each time by the switch is pushed.
■ Dual Speed Indicator
The indicator comes on when the dual speed switch
is set to LO.
The indicator goes off, when the dual speed switch is
set to HI.
(1) Dual Speed Shift Switch
(2) Dual Speed Indicator
(3) Dual Speed Clutch
A : LO Speed
B : HI Speed
W1014755
3-M8
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
3. POWER TRAIN FOR TRAVELING GEAR
[1] SHUTTLE SHIFT SECTION
■ Forward Shift
Input shaft (3) → clutch body (11) → forward clutch
pack (5) → 29T gear (6).
■ Reverse Shift
Input shaft (3) → clutch body (11) → reverse clutch
pack (4) → 27T gear (10) → 26T gear (9) → 24T gear (8)
→ 26T gear shaft (7) → 29T gear (6).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Flywheel
Damper Disc
Input Shaft
Reverse Clutch Pack
Forward Clutch Pack
29T Gear
26T Gear Shaft
(8)
(9)
(10)
(11)
24T Gear
26T Gear
27T Gear
Clutch Body
F : Forward
R : Reverse
W1015037
3-M9
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[2] MAIN GEAR SHIFT AND SWING SHIFT (LO-HI) SECTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
A:
B:
C:
D:
E:
F:
Main Shaft
19T Gear
Hub
22T Gear
28T Gear
31T-18T Gear
Counter Shaft
Hub
33T Gear
Hub
30T Gear
31T Gear
Hub
27T Gear
Shifter
40T Gear
Hub
1st Speed Range
2nd Speed Range
3rd Speed Range
4th Speed Range
Low Speed Range
High Speed Range
W1015524
Beside neutral, four ways of power flow from main shaft to counter shaft and 2 ways of power flow (from 31T-18T
gear (6) to clutch hub shaft) are available by operating the main gear shift lever with swing shift to shift positions of the
shifter (3), (5), (15).
■ Main Gear Shift Lever
● 1st Position
Main shaft (1) → hub (10) → shifter (3) → 19T gear (2) → 33T gear (9) → counter shaft (7).
● 2nd Position
Main shaft (1) → hub (10) → shifter (3) → 22T gear (3) → 30T gear (11) → counter shaft (7).
● 3rd Position
Main shaft (1) → hub (13) → shifter (8) → 28T gear (4) → 31T gear (12) → counter shaft (7).
● 4th Position
Main shaft (1) → hub (13) → shifter (8) → 31T gear (6) → 27T gear (14) → counter shaft (7).
● Low (Turtle) Position
31T-18T gear (6) → 40T gear (16) → shifter (15) → hub (17).
● High (Rabbit) Position
27T gear (14) → shifter (15) → hub (17).
3-M10
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[3] DUAL SPEED SECTION
The dual speed clutch is controlled by the
combination of the solenoid valve and the hydraulic flow.
When the dual speed shift switch is pushed and
indicator comes on, LO speed clutch (7) is engaged.
When indicator goes off, HI speed clutch (8) is
engaged.
Two ways of power train are available as follows.
■ LO Speed
Hub (1) → 25T Gear (2) → 27T Gear (3) → 25T Gear
(4) → 28T Gear (5) → LO Speed Clutch (7) → Clutch
Body (6) → Range Shift Gear Shaft (9).
(Reference)
• Reduction ratio : Approx. 0.827 (cut by 17.3 %)
• Torque ratio : Approx. 1.209 (boost 20.9 %)
■ HI Speed
Hub (1) → 25T Gear (2) → HI Speed Clutch (8) →
Clutch Body (6) → Range Shift Gear Shaft
(1)
(2)
(3)
(4)
(5)
Hub
25T Gear
27T Gear
25T Gear
28T Gear
(6)
(7)
(8)
(9)
Clutch Body
LO Speed Clutch
HI Speed Clutch
Range Shift Gear Shaft
W1017027
[4] RANGE GEAR SHIFT SECTION
Besides neutral, two ways of power flow (from range
shift gear shaft (1) to spiral bevel pinion shaft (4)) are
available by operating the range gear shift lever to shift
the shifter (2) on the spiral bevel pinion shaft (4).
■ L Position
Range Shift Gear Shaft (20T Gear) (1) → 33T Gear
(6) → Half Shaft (8) → 17T Gear (7) → 36T Gear (3) →
shifter (2) → Hub (5) → Spiral Bevel Pinion Shaft (4).
■ H Position
Range Shift Gear Shaft (1) → Shifter (2) → Hub (5) →
Spiral Bevel Pinion Shaft (4).
(1) Range Shift Gear Shaft
(20T Gear)
(2) Shifter
(3) 36T Gear
(4) Spiral Bevel Pinion Shaft
(5)
(6)
(7)
(8)
Hub
33T Gear
17T Gear
Half Shaft
W1017637
3-M11
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[5] FOUR-WHEEL DRIVE SECTION
(1) Spiral Bevel Pinion Shaft
(2) 32T Gear
(3) 30T Gear
(4) Drive Shaft
(5) Coupling
(6) Shifter
(7) Coupling
(8) Front Wheel Drive Shaft
2-wheel drive or 4-wheel drive is selected by changing position of the shifter (6) on drive shaft (4) using the front
wheel drive lever.
When the front wheel drive lever is set to “Disengage”, the shifter is in neutral and power is not transmitted to the
front wheel drive shaft (8) when the front wheel drive lever is set to “Engage”, the shifter slides to the left to engage
with the front wheel drive shaft (8).
■ Power is transmitted as follows:
Spiral bevel pinion shaft (1) → 32T gear (2) → 30T gear (3) → Drive shaft (4) → coupling (5) → shifter (6) →
coupling (7) → front wheel drive shaft (8).
3-M12
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
4. POWER TRAIN FOR PTO SYSTEM
[1] PTO GEAR SECTION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
PTO Propeller Shaft
PTO Clutch
12T Gear Shaft
16T Gear
49T Gear
45T Gear
Shifter
Coupling
PTO Shaft
W1018599
PTO system is live PTO (Independent PTO) which has its own clutch controls completely separated from the
traveling clutch and transmission.
Therefore, the PTO can operate while the tractor is stopped and also the PTO can be disengaged and engaged
while the tractor is moving.
Power is transmitted as follows:
■ A Speed (540 min−1 (rpm) at engine speed 2205 min−1 (rpm))
12T Gear Shaft (3) → 16T Gear (4) → 45T Gear (6) → Shifter (7) → Coupling (8) → PTO Shaft (9)
■ B Speed (540 min−1 (rpm) at engine speed 1519 min−1 (rpm))
12T Gear Shaft (3) → 49T Gear (5) → Shifter (7) → Coupling (8) → PTO Shaft (9)
3-M13
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................3-S1
SERVICING SPECIFICATIONS ....................................................................3-S3
TIGHTENING TORQUES ..............................................................................3-S5
CHECKING, DISASSEMBLING AND SERVICING......................................3-S6
[1] CHECKING AND ADJUSTING ...............................................................3-S6
(1) Shuttle Lever .......................................................................................3-S6
(2) Main Gear Shift Lever .......................................................................3-S11
(3) Range Gear Shift Lever ....................................................................3-S12
[2] DISASSEMBLING AND ASSEMBLING................................................3-S13
(1) Separating Each Block (Clutch Housing Case and Transmission) ...3-S13
(2) Disassembling Shuttle Case .............................................................3-S19
(3) Disassembling Speed Change Cover ..............................................3-S22
(4) Disassembling Clutch Housing .........................................................3-S25
(5) Disassembling Mid Case (Dual Speed Clutch) .................................3-S27
(6) Disassembling HI-LO Shift Case (Creep Gear Case) .......................3-S29
(7) Disassembling PTO Gear Case........................................................3-S30
(8) Disassembling Differential Gear .......................................................3-S31
(9) Disassembling Rear Drive Shaft (Parking Brake Shaft)....................3-S36
[3] SERVICING ............................................................................................3-S37
(1) Bearing, Shift Fork and Synchronizer ...............................................3-S37
(2) Shuttle Clutch....................................................................................3-S38
(3) Thrust Clearance on Shaft ................................................................3-S39
(4) Dual Speed Clutch ............................................................................3-S40
(5) Differential Gear ................................................................................3-S41
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
1. TROUBLESHOOTING
Symptom
Excessive
Transmission Noise
Gear Slip Out of
Mesh
Hard Shifting
Swing Shift
Malfunctioning
Dual Speed Clutch
Slips
Probable Cause
Solution
Reference
Page
Transmission fluid insufficient
Replenish
G-8
Improper backlash between bevel pinion shaft
and spiral bevel gear
Repair
3-S43
Improper backlash between differential pinion
and side gear
Adjust
3-S46
Collars or shims have not been installed
Repair
–
Bearing worn or damaged
Replace
3-S37
Shifter or shift fork worn or damaged
Replace
3-S37
Shift fork spring weaken or damaged
Replace
–
Interlock ball fallen
Reassemble
–
Synchronizer unit damaged
Repair or replace
3-S37
Shifter or shift fork worn or damaged
Replace
3-S37
Shift fork bent
Replace
–
Synchronizer unit damaged
Repair or replace
3-S37
Shuttle clutch lever linkage, cable improperly
adjusted
Adjust
3-S6
Main gear shift lever linkage improperly adjusted
Adjust
3-S11
Range gear shift linkage improperly adjusted
Adjust
3-S12
Fuse blown
Replace
G-41
Wiring harness disconnected or improperly
connected (between swing shift switch, Hi-Lo
solenoid valve)
Repair
Hi-Lo solenoid valve defected
Replace
9-S26
Swing shift switch defected
Replace
9-S22
Swing shift switch linkage, cable improper
adjusted
Adjust
3-S11
Hi-Lo monitor switch defected
Replace
9-S21
Relief valve setting pressure too low (Regulator
valve)
Adjust
8-S12
Clutch disc excessively worn
Replace
3-S40
Clutch disc or drive plate warped
Replace
3-S40
Seal-ring or D-ring broken
Replace
3-S28
Relief valve setting pressure too low
Replace
8-S13
Hydraulic pump malfunctioning
Replace
8-S7, S24
Pipes or joints loose
Tighten or replace
–
–
W1014322
3-S1
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Symptom
Probable Cause
Solution
Reference
Page
Gears Clash When
Shifting
Synchronizer unit damaged
Repair or replace
3-S37
Clutch does not release
Adjust
2-S4
Differential Lock Can
Not Be Set
Differential lock shift fork damage
Replace
3-S32
Differential lock shift fork mounting spring pin
damaged
Replace
3-S32
Movement of differential lock shifter improperly
adjusted
Adjust
3-S46
Differential Lock
Pedal Does Not
Return
Differential lock cam spring weaken or damaged
Replace
3-S32
Rear Wheels Can Not
Driven
Gears broken
Replace
–
Differential gear broken
Replace
3-S34
Planetary gears broken
Replace
4-S7
W1014322
3-S2
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
Shuttle Rod
Length
65.0 mm
2.56 in.
–
Main Shift Rod 1
Length
489 mm
19.25 in.
–
Main Shift Rod 2
Length
(Initial adjustment)
120 mm
4.72 in.
–
Range Gear Shift Rod
Length
(Initial adjustment)
285 mm
11.22 in.
–
Shift Fork to Shifter Groove
Clearance
0.13 to 0.40 mm
0.0051 to 0.0157 in.
0.8 mm
0.031 in.
Shuttle Clutch Internal Snap Ring to
Pressure Plate (F and R side)
Clearance
2.0 to 2.2 mm
0.079 to 0.087 in.
3.6 mm
0.142 in.
Shuttle Clutch Steel Plate
Thickness
1.94 to 2.06 mm
0.077 to 0.081 in.
–
Shuttle Clutch Pressure Plate
Thickness
4.42 to 4.58 mm
0.174 to 0.180 in.
–
Shuttle Clutch Disc
(Code No. 3F750-23920)
Thickness
2.10 to 2.20 mm
0.083 to 0.087 in.
–
Shuttle Clutch Disc
(Code No. 3F750-23680)
Thickness
2.30 to 2.40 mm
0.091 to 0.094 in.
–
Shuttle Clutch Piston
Thickness
10.9 to 11.1 mm
0.429 to 0.431 in.
–
Main Shaft
(Thrust Bearing to Bearing Washer)
Side Clearance
0.1 to 0.3 mm
0.0039 to 0.0118 in.
–
Counter Shaft
(37T Gear to Collar)
Side Clearance
0.1 to 0.3 mm
0.0039 to 0.0118 in.
–
Dual Speed Clutch
(Internal Snap Ring to Pressure Plate HI
and LO side)
Thickness
2.0 to 2.2 mm
0.079 to 0.087 in.
3.5 mm
0.138 in.
Dual Speed Clutch Steel Plate
(Code No. 3F750-28542)
Thickness
1.35 to 1.45 mm
0.053 to 0.057 in.
–
Dual Speed Clutch Steel Plate
(Code No. 3F750-28522)
Thickness
1.55 to 1.65 mm
0.061 to 0.065 in.
–
Dual Speed Clutch Steel Plate
Thickness
3.92 to 4.08 mm
0.154 to 0.161 in.
–
Dual Speed Clutch Disc
Thickness
2.12 to 2.28 mm
0.083 to 0.090 in.
–
Dual Speed Clutch Piston
Thickness
9.9 to 10.1 mm
0.390 to 0.398 in.
–
Spiral Bevel Pinion Shaft Only
Turning Torque
1.47 to 1.96 N·m
0.15 to 0.20 kgf·m
1.10 to 1.45 ft-lbs
–
W1013874
3-S3
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Item
Factory Specification
Allowable Limit
(Measurement valve of
spiral bevel pinion shaft
only turning torque)
1.47 to 1.96 N·m
0.15 to 0.20 kgf·m
1.10 to 1.45 ft-lbs
–
Spiral Bevel Pinion and Differential
Assembly
Turning Torque
Spiral Bevel Gear to Spiral Bevel Pinion
Shaft
Backlash
0.15 to 0.25 mm
0.0059 to 0.0098 in.
0.4 mm
0.016 in.
Differential Case Bore (Differential Case
Cover Bore) to Differential Side Gear Boss
Clearance
0.070 to 0.169 mm
0.00276 to 0.00665 in.
0.35 mm
0.014 in.
Differential Case
Bore
(I.D.)
49.070 to 49.150 mm
1.93189 to 1.93504 in.
–
Differential Case
Cover Bore
(I.D.)
49.070 to 49.150 mm
1.93189 to 1.93504 in.
–
Differential Side
Gear Boss
(O.D.)
48.961 to 49.000 mm
1.92760 to 1.92913 in.
–
Clearance
0.080 to 0.122 mm
0.00315 to 0.00480 in.
0.25 mm
0.0098 in.
Differential Pinion
Shaft
(I.D.)
25.939 to 25.960 mm
1.02122 to 1.02205 in.
–
Differential Pinion
(O.D.)
26.040 to 26.061 mm
1.02520 to 1.02602 in.
–
Differential Pinion Shaft to Differential
Pinion
Differential Pinion to Differential Side Gear
Backlash
0.15 to 0.30 mm
0.0059 to 0.0118 in.
0.4 mm
0.016 in.
Differential Lock Shifter
Clearance
1.0 to 2.0 mm
0.0394 to 0.0790 in.
–
W1013874
3-S4
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
196.1 to 225.6
20.0 to 23.0
144.7 to 166.4
Engine and clutch housing mounting screw, nut
124 to 147
12.6 to 15.0
91.2 to 108
Engine and clutch housing mounting stud bolt
38.2 to 45.1
3.9 to 4.6
28.2 to 33.3
107.9 to 117.7
11.0 to 12.0
79.6 to 86.8
Lubricating pipe and HI-LO pipe retaining nut
49.0 to 65.6
5.0 to 7.0
36.1 to 50.6
Pump base mounting nut
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
103.0 to 117.7
10.5 to 12.0
76.0 to 86.8
Bearing support mounting screw
77.5 to 90.2
7.9 to 9.2
57.0 to 66.5
Mid case mounting screw and nut
103.0 to 117.7
10.5 to 12.0
76.0 to 86.8
Hydraulic cylinder assembly mounting screw and nut
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Rear axle case mounting screw
124 to 147
12.0 to 15.0
91.2 to 108.5
Rear cover (PTO cover) mounting screw
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Shuttle case mounting screw and nut
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Shuttle valve mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Speed change cover mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Bearing retainer mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Rear bearing support mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
HI-LO shift case mounting screw
48.1 to 55.8
4.9 to 5.7
35.5 to 41.2
225.5 to 264.8
23 to 27
166.4 to 195.3
PTO case cover mounting screws and reamer bolt
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Differential bearing support mounting screw
48.1 to 55.8
4.9 to 5.7
35.4 to 41.2
142.2 to 161.8
14.5 to 16.5
104.9 to 119.3
Spiral bevel pinion shaft staking nut
275 to 343
28 to 35
202.8 to 253.0
Parking brake case mounting screw
77.5 to 90.1
7.9 to 9.2
57.1 to 66.5
Tank stay mounting screw
Delivery pipe retaining nut
Mid case and transmission case mounting screw and
nut
PTO shaft staking nut
Spiral bevel gear mounting screw
W1012736
3-S5
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
CAUTION
• Park the machine on a firm, flat and level surface, set the parking brake and place the gear shift in neutral.
• Stop the engine and remove the key before checking and adjusting.
(1) Shuttle Lever
Preparation
1. Remove the steering post cover (2).
(1) Shuttle Lever
(2) Steering Post Cover
W1013598
Shuttle Cable 1
The movement of shuttle lever is adjusted in installation part (A),
(B) of the shuttle cable.
(1) Shuttle Cable
A : Installation Part
B : Installation Part
W1013693
3-S6
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Checking Shuttle Valve Neutral Position and Lever Guide
Neutral Position
1. The shuttle valve spool is provided with F, N and R ball detents.
(Lift the shuttle lever (1) and slowly move it to the F and R
directions until you feel the lever clicking at the ball detents.)
2. The steering column also has the f, n and r grooves for the
shuttle lever.
3. In this adjustment procedure, make alignment between the
shuttle valve N detent and shuttle lever guide n groove.
(1) Shuttle Lever
(2) Shuttle Lever Guide
f : Groove F
n : Groove N
r : Groove R
F : Forward
R : Reverse
N : Neutral
W1013805
Checking Shuttle Lever Free Play (How to Check and Adjust)
1. Place the shuttle lever to the neutral position.
2. Lift the shuttle lever (1) then move it back and forward, and
confirm the free play “D” of the shuttle lever (1) at neutral
position.
(1) Shuttle Lever
D : Free Play
W1014421
3-S7
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Adjusting Shuttle Lever Neutral Position (To be continue)
1. Shift the free play “D” toward the forward direction and slowly
lower the shuttle lever as shown in the figure 1 [A]. And visually
inspect the clearance “X”.
(1) Shuttle Lever
(2) Shuttle Lever Guide
D : Free Play
X : Clearance
[A] Figure 1
W1014688
3-S8
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Adjusting Shuttle Lever Neutral Position (Continued)
1. Shift the free play “D” toward the rear direction and slowly lower
the shuttle lever (1) as shown in the figure 2 [B]. And visually
inspect the clearance “Y”.
2. Make sure the two clearances “X” and “Y” are just the same.
■ NOTE
• The figure 3 [C] below is an example when the length of the
cable is misadjusted.
3. If these clearances are not same, execute the following step.
(1) Shuttle Lever
(2) Shuttle Lever Guide
D:
X:
Y:
[B]
[C]
Free Play
Clearance
Clearance
Figure 2
Figure 3
W1015057
3-S9
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Adjusting Shuttle Lever Neutral Position (Continued)
1. If these clearances “X” and “Y” are not the same, readjust the
shuttle cable (4) length “Z” with the retaining nuts (3).
■ NOTE
• Use two wrench to prevent the stay bends when adjust the
length of the shuttle cable (4).
1. If displaced too much in the F direction.
Clearance X > Y : Shorten “Z”
2. If displaced too much in the R direction.
Clearance X < Y : Lengthen “Z”
3. Adjust the length Z to become the clearances X and Y are same.
(1)
(2)
(3)
(4)
(5)
Shuttle Lever
Shuttle Lever Guide
Retaining Nut
Shuttle Cable
Retaining Nut
X : Clearance
Y : Clearance
Z : Length
W1015490
3-S10
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(2) Main Gear Shift Lever
Checking Function of Main Gear Shift and Swing Shift (HI-LO)
1. Check the function of the main gear shift and swing shift (HI-LO).
- Neutral position to 1st gear position.
- Neutral position to 2nd gear position.
- Neutral position to 3rd gear position.
- Neutral position to 4th gear position.
- Swing shift switching condition (HI-LO).
2. If shifting is not smooth, check the length of main shift rod 1 (1),
main shift rod 2 (2) and the installation of the select cable (3).
• Length of rod
Length of main shift rod
1 (L1) between both
ends of the rod
Factory spec.
489 mm
19.25 in.
Length of main shift rod
2 (L2)
Initial adjustment
120 mm
4.72 in.
• Check and adjust points of the select cable (3).
- (A) : Tighten until the bottoms up thread (7).
- (B) : Approx. 3 mm (0.12 in.) of thread
- (C) : The clearance between link (4) and plate (5) to 3 mm (0.12
in.) by adjusting (D) part.
(1)
(2)
(3)
(4)
Main Shift Rod 1
Main Shift Rod 2
Select Cable
Link
(5) Plate
(6) Swing Shift Switch
(7) Thread
W1016897
3-S11
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(3) Range Gear Shift Lever
Check Function of Range Shift
1. Check the function of the range gear shift.
- Hi and Lo position.
2. If feeling abnormal shifting, check the length of range gear shift
rod (2).
Length of range gear
shift rod: L
(1) Range Gear Shift Lever
(2) Range Gear Shift Rod
Initial adjustment
285 mm
11.22 in.
L : Length of Range Gear Shift Rod
W1018307
3-S12
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Separating Each Block (Clutch Housing Case and Transmission)
Draining Transmission Fluid
1. Place an oil pan underneath the transmission case.
2. Remove the drain plugs (1).
3. Drain the transmission fluid.
4. Reinstall the drain plugs (1).
(When reassembling)
• Fill up from filling port after removing the filling plug until reaching
the gauge.
• After running the engine for few minutes, stop it and check the
fluid level again, add the fluid to prescribed level if it is not correct
level.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other fluids
may damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-8.)
• Do not mix difference brands oil together.
Transmission fluid
60.0 L
63.4 U.S.qts
52.8 Imp.qts
Capacity
(1) Drain Plug
W1028741
Draining Fuel
1. Place oil pans under the right side fuel tank.
2. Remove the drain cover (2) at the bottom of side fuel tank (1).
3. Drain the fuel.
4. Reinstall the drain cover (2) on the fuel tank (1).
(When reassembling)
• Be sure to fix the O-ring (3) is in position on the drain cover (2).
Fuel Tank
(1) Fuel Tank
(2) Drain Cover
175 L
46.2 U.S.gals
38.5 Imp.gals
Capacity
(3) O-ring
(4) Screw
W1028925
Separating Cabin from Tractor Body
1. See “10. CABIN” (Page 10-S35).
2. Check the clutch housing case and transmission case are
securely mounted on the disassembling stands.
3. Remove the rear wheels.
(When reassembling)
Tightening torque
Rear wheel mounting nut
343 to 401 N·m
35 to 41 kgf·m
254 to 294 ft-lbs
W1029089
3-S13
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Propeller Shaft
1. Remove the clutch housing under cover (1).
2. Tap out the spring pin (2) and then slide the coupling (3) to the
front.
(When reassembling)
• Apply grease to the splines of coupling (3).
• Be sure to assembling the coupling after assemble the engine
and clutch housing case.
• Tap in the spring pins (2) as shown in figure.
• Apply liquid gasket (Three Bond 1208D, 1206D or equivalent) to
joint face of under cover and clutch housing case.
(1) Under Cover
(2) Spring Pin
(3) Coupling
(4) Propeller Shaft
(5) Propeller Shaft Cover
W1019942
Differential Lock Spring
1. Loosen the lock nut (1) and disconnect spring (2) from differential
lock lever (3).
(When reassembling)
• Be sure to fix the front edge of differential lock cable at the center
of thread.
(1) Lock Nut
(2) Spring
(3) Differential Lock Lever
(4) Differential Lock Cable
W1029357
3-S14
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Fuel Tank and Auxiliary Step
1. Remove the auxiliary steps (1), (2).
2. Disconnect the 2P connector fuel tank unit (3).
3. Disconnect the fuel tank connector hose between left and right
side fuel tanks.
4. Remove the fuel tank bands (4).
5. Remove the fuel tank (5), (6) and fuel tank stay (7).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
Auxiliary Step RH
Auxiliary Step LH
2P Connector
Fuel Tank Band
Tank stay mounting screw
196.1 to 225.6 N·m
20.0 to 23.0 kgf·m
144.7 to 166.4 ft-lbs
(5) Fuel Tank RH
(6) Fuel Tank LH
(7) Fuel Tank Stay
W1029474
Separating Engine from Clutch Housing
1. Remove the engine mounting screws and nuts, and separate the
engine from the clutch housing.
(When reassembling)
• Apply molydenum disulphide (Three Bond 1901 or equivalent) to
the splines of damper disc boss.
• Apply liquid gasket (Three Bond 1211, 1141 or equivalent) to the
seam of engine and clutch housing.
• When connecting the engine to the clutch housing, be sure to
align the input shaft spline to the damper hub center.
Engine and clutch housing
mounting screw, nut
124 to 147 N·m
12.6 to 15.0 kgf·m
91.2 to 108 ft-lbs
Engine and clutch housing
mounting stud bolt
38.2 to 45.1 N·m
3.9 to 4.6 kgf·m
28.2 to 33.3 ft-lbs
Tightening torque
(1) Greasing Point
(2) Damper Disc
W1019749
3-S15
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Gear Pump and Pump Base
1. Remove the suction pipes (1).
2. Remove the delivery pipes (2).
3. Remove the PTO pipe (3).
4. Remove the pump base with gear pumps.
(When reassembling)
• Replace the oil pipes with new ones and apply oil to them.
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of pump base and transmission case.
Tightening torque
(1) Suction Pipe
(2) Delivery Pipe
(3) PTO Pipe
Delivery pipe 1 and 2
retaining nut
107.9 to 117.7 N·m
11.0 to 12.0 kgf·m
79.6 to 86.8 ft-lbs
PTO pipe retaining nut
29.4 to 39.2 N·m
3.0 to 4.0 kgf·m
21.7 to 28.9 ft-lbs
Pump base mounting nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
(4) Pump Base
(5) Oil Pipe
W1019997
3-S16
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Separating Mid Case from Transmission Case
1. Remove the dual speed HI clutch pipe (4) and LO clutch pipe (5).
2. Remove the resonator pipe (9).
3. Remove the parking brake cable stay (6).
4. Remove the delivery pipe (8).
5. Remove the lubrication pipe (7).
6. Remove the transmission case mounting screws and nuts.
7. Separating the mid case (1) from transmission case (2).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of the valve case and transmission case.
Transmission case and
mid case mounting screw
and nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Delivery pipe retaining nut
107.9 to 117.7 N·m
11.0 to 12.0 kgf·m
79.6 to 86.8 ft-lbs
Lubricating pipe and Hi-Lo
pipe retaining nut
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.1 to 50.6 ft-lbs
Pump base mounting nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
Mid Case
Transmission Case
Nut
HI Clutch Pipe
LO Clutch Pipe
(6)
(7)
(8)
(9)
Parking Brake Cable Stay
Lubrication Pipe
Delivery Pipe
Resonator Pipe
W1020614
Separating Mid Case from Clutch Housing Case
1. Remove the mid case (1).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of mid case and clutch housing.
Tightening torque
Mid case mounting screw
and nut
103.0 to 117.7 N·m
10.5 to 12.0 kgf·m
76.0 to 86.8 ft-lbs
(1) Mid Case
W1021161
3-S17
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Separating Hydraulic Cylinder Assembly
1. Remove the hydraulic cylinder assembly mounting screws and
nuts.
2. Support the hydraulic cylinder assembly (1) with nylon lift strap
and hoist, and then remove it.
3. Remove the return pipe (2).
(When reassembling)
• Replace the gasket with new.
Tightening torque
Hydraulic cylinder
assembly mounting screw
and nut
(1) Hydraulic Cylinder Assembly
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
(2) Return Pipe
W1021355
Separating Transmission Case
1. Support the rear axle case with nylon lift strap and hoist.
2. Separate the rear axle case (1) from brake case (2).
3. Remove the brake case (2).
4. Remove the rear cover (3).
(When reassembling)
• Replace the O-ring with new one.
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of mid case and transmission case.
• Replace the rear cover gasket with new one.
Rear axle case mounting
screw
124 to 147 N·m
12.0 to 15.0 N·m
91.2 to 108.5 ft-lbs
Rear cover mounting
screw
77.5 to 90.2 N·m
7.9 to 9.2 N·m
57.1 to 66.5 ft-lbs
Tightening torque
(1) Rear Axle Case
(2) Brake Case
(3) Rear Cover
W1021576
3-S18
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(2) Disassembling Shuttle Case
Shuttle Case Assembly
CAUTION
• The shuttle case assembly is heavy, so that take care it when
handling.
1. Remove the screws and nut.
2. Remove the shuttle case assembly (1) by using M8 x Pitch 1.25
screws into holes A and B.
(When reassembling)
• The passage hole of oil is not closed with liquid gaskets.
• Apply liquid gaskets (Three Bond 1208D, 1216 or equivalent) to
joint face of the shuttle case and clutch housing case.
Tightening torque
Shuttle case mounting
screw and nut
(1) Shuttle Case Assembly
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
A : Threaded Hole
B : Threaded Hole
W1021922
3-S19
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Disassembling Shuttle Case Assembly
1. Remove the external snap ring (8).
2. Top out the input shaft (2) with shuttle clutch and 26T gear shaft
(3) together.
(When reassembling)
• Replace the seal rings (5), oil seal (6), sleeve (7) external snap
rings (8) with new ones.
• Be sure to install sleeve (7) as shown figure.
• Apply transmission fluid to seal rings (5) and bearings.
• Apply grease to oil seal and sleeve.
■ NOTE
• Do not get in the seal rings (5) between input shaft (2) and
shuttle case.
(1)
(2)
(3)
(4)
(5)
(6)
Shuttle Case Assembly
Input Shaft
26T Gear Shaft
Shuttle Clutch Assembly
Seal Ring
Oil Seal
(7) Sleeve
(8) External Snap Ring
a : Front Side
b : Rounded Edge
W1022188
3-S20
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Shuttle Clutch Assembly
1. Remove the internal snap ring (1).
2. Remove the pressure plate (2), the drive plates (3), (4) and the
clutch discs (5).
3. Remove the bearing (12).
4. Press the thrust collar (13) lightly with hand press, using
hydraulic clutch spring compressor (15) (see page G-72), and
remove the external snap ring (14).
5. Tap out the input shaft (11) from the clutch body (9).
(When reassembling)
• Replace the external snap rings with new ones.
• Instal the clutch discs (5) and the drive plate (3), (4) mutually.
• When installing the internal snap ring (1) to the clutch body, align
its split portion to the notched portion of clutch body.
• Apply enough transmission fluid to the clutch discs (5).
• Do not confuse the two types of drive plates.
The drive plate with the plug rubbers (16) and without plug
rubbers.
• Three drive plates match the position of plug rubber from the
piston side, and one remaining drive disc is not matched.
• Do not confuse the pressure plate (2), (7) and drive plates (4).
The pressure plate (2) is thicker than the drive plate.
• Confirm the moving of the piston (17) smoothly when pressure air
at 0.5 to 1.0 MPa (5 to 10 kgf/cm2, 71 to 142 psi) is sent to clutch
pack. (Refer to photo left.)
W1022740
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Internal Snap Ring
Pressure Plate
Drive Plate with Rubber
Drive Plate without Rubber
Clutch Disc
Internal Snap Ring
Pressure Plate
Spring
Clutch Body
Spring Holder
Input Shaft
Bearing
Thrust Collar
External Snap Ring
Hydraulic Clutch Spring
Compressor
(16) Plug Rubber
(17) Piston
W1024042
3-S21
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(3) Disassembling Speed Change Cover
Speed Change Cover
1. Remove the shuttle valve (1).
2. Remove the speed change cover (2).
(When reassembling)
• When reassembling the speed change cover (2) to clutch
housing, set the 1-2 shift fork (4), 3-4 shift fork (5) and shifter in
the transmission on neutral position, and Hi-Lo shift fork (3) and
shifter in the transmission on Lo side.
• Apply grease to the Hi-Lo shift fork's guide chips as not to drop
them.
• Replace gasket (6) with new one.
• Mount O-ring on shuttle valve (1) without fail.
Shuttle valve mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
Speed change cover
mounting screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.2 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
Shuttle Valve
Speed Change Cover
Hi-Lo Shift Fork
1-2 Shift Fork
(5)
(6)
(7)
(8)
3-4 Shift Fork
Gasket
1-2 Shifter
3-4 Shifter
W1024424
Hi-Lo Shift Valve
1. Disconnect the shift valve connector (7).
2. Remove the shift valve mounting screws (8).
3. Remove the plate (5) and spring disc (6).
4. Remove the HI shift valve (1) and LO shift valve (2).
(When reassembling)
• The shift valve with a yellow lead (3) is attached to the HI side,
and the shift valve with white lead (4) is attached to the LO side.
(1)
(2)
(3)
(4)
(5)
Hi Shift Valve
Lo Shift Valve
Yellow Lead
White Lead
Plate
(6)
(7)
(8)
(9)
(10)
Spring Disc
Connector
Screw
Monitor Switch
Safety Switch
W1025014
3-S22
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
HI-LO Shift Fork
1. Remove the Hi and Lo monitor switch (9).
2. Remove the internal snap ring (1) and the seal cap (2).
3. Remove the spring pin (4).
4. Remove the fork rod (3) by using M6 x Pitch 1 screw into the
thread (10).
■ NOTE
• Pay attention so as not to lose the detent ball (7) and the
spring (8).
(When reassembling)
• Apply grease to the detent ball (7).
• Apply transmission fluid to the seal cap (2) and fork rod (3).
(1)
(2)
(3)
(4)
(5)
Internal Snap Ring
Seal Cap
Fork Rod
Spring Pin
HI-LO Shift Fork
(6)
(7)
(8)
(9)
(10)
Guide Chip
Detent Ball
Spring
Monitor Switch
Thread
W1025356
3-S23
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Shift Fork and Fork Rod
1. Set the both shift fork on neutral position.
2. Remove the both safety switches (10) on 1-2 shift fork rod (8) and
3-4 shift fork rod (7).
3. Remove the spring pin (3), (4).
4. Tap out the 1-2 shift fork rod (8), then remove the interlocking
balls (5).
5. Tap out the 3-4 shift fork rod (7).
■ NOTE
• Pay attention so as not to lose the balls and springs.
(When reassembling)
• Apply grease to the balls (1), (5).
• Apply transmission fluid to the fork rod (3).
(1)
(2)
(3)
(4)
(5)
Detent Ball
Spring
Spring Pin
Spring Pin
Interlocking Ball
(6)
(7)
(8)
(9)
(10)
3-4 Shift Fork
3-4 Shift Fork Rod
1-2 Shift Fork Rod
1-2 Shift Fork
Safety Switch
W1025835
Main Speed Change Lever (Inner) and Main Speed Change Cam
1. Remove the external snap ring (2) after removing oil seal (1),
then remove the select arm (3).
2. Remove the positioning screw (4) and ball (5).
3. Remove the oil seal (6) and internal snap ring (7).
4. Remove the shaft (8) and cam (9).
■ NOTE
• Pay attention so as not to lose the detent ball (11) and the
spring (12).
• Align the alignment mark of the cam (9) and the shaft (8) is
inserting mutually face to face.
• Apply grease to the balls and oil seals.
• Apply transmission fluid to the needle bearing (13).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Oil Seal
External Snap Ring
Select Arm
Positioning Screw
Ball
Oil Seal
Internal Snap Ring
(8)
(9)
(10)
(11)
(12)
(13)
Shaft
Cam
Spring
Ball
Spring
Needle Bearing
W1026525
3-S24
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(4) Disassembling Clutch Housing
Bearing Support and Main Shaft
1. Remove the bearing retainers (1).
2. Remove the external snap ring (2).
3. Tap out the main shaft (6) to the rear.
4. Remove the bearing support (5) by M8 x Pitch 1.25 screws into
holes (A), (B).
■ NOTE
• When tapping out the main shaft (6), hold the bearing
washer (8), the needle bearing (3), the collar (7) and the
shims (4) for prevent the drop.
(When reassembling)
• Be sure to direct the groove side of the thrust collar.
• Apply transmission fluid to the bearing.
• Be sure to change the external snap ring.
• Be sure to check the main shaft rotation smoothly after
assembling the support.
• After assembling support, be sure to check the side clearance on
the main shaft of gears. (See page 3-S39.)
Bearing retainer mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.8 ft-lbs
Bearing support mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.8 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Bearing Retainer
External Snap Ring
Needle Bearing
Shim
Bearing Support
Main Shaft
(7) Collar
(8) Bearing Washer
(9) Thrust Washer
(A) Hole
(B) Hole
W1027124
3-S25
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Counter Shaft
1. Tap out the counter shaft (1) to front through the hole of the clutch
hub (2).
2. Remove the external snap ring (3), then tap in the clutch hub (2)
with bearing to the clutch housing.
(When reassembling)
• Be sure to direct the groove side of the thrust collar.
• Apply transmission fluid to the external snap ring.
• Be sure to change the external snap ring with new one.
• Be sure to check the counter shaft rotation smoothly after
assembling the support.
• After assembling support, be sure to check the thrust excess play
on the counter shaft of gear.
• Be sure to assembling the needle bearing (6) with narrow width
to inside.
(1)
(2)
(3)
(4)
(5)
Counter Shaft
Clutch Hub
External Snap Ring
Shim
Needle Bearing (Wide)
(6) Needle Bearing (Narrow)
(7) Bearing Support
(8) Clutch Housing
(A) Tapping
W1028579
Front Drive Shaft
1. Remove the bearing retainer (1).
2. Remove the drive shaft support by screwing M8 screw in to holes
A and B.
3. Tap out the front drive shaft (2).
(When reassembling)
• Be sure to change the oil seal and O-ring with new ones.
• Apply grease to the oil seal.
(1)
(2)
(3)
(4)
(5)
Bearing Retainer
Front Drive Shaft
Drive Shaft Support
Oil Seal
O-ring
A : Hole
B : Hole
W1029227
3-S26
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(5) Disassembling Mid Case (Dual Speed Clutch)
Bearing Support and Dual Speed Clutch
1. Tap out the 27T gear shaft (2) and the 25T gear (4) with the
bearing (3) together.
2. Remove the bearing (6) and the external snap ring (5).
3. Remove the bearing support mounting screws.
4. Tap out the 20T gear shaft (7) with bearing support.
(When reassembling)
• Check the 20T gear shaft rotation smoothly after assembling the
bearing support to mid case.
• Apply transmission fluid to the bearings.
• Confirm the moving of the piston smoothly when pressure air at
0.5 to 1.0 MPa (5 to 10 kgf/cm2, 71 to 142 psi) is sent to clutch
pack from oil supply port on mid case side.
Tightening torque
(1)
(2)
(3)
(4)
Bearing Support
27T Gear Shaft
Bearing
25T Gear Shaft
Bearing support mounting
screw
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.0 to 66.5 ft-lbs
(5) External Snap Ring
(6) Bearing
(7) 20T Gear Shaft
W1029698
Bearing Support
1. Remove the external snap ring (1).
2. Remove the feather key (2) and tap out the 20T gear shaft (3).
(When reassembling)
• Replace the seal rings (5) to new ones.
• Apply transmission fluid to the seal rings and bearings.
• Take care not to damage the seal rings when installing the
support.
(1) External Snap Ring
(2) Feather Key
(3) 20T Gear Shaft
(4) Bearing Support
(5) Seal Ring
W1030937
3-S27
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Dual Speed Clutch Assembly
1. Remove the thrust collar (1) at LO clutch side.
2. Remove the internal snap ring (2).
3. Take out the pressure plate (3), clutch disc (4) and drive plate (5).
4. Press the spring retainer plate (6) lightly with clutch compression
tool (8) (see page G-73) for removing the external snap ring (7).
5. Take out the piston (9), the D-ring (10) and the square ring (11)
by compression air.
6. Remove the parts for other side as above.
(When reassembling)
• Apply transmission fluid to D-ring (10) and square ring (11).
• Confirm the moving of piston (9) smoothly when pressure air at
0.5 to 1.0 MPa (5 to 10 kgf/cm2, 71 to 142 psi) is sent to clutch
pack.
(1)
(2)
(3)
(4)
(5)
(6)
Thrust Collar
Internal Snap Ring
Pressure Plate
Clutch Disc
Drive Plate
Spring Retainer Plate
(7)
(8)
(9)
(10)
(11)
External Snap Ring
Clutch Compression Tool
Piston
D-ring
Square Ring
W1031402
3-S28
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(6) Disassembling HI-LO Shift Case (Creep Gear Case)
Hi-Lo Shift Case
1. Remove the HI-LO shift case mounting screws.
2. Remove the HI-LO shift case (1) by using M6 x Pitch 1 screws
into holes A and B.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of transmission case and HI-LO shift case.
Tightening torque
HI-LO shift case mounting
screw
(1) HI-LO Shift Case
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.5 to 41.2 ft-lbs
A : Hole
B : Hole
W1032403
Disassembling Hi-Lo Shift Gear Case
1. Remove the internal snap ring (2).
2. Tap out the gear shaft (3).
(1) Hi-Lo Shift Gear Case
(2) Internal Snap Ring
(3) Gear Shaft
W1033034
Disassembling Creep Gear (Optional)
1. Remove the plug (1) and tap out the spring pin (2).
2. Remove the internal snap ring (3).
3. Tap out the gear shaft (4).
4. Draw out the shift rod (7).
5. Remove the external snap ring (5) and tap out the creep shaft (6).
(When reassembling)
• Take care not to damage the O-ring (8).
(1)
(2)
(3)
(4)
Plug
Spring Pin
Internal Snap Ring
Gear Shaft
(5)
(6)
(7)
(8)
External Snap Ring
Creep Shaft
Shift Rod
O-ring
W1033152
3-S29
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(7) Disassembling PTO Gear Case
Rear Cover Assembly
1. Remove the rear cover and PTO drive shaft as a unit.
(When reassembling)
Tightening torque
Rear cover mounting
screw
77.5 to 90.1 N·m
7.9 to 9.2 kgf·m
57.2 to 66.5 ft-lbs
W1033916
Disassembling PTO Gear Case
1. Remove the PTO case cover mounting screws and then remove
the PTO gear case cover (6).
2. Remove the stake of the staking nut (8), and then remove it.
3. Remove the bearing (7) by using the bearing puller.
4. Tap out the PTO shaft to the rear side.
5. Remove the gears (11), (14), the thrust collars (9), (17), the inner
rings (10), (15), the hub (13) and the shifter (12).
6. Pull out the PTO drive shaft (1) as a unit.
7. Remove the PTO shift fork parts and PTO shift lever parts.
(When reassembling)
• Reinstall the reamer screw at correct position to mount the PTO
cover case.
• Direct the grooves of the thrust collars (9), (17) to the inner rings
(10), (15) sides.
• Replace the PTO shaft staking nut (8) with new one, and stake it
firmly after tightening.
• Apply molybdenum disulfide (Three Bond 1901 or equivalent) to
the inner rings (10) and (15).
• Apply grease to the oil seal (19) and O-ring.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
PTO shaft staking nut
225.6 to 264.8 N·m
23 to 27 kgf·m
166.4 to 195.3 ft-lbs
PTO gear case cover
mounting screws and
reamer screw
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
PTO Drive Shaft
Ball Bearing
Gear
Gear
Ball Bearing
PTO Gear Case Cover
Ball Bearing
Stake Nut
Thrust Collar
Inner Ring
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Gear
Shifter
Hub
Gear
Inner Ring
Internal Snap Ring
Thrust Collar
Ball Bearing
Oil Seal
PTO Shaft
W1034001
3-S30
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(8) Disassembling Differential Gear
Shift Fork and Shift Rod
1. Remove the HI-LO shift case mounting screws.
2. Remove the HI-LO shift case (6) by M6 x Pitch 1 screws in to the
holes.
3. Remove the HI-LO shift fork (3) with fork rod (2) after removing
the fork rod setting screws (8).
4. Remove the range shift rod stopper screw (9), and tap out the
range shift shaft (7) and range shift cam (1).
5. Remove the DT shifter (4) and the DT shift fork (5).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of transmission case and HI-LO shift case.
• Apply grease to the ball.
• Align the alignment mark (10) of the range shift shaft (7) and the
range shift cam (1).
• When installing the range shift shaft (7), a-b-c let the fix position
of O-ring (11) go to the outside of the transmission case (15) with
the process alternately, and the O-ring (12) is assembled into the
shaft as shown in figure.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Range Shift Cam
Fork Rod
HI-LO Shift Fork
DT Shifter
DT Shift Fork
HI-LO Shift Case
Range Shift Shaft
Fork Rod Setting Screw
Stopper Screw
Alignment Mark
(11)
(12)
(13)
(14)
(15)
O-ring
O-ring
Chamfer
Stopper
Transmission Case
a : First Step
b : Second Step
c : Third Step
W1035462
3-S31
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
PTO Clutch Assembly
1. Remove the bearing retainer (1).
2. Tap out the coupling (2) with bearing to the rear.
3. Remove the internal snap ring (3).
4. Remove the external snap ring (4).
5. Tap out the PTO clutch shaft (5) to the front and remove the PTO
clutch assembly (6).
■ IMPORTANT
• When reassembling the PTO clutch assembly (6), direct the
projection part of brake ring (7) to left side in view of the
back.
• Confirm the moving of the piston smoothly when pressure
air at 0.29 to 0.39 MPa (3 to 4 kgf/cm2, 42 to 57 psi) is sent to
clutch pack.
(1)
(2)
(3)
(4)
Bearing Retainer
Coupling
Internal Snap Ring
External Snap Ring
(5) PTO Clutch Shaft
(6) PTO Clutch Assembly
(7) Brake Ring
W1036548
Differential Lock Fork
1. Remove the clevis pin (3) and the plug (6).
2. Draw out the differential lock shaft (5).
3. Take out the differential lock shift fork (4) and the spring (2).
(When reassembling)
• Apply grease to the oil seal.
(1)
(2)
(3)
(4)
Differential Lock Clutch
Spring
Clevis Pin
Differential Lock Shift Fork
(5)
(6)
(7)
(8)
Differential Lock Shaft
Plug
Shim
Oil Seal
W1037031
3-S32
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Differential Gear Assembly
1. Remove the differential support (1), (5), noting the number of the
left and the right shims (2), (4).
2. Take out the differential gear assembly (3) from transmission
case.
(When reassembling)
• Be sure to adjust the turning torque of spiral bevel pinion shaft
and differential assembly combined. (See page 3-S42.)
• Be sure to adjust the backlash and tooth contact between the
spiral bevel gear and spiral bevel pinion shaft. (See page 3-S43.)
Tightening torque
Differential bearing support
mounting screw
(1) Differential Support
(2) Shim
(3) Differential Gear Assembly
48.1 to 55.8 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
(4) Shim
(5) Differential Support
W1037396
Spiral Bevel Gear
1. Remove the spiral bevel gear (1).
(When reassembling)
• Check the spiral bevel gear for wear or damage. If it is no longer
serviceable, replace it. Then, also replace the spiral bevel pinion
shaft.
• Apply liquid lock (Three Bond 1372 or equivalent) to the spiral
bevel gear mounting UBS screws.
Tightening torque
(1) Spiral Bevel Gear
Spiral bevel gear mounting
UBS screw
142.2 to 161.8 N·m
14.5 to 16.5 kgf·m
104.9 to 119.3 ft-lbs
(2) Differential Cover
W1037845
3-S33
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Taper Roller Bearing
1. Place the differential cover (1) on the vise.
2. Tap out the taper roller bearing (2) from the inside of the
differential cap, taking care not to damage the outer race and
separator.
(1) Differential Cover
(2) Taper Roller Bearing
W1038799
Differential Pinion Shaft and Differential Pinion
1. Draw out the differential pinion shaft 2 (5), and take out the
differential pinion (3) and differential pinion washer (4).
2. Draw out the differential pinion shaft (1), and take out the
differential pinion (2) and the differential pinion washer (4).
■ NOTE
• Arrange the parts to know their original position.
(When reassembling)
• Check the differential pinions (2) and (3), and the differential
pinion shafts (1) and (5) for excessive wear. If these parts are
damaged or excessively worn, replace their parts they are in
mesh with, or they sliding on.
• Apply molybdenum disulfide (Three Bond 1901 or equivalent) to
the inner circumferential surface of the differential pinions.
• Install the parts to their original position.
• Install the differential pinion washer (4), noting its groove
position.
(1)
(2)
(3)
(4)
(5)
(6)
Differential Pinion Shaft
Differential Pinion
Differential Pinion
Differential Pinion Washer
Differential Pinion Shaft 2
Differential Case
A : Fit Groove
W1038944
Differential Side Gear
1. Take out the differential side gear (2) and the differential side
gear washer (1).
(When reassembling)
• Check the thrust and bearing surface of both differential side
gears (2). If they are worn or damaged, bores in the differential
case may also be damaged. Be sure to replace their parts.
(1) Differential Side Gear Washer
(2) Differential Side Gear
W1039489
3-S34
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Spiral Bevel Pinion Shaft
1. Remove the stake of the staking nut (1).
2. Set the pinion locking tool (2) (Code No. 07916-52311).
3. Remove the staking nut (1).
4. Tap out the bevel pinion shaft (3) to the rear.
(When reassembling)
• Replace the staking nut with new one, and be sure to adjust the
turning torque of spiral bevel pinion shaft only. (See page 3S41.)
• There staking groove (4) and lubrication groove (5) on the pinion
shaft (3), be sure to stake the nut on right side groove.
(Reference)
1.2 mm (0.047 in.) collar (6) is built in the standard.
Tightening torque
(1) Staking Nut
(2) Pinion Locking Tool
(3) Bevel Pinion Shaft
Spiral bevel pinion shaft
staking nut
275 to 343 N·m
28 to 35 kgf·m
202.8 to 253.0 ft-lbs
(4) Staking Groove
(5) Lubrication Groove
(6) Collar
W1039618
3-S35
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(9) Disassembling Rear Drive Shaft (Parking Brake Shaft)
Rear Drive Shaft
1. Remove the parking brake case assembly (1) from transmission
case.
2. Remove the bearing retainer (2), (3).
3. Tap out the rear drive shaft (4) to front.
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of transmission case and parking brake case.
Parking brake case
mounting screw
77.5 to 90.1 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Bearing retainer mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Tightening torque
(1) Parking Brake Case
(2) Bearing Retainer
(3) Bearing Retainer
(4) Rear Drive Shaft
(5) Parking Brake Friction
W1040231
3-S36
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
[3] SERVICING
(1) Bearing, Shift Fork and Synchronizer
Checking Bearing
1. Hold the inner race, and push and pull the outer race in all
directions to check for wear and roughness.
2. Apply transmission fluid to the bearing, and hold the inner race.
Then, turn the outer race to check rotation.
3. If there is any defect, replace it.
W1041204
Clearance between Shift Fork and Shifter Groove
1. Measure the width of shift fork.
2. Measure the shifter groove width, and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace them.
Clearance between shift
fork and shifter groove
Factory spec.
0.13 to 0.40 mm
0.0051 to 0.0157 in.
Allowable limit
0.80 mm
0.031 in.
W1041518
Checking Contact between Coupling and Shifter
1. Check to see if there is flaw or wear on the spline of the coupling
and shifter, and the key groove on the coupling.
2. Engage the shifter with the coupling, and check that they slide
smoothly.
3. Similarly, check that there is any flaw or wear on the gear splines.
4. If there is any defect, replace them.
W1041907
Flaw on Synchronizer Key and Spring
1. Check the projection in the center of the synchronizer key for
wear.
2. Check the spring for fatigue or wear on the area where the spring
contacts with the keys.
3. If there is any defect, replace them.
W1042016
3-S37
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(2) Shuttle Clutch
Clearance between Internal Snap Ring and Pressure Plate
1. Measure the clearance between internal snap ring and pressure
plate with a feeler gauge while applying the specified force.
Specified force : 176 to 296 N (de 18 to 30 kgf, 39.6 to 66.1 lbs).
2. Three points are measured, and the smallest value is assumed
to be clearance.
3. If the clearance exceeds the allowable limit, measure the
thickness of clutch disc and steel plate with vernier calipers.
4. If the thickness is less than the allowable limit, replace them.
5. Remeasure to confirm the correct clearance.
■ NOTE
• Clearance between internal snap ring and pressure plate is
adjusted by two kinds of clutch discs with different
thickness. Therefore, use the one of the same thickness
when you change clutch disc.
Clearance between
internal snap ring and
pressure plate
(F and R side)
Factory spec.
2.0 to 2.2 mm
0.079 to 0.087 in.
Allowable limit
3.6 mm
0.142 in.
(Reference)
• There are two kinds of thickness of clutch discs.
• Thickness of plate, disc and piston.
Steel plate
Factory spec.
1.94 to 2.06 mm
0.077 to 0.081 in.
Pressure plate
Factory spec.
4.42 to 4.58 mm
0.174 to 0.180 in.
3F75023920
Factory spec.
2.10 to 2.20 mm
0.083 to 0.087 in.
3F75023680
Factory spec.
2.30 to 2.40 mm
0.091 to 0.094 in.
Factory spec.
10.9 to 11.1 mm
0.429 to 0.431 in.
Clutch disc
Piston
W1042118
3-S38
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(3) Thrust Clearance on Shaft
Checking side clearance on Main Shaft Gear
1. Measure the side clearance between thrust bearing and bearing
washer.
2. If the measurement is not within the factory specifications, adjust
the clearance with shim on the front end of main shaft.
(Reference)
• Thickness of shim (4)
0.2 mm (0.0079 in.) [Code No. 3F740-28420]
0.3 mm (0.0118 in.) [Code No. 3F740-28410]
0.5 mm (0.0197 in.) [Code No. 3F740-28440]
Side clearance between
thrust bearing and
bearing washer
(1) Main Shaft
(2) Thrust Bearing
Factory spec.
0.1 to 0.3 mm
0.0039 to 0.0118 in.
(3) Bearing Washer
(4) Shim
W1043048
Checking side clearance on Counter Shaft
1. Measure the side clearance between 33T gear (1) and collar (2).
2. If the measurement is not within the factory specifications, adjust
the clearance with shim on the front end of counter shaft.
(Reference)
• Thickness of shims
0.2 mm (0.0079 in.) [Code No. 3F740-28420]
0.3 mm (0.0118 in.) [Code No. 3F740-28410]
0.5 mm (0.0197 in.) [Code No. 3F740-28430]
Side clearance between
33T gear and collar
(1) 33T Gear
(2) Collar
Factory spec.
0.1 to 0.3 mm
0.0039 to 0.0118 in.
(3) Counter Shaft
(4) Shim
W1044496
3-S39
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(4) Dual Speed Clutch
Clearance between Internal Snap Ring and Pressure Plate
1. Measure the clearance between internal snap ring and pressure
plate with a feeler gauge while applying the specified force.
Specified force: 176 to 296 N (de 18 to 30 kgf, 39.6 to 66.1 lbs).
2. Three points are measured, and the smallest value is assumed
to be clearance.
3. If the clearance exceeds the allowable limit, measure the
thickness of clutch disc and steel plate with vernier calipers.
4. If the thickness is less than the allowable limit, replace them.
5. Remeasure to confirm the correct clearance.
■ NOTE
• Clearance between internal snap ring and pressure plate is
adjusted by two kinds of steel plates with different
thickness. Therefore, use the one of the same thickness
when you change steel plate.
Clearance between
internal snap ring and
pressure plate
(LO and HI side)
Factory spec.
2.0 to 2.2 mm
0.079 to 0.087 in.
Allowable limit
3.5 mm
0.138 in.
(Reference)
• There are two kinds of thickness of steel plates.
• Thickness of plate, disc and piston
3F75028542
Factory spec.
1.35 to 1.45 mm
0.053 to 0.057 in.
3F75028522
Factory spec.
1.55 to 1.65 mm
0.061 to 0.065 in.
Pressure plate
Factory spec.
3.92 to 4.08 mm
0.154 to 0.161 in.
Clutch disc
Factory spec.
2.12 to 2.28 mm
0.083 to 0.090 in.
Piston
Factory spec.
9.9 to 10.1 mm
0.390 to 0.398 in.
Steel plate
W1044863
3-S40
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
(5) Differential Gear
■
•
•
•
•
IMPORTANT
When reassembling spiral bevel pinion shaft and differential assembly, be sure to adjust the following.
Turning torque of spiral bevel pinion shaft only.
Turning torque of spiral bevel pinion shaft and differential assembly combined.
Backlash and tooth contact between spiral bevel pinion shaft and spiral bevel gear.
Turning Torque of Spiral Bevel Pinion Shaft Only
1. Reassemble the spiral bevel pinion shaft and tighten the staking
nut (2) with locking wrench and turning wrench.
2. After striking the bevel pinion shaft to the front and rear, retighten
the staking nut (2) to specified torque.
3. Measure the turning torque of spiral bevel pinion shaft.
4. If the measurement is not within the factory specifications, adjust
the tightening torque of staking nut (2).
Turning torque of
spiral bevel pinion
shaft only
Factory spec.
1.47 to 1.96 N·m
0.15 to 0.20 kgf·m
1.10 to 1.45 ft-lbs
(When reassembling)
Tightening torque
Staking nut
275 to 343 N·m
28 to 35 kgf·m
203 to 253 ft-lbs
(Reference)
• Thickness of adjusting collar (1)
1.0 mm (0.0394 in.) [Code No. 33251-32450]
1.5 mm (0.0591 in.) [Code No. 33251-32460]
1.7 mm (0.0669 in.) [Code No. 33251-32470]
1.75 mm (0.0689 in.) [Code No. 33251-32480]
1.8 mm (0.0709 in.) [Code No. 33251-32490]
1.9 mm (0.0748 in.) [Code No. 33251-32510]
2.0 mm (0.0787 in.) [Code No. 33251-32520]
2.1 mm (0.0827 in.) [Code No. 33251-32530]
2.2 mm (0.0866 in.) [Code No. 33251-32540]
2.25 mm (0.0886 in.) [Code No. 33251-32550]
2.3 mm (0.0906 in.) [Code No. 33251-32560]
■ NOTE
• Stake the staking nut after performing adjustment described
in the following pages.
(1) Collar 1
(2) Staking Nut
(3) Bevel Gear Shaft
(4) Groove for Lubrication
(5) Groove for Staking Nut
W1046371
3-S41
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Turning torque of Spiral Bevel Pinion Shaft and Differential
Assembly Combined
1. Reassembling the differential assembly with the left shims (2)
and the right shims (1) same as before assembling.
2. Check that there is a backlash. If there is no backlash, remove a
right shim (1) and add a left shim (2).
(Reference)
• If the thickness of shims is not known, refer to the following.
Reassembling the differential assembly with no shim at bearing
support R (4) side and with an adequate number of shims at the
bearing support L (3) side. And proceed to the next step.
3. Measure the turning torque by turning the spiral bevel pinion
shaft (5), and then add a shim to the bearing support R (4) if the
turning torque exceeds the factory specifications, or add a shim
to there if the turning torque is less than the factory specifications.
4. And repeat the above procedure until the turning torque becomes
the factory specifications.
Turning torque of spiral
bevel pinion shaft and
differential assembly
combination
Factory spec.
(Measurement value of
spiral bevel pinion shaft
only turning torque)
Plus 1.27 to 2.45 N·m
0.13 to 0.25 kgf·m
0.94 to 1.81 ft-lbs
(Reference)
• Thickness of adjusting shims (1), (2)
0.1 mm (0.004 in.) [Code No. 33740-32130]
0.3 mm (0.012 in.) [Code No. 33740-32140]
0.5 mm (0.020 in.) [Code No. 33740-32150]
(1) Shim
(2) Shim
(3) Bearing Support L
(4) Bearing Support R
(5) Spiral Bevel Pinion Shaft
W1047603
3-S42
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Backlash and Tooth Contact between Spiral Bevel Gear and
Spiral Bevel Pinion Shaft
1. Set the dial indicator (lever type) with its finger on the tooth
surface.
2. Measure the backlash by fixing the spiral bevel pinion shaft (1)
and moving the spiral bevel gear (2) by hand.
3. When the backlash is too large, decrease the number of shims
(3) in the side of spiral bevel gear, and insert the removed shims
in the opposite side.
When the backlash is too small, decrease the number of shims
(4) in the side of the differential case (6), and insert the removed
shims in the opposite side.
4. Adjust the backlash properly by repeating the above procedure.
5. Apply red lead lightly over several teeth at three positions equally
spaced on the spiral bevel gear.
6. Turn the spiral bevel pinion shaft, while pressing a wooden piece
against the periphery on the spiral bevel gear.
7. Check the tooth contact. If not proper, adjust according to the
instructions next page.
Backlash between spiral
bevel gear and spiral
bevel pinion shaft
Factory spec.
0.15 to 0.25 mm
0.0059 to 0.0098 in.
Allowable limit
0.4 mm
0.016 in.
(Reference)
• Thickness of adjusting shim (3), (4)
0.1 mm (0.004 in.) [Code No. 33740-32130]
0.3 mm (0.012 in.) [Code No. 33740-32140]
0.5 mm (0.020 in.) [Code No. 33740-32150]
• Thickness of adjusting collar (5)
1.2 mm (0.047 in.) Collar is built in standard.
0.8 mm (0.031 in.) [Code No. 3E251-32610]
1.0 mm (0.039 in.) [Code No. 3E251-32620]
1.2 mm (0.047 in.) [Code No. 3E251-32630]
1.4 mm (0.055 in.) [Code No. 3E251-32640]
1.6 mm (0.063 in.) [Code No. 3E251-32650]
(1) Spiral Bevel Pinion Shaft
(2) Spiral Bevel Gear
(3) Shim
(4) Shim
(5) Adjusting Collar
(6) Differential Case
W1048267
3-S43
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
• Proper Contact
More than 35 % red lead contact area on the gear tooth surface.
The center of tooth contact at 1/3 of the entire width from the
small end.
(A) Proper Contact
W1049310
• Shallow or Heel Contact
Replace the adjusting collar (5) with thicker one to move the
spiral bevel pinion shaft backward.
And reduce the shim (4) and shim (3) to move the spiral bevel
gear rightward.
Repeat above until the proper tooth contact and backlash are
achieved.
(B) Shallow Contact
(C) Heel Contact
W1049426
• Deep or Toe contact
Replace the adjusting collar (5) with a thinner one to move the
spiral bevel pinion shaft forward.
And increase the shim (4) and shim (3) to move the spiral bevel
gear leftward.
Repeat above until the proper tooth contact and backlash are
achieved.
(D) Deep Contact
(E) Toe Contact
W1049528
(1) Spiral Bevel Pinion Shaft
(2) Spiral Bevel Gear
(3) Shim
(4) Shim
(5) Adjusting Collar
(6) Differential Case
W1049630
3-S44
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Clearance between Differential Case Bore (Differential Case
Cover Bore) and Differential Side Gear Boss
1. Measure the bore I.D. of the differential case and differential case
cover.
2. Measure the differential side gear boss O.D. and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace them.
Factory spec.
0.070 to 0.169 mm
0.00276 to 0.00665 in.
Allowable limit
0.35 mm
0.014 in.
Differential case bore
I.D.
Factory spec.
49.070 to 49.150 mm
1.93189 to 1.93504 in.
Differential side gear
boss O.D.
Factory spec.
48.961 to 49.000 mm
1.92760 to 1.92913 in.
Factory spec.
0.070 to 0.169 mm
0.00276 to 0.00665 in.
Allowable limit
0.35 mm
0.014 in.
Differential case cover
bore I.D.
Factory spec.
49.070 to 49.150 mm
1.93189 to 1.93504 in.
Differential side gear
boss O.D.
Factory spec.
48.961 to 49.000 mm
1.92760 to 1.92913 in.
Clearance between
differential case bore
and differential side gear
boss
Clearance between
differential case cover
bore and differential side
gear boss
W1049726
Clearance between Differential Pinion Shaft and Differential
Pinion
1. Measure the differential pinion shaft O.D.
2. Measure the differential pinion I.D. and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace them.
Factory spec.
0.080 to 0.122 mm
0.00315 to 0.00480 in.
Allowable limit
0.25 mm
0.010 in.
Differential pinion shaft
O.D.
Factory spec.
25.939 to 25.960 mm
1.02122 to 1.02205 in.
Differential pinion I.D.
Factory spec.
26.040 to 26.061 mm
1.02520 to 1.02602 in.
Clearance between
differential pinion shaft
and differential pinion
W1050116
3-S45
KiSC issued 03, 2007 A
TRANSMISSION
M105S, WSM
Backlash between Differential Pinion and Differential Side Gear
1. Set a dial indicator (lever type) on the tooth of the differential
pinion.
2. Hold the differential side gear and move the differential pinion to
measure the backlash.
3. If the measurement is not within the factory specifications, adjust
with the differential side gear washer.
Backlash between
differential pinion and
differential side gear
Factory spec.
0.15 to 0.30 mm
0.0059 to 0.0118 in.
Allowable limit
0.4 mm
0.016 in.
(Reference)
• Thickness of differential side gear washer:
1.5 mm (0.059 in.) 1.7 mm (0.067 in.)
1.6 mm (0.063 in.)
(1) Side Gear Washer
W1050323
Clearance of Differential Lock Shifter
1. Measure the clearance (A) between differential lock shifter and
differential case when the differential lock pedal does not
operate.
2. If the measurement is not within the factory specifications, adjust
with adjusting shim (2).
Clearance (A)
Factory spec.
1.0 to 2.0 mm
0.0394 to 0.079 in.
(Reference)
• Thickness of adjusting shim (2): 0.5 mm (0.020 in.)
1.0 mm (0.039 in.)
(1) Plug
(2) Adjusting Shim
(3) Shift Fork
(4) Differential Lock Shifter
W1050884
3-S46
KiSC issued 03, 2007 A
4
REAR AXLE
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 4-M1
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
1. STRUCTURE
(1)
(2)
(3)
(4)
Rear Axle
Rear Axle Case
Planetary Gear Support
Bearing
(5)
(6)
(7)
(8)
56T Internal Gear
21T Planetary Gear
Differential Lock Shift Fork
Differential Case
(9)
(10)
(11)
(12)
Differential Side Gear
Differential Pinion Gear
35T Bevel Gear
Differential Pinion Shaft
(13) Differential Lock
(14) Brake Case
(15) Brake Shaft (13T)
The rear axles are the final mechanism which transmits power from the transmission to the rear wheels. Direction
of power transmitted is changed at a right angle by the differential gear and, at the same time, speed is reduced. It is
further reduced by the planetary gear (6) to drive the rear axles (1).
The rear axles (1) are semi-floating type with the ball bearing between the rear axle (1) and rear axle case (2),
which support the rear wheel load as well as transmitting power to the rear wheel. They withstand all the forces
caused by tire rotation and side skidding.
■ NOTE
• Refer to “4. REAR AXLE” section in the workshop manual of tractor mechanism (Code No. 97897-18200).
4-M1
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................4-S1
SERVICING SPECIFICATIONS ....................................................................4-S2
TIGHTENING TORQUES ..............................................................................4-S3
CHECKING, DISASSEMBLING AND SERVICING......................................4-S4
[1] DISASSEMBLING AND ASSEMBLING..................................................4-S4
(1) Separating Rear Axle Case from Transmission ..................................4-S4
(2) Disassembling Rear Axle Case ..........................................................4-S7
[2] SERVICING ..............................................................................................4-S9
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
1. TROUBLESHOOTING
Symptom
Excessive or
Unusual Noise at All
Time
Noise while Turning
Probable Cause
Solution
Reference
Page
Improper backlash between brake shaft's 12T
gear and planetary gear
Replace
4-S9
Improper backlash between planetary gear and
internal gear
Replace
4-S9
Bearings worn
Replace
4-S9
Insufficient or improper type of transmission fluid
used
Replace
G-8
Brake shaft gear, planetary gears and internal
gear worn or damaged
Replace
4-S9
Planetary support or bearing worn or broken
Replace
4-S7
W1014322
4-S1
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
Internal Gear to Planetary Gear
Backlash
0.10 to 0.20 mm
0.0039 to 0.0079 in.
0.5 mm
0.020 in.
Planetary Gear Thrust Collar
Thickness
1.55 to 1.65 mm
0.0610 to 0.0650 in.
1.2 mm
0.047 in.
Planetary Gear to Planetary Gear Shaft
Clearance
0.009 to 0.048 mm
0.00035 to 0.00189 in.
0.30 mm
0.0118 in.
Planetary Gear
Shaft
(O.D.)
34.989 to 35.000 mm
1.37752 to 1.37795 in.
–
Planetary Gear
(I.D.)
49.009 to 49.025 mm
1.92949 to 1.93012 in.
–
Needle
(O.D.)
6.994 to 7.000 mm
0.27535 to 0.27559 in.
–
W1013874
4-S2
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
343 to 401
35.0 to 41.0
254 to 297
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Rear bracket mounting bolt and nut
196 to 225
20.0 to 23.0
145 to 166
Rear axle case mounting screw and nut
124 to 147
12.6 to 15.0
91.1 to 108.5
Planetary gear support mounting USB screw
90.0 to 104.0
9.2 to 10.6
66.4 to 76.7
Rear axle cover mounting screw
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Rear axle nut
392 to 588
40.0 to 60.0
289 to 434
Rear wheel mounting nut
Cabin mounting bolt and nut
W1012736
4-S3
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] DISASSEMBLING AND ASSEMBLING
(1) Separating Rear Axle Case from Transmission
Draining Transmission Fluid
1. Place oil pan underneath the transmission case.
2. Remove the drain plugs (1).
3. Drain the transmission fluid.
4. Reinstall the drain plugs (1).
(When reassembling)
• Fill up from filling port (2) after removing the filling plug up to the
upper notch on the dipstick (3).
• After running the engine for few minutes, stop it and check the
fluid level again, add the fluid to prescribed level if it is not correct
level.
Capacity
Transmission fluid
60.0 L
63.4 U.S.qts.
52.8 Imp.qts.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oil may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-8.)
• Do not mixed different brands fluid together.
(1) Drain Plug
(2) Dipstick
(3) Filling Port
A : Oil level is acceptable with this
range.
W1011383
Draining Fuel
(When remove the brake case LH)
1. Place an oil pan under the right side fuel tank (1).
2. Remove the drain cover (2).
3. Drain the fuel.
(When reassembling)
• Be sure to fix the O-ring (3) on the drain cover (2).
• Bleed the fuel system.
■ IMPORTANT
• The fuel tank is made of plastic.
Be careful not to over tighten the screws.
(1) Fuel Tank
(2) Drain Cover
(3) O-ring
(4) Screw
W1011724
4-S4
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
Rear Wheel and 3-Points Hitch
1. Set the front axle rocking restrictor (See page G-72) (1) to the
front axle.
2. Place the disassembling stand under the transmission case.
3. Remove the rear wheel (2).
4. Remove the lifting rod (3) and the lower link (4) with the stabilizer
(5).
(When reassembling)
Tightening torque
Rear wheel mounting nut
(1) Front Axle Rocking Restrictor
(2) Rear Wheel
(3) Lift Rod
343 to 401 N·m
35.0 to 41.0 kgf·m
254 to 297 ft-lbs
(4) Lower Link
(5) Stabilizer
W1011956
Fuel Tank
(When removing the brake case LH)
1. Remove the hose cover (1) and hose (2).
2. Remove the fuel tank band (3).
3. Remove the tank (4).
(1) Hose Cover
(2) Hose
(3) Fuel Tank Band
(4) Fuel Tank
W1012383
4-S5
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
Cabin Mount Bracket Rear
1. Remove the cabin mounting screw and nut (1).
2. Hoist the cabin.
3. Remove the stabilizer bracket (2).
4. Raise the cabin until the rear bracket becomes free to move.
5. Remove the rear bracket (3).
Cabin mounting bolt and
nut
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
Rear bracket mounting
screws and nuts
196 to 225 N·m
20.0 to 23.0 kgf·m
145 to 166 ft-lbs
Tightening torque
(1) Cabin Mounting Screw and Nut
(2) Rear Stabilizer Bracket
(3) Rear Bracket
[A] LH
[B] RH
W1012573
Rear Axle Case
1. Set the disassembling stand to the rear axle case.
2. Disconnect the brake hose.
3. Remove the rear axle case (1) and brake case (2).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
the seam of brake case and transmission case.
• Apply grease to the O-ring.
Tightening torque
(1) Rear Axle Case
Rear axle case mounting
screw and nut
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
(2) Brake Case
W1013184
4-S6
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
(2) Disassembling Rear Axle Case
Planetary Gear Support
1. Remove the planetary gear support mounting UBS screw (1).
2. Remove the planetary gear support (2).
(When reassembling)
Tightening torque
Planetary gear support
mounting UBS screw
(1) Planetary Gear Support Mounting
UBS Screw
90.0 to 104.0 N·m
9.2 to 10.6 kgf·m
66.4 to 76.7 ft-lbs
(2) Planetary Gear Support
W1013445
Planetary Gear
1. Tap the spring pin (1) into the planetary gear shaft (3).
2. Draw out the planetary gear shaft (3), and remove the planetary
gear (2).
3. Tap out the spring pin (1) from the planetary gear shaft (3).
(When reassembling)
• Apply transmission fluid to the inner surface of planetary gear (2)
and bearing.
• Tap in the spring pin (1) as shown in the figure.
(1) Spring Pin
(2) Planetary Gear
(3) Planetary Gear Shaft
W1013638
Rear Axle
1. Remove the rear axle cover mounting screw.
2. Hammer out the rear axle (1).
(When reassembling)
Tightening torque
(1) Rear Axle
Rear axle cover mounting
screw
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
(2) Rear Axle Cover
W1013999
4-S7
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
Rear Axle Nut
1. Fix the rear axle on the repair table or set to the rear wheel.
2. Remove the stake on the rear axle nut.
3. Remove the rear axle nut with a rear axle nut wrench 98 (Code
No. 07916-52521).
(When reassembling)
Tightening torque
Rear axle nut
392 to 588 N·m
40.0 to 60.0 kgf·m
289 to 434 ft-lbs
(1) Rear Axle Nut Wrench
W1014181
Rear Axle Cover
1. Remove the rear axle cover (2) with a rear axle cover puller (1)
(Code No. 07916-51041).
(When reassembling)
• Apply grease to the oil seal lips.
(1) Rear Axle Cover Puller
(2) Rear Axle Cover
W1014398
4-S8
KiSC issued 03, 2007 A
REAR AXLE
M105S, WSM
[2] SERVICING
Backlash between Internal Gear and Planetary Gear
1. Set a dial indicator (lever type) on the tooth of the planetary gear.
2. Hold the planetary gear support and move only the planetary
gear to measure the backlash.
3. If the measurement exceeds the allowable limit, check the
planetary gear and planetary shaft.
Backlash between
internal gear and
planetary gear
Factory spec.
0.10 to 0.20 mm
0.0039 to 0.0079 in.
Allowable limit
0.5 mm
0.020 in.
W1014587
Thrust Collar Thickness
1. Measure the thickness of the thrust collar.
2. If the measurement is less than the allowable limit, replace it.
Factory spec.
1.55 to 1.65 mm
0.0610 to 0.0650 in.
Allowable limit
1.2 mm
0.047 in.
Thrust collar thickness
W1014969
Clearance between Planetary Gear and Planetary Gear Shaft
1. Measure the planetary gear shaft O.D. (rubbing surface).
2. Measure planetary gear I.D. (rubbing surface).
3. Measure the O.D. of the two needles installed diagonally in the
needle bearing.
4. Calculate the clearance.
5. (Clearance = Planetary gear I.D. - {(2 x Needle O.D.) + Planetary
gear shaft O.D.}).
6. If the clearance exceeds the allowable limit, replace them.
Factory spec.
0.009 to 0.048 mm
0.00035 to 0.00189 in.
Allowable limit
0.30 mm
0.0118 in.
Planetary gear shaft
O.D.
Factory spec.
34.989 to 35.000 mm
1.37752 to 1.37795 in.
Planetary gear I.D.
Factory spec.
49.009 to 49.025 mm
1.92949 to 1.93012 in.
Needle O.D.
Factory spec.
6.994 to 7.000 mm
0.27535 to 0.27559 in.
Clearance between
planetary gear and
planetary gear shaft
W1015109
4-S9
KiSC issued 03, 2007 A
5
BRAKES
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. FEATURE ...................................................................................................... 5-M1
[1] TRAVELING AND PARKING BRAKE................................................... 5-M1
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
1. FEATURE
[1] TRAVELING AND PARKING BRAKE
The travelling brake is a hydraulic wet disc type,
which consists of the master cylinder (4), equalizer (6),
brake pipe (2), brake oil reservoir (5) and others. This
type provides high and stable braking effect and requires
almost no adjustment.
In addition, the hydraulic trailer brake valve (11) is
provided in this tractor, which brings a steady braking
power at work to use the heavy trailer. The oil pressure
rise in the brake case (10) is perceived to the trailer brake
valve (11) through the pilot pipe (12). Then the trailer
brake valve (11) feeds pressurized oil to the trailer
through the coupler (13) corresponding to the brake oil
pressure.
■ NOTE
• Refer to “5. BRAKES” section in the workshop
manual of tractor mechanism (Code No. 9789718200).
• As for the trailer brake valve, refer to “8.
HYDRAULIC SYSTEM” section.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Parking Brake Lever
Brake Pipes
Brake Pedal
Master Cylinder
Brake Oil Reservoir
Equalizer
Parking Brake Wire
(8)
(9)
(10)
(11)
(12)
(13)
Parking Brake Camshaft
Brake Hose
Brake Case
Trailer Brake Valve
Pilot Pipe
Coupler
W1012661
5-M1
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................5-S1
SERVICING SPECIFICATIONS ....................................................................5-S2
TIGHTENING TORQUES ..............................................................................5-S4
CHECKING, DISASSEMBLING AND SERVICING......................................5-S5
[1] CHECKING AND ADJUSTING ...............................................................5-S5
[2] DISASSEMBLING AND ASSEMBLING................................................5-S10
(1) Removing Brake Pedal .....................................................................5-S10
(2) Removing Master Cylinder and Equalizer.........................................5-S11
(3) Removing Brake Case ......................................................................5-S13
(4) Removing Parking Brake Case.........................................................5-S16
[3] SERVICING ............................................................................................5-S18
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
1. TROUBLESHOOTING
Symptom
Poor Braking Force
Probable Cause
Reference
Page
Solution
Brake pedal free travel excessive
Adjust
5-S5
Brake disc worn
Replace
5-S16
Brake piston warped
Replace
5-S16
Brake oil insufficient or improper
Replenish or change
with specified oil
Brake oil leakage from brake pipes, bleeder,
master cylinder or equalizer
Repair or replace
–
Master cylinder or equalizer malfunctioning
Repair or replace
5-S11
Brake pedal free travel unevenly adjusted
Adjust
5-S5
Brake disc worn
Replace
5-S16
Brake piston warped
Replace
5-S16
Brake oil leakage from brake pipes, bleeder,
master cylinder or equalizer
Repair or replace
–
Master cylinder or equalizer malfunctioning
Repair or replace
5-S11
Brake pedal free travel too small
Adjust
5-S5
Master cylinder return spring weaken or broken
Replace
5-S11
Master cylinder malfunctioning
Repair or replace
5-S11
Brake seal failure
Replace
5-S16
Brake lines clogged
Clean
Brake pedal return spring weaken or broken
Replace
Brake oil improper
Change with
specified oil
G-8
Brake oil insufficient or improper
Replenish or change
with specified oil
G-8
Air in brake system
Bleed air
5-S8
Brake Oil Consumed
Excessively
Brake seal failure
Replace
5-S16
Brake oil leakage in brake lines
Repair or replace
Poor Parking Brake
Force
Parking brake lever free play excessive
Adjust
5-S9
Parking Brake Drags
Parking brake lever free play too small
Adjust
5-S9
Trailer Brake Drags
Trailer brake pilot pipe clogged
Clean
5-S9
Trailer brake valve malfunctioning
Repair or replace
5-S9
Trailer brake pilot pipe clogged
Clean
5-S9
Trailer brake valve malfunctioning
Repair or replace
5-S9
Air in brake system
Bleed air
5-S8
Master cylinder malfunctioning
Repair or replace
5-S11
Uneven Braking
Force
Brake Drags
Spongy Brake Pedal
Poor Trailer Brake
Force
G-8
–
5-S11
–
W1014322
5-S1
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
2. SERVICING SPECIFICATIONS
TRAVELING BRAKE
Item
Brake Pedal
Factory Specification
Allowable Limit
7 to 14 mm
0.28 to 0.55 in.
–
Less than 100 mm
3.9 in.
–
Difference
0 to 5 mm
0 to 0.20 in.
–
Clearance
0.007 to 0.097 mm
0.00028 to 0.00386 in.
0.4 mm
0.016 in.
Brake Pedal Shaft
(O.D.)
21.948 to 22.000 mm
0.864 to 0.866 in.
–
Brake Pedal
Bushing (I.D.)
22.007 to 22.045 mm
0.866 to 0.868 in.
–
–
0.3 mm
0.012 in.
Play
Right and Left
(Stroke)
Brake pedal Shaft and Bushing
Brake Piston
Flatness
Brake Disc
Thickness
4.15 to 4.35 mm
0.1634 to 0.1713 in.
3.3 mm
0.130 in.
Plate
Thickness
2.1 to 2.5 mm
0.083 to 0.098 in.
1.5 mm
0.059 in.
Master Cylinder Return Spring
Free Length
78.4 mm
3.087 in.
–
29.4 N / 60.6 mm
3.0 kgf / 60.6 mm
6.6 lbs / 2.386 in.
–
22.2 mm
0.874 in.
–
12.7 N / 13.5 mm
1.3 kgf / 13.5 mm
2.9 lbs / 0.531 in.
–
Setting Load /
Setting Length
Equalizer Spring
Free Length
Setting Load /
Setting Length
W1013874
5-S2
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
PARKING BRAKE
Item
Factory Specification
Allowable Limit
Parking Brake Lever
Lever Travel
(Number of
notches)
2 notches
–
Brake Pad
Thickness
[Pad 1]
2.20 mm
0.0866 in.
1.95 mm
0.0768 in.
Thickness
[Pad 2]
2.80 mm
0.1102 in.
2.30 mm
0.0906 in.
Brake Plate
Thickness
6.60 mm
0.2598 in.
6.30 mm
0.2480 in.
Friction Plate
Thickness
3.16 to 3.20 mm
0.1244 to 0.1259 in.
2.60 mm
0.1023 in.
W1011887
5-S3
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
16.0 to 24.0
1.6 to 2.5
11.8 to 17.7
78 to 118
8 to 12
58 to 87
343 to 401
35 to 41
254 to 297
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Rear bracket mounting bolt and nut (M16)
196 to 225
20 to 23
145 to 166
Rear bracket mounting bolt and nut (M18)
275 to 313
28 to 32
203 to 231
Rear axle case mounting screw
124 to 147
12.6 to 15.0
91.1 to 108
Tank stay mounting screw
196 to 225
20 to 23
145 to 166
Parking brake case
77.5 to 90.1
7.9 to 9.2
57.1 to 66.5
Stud
49.0 to 58.8
5.0 to 6.0
36.2 to 43.4
9.8
1.0
7.3
Front brake pipe lock nut
Equalizer plug
Rear wheel mounting nut
Cabin mounting bolt and nut
Stud lock nut
W1012736
5-S4
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Adjusting Brake Pedal
1) Brake Pedal Free Travel
CAUTION
• When checking, parking the tractor on flat ground, and stop
the engine.
1. Measure the free travel by depressing the brake pedals.
2. Slightly depress the brake pedals and measure free travel at the
top of pedal stroke.
3. If the measurement is not within the factory specifications, adjust
the free travel by the push rod (2).
4. After adjustment, tighten the lock nut firmly.
■ IMPORTANT
• Keep the free travel in the right and left brake pedals equal.
Brake pedal free travel
(1) Brake Pedal
(2) Push Rod
Factory spec.
7 to 14 mm
0.28 to 0.55 in.
A : Free Travel
W1012803
2) Brake Pedal Stroke and Difference between Right and Left
Pedal Strokes
•
1.
2.
3.
4.
CAUTION
When checking, park the tractor on flat ground, and stop the
engine.
Disengage the brake pedal lock.
Step on either side brake pedal and measure the level difference
(pedal stroke) between right and left pedals.
Do the same for the other side.
If the pedal stroke exceeds the factory specification, check the air
bleeding, master cylinder, equalizer or brake case.
Brake pedal stroke
Factory spec.
Less than 100 mm
3.9 in.
Difference between left
and right brake pedal
stroke
Factory spec.
0 to 5 mm
0 to 0.20 in.
(1) Brake Pedal LH
(2) Brake Pedal RH
(3) Brake Pedal Lock
A : Pedal Stroke
W1012972
5-S5
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
3) Equalizer Working Level
1. Gently step on both the right and left pedals at once with your
both feet. Step on the right pedal all the way (the left pedal rises).
Measure the level difference between the two pedals.
2. Next step on the left pedal all the way and measure the level
difference.
3. If the measurement is not within the factory specification, check
the equalizer (3).
Level difference
between two pedals
Factory spec.
(1) Brake Pedal
(2) Master Cylinder
Less than 10 mm
0.4 in.
(3) Equalizer
W1013135
Brake Oil
1. Make sure that the brake oil reservoir is filled with the specified
amount of brake oil.
2. If the brake oil is insufficient, replenish the specified brake oil.
■ IMPORTANT
• Never operate the tractor, if the brake oil is below the “MIN”
line.
• Wipe the oil reservoir cap (1) and its surrounding before
removing it.
• When pouring the brake oil, be sure to use the filter and take
care not to allow dust or water to enter.
Brake Oil
(1) Reservoir Cap
Capacity
0.3 L
0.32 U.S.qts
0.26 Imp.qts
A : MAX Level
B : MIN Level
W1013270
■ Precautions for Brake Oil Handling
• Do not mix brake oils of different brands. If brake oils of different
brands are mixed, chemical reaction may occur, causing the
boiling point to drop remarkably. The boiling point may also drop
even when chemical reaction does not occur, which could result
in possible vapor lock. Therefore, when disassembling, use the
specified brake oil for cleaning.
• Prevent entry of moisture.
Entry of moisture results in lower the boiling point.
• Do not mix with brake fluid for automobiles.
The specified brake oil is mineral oil. The cylinder cups and
brake seals used are made of nitrile rubber (NBR) that is
compatible to mineral oils. Automobile brake oil, which is
vegetable oil, can deteriorate cylinder cups and brake seals
rubber when mixed, and the brake may malfunction.
• Be sure to cover brake oil containers to prevent dust, dirt and
water from entering.
W1013593
5-S6
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Brake Oil Level Switch
1. See page 9-S38.
W1013715
Brake Test
1. Remove the bleeder from brake case and set the hydraulic brake
adaptor (Code No. 07916-52970) (1), joint (Code No. 0791650401) (2), cable (Code No. 07916-50331) (3) and pressure
gauge (Code No. 07916-52961) (4).
2. Set the pedal fixing plate between the pedal and pedal stopper
after depressing the brake pedal to reach the pressure between
2.94 to 3.24 MPa (30 to 33 kgf/cm2, 426.7 to 469.4 psi).
3. Read the pressure P after one minute.
4. After reading the pressure P, wait another five minutes to read
the pressure P' and check the pressure drop. The pressure drop
should be within P x 0.1 MPa (P x 0.1 kgf/cm2, P x 0.1 psi).
5. If the pressure drop is too big, attach the pressure gauge to
equalizer (brake pipe rear end) and master cylinder (brake pipe
front end) to find out the problem area.
CAUTION
• If the air is in the master cylinder, brake pipe and case, bleed
the air completely.
(1) Hydraulic Brake Adaptor
(2) Joint
(3) Cable
(4) Pressure Gauge
W1013769
Brake Disc Thickness
1. Remove the checking plug of brake disc thickness at brake case.
2. Press the brake pedal and measure the clearance A between two
brake discs by the thickness gauge.
3. If the measurement is less than the allowable limit, replace the
brake disc.
Clearance between two
brake discs (A)
Allowable limit
3.3 mm
0.13 in.
A : Clearance between two brake
discs
W1014210
5-S7
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Bleeding Brake System
■ NOTE
• While bleeding, make sure to keep enough brake oil in the
brake oil reservoir.
1. Disconnect the brake pipes (1) from the master cylinder.
2. Move the brake pedal up and down by hand. At this time, when
raising the pedal, close the master cylinder outlet by a finger, and
when lowering, release the finger.
Repeat this operation several times. (Prepare and oil can)
3. After bleeding the master cylinder, install the front brake pipes.
4. After installing the vinyl pipe (3) to the bleeder (2) loosen the
bleeder two turns.
5. Move the brake pedal up and down.
Repeat this motion until air bubble in brake oil disappears.
After bleeding, tighten the bleeders firmly.
Tightening torque
Brake pipe nut
16.0 to 24.0 N·m
1.6 to 2.5 kgf·m
11.8 to 17.7 ft-lbs
(Reference : Importance of Bleeding)
• If the air mixes in the brake hydraulic circuit, poor or no braking
force is obtained due to compress the air even when the brake
pedal is pressed.
Accordingly whenever the hydraulic brake system is
disassembled, be sure to bleed the air in the brake system after
reassembling.
(1) Brake Pipe
(2) Bleeder (on Brake Case)
(3) Vinyl Pipe
W1014373
5-S8
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Adjusting Parking Brake Lever Free Play
1. Release the parking brake lever.
2. Pull the parking brake lever with a force of 30 kg (66.2 lbs) for
checking the free play and check the number of notches (A).
3. If the number of notches is not within the factory specifications,
loosen the lock nuts (1) and adjust the length of the parking brake
wire (2).
4. After adjustment, tighten the lock nuts firmly.
Parking brake lever
travel
(number of notches)
Factory spec.
2 notches
■ IMPORTANT
• After adjustment, check the parking brake performance
according to steps 1 to 5.
1. Set the parking brake lever to the 7th notch.
2. Start the engine and set at the idling speed.
3. Shift the travelling speed to the maximum speed range.
4. Release the clutch pedal slowly, and check that the engine
is stopped.
5. If the engine is not stopped, check the parking brake pad
and brake plate. (See page 5-S17 to 18.)
(1)
(2)
(3)
(4)
Parking Brake Lever
Parking Brake Wire
Notches
Lock Nut
A : Pull
B : Release
W1014561
Checking Brake Pressure
1. Remove the trailer brake coupler (5), and set the hydraulic brake
adaptor (3), joint (Code No. 07616-50401), cable (2) (Code No.
07916-50331) and pressure gauge (1) (Code No. 07916-50321).
2. Interlock the left and right pedals.
3. Start the engine and fully depress the brake pedal to measure the
braking pressure.
4. If the measurement is not within the factory specifications, check
the pilot pipe (4) and braking system.
(Reference)
Braking pressure
Reference value
9.8 to 12.7 MPa
100 to 130 kgf/cm2
1422 to 1849 psi
Condition
• Oil temperature...... 45 to 55 °C
113 to 131 °F
(1) Pressure Gauge
(2) Cable
(3) Hydraulic Brake Adaptor
(4) Pilot Pipe
(5) Brake Coupler
W1014779
5-S9
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Removing Brake Pedal
Brake Pedal
1. Remove the meter panel.
2. Remove the bonnet rear.
3. Remove the brake pedal return spring and clevis pin from the
turnbuckle of master cylinder.
4. Remove the circlip (4) and spring pin (5) and draw out the brake
pedal shaft (1), then remove the left and right brake pedal (2), (3).
(When reassembling)
• Apply small amount grease to the brake pedal bearings.
■ IMPORTANT
• After reassembling the brake pedals, be sure to adjust the
brake pedal free play.
(1) Brake Shaft
(2) Brake Pedal (LH)
(3) Brake Pedal (RH)
(4) Circlip
(5) Spring Pin
(6) Brake Pedal Bearing
W1015227
5-S10
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
(2) Removing Master Cylinder and Equalizer
Removing Master Cylinder and Equalizer
■ Precaution of Disassembling and Assembling for Hydraulic
Brake
• Wash all parts with clean brake oil (Refer to see page G-8).
• Before assembling the cylinder cups and O-rings, immerse them
in clean brake oil or apply silicon grease to them.
Use only the brake oil or silicon grease, otherwise the cylinder
cups may be deteriorated.
• It is recommended to replace the cylinder cups and gasket with
new ones.
• Check the cylinder port for clogging, the inner surface of cylinder
and piston sliding part for damage, wear and rust the spacer for
breakage and deformation, the return spring for fatigue and rust.
If any defect is found, replace.
1. Open the bonnet (1) and remove the bonnet dampers (2).
2. Close the bonnet, then remove the bonnet hinge mounting
screws (3) from the holes (4) in the upper part of bonnet.
3. Remove the bonnet (1) and muffler pipe (5).
4. Remove the front brake pipes (6).
5. Remove the clevis pin from push rod end.
6. Remove the master cylinder (7).
7. Remove the equalizer (8).
(When reassembling)
Tightening torque
16.0 to 24.0 N·m
1.6 to 2.5 kgf·m
11.8 to 17.7 ft-lbs
Brake pipe nut
• After mounting the master cylinder and equalizer, be sure to
bleed air (Refer to page 5-S8).
(1)
(2)
(3)
(4)
Bonnet
Damper
Hole
Screw
(5)
(6)
(7)
(8)
Muffler Pipe
Front Brake Pipe
Master Cylinder
Equalizer
W1015622
5-S11
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Master Cylinder
1. Drain the brake oil from the master cylinder.
2. Secure the master cylinder in a vise.
Remove the push rod (3) and boot (4) as a unit from the master
cylinder.
3. Remove the internal snap ring (5), and pull out the piston (6),
return spring (7) and outlet valve (8).
(Reference)
• When taking out the piston, supply compressed air slowly to the
brake pipe mounting portion.
(When reassembling)
• Install the outlet valve, noting its direction.
• Install the piston, taking care not to damage the cylinder cup lip.
Master cylinder return
spring
(1)
(2)
(3)
(4)
(5)
(6)
Free length
78.4 mm
3.09 in.
Setting load /
Setting length
29.4 N / 60.6 mm
3.0 kgf / 60.6 mm
6.6 lbs / 2.39 in.
Turnbuckle
Nut
Push Rod
Boot
Internal Snap Ring
Piston
(7)
(8)
(9)
(10)
(11)
(12)
Return Spring
Outlet Valve
Master Cylinder Body
Secondary Cylinder Cup
Spacer (Shim)
Primary Cylinder Cup
W1016581
Equalizer
1. Drain the brake oil from the equalizer.
2. Secure the equalizer in a vise, remove the plug (1) to pull out the
piston sub-assembly.
(When reassembling)
• Install the piston sub-assembly and plug, noting the O-ring.
Tightening torque
78 to 118 N·m
8 to 12 kgf·m
58 to 87 ft-lbs
Plug
(Reference)
Spring
(1)
(2)
(3)
(4)
(5)
Plug
Equalizer Body
Backup Ring
O-ring
Retainer
Free length
22.2 mm
0.874 in.
Setting load /
Setting length
12.7 N / 13.5 mm
1.3 kgf / 13.5 mm
2.9 lbs / 0.531 in.
(6)
(7)
(8)
(9)
(10)
Spring
Piston
O-ring
Backup Ring
E Snap Ring
W1017215
5-S12
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
(3) Removing Brake Case
Draining Transmission Fluid
1. Place oil pan underneath the transmission case.
2. Remove the drain plugs (1).
3. Drain the transmission fluid.
4. Reinstall the drain plugs (1).
(When reassembling)
• Fill up from filling port (3) after removing the filling plug up to the
upper notch on the dipstick (2).
• After running the engine for few minutes, stop it and check the
fluid level again, add the fluid to prescribed level if it is not correct
level.
Capacity
Transmission fluid
60.0 L
63.4 U.S.qts.
52.8 Imp.qts.
■ IMPORTANT
• Use only KUBOTA SUPER UDT fluid. Use of other oil may
damage the transmission or hydraulic system.
• Refer to “LUBRICANTS, FUEL AND COOLANT” (See page
G-8.)
• Do not mixed different brands fluid together.
(1) Drain Plug
(2) Dipstick
(3) Filling Port
A : Oil level is acceptable with this
range.
W1020945
Draining Fuel
(When remove the brake case LH)
1. Place an oil pan under the right side fuel tank (1).
2. Remove the drain cover (2).
3. Drain the fuel.
(When reassembling)
• Be sure to fix the O-ring (3) on the drain cover (2).
• Bleed the fuel system.
■ IMPORTANT
• The fuel tank is made of plastic.
Be careful not to over tighten the screws.
(1) Fuel Tank
(2) Drain Cover
(3) O-ring
(4) Screw
W1021200
5-S13
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Rear Wheel and 3-Points Hitch
1. Set the front axle rocking restrictor (See page G-72) (1) to the
front axle.
2. Place the disassembling stand under the transmission case.
3. Remove the rear wheel (2).
4. Remove the lifting rod (3) and lower link (4) with stabilizer (5).
(When reassembling)
Tightening torque
Rear wheel mounting nut
(1) Front Axle Rocking Restrictor
(2) Rear Wheel
(3) Lift Rod
343 to 401 N·m
35.0 to 41.0 kgf·m
254 to 297 ft-lbs
(4) Lower Link
(5) Stabilizer
W1021392
Fuel Tank
(When removing the brake case LH)
1. Remove the hose cover (1) and hose (2).
2. Remove the fuel tank band (3).
3. Remove the tank (4).
(1) Hose Cover
(2) Hose
(3) Fuel Tank Band
(4) Fuel Tank
W1021560
5-S14
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Cabin Mount Bracket Rear
1. Remove the cabin mounting screw and nut (1).
2. Hoist the cabin.
3. Remove the stabilizer bracket (2).
4. Raise the cabin until the rear bracket becomes free to move.
5. Remove the rear bracket (3).
Cabin mounting bolt and
nut
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
Rear bracket mounting
screws and nuts
196 to 225 N·m
20.0 to 23.0 kgf·m
145 to 166 ft-lbs
Tightening torque
(1) Cabin Mounting Screw and Nut
(2) Rear Stabilizer Bracket
(3) Rear Bracket
[A] LH
[B] RH
W1021694
Rear Axle Case
1. Set the disassembling stand to the rear axle case.
2. Disconnect the brake hose.
3. Remove the rear axle case (1) and brake case (2).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
the seam of brake case and transmission case.
• Apply grease to the O-ring.
Tightening torque
(1) Rear Axle Case
Rear axle case mounting
screw and nut
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
(2) Brake Case
W1021861
5-S15
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Brake Case
1. Draw out the brake shaft (1) with brake discs (6) and plates (3).
2. Remove the external snap ring (2) and remove the brake discs
and plates.
3. Remove the brake piston (7) from the brake case (8) with
compressed air. (Slowly inject an air from brake hose joint (9).)
(When reassembling)
• Install the brake seal (4), (5), noting its direction and distortion.
• Take care not to enter the foreign matter into the seal groove
inside brake case.
• Install the plates, noting its direction (flat edge down).
• Install the brake discs with their holes aligned to the next holes.
• When installing the brake piston, apply silicon grease to the
brake seals, and tap it in evenly and lightly using a soft hammer.
(1)
(2)
(3)
(4)
(5)
Brake Shaft
External Snap Ring
Plate
Brake Seal 2
Brake Seal 1
(6)
(7)
(8)
(9)
Brake Disc
Brake Piston
Brake Case
Brake Hose Joint
W1018558
(4) Removing Parking Brake Case
Draining Transmission Fluid
1. See page G-16.
W1019077
Draining Fuel
1. See page G-26.
W1019123
5-S16
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Parking Brake Case Assembly
1. Set the front axle rocking restrictor (1) (See page G-72) to the
front axle.
2. Place the disassembling stand under the transmission case.
3. Remove the rear wheel RH.
4. Remove the fuel tank RH (2).
5. Remove the hydraulic oil filter bracket (3) with oil filters.
6. Remove the return spring (5).
7. Loosen the rock nut (6) and disconnect the parking brake wire
(7).
8. Remove the parking brake assembly (4).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of parking brake case and transmission case after
eliminate the water, oil and stuck liquid gasket.
• After assembling the parking brake wire be sure to adjust the
parking brake lever free play (See page 5-S9).
Tightening torque
(1)
(2)
(3)
(4)
Parking brake case and oil
filter bracket mounting
screw
Front Axle Rocking Restrictor
Fuel Tank RH
Oil Filter Bracket
Parking Brake Assembly
77.5 to 90.1 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
(5) Return Spring
(6) Rock Nut
(7) Parking Brake Wire
W1019188
5-S17
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Parking Brake Pad
1. Remove the E snap ring (1), and put out the parking brake
camshaft (2) and parking brake cam (3).
2. Straighten the lock plate (4) and loosen the nut (5).
3. Remove the parking brake pads.
(When reassembling)
• Align the alignment marks (6) of the parking brake camshaft (2)
and parking brake cam (3).
• Install the parking brake pad, noting its direction.
• After tightening the nut (5), bend the lock plate (4) firmly.
• Apply grease to the O-rings.
Stud (7)
49.0 to 58.8 N·m
5.0 to 6.0 kgf·m
36.2 to 43.4 ft-lbs
Stud lock nut
Approx. 9.8 N·m
1.0 kgf·m
7.3 ft-lbs
Tightening torque
■ NOTE
• Excessively tightened the stud lock nut (5) causes damage
to the parking brake case.
Tighten it to the specified torque.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
E Snap Ring
Parking Brake Camshaft
Parking Brake Cam
Lock Plate
Nut
Alignment Marks
Stud
(8)
(9)
(10)
(11)
(12)
(13)
(14)
O-ring
Parking Brake Case
Brake Plate
Brake Pad 1
Brake Pad 2
Friction Plate
Spring
W1019946
Parking Brake Friction Plate
1. See page 3-S36.
W1020830
[3] SERVICING
Brake Piston Flatness
1. Place the brake piston on flat surface (surface plate) and
determine if a 0.3 mm (0.012 in.) feeler gauge will fit underneath.
2. Check this at four points on a diagonal line.
3. If it will fit, grind in a circular motion with sandpaper or replace it.
4. Inspect the sliding portion of the brake piston and brake case
interior. If damage or wear is found, replace it.
Brake piston flatness
Allowable limit
0.3 mm
0.012 in.
W1020903
5-S18
KiSC issued 03, 2007 A
BRAKES
M105S, WSM
Brake Disc Wear
1. Measure the brake disc thickness with a vernier caliper.
2. If the measurement is less than the allowable limit, replace it.
Factory spec.
4.15 to 4.35 mm
0.1634 to 0.1713 in.
Allowable limit
3.3 mm
0.130 in.
Brake disc wear
W1021056
Brake Plate Wear
1. Measure the brake plate thickness with a vernier caliper.
2. If the measurement is less than the allowable limit, replace it.
Factory spec.
2.25 to 2.35 mm
0.0886 to 0.0925 in.
Allowable limit
1.5 mm
0.059 in.
Brake plate wear
W1021153
Parking Brake Pad and Friction Plate Wear
1. Measure the brake pad thickness with a vernier caliper.
2. Measure the friction plate thickness with a vernier caliper.
3. If the thickness is less than the allowable limit, replace it.
Factory
spec.
Pad 1
2.20 mm
0.0866 in.
Pad 2
2.80 mm
0.1102 in.
Pad 1
1.95 mm
0.0768 in.
Pad 2
2.30 mm
0.0906 in.
Brake pad thickness
Allowable
limit
Factory spec.
6.60 mm
0.2598 in.
Allowable limit
6.30 mm
0.2480 in.
Factory spec.
3.16 to 3.20 mm
0.1244 to 0.1259 in.
Allowable limit
2.60 mm
0.1023 in.
Brake plate thickness
Friction plate thickness
(1) Brake Pad 1
(2) Brake Pad 2
(3) Brake Plate
(4) Friction Plate
W1021315
5-S19
KiSC issued 03, 2007 A
6
FRONT AXLE
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 6-M1
[1] 4-WHEEL DRIVE TYPE......................................................................... 6-M2
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
1. STRUCTURE
The front axle supports the front of tractor and facilitates steering.
■ NOTE
• Refer to “6. FRONT AXLE” section in the workshop manual of tractor mechanism (Code No. 97897-18200).
[1] 4-WHEEL DRIVE TYPE
(1)
(2)
(3)
(4)
(5)
Front Axle
Planetary Gear Pin
22T Planetary Gear
19T Bevel Gear
Front Axle Case Support
(6)
(7)
(8)
(9)
(10)
(11)
Clutch 1
Clutch 2
Bracket (Front)
34T Bevel Gear
Front Axle Case Cover
63T Internal Gear
(12)
(13)
(14)
(15)
(16)
(17)
Front Axle Case
13T Bevel Gear
Bevel Gear Shaft
18T Bevel Gear
Differential Yoke Shaft
Front Differential Case
(18)
(19)
(20)
(21)
(22)
(23)
Differential Bearing Support
Differential Case
Bracket (Rear)
18T Bevel Pinion Shaft
27T Bevel Gear
Pinion Bearing Case
The front axle of the 4WD is constructed as shown above. Power is transmitted from the transmission through the
propeller shaft and to the bevel pinion shaft (21), then to the bevel gear (22) after that to the differential gear.
The power through the bevel gear is transmitted to the differential yoke shaft (16),and to the bevel gear shaft (14)
in the front axle case (12).
The revolution is greatly reduced by the 13T bevel gear (13) and 34T bevel gear (9) and planetary gear, then the
power is transmitted to the axle (1).
The differential system allows each wheel to rotate at a different speed to make turning easier.
6-M1
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................6-S1
SERVICING SPECIFICATIONS ....................................................................6-S2
TIGHTENING TORQUES ..............................................................................6-S4
CHECKING, DISASSEMBLING AND SERVICING......................................6-S5
[1] CHECKING AND ADJUSTING ...............................................................6-S5
[2] DISASSEMBLING AND ASSEMBLING..................................................6-S7
(1) Separating Front Axle .........................................................................6-S7
(2) Disassembling Front Axle .................................................................6-S11
[3] SERVICING ............................................................................................6-S18
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
1. TROUBLESHOOTING
Symptom
Front Wheels
Wander to Right or
Left
Front Wheels Can
Not Be Driven
Noise
Probable Cause
Solution
Reference
Page
Tire pressure uneven
Adjust
G-77
Improper toe-in adjustment (improper alignment)
Adjust
6-S5
Clearance between front axle case boss and
front axle bracket (front, rear) bushing excessive
Replace
6-S20
Poor tightening torque of front axle adjusting
screw
Adjust
6-S6
Front wheel sway excessive
Replace
6-S5
Tie-rod end loose
Tighten
6-S11
Air sucked in power steering circuit
Bleed
–
Poor tightening torque of king pin pivot adjusting
screw
Adjust
6-S6
Propeller shaft broken
Replace
6-S8
Front wheel drive gears in transmission broken
Replace
3-S26
Front differential gear broken
Replace
6-S17
Shift fork broken
Replace
–
Coupling displaced
Reassemble
Gear backlash excessive
Adjust or replace
6-S18, 21
to 23
Oil insufficient
Replenish
6-S7 to 8
Bearings damaged or broken
Replace
–
Gears damaged or broken
Replace
–
6-S8
W1014322
6-S1
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
2. SERVICING SPECIFICATIONS
Item
Front Wheel Alignment
Toe-in
Front Wheel
Axle Sway
Steering Angle
Factory Specification
Allowable Limit
2.0 to 8.0 mm
0.078 to 0.315 in.
–
5.0 mm
0.197 in.
–
0.840 to 0.873 rad
48 ° to 50 °
–
Bevel Gear Case and Stopper
Clearance
Below 0.5 mm
0.02 in.
–
Bevel Pinion Shaft and Bevel Gear
Backlash
0.20 to 0.30 mm
0.0079 to 0.0118 in.
0.4 mm
0.016 in.
Differential Case and Differential Side Gear
Clearance
0.050 to 0.091 mm
0.00197 to 0.00358 in.
0.35 mm
0.0138 in.
Differential Case
I.D.
32.025 to 32.050 mm
1.26083 to 1.26181 in.
–
Differential Side
Gear O.D.
31.959 to 31.975 mm
1.25823 to 1.25886 in.
–
Clearance
0.048 to 0.084 mm
0.00189 to 0.00331 in.
0.25 mm
0.0098 in.
Differential Pinion
Shaft O.D.
12.966 to 12.984 mm
0.51047 to 0.51118 in.
–
Differential Pinion
Gear I.D.
13.032 to 13.050 mm
0.51307 to 0.51378 in.
–
Pinion Bearing Case
O.D.
64.970 to 65.000 mm
2.55787 to 2.55906 in.
–
Bearing Retainer
O.D.
64.970 to 65.000 mm
2.55787 to 2.55906 in.
–
Bevel Gear Case
O.D.
49.975 to 50.000 mm
1.96752 to 1.96850 in.
–
Bevel Gear in Bevel Gear Case
Backlash
0.20 to 0.30 mm
0.0079 to 0.0118 in.
0.4 mm
0.016 in.
Planetary Gear, Needle Bearing and Shaft
Clearance
0.009 to 0.046 mm
0.00035 to 0.00181 in.
0.3 mm
0.012 in.
Shaft O.D.
24.991 to 25.000 mm
0.98390 to 0.98425 in.
–
Planetary Gear I.D.
33.009 to 33.025 mm
1.29957 to 1.30020 in.
–
Needle O.D.
3.994 to 4.000 mm
0.15724 to 0.15748 in.
–
Differential Pinion Shaft to Differential
Pinion Gear
Internal Gear to Planetary Gear
Backlash
0.10 to 0.30 mm
0.0039 to 0.0118 in.
0.5 mm
0.020 in.
Bevel Gear in Front Wheel Case
Backlash
0.20 to 0.30 mm
0.0079 to 0.0118 in.
0.4 mm
0.016 in.
W1013874
6-S2
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Item
Thrust Collar
Thickness
Factory Specification
Allowable Limit
1.55 to 1.65 mm
0.0610 to 0.0650 in.
1.0 mm
0.039 in.
W1011456
6-S3
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10)
Item
N·m
kgf·m
ft-lbs
Front axle pivot adjusting screw
19.6 to 29.4
2.0 to 3.0
14.5 to 21.7
Front axle pivot adjusting screw and lock nut
98.1 to 147.1
10.0 to 15.0
72.3 to 108.5
4.9 to 9.8
0.5 to 1.0
3.62 to 7.24
King pin pivot adjusting screw lock nut
98.1 to 147.0
10.0 to 15.0
72.4 to 108.4
Power steering hose retaining nut
22.0 to 27.0
2.2 to 2.8
16.2 to 20.0
Cylinder cover mounting screw
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
Front wheel mounting nut
260 to 303
26.5 to 31.0
192 to 224
Bracket mounting nut
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Bracket mounting screw
166.7 to 196.1
17.0 to 20.0
123.0 to 144.7
Knuckle arm mounting screw
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Tie-rod end slotted nut
156.9 to 196.1
16.0 to 20.0
115.7 to 144.6
Tie-rod joint lock nut
166.7 to 196.1
17.0 to 20.0
123.0 to 144.7
Bevel gear case mounting screw (M12, UBS, 9T)
127.5 to 142.2
13.0 to 14.5
94.0 to 104.9
Bevel gear case mounting screw (M14, 7T)
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Front wheel case support mounting screw (M14, 9T)
166.7 to 196.1
17.0 to 20.0
123.0 to 144.7
Bearing retainer mounting screw (M8)
23.5 to 27.5
2.4 to 2.8
17.4 to 20.2
Front wheel case cover mounting screw
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
Pinion bearing case mounting screw (M12, UBS, 9T)
117.7 to 142.2
12.0 to 14.5
86.8 to 104.9
Pinion bearing case mounting screw (M14, 7T)
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Differential bearing support mounting screw
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
Spiral bevel gear mounting UBS screw
29.4 to 34.3
3.0 to 3.5
21.7 to 25.3
King pin pivot adjusting screw
W1012736
6-S4
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
Adjusting Toe-in
1. Park tractor on a flat place.
2. Turn steering wheel so that front wheels are in the straight ahead
position.
3. Lower the implement, lock the park brake and stop the engine.
4. Measure distance between tire beads at front of tire, hub height.
5. Measure distance between tire beads at rear of tire, hub height.
6. Front distance should be shorter than rear distance.
7. If not, adjust tie-rod length.
Toe-in (b-a)
Factory spec.
2.0 to 8.0 mm
0.08 to 0.31 in.
■
1.
2.
3.
Toe-in Adjustment
Detach the snap ring (1).
Loosen the tie-rod joint lock nut (3).
Turn the tie-rod joint (2) to adjust the rod length until the proper
toe-in measurement is obtained.
4. Retighten the tie-rod joint lock nut (3).
5. Attach the snap ring (1) of the tie-rod joint.
Tightening torque
Tie-rod joint lock nut
(1) Snap Ring
(2) Tie-rod Joint
(3) Tie-rod Joint Lock Nut
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
(a) Wheel-to-wheel distance at front
(b) Wheel-to-wheel distance at rear
(c) Front
W1018163
Axial Sway of Front Wheel
1. Jack up the front side of tractor.
2. Set a dial gauge on the outside of rim.
3. Turn the wheel slowly and read the runout of rim.
4. If the measurement exceeds the factory specifications, check the
bearing, rim and front wheel hub.
Axial sway of front wheel
Factory spec.
Less than 5.0 mm
0.197 in.
W1012824
6-S5
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Adjusting Front Axle Pivot
1. Jack up the tractor body, then loosen the lock nut (2).
2. Measure the adjusting screw tightening torque.
3. If tightening torque is not within the factory specifications, adjust
the adjusting screw (1).
4. After adjustment, tighten the lock nut (2) firmly.
Front axle pivot adjusting
screw
19.6 to 29.4 N·m
2.0 to 3.0 kgf·m
14.5 to 21.7 ft-lbs
Lock nut
98.1 to 147.1 N·m
10.0 to 15.0 kgf·m
72.3 to 108.5 ft-lbs
Tightening torque
(1) Adjusting Screw
(2) Lock Nut
W1012987
Adjusting King-pin Pivot
1. Jack up the tractor, then loosen the lock nut (2).
2. Measure the adjusting screw tightening torque.
3. If tightening torque is not within the factory specifications, adjust
the adjusting screw (1).
4. After adjustment, tighten the lock nut (2) firmly.
Adjusting screw
4.9 to 9.8 N·m
0.5 to 1.0 kgf·m
3.62 to 7.24 ft-lbs
Lock nut
98.1 to 147.0 N·m
10.0 to 15.0 kgf·m
72.4 to 108.4 ft-lbs
Tightening torque
(1) Screw
(2) Lock Nut
W1013116
6-S6
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Front Wheel Steering Angle
1. Inflate the tires to the specified pressure.
2. Adjust turning angle with the stopper bolts table below.
3. The right side is similarly adjusted.
■ IMPORTANT
• Always check if tires contact with tractor or loader frame
assemblies.
(1) Stopper Bolt
B : Front
W1057295
Stopper Bolt (ex. LH stopper bolt)
Angle
0.52 rad (30 °) 0.58 rad (33 °) 0.65 rad (37 °) 0.73 rad (42 °) 0.79 rad (45 °) 0.87 rad (50 °)
Stopper
A : 5 mm (0.2 in.) Collar
[2] DISASSEMBLING AND ASSEMBLING
(1) Separating Front Axle
Draining Front Differential Case Oil
1. To drain the used oil, remove the drain and filling plug (1), (2) at
the front differential case and drain the oil completely into the oil
pan.
2. After draining, reinstall the drain plug (1).
3. Remove the oil level check plug (3).
4. Fill with the new oil up to the lower rim of check plug port.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
5. After filling, reinstall the filling plug (2) and check plugs (3).
Front differential case oil
(1) Drain Plug
(2) Filling Plug
Capacity
7.0 L
7.4 U.S.qts
6.2 Imp.qts
(3) Check Plug
W1013503
6-S7
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Draining Front Axle Gear Case Oil
1. To drain the used oil, remove the right and left drain plugs (2) and
filling plugs (1) at the front axle gear case and drain the oil
completely into the oil pan.
2. After draining reinstall the drain plugs (2).
3. Fill with the new oil up to the filling plug port.
Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page
G-8.)
4. After filling, reinstall the filling plugs (1).
Front Axle Gear Case
Oil
(1) Filling Plug
Capacity
3.5 L
3.7 U.S.qts.
3.1 Imp.qts.
for each side
(2) Drain Plug
W1013799
Propeller Shaft
1. Slide the propeller shaft cover (3) after removing the screw (5).
2. Tap out the spring pins (2) and then slide the coupling (1) to the
rear.
(When reassembling)
• Apply grease to the splines of the propeller shaft (6) and pinion
shaft.
• Tap in the spring pins (2) as shown in figure.
(1)
(2)
(3)
(4)
Coupling
Spring Pin
Propeller Shaft Cover
Spring Pin
(5) Screw
(6) Propeller Shaft
(7) Coupling
W1019695
6-S8
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Front Wheel and Power Steering Hoses
1. Check the front axle and engine are securely mounted on the
disassembly stand.
2. Loosen the front wheel mounting nuts.
3. Lift the front axle and remove the front wheels.
4. Remove the cylinder cover (3).
5. Disconnect the power steering hoses (1), (2).
(When reassembling)
Tightening torque
Power steering hose
retaining nut
22.0 to 27.0 N·m
2.2 to 2.8 kgf·m
16.2 to 20.0 ft-lbs
Cylinder cover mounting
screw
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
Front wheel mounting nut
260 to 303 N·m
26.5 to 31.0 kgf·m
192 to 224 ft-lbs
(1) Power Steering Hose 1
(2) Power Steering Hose 2
(3) Cylinder Cover
W1013932
6-S9
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Front Axle
1. Place a disassembling stand under the front axle bracket and
support it with jack.
2. Hoist and hold the front axle with nylon slings.
3. Loosen the lock nut (1) and remove the spring (2) from differential
lock lever (3).
4. Remove the bracket (front and rear) mounting screws and nuts.
5. Separate the front axle from front axle bracket.
(When reassembling)
• Be sure to fix the front edge of differential lock cable (4) at the
center of thread.
Differential lock pedal
free play
Factory spec.
15 to 25 mm
0.60 to 0.98 in.
Bracket mounting nut
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
Bracket mounting screw
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
Tightening torque
■ IMPORTANT
• Be sure to check the front differential lock pedal free play.
If the pedal free play is not within the factory specifications,
adjust at pedal side of differential lock cable.
(1) Lock Nut
(2) Spring
(3) Differential Lock Lever
(4) Front Edge of Cable
(5) Differential Lock Pedal
(6) Pedal Free Play adjuster
W1014435
6-S10
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
(2) Disassembling Front Axle
Tie-rod
1. Pull out the cotter pin and remove the tie-rod end slotted nuts.
2. Remove the tie-rod with a tie-rod end lifter (Code No. 0790939051).
(When reassembling)
• Replace cotter pin with a new one.
• Bend the cotter pin as shown in the figure.
Tightening torque
Tie-rod slotted nut
156.9 to 196.1 N·m
16.0 to 20.0 kgf·m
115.7 to 144.6 ft-lbs
Tie-rod joint lock nut
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
Knuckle arm mounting
screw
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.0 to 108.5 ft-lbs
(1) Tie-rod
(2) Knuckle Arm
(3) Tie-rod End Litter
W1015363
Separation of Front Differential Case and Bevel Gear Case
1. Remove the bevel gear case (2) and the front wheel case (3) as
a unit from the front differential case (1).
(When reassembling)
• Apply grease to the O-ring.
• Install the bevel gear case to the front differential case, noting the
O-ring.
Tightening torque
Bevel gear case mounting
screw (M12, UBS screw
9T)
127.5 to 142.2 N·m
13.0 to 14.5 kgf·m
94.0 to 104.9 ft-lbs
Bevel gear case mounting
screw
(M14, 7T)
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
(1) Front Differential Case
(2) Bevel Gear Case
(3) Front Wheel Case
W1016047
6-S11
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Bevel Gear Case
1. Separate the bevel gear case (3) from front wheel case (4).
2. Remove the front wheel case support (1).
3. Loosen the bearing retainer (2) mounting screws.
4. Remove the bearing retainer (2) by screwing M8 screw into holes
A and B.
5. Remove the external snap ring (8).
6. Draw out the bevel gear (7) and bevel gear shaft (9).
7. Take out the shim (5).
(When reassembling)
• Apply liquid gasket (Three Bond 1216, 1208D or equivalent) to
the bevel gear case.
• Apply grease to the front wheel case support DX bushing and
front wheel case DX bushing.
• Install the oil seal to the front case support so that its lip faces the
outward.
• Apply gear oil to the bearing.
■ IMPORTANT
• Be sure to adjust the kingpin pivot. (See page 6-S6.)
Front wheel case support
mounting screw (M14, 9T)
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
Bearing retainer mounting
screw
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
Front Wheel Case Support
Bearing Retainer
Bevel Gear Case
Front Wheel Case
Shim
Bearing
(7) Bevel Gear
(8) External Snap Ring
(9) Bevel Gear Shaft
A : Hole
B : Hole
W1016334
Front Wheel Case Cover
1. Remove the front wheel case cover from the front wheel case by
screwing M10 screws into hole A and B.
(When reassembling)
• Apply liquid gasket (Three Bond 1216 or equivalent) to the front
wheel case cover.
Tightening torque
Front wheel case cover
mounting screw
48.1 to 55.1 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
W1017129
6-S12
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Front Wheel Case
1. Remove the internal snap ring (13).
2. Remove the cap (12) which is installed in the bottom of front
wheel case.
3. Remove the internal snap ring (11) and take out the adjusting
shims (10).
4. Tap out bevel gear to downward, and take out the bevel gear (8)
and bearing (9) as a unit.
(When reassembling)
• Apply grease to the front wheel case DX bushing (2).
• Apply grease to the oil seal.
• Install the oil seal (1) to the front wheel case so that its lips faces
the inward.
• Install the internal snap ring (11) as shown in the figure left side
so that align the gap of internal snap ring (11) and by-pass hole
(A).
• Apply gear oil to the cap.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Oil Seal
DX Bushing
Thrust Ball Bearing
Plug
Front Wheel Case
Plug
Ball Bearing
Bevel Gear
(9)
(10)
(11)
(12)
(13)
Ball Bearing
Shim
Internal Snap Ring
Cap
Internal Snap Ring
A : By-pass Hole
W1017321
Bevel Gear
1. Remove the bevel gear and bearing with a puller.
W1018011
6-S13
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Planetary Gear
1. Remove the external snap ring (1).
2. Remove the planetary gear support assembly.
3. Tap the spring pin (6) into the planetary gear shaft (5).
4. Draw out the planetary gear shaft (5), and remove the planetary
gear (3).
5. Tap out the spring pin (6) from the planetary gear shaft (5).
(When reassembling)
• Apply gear oil to the needle bearing (4).
• Tap in the spring pin (6) as shown in the figure left.
(1) External Snap Ring
(2) Thrust Collar
(3) Planetary Gear
(4) Needle Bearing
(5) Planetary Gear Shaft
(6) Spring Pin
W1018079
Front Axle
1. Tap out the front axle from front wheel case cover.
(When reassembling)
• Apply grease to the front axle oil seal (1).
• Install the oil seal to the front wheel case cover so that its lip faces
the inward.
(1) Oil Seal
W1018551
6-S14
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Bevel Gear and Differential Yoke Shaft
1. Remove the bevel gear (5), bearing (4) and differential yoke shaft
(3) as a unit from the differential case (1).
2. Remove the external snap ring (6) and remove the bevel gear (5).
(When reassembling)
• Install the adjusting shims (2) correctly noting their location.
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
the front differential case (1).
(1) Differential Case
(2) Shim
(3) Yoke Shaft
(4) Bearing
(5) 18T Bevel Gear
(6) External Snap Ring
W1018729
Pinion Bearing Case
1. Remove the pinion bearing case mounting screws.
2. Remove the pinion bearing case.
Tightening
torque
Pinion bearing case
mounting screw
M12
screw,
USB
117.7 to 142.2 N·m
12.0 to 14.5 kgf·m
86.8 to 104.9 ft-lbs
M14
screw,
7T
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
W1019091
6-S15
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Differential Assembly
1. Remove the plug (2), and tap out the spring pin (3).
2. Draw out the differential lock lever shaft (1).
3. Remove the differential lock lever (4).
4. Remove the bearing support 1 (7) and shim (8) and differential
lock clutch 2 (9).
5. Remove the differential assembly (10) from the pinion bearing
case (13), noting the shims (8), (12).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Differential bearing support
mounting screw
Differential Lock Lever Shaft
Plug
Spring Pin
Differential Lock Lever
Differential Lock Clutch 1
Spring
Bearing Support 1
(8)
(9)
(10)
(11)
(12)
(13)
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 4 to 51.2 ft-lbs
Shim
Differential Lock Clutch 2
Differential Assembly
Bearing Support 2
Shim
Pinion Bearing Case
W1019337
Spiral Bevel Pinion Shaft
1. Pull out the spiral bevel pinion shaft (1) from the pinion bearing
case (4).
2. Tap out the oil seal (3) from the case if necessary.
(When reassembling)
• Apply grease to the oil seal (3).
• Apply gear oil to the bearing.
• Be sure to direct the chamfer side of the shim to the pinion
bearing case.
• Install the oil seal (3) to the pinion bearing case (4) so that its lip
faces the inward.
(1) Spiral Bevel Pinion Shaft
(2) Shim
(3) Oil Seal
(4) Pinion Bearing Case
W1019958
6-S16
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Spiral Bevel Gear
1. Remove the spiral bevel gear UBS screws.
2. Tap out the spiral bevel gear (2) from the differential gear case.
(When reassembling)
• Apply lock tight (Three Bond 1324B or equivalent) to the spiral
bevel gear UBS screws.
Tightening torque
(1)
(2)
(3)
(4)
(5)
Spiral bevel gear UBS
screw
Bearing
27T Spiral Bevel Gear
Differential Side Gear Washer
Pin
Differential Pinion Shaft
(6)
(7)
(8)
(9)
(10)
29.4 to 34.3 N·m
3.0 to 3.5 kgf·m
21.7 to 25.3 ft-lbs
Differential Pinion Washer
Differential Pinion Gear
Differential Side Gear
Differential Case
Bearing
W1020208
6-S17
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
[3] SERVICING
Backlash and Tooth Contact between Bevel Pinion Shaft and
Bevel Gear
1. Set a dial indicator (lever type) with its finger on the tooth surface.
2. Measure the backlash by fixing the bevel pinion shaft (5) and
moving the bevel gear (3) by hand.
3. If the backlash exceeds the allowable limit, adjust with the shim
(2).
4. Adjust the backlash properly by repeating the above procedure.
Backlash between bevel
gear and bevel pinion
shaft
Factory spec.
0.20 to 0.30 mm
0.0079 to 0.0118 in.
Allowable limit
0.4 mm
0.016 in.
5. Apply red lead lightly over several teeth at three positions equally
spaced on the bevel gear (3).
6. Turn the bevel pinion shaft (5), while pressing a wooden piece
against the periphery of the bevel gear.
7. Check the tooth contact. If not proper, adjust according to the
instructions shown in the figure.
(Reference)
• Thickness of adjusting shim (2):
• The 1.0 mm (0.039 in.) shims are built both side in the standard.
0.1 mm (0.004 in.)
0.8 mm (0.031 in.)
0.2 mm (0.008 in.)
1.0 mm (0.039 in.)
0.4 mm (0.012 in.)
1.2 mm (0.047 in.)
• Thickness of adjusting shims (6):
• The 0.4 mm (0.012 in.) shim is built in the standard.
0.1 mm (0.004 in.)
0.4 mm (0.012 in.)
0.2 mm (0.008 in.)
1.6 mm (0.063 in.)
• Backlash changes per 0.1 mm (0.004 in.) shim : Approx. 0.05 mm
(0.002 in.).
■ IMPORTANT
• Adjust the tooth contact with shims (2) and (6) so that the
spiral bevel pinion shaft may not contact with the differential
case.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Differential Bearing Support 2
Shim
Bevel Gear
Differential Bearing Support 1
Bevel Pinion Shaft
Shim
Pinion Bearing Case
(A) Proper Contact : More than 35 %
red lead contact area on the gear
tooth surface. The center of tooth
contact at 1/3 of the entire width
from the small end.
(B) Deep Contact :
Decrease the shims.
(C) Shallow Contact :
Increase the shims.
W1020806
6-S18
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Clearance between Differential Case and Differential Side Gear
1. Measure the differential side gear boss O.D..
2. Measure the differential case bore I.D., and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace it.
Factory spec.
0.050 to 0.091 mm
0.00197 to 0.00358 in.
Allowable limit
0.35 mm
0.0138 in.
Differential case bore
I.D.
Factory spec.
32.025 to 32.050 mm
1.26083 to 1.26181 in.
Bevel gear bore I.D.
Factory spec.
32.025 to 32.050 mm
1.26083 to 1.26181 in.
Differential side gear
O.D.
Factory spec.
31.959 to 31.975 mm
1.25823 to 1.25886 in.
Clearance between
differential case and
differential side gear
W1021455
Clearance between Differential Pinion Shaft and Pinion Gear
1. Measure the differential pinion shaft O.D..
2. Measure the differential pinion gear I.D., and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace.
Factory spec.
0.048 to 0.084 mm
0.00189 to 0.00331 in.
Allowable limit
0.25 mm
0.0096 in.
Differential pinion shaft
O.D.
Factory spec.
12.966 to 12.984 mm
0.51047 to 0.51118 in.
Differential pinion gear
I.D.
Factory spec.
13.032 to 13.050 mm
0.51307 to 0.51378 in.
Clearance between
differential pinion shaft
and pinion gear
W1021795
6-S19
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Front Bracket and Rear Bracket Bushing
1. Visually inspect the DX bushing for signs of wear or damage.
(The DX bushing tends to show concentrated wear.)
2. If the DX bushing is worn beyond the alloy portion (A), replace it.
Front bracket and rear
bracket bushing
Alloy thickness (A)
0.57 mm
0.0224 in.
Pinion bearing case
O.D.
Factory spec.
64.970 to 65.000 mm
2.55787 to 2.55906 in.
Front differential case
boss I.D.
Factory spec.
64.970 to 65.000 mm
2.55787 to 2.55906 in.
W1022130
Bearing Retainer and Front Wheel Case Support Bushing
1. Visually inspect the DX bushing for signs of wear or damage.
(The DX bushing tends to show concentrated wear.)
2. If the DX bushing is worn beyond the alloy portion (A), replace it.
Front wheel case
support bushing
Alloy thickness (A)
0.57 mm
0.0224 in.
Bearing retainer O.D.
Factory spec.
64.970 to 65.000 mm
2.55787 to 2.55906 in.
W1022243
6-S20
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Bevel Gear Case and Front Wheel Case Bushing
1. Visually inspect the DX bushing for signs of wear or damage.
(The DX bushing tends to show concentrated wear.)
2. If the DX bushing is worn beyond the alloy portion (A), replace it.
Front wheel case
bushing
Alloy thickness (A)
0.57 mm
0.0224 in.
Bevel gear case O.D.
Factory spec.
49.975 to 50.000 mm
1.93752 to 1.96850 in.
W1022017
Backlash of Bevel Gear in Bevel Gear Case
1. Set a dial indicator (lever type) on the shaft (Kingpin).
2. Move the shaft (Kingpin) by hand and measure the
circumferential play of the shaft.
3. Calculate the backlash from the ratio of the shaft diameter to the
gear diameter.
Backlash = Play x 2
4. If the backlash exceeds the allowable limit, adjust with the shims
(1).
Backlash of bevel gear
in bevel gear case
Factory spec.
0.20 to 0.30 mm
0.0079 to 0.0118 in.
Allowable limit
0.4 mm
0.016 in.
(Reference)
• Thickness of adjusting shim (1):
• The 1.0 mm (0.039 in.) shim is built in the standard.
0.1 mm (0.004 in.)
0.8 mm (0.031 in.)
0.2 mm (0.008 in.)
1.0 mm (0.039 in.)
0.4 mm (0.012 in.)
1.2 mm (0.047 in.)
• Backlash changes per 0.1 mm (0.004 in.) shim :
Approx. 0.04 mm (0.015 in.).
(1) Shim
W1022641
6-S21
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Backlash between Internal Gear and Planetary Gear
1. Set a dial indicator (lever type) on the tooth of the planetary gear.
2. Hold the planetary gear support and move only the planetary
gear.
3. If the measurement exceeds the allowable limit, check the
planetary gear and planetary shaft.
Backlash between
internal gear and
planetary gear
Factory spec.
0.10 to 0.30 mm
0.0039 to 0.0118 in.
Allowable limit
0.5 mm
0.020 in.
W1022988
Clearance between Planetary Gear and Shaft
1. Measure the planetary gear I.D. and the planetary gear shaft
O.D. (rubbing surface).
2. Measure the O.D. of two needles installed diagonally in the
needle bearing.
3. Calculate the clearance.
4. If the clearance exceeds the allowable limit, replace them.
Factory spec.
0.009 to 0.046 mm
0.00035 to 0.00181 in.
Allowable limit
0.3 mm
0.012 in.
Planetary gear I.D.
Factory spec.
33.009 to 33.025 mm
1.29957 to 1.30020 in.
Shaft O.D.
Factory spec.
24.991 to 25.000 mm
0.98390 to 0.98425 in.
Needle O.D.
Factory spec.
3.994 to 4.000 mm
0.15724 to 0.15748 in.
Clearance between
planetary gear and shaft
W1023313
Thrust Collar Thickness
1. Measure the thickness of the thrust collar.
2. If the measurement is less than the allowable limit, replace it.
Factory spec.
1.55 to 1.65 mm
0.0610 to 0.0650 in.
Allowable limit
1.0 mm
0.039 in.
Thrust collar thickness
W1023552
6-S22
KiSC issued 03, 2007 A
FRONT AXLE
M105S, WSM
Backlash of Bevel Gear in Front Wheel Case
1. Set a dial indicator (lever type) on the shaft (Kingpin).
2. Move the shaft (Kingpin) by hand and measure the
circumferential play of the shaft.
3. Calculate the backlash from the ratio of the shaft diameter to the
gear diameter.
Backlash = Play x 2
4. If the backlash exceeds the allowable limit, adjust with the shims
(1).
Backlash of bevel gear
in front wheel case
Factory spec.
0.20 to 0.30 mm
0.0079 to 0.0118 in.
Allowable limit
0.4 mm
0.016 in.
(Reference)
• Thickness of adjusting shim (1):
• The 2.0 mm (0.078 in.) shim is built in the standard.
0.1 mm (0.004 in.)
1.2 mm (0.047 in.)
0.2 mm (0.008 in.)
1.8 mm (0.070 in.)
0.4 mm (0.012 in.)
2.0 mm (0.078 in.)
0.8 mm (0.031 in.)
2.3 mm (0.090 in.)
1.0 mm (0.039 in.)
(1) Shim
W1023691
6-S23
KiSC issued 03, 2007 A
7
STEERING
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 7-M1
[1] STEERING MECHANISM....................................................................... 7-M1
KiSC issued 03, 2007 A
STEERING
M105S, WSM
1. STRUCTURE
[1] STEERING MECHANISM
This model is provided with a full hydrostatic power
steering. Generally power steerings are divided into 4
types: booster type, integral type, semi-integral type and
full hydrostatic type.
In the full hydrostatic power steering, the steering
controller is connected to the steering cylinder with only
the hydraulic pipe. This steering is actuated by oil
pressure. Accordingly, it does not have mechanical
transmitting parts such as steering gear, pitman arm,
drag link, etc.. Therefore, it is simple in construction.
This steering system consists of the hydraulic pump
(1), steering controller (2), steering cylinder (3),etc..
This power steering system has double-acting safety
valve (11) which restricts maximum pressure in the
power steering cylinder (3).
The full hydrostatic power steering systems are
divided into two types : non-load reaction type and load
reaction type.
They are distinguished by whether the cylinder port is
blocked or not with the controller in neutral. In this
models, load reaction type is used.
With the load reaction type power steering, the
steering wheel returns almost to the straight forward
position as with an automobile when the operator
releases his hands from the steering wheel.
(Reference)
With the non-load reaction type power steering, the
steering wheel maintain their position when the operator
releases his hands from the steering wheel.
Vibration at the wheels is not transmitted to the
steering wheel.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Hydraulic Pump
Steering Controller
Steering Cylinder
Gerotor
Check Valve
Control Valve
Regulator Valve
Relief Valve
Steering Wheel
Oil Cooler
Double Acting Safety Valve
(a) To Shuttle Clutch Pack for
Lubrication
(b) To PTO Clutch Pack for
Lubrication
W1012661
■ NOTE
• Refer to “7. STEERING” section in the workshop manual of tractor mechanism (Code No. 9Y021-18200).
7-M1
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1. TROUBLESHOOTING ....................................................................................7-S1
2. TIGHTENING TORQUES ..............................................................................7-S2
3. CHECKING, DISASSEMBLING AND SERVICING......................................7-S3
[1] CHECKING AND ADJUSTING ...............................................................7-S3
[2] DISASSEMBLING AND ASSEMBLING..................................................7-S3
(1) Removing Steering Controller .............................................................7-S3
(2) Removing Steering Cylinder ...............................................................7-S4
KiSC issued 03, 2007 A
STEERING
M105S, WSM
1. TROUBLESHOOTING
Symptom
Tractor Cannot Be
Steered
Probable Cause
Solution
Reference
Page
Drive shaft in the steering controller improperly
assembled
Reassemble
8-S26
Turning delivery hose damaged
Replace
7-S4
Oil improper
Change with
specified oil
G-8
Hydraulic pump malfunctioning
Replace
8-S7
Relief valve malfunctioning
Replace
8-S15, 16
Control valve (spool and sleeve) malfunctioning
Repair or replace
Oil leak due to seal damaged
Replace
–
Control valve malfunctioning
Replace
8-S26
Air sucked in pump due to leaking or missing of
oil
Replenish
Air sucked in pump from suction circuit
Repair
Heavy Steering
Especially in the
Beginning of
Steering
Control valve malfunctioning
Repair or replace
8-S26
Steering Wheel
Turns
Spontaneously When
Released
Control valve malfunctioning
Repair or replace
8-S26
Front Wheels
Wander to Right and
Left
Control valve malfunctioning
Repair or replace
8-S26
Air sucked in pump due to lack of oil
Replenish
Air sucked in pump from suction circuit
Repair
–
Insufficient bleeding
Bleed
–
Cylinder malfunctioning
Repair or replace
8-S28
Wheels Are Turned
to a Direction
Opposite to Steering
Direction
Cylinder piping connected in reverse
Repair
7-S4
Steering Wheel
Turns Idle in Manual
Steering
Insufficient bleeding
Bleed
–
Air sucked in pump due to lack of oil
Replenish
G-8
Noise
Air sucked in pump due to lack of oil
Replenish
G-8
Air sucked in pump from suction circuit
Repair
–
Pipe deformed
Replace
–
Oil Temperature
Increases Rapidly
Relief valve malfunctioning
Replace
8-S15, 16
Front Wheels Vibrate
Mechanical connections or wheel bearings worn
Replace defective
parts
Hard Steering
Steering Force
Fluctuates
8-S26
G-8
–
G-8
–
W1014322
7-S1
KiSC issued 03, 2007 A
STEERING
M105S, WSM
2. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
Main delivery pipe and return pipe retaining nut
47.1 to 51.0
4.8 to 5.2
34.7 to 37.6
Turning delivery hose retaining nut
22.0 to 27.0
2.2 to 2.8
16.2 to 20.0
Steering controller mounting screw
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
Tie-rod end slotted nut
156.9 to 176.5
16.0 to 18.0
115.7 to 130.2
Tie-rod joint lock nut
166.7 to 196.1
17.0 to 20.0
123.0 to 144.7
48.1 to 55.9
4.9 to 5.7
35.4 to 41.2
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Cylinder cover mounting screw
Cylinder bracket mounting screw
W1012736
7-S2
KiSC issued 03, 2007 A
STEERING
M105S, WSM
3. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
• Refer to checking “Steering Controller” in “8. HYDRAULIC SYSTEM” section.
[2] DISASSEMBLING AND ASSEMBLING
(1) Removing Steering Controller
Bonnet and Muffler Pipe
1. Remove the bonnet (1).
2. Remove the muffler pipe (2).
(1) Bonnet
(2) Muffler Pipe
W1011906
Piping for Power Steering
1. Disconnect the turning delivery hoses (1).
2. Disconnect the main delivery pipe (2).
3. Disconnect the return pipe (3).
4. Disconnect the steering controller joint (4).
5. Remove the steering controller bracket (5).
6. Remove the steering controller (6).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
(5)
Main delivery pipe and
return pipe retaining nut
47.1 to 51.0 N·m
4.8 to 5.2 kgf·m
34.7 to 37.6 ft-lbs
Turning delivery hose
retaining nut
22.0 to 27.0 N·m
2.2 to 2.8 kgf·m
16.2 to 20.0 ft-lbs
Steering controller
mounting screws
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
Turning Delivery Hose
Main Delivery Pipe
Return Pipe
Steering Controller Joint
Controller Bracket
(6)
(7)
(8)
(9)
(10)
Steering Controller
Pump Port
Return Port
Left Turning Port
Right Turning Port
W1012259
7-S3
KiSC issued 03, 2007 A
STEERING
M105S, WSM
(2) Removing Steering Cylinder
Tie-rod
1. Pull out the cotter pin and remove the tie-rod end slotted nuts.
2. Remove the tie-rod with a tie-rod end lifter (Code No. 0790939051).
(When reassembling)
• Replace cotter pin with a new one.
• Bend the cotter pin as shown in the figure.
Tie-rod end slotted nut
156.9 to 176.5 N·m
16.0 to 18.0 kgf·m
115.7 to 130.2 ft-lbs
Tie-rod joint lock nut
166.7 to 196.1 N·m
17.0 to 20.0 kgf·m
123.0 to 144.7 ft-lbs
Tightening torque
W1012890
Power Steering Hoses and Cylinder
1. Remove the cylinder cover (3) (4).
2. Disconnect the turning delivery hose (1), (2).
3. Remove the cylinder bracket (5), (6).
4. Take out the cylinder.
(When reassembling)
Tightening torque
Turning delivery hose
retaining nut
22.0 to 27.0 N·m
2.2 to 2.8 kgf·m
16.2 to 20.0 ft-lbs
Cylinder cover mounting
screw
48.1 to 55.9 N·m
4.9 to 5.7 kgf·m
35.4 to 41.2 ft-lbs
Cylinder bracket mounting
screw
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
(1) Turning Delivery Hose RH
(2) Turning Delivery Hose LH
(3) Cylinder Cover LH
(4) Cylinder Cover
(5) Cylinder Bracket LH
(6) Cylinder Bracket RH
W1013465
7-S4
KiSC issued 03, 2007 A
8
HYDRAULIC SYSTEM
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. STRUCTURE ................................................................................................. 8-M1
2. HYDRUALIC CIRCUIT .................................................................................. 8-M3
3. HYDRAULIC SHUTTLE VALVE .................................................................. 8-M4
[1] STRUCTURE ........................................................................................... 8-M4
[2] OPERATION ............................................................................................ 8-M6
4. REGULATOR VALVE ................................................................................. 8-M16
[1] STRUCTURE AND OIL FLOW ........................................................... 8-M16
5. PTO CLUCH ............................................................................................... 8-M18
6. DUAL SPEED VALVE ................................................................................ 8-M19
7. HYDRAULIC TRAILER BRAKE ................................................................. 8-M20
[1] HYDRAULIC CIRCUIT.......................................................................... 8-M20
[2] TRAILER BRAKE VALVE .................................................................... 8-M21
[3] OPERATION .......................................................................................... 8-M22
8. POWER STEERING HYDRAULIC CIRCUIT ............................................ 8-M26
9. THREE-POINT HYDRAULIC SYSTEM ..................................................... 8-M27
[1] HYDRAULIC CIRCUIT.......................................................................... 8-M27
[2] CONTROL VALVE ................................................................................ 8-M28
[3] POSITION CONTROL .......................................................................... 8-M30
[4] DRAFT CONTROL................................................................................ 8-M31
[5] MIXED CONTROL ................................................................................ 8-M32
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
1. STRUCTURE
(1)
(2)
(3)
(4)
Auxiliary Control Valve
Hydraulic Cylinder Body
Shuttle Valve
Power Steering Controller
(5) Oil Cooler
(6) Hydraulic Pump (for Power
Steering, Shuttle)
(7) Hydraulic Pump (for 3P Hitch)
(8)
(9)
(10)
(11)
Oil Filter Cartridge
Regulator Valve
Safety Valve for 3P
PTO Valve
(12) Swing Shift
(13) Dual Speed Valve
(14) Trailer Brake Valve
The hydraulic system of M105S tractor is composed of three point hitch, remote hydraulic control for implements,
power steering, PTO clutch, shuttle clutch, swing shift, dual speed and trailer brake shown above.
This system has following functions.
1. To raise and lower implements connected to the three point hitch. The hydraulic lift is a subject to position control
and draft control (mixed) control.
2. To draw hydraulic power from auxiliary control valve to operate implement hydraulic actuators.
1) For implements with double acting actuators, hydraulic power can be easily drawn from the quick coupler.
2) The auxiliary control permits the simultaneous operation of implements powered by hydraulic pressure along
with the attached to the 3-point hitch.
3) Oil flowed from 3-point hitch pump can be connected with oil flowed from auxiliary control valve.
- Total oil flow is 65 L/min (17.2 U.S.gal/min, 14.3 Imp.gal/min).
- Operating pressure is 19.1 MPa (195 kgf/cm2, 2773 psi).
4) Maximum installation of remote valve is four valves (3 valves with a flow control valve).
3. To operate power steering through the steering controller.
Refer to “7. STEERING” section in this workshop manual.
4. To operate hydraulic PTO clutch.
Refer to “2. CLUTCH” section in this workshop manual.
5. To operate hydraulic shuttle.
The hydraulic shuttle is controlled by shuttle lever. The shuttle lever and clutch pedal. Two ways of travelling
direction are controlled forward and reverse by the change of forward and reverse performed with a shuttle lever
can be performed without clutch pedal operation.
The clutch pedal operation, a run and stop, and inching action are controlled.
8-M1
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
6. To operate swing shift HI-LO.
The swing shift (HI-LO) is controlled by the combination of solenoid valve and hydraulic flow.
Two ways of power train are available low speed range and high speed range of travelling speed.
7. To operate dual speed HI-LO.
The dual speed (HI-LO) is controlled by combination of solenoid valve and hydraulic flow.
Two way of power train are available low speed range and high speed range of traveling speed.
8. To draw hydraulic power from trailer brake valve to operate trailer hydraulic brake actuator.
■ NOTE
• Refer to see “8. HYDRAULIC SYSTEM” section in the workshop manual of tractor mechanism (Code No.
97897-18200).
8-M2
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
2. HYDRUALIC CIRCUIT
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Auxiliary Control Valve
Control Valve for 3P
Power Steering Controller
Oil Cooler
PTO Valve
Shuttle Valve
Oil Tank (Transmission Case)
(8) Hydraulic Oil Filter Cartridge
(9) Hydraulic Pump (for 3P)
(10) Hydraulic Pump (PTO Clutch,
Shuttle Clutch, Swing Shift,
Dual Speed)
(11) Cylinder Safety Valve
(12) Relief Valve for 3P
(13)
(14)
(15)
(16)
(17)
(18)
(19)
8-M3
Hydraulic Cylinder
Regulator Valve
Swing Shift
Steering Cylinder
PTO Clutch
Shuttle Clutch R
Shuttle Clutch F
(20)
(21)
(22)
(23)
(24)
(25)
Pump Base
Solenoid Valve
Dual Speed Clutch HI
Dual Speed Clutch LO
Dual Speed Valve
Trailer Brake Valve
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
3. HYDRAULIC SHUTTLE VALVE
[1] STRUCTURE
(1) Shuttle Valve
(2) Accumulate Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4) Proportionally Reducing Valve
(5) Line Filter
(6) Filter
(7) Inching Valve Spool
(8) Modulating Valve
(a) Clutch Pedal Released
Position
(b) Clutch Pedal Depressed
Position
(c)
(d)
(e)
(f)
Shuttle Forward Position
Shuttle Neutral Position
Shuttle Reverse Position
Oil from Regulator Valve
A : Pressure Check Port
(Modulation)
8-M4
B : Pressure Check Port
(Reverse)
C : Pressure Check Port
(Forward)
F : To Clutch Body (Forward)
R : To Clutch Body (Reverse)
T1 to T5 : Tank Port
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(1) Power Steering Controller
(2) Modulation Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4)
(5)
(6)
(7)
(8)
Proportionally Reducing Valve
(9) Regulator Valve
Accumulate Valve
(10) Pump Base
Shuttle Valve
(11) Hydraulic Pump for PTO,
PTO Clutch Control Valve
Power Steering, Shuttle,
Oil Cooler
Swing Shift, Dual Speed
(12) Shuttle Clutch R
(13) Shuttle Clutch F
Hydraulic shuttle valve is composed of modulating valve (2), proportionally reducing valve (4), shuttle shift spool
(3), accumulate valve (5) and other component parts.
8-M5
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[2] OPERATION
■ Shuttle Lever at Neutral Position
8-M6
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(1) Modulating Valve
(2) Proportionally Reducing Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4) Accumulate Valve
(5)
(6)
(7)
(8)
Shuttle Valve
Inching Valve
Shuttle Lever
Clutch Pedal
A : Check Port (Modulation)
B : Check Port (Reverse)
C : Check Port (Forward)
D : Check Port (Pump)
P : From Regulator Valve
C1, C2 : Connection Port
T1 to T5: To Transmission Case
N1 : Port N1
N2 : Port N2
a : Connect to Shuttle Lever
b : Connect to Clutch Pedal
When the shuttle lever is at Neutral position, as the oil passage between P port to F or R port is closed by shuttle
shift spool (3), pressure-fed oil from P port flows to the T5 port. Thus the shuttle clutch is not engage.
8-M7
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ When Shuttle Lever is Shifting Neutral to Reverse or Forward Position (Clutch Pedal is Released)
8-M8
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(1) Modulating Valve
(2) Proportionally Reducing Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4) Accumulate Valve
(5)
(6)
(7)
(8)
Shuttle Valve
Inching Valve
Shuttle Lever
Clutch Pedal
A : Check Port (Modulation)
B : Check Port (Reverse)
C : Check Port (Forward)
D : Check Port (Pump)
P : From Regulator Valve
C1, C2 : Connection Port
T1 to T5: To Transmission Case
N1 : Port N1
N2 : Port N2
a : Connect to Shuttle Lever
b : Connect to Clutch Pedal
When the shuttle lever is moved to “REVERSE” or “FORWARD”, pressure-fed oil from P port flows into shuttle
clutch via R or F port. At this time, the pressure of R or F port is increased gradually by modulating valve (1).
When the shuttle clutch is engaging, the accumulate valve (4) assists the operation of modulating valve (1) to
reduce a shock.
8-M9
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ Shuttle Lever at Reverse Position (Clutch Pedal is Released)
8-M10
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(1) Modulating Valve
(2) Proportionally Reducing Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4) Accumulate Valve
(5)
(6)
(7)
(8)
Shuttle Valve
Inching Valve
Shuttle Lever
Clutch Pedal
A : Check Port (Modulation)
B : Check Port (Reverse)
C : Check Port (Forward)
D : Check Port (Pump)
P : From Regulator Valve
C1, C2 : Connection Port
T1 to T5: To Transmission Case
N1 : Port N1
N2 : Port N2
a : Connect to Shuttle Lever
b : Connect to Clutch Pedal
When the shuttle lever have been setting on the R side, the oil pressure on R port is constantly controlled by
proportionally reducing valve (2).
On the other hand, the oil in the F side of shuttle clutch returns to T4 and T3 port through F port and shuttle shift
spool (3).
8-M11
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ Shuttle Lever at Forward Position (Clutch Pedal is Released)
8-M12
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(1) Modulating Valve
(2) Proportionally Reducing Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4) Accumulate Valve
(5)
(6)
(7)
(8)
Shuttle Valve
Inching Valve
Shuttle Lever
Clutch Pedal
A : Check Port (Modulation)
B : Check Port (Reverse)
C : Check Port (Forward)
D : Check Port (Pump)
P : From Regulator Valve
C1, C2 : Connection Port
T1 to T5: To Transmission Case
N1 : Port N1
N2 : Port N2
a : Connect to Shuttle Lever
b : Connect to Clutch Pedal
When the shuttle lever have been setting on the F side, the oil pressure on F port is constantly controlled by
proportionally reducing valve (2).
On the other hand, the oil in the R side of shuttle clutch returns to T4 and T3 port through R port and shuttle shift
spool (3).
8-M13
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ When Clutch Pedal is Depressed (with Shuttle Lever at Reverse or Forward Position)
8-M14
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(1) Modulating Valve
(2) Proportionally Reducing Valve
(3) Shuttle Shift Spool (Forward,
Reverse)
(4) Accumulate Valve
(5) Shuttle Valve
(6) Inching Valve
(7) Shuttle Lever
(8) Clutch Pedal
A : Check Port
B : Check Port (Reverse)
C : Check Port
D : Check Port (Pump)
P : From Regulator Valve
C1, C2 : Connection Port
T1 to T5: To Transmission Case
N1 : Port N1
N2 : Port N2
a:
b:
c:
d:
e:
f:
g:
Connect to Shuttle Lever
Connect to Clutch Pedal
Part c
Part d
Hole e
Passage f
Hole g
With the shuttle lever at R or F position, when the clutch pedal is depressed, the inching valve (6) is moved to the
left. And pressure difference between c part and d part is generated. As the proportionally reducing valve (2) is moved
to the left by pressure difference, R port (or F port) and T2 port are connected.
The oil in the shuttle clutch returns into the transmission case via R port (or F port), notched portion of proportionally
reducing valve (2) and T2 port. This cause the shuttle clutch to be set to off.
At the same time, as the hole e and passage f are connected, oil passage among the hole g, hole e and T2 port
are connected. As a result, even when the proportionally reducing valve (2) does not move, the oil passage from R
port (or F side) to T2 port is secured.
8-M15
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
4. REGULATOR VALVE
[1] STRUCTURE AND OIL FLOW
(1) Flow Priority Valve
(2) Charge Relief Valve (Power
Steering)
(3) Relief Valve (PTO, Shuttle
Shift, Swing Shift)
(4) Relief Valve Adjusting Screw
(5) Charge Relief Valve Adjusting
Screw
(6) Check Port 1
(7) Check Port 2
(8) Check Port 3
A : From Hydraulic Pump
B : To Shuttle Clutch Pack for
Lubrication
C : To Oil Cooler
D : To PTO Clutch Pack for
Lubrication
8-M16
E : To Power Steering Controller
F : To PTO Clutch Valve
G : To Shuttle Clutch Valve
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Sectional view of the regulator valve and its hydraulic circuit are shown in the figure above.
This valve has three functions following.
1. Flow priority valve (1)
The flow priority valve is a flow divider that divides the flow single hydraulic source (hydraulic pump) and actuates
the power steering, PTO clutch and shuttle clutch simultaneously. This valve regulates the oil flowing (13 to 17 L/
min, 13.7 to 18.0 U.S.qts/min, 11.4 to 15.0 Imp.qts/min) to power steering.
2. Charge relief valve (2)
This valve controls the oil flow with pressure-feeding to the power steering system.
The relief valve setting pressure is 2.69 to 2.79 MPa (27.4 to 28.5 kgf/cm2, 390 to 404 psi).
3. Relief valve (PTO, shuttle shift, swing shift and dual speed) (3)
This valve controls the operating pressure of the PTO clutch, shuttle shift, swing shift and dual speed.
The relief valve setting pressure is 19.6 to 2.11 MPa (20.0 to 21.5 kgf/cm2, 284 to 306 psi).
8-M17
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
5. PTO CLUCH
■ PTO Valve
This valve change the oil flow to PTO clutch. This is
rotated by the PTO operation lever via to PTO clutch
cable. The oil from the regulator valve passes through
orifice (1) and flow to the PTO clutch.
(1)
(2)
(3)
(4)
(5)
Orifice
Rotary Valve
Return Spring
Pump Base
Check Port Plug
[A]
[B]
(a)
(b)
PTO Clutch “Disengaged”
PTO Clutch “Engaged”
From Regulator Valve
To PTO Clutch
W1016631
■ Accumulator (Modulating Valve)
The accumulator (2) is built into the PTO clutch
support (1).
When PTO clutch shift lever is set at the “Engaged”
position, oil flows through the rotary valve into the
accumulator and the clutch pack.
The accumulating action absorbs shock according to
the spring tension and the size of piston at the engaging
the PTO clutch.
(1) PTO Clutch Support
(2) Accumulator
(3) Piston
(4) Spring
W1016922
8-M18
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
6. DUAL SPEED VALVE
This valve change the oil flow to the dual speed HI
clutch or LO clutch.
As the pilot valve DS (8) operates by energizing the
solenoid valve (4), the flow of oil is switched to the HI side
or LO side of dual speed clutch with DS spool (5).
When one of clutches are engaged, pilot valve HI and
pilot valve LO are object in free which makes it do as for
the other clutch.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Valve Body
Line Filter
Connector
Solenoid Valve
DS Spool
Pilot Valve LO
Pilot Valve HI
Pilot Valve DS
A:
B:
C:
D:
E:
F:
G:
X-X :
Y-Y :
Check Port HI
Check Port P
Check Port LO
Check Port System
From Regulator Valve
To Clutch Pack HI
To Clutch Pack LO
View X
View Y
W1017062
8-M19
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
7. HYDRAULIC TRAILER BRAKE
[1] HYDRAULIC CIRCUIT
1. When the brake pedal (1) is depressed, the brake oil
is pressurized with brake master cylinder (2)
connected with the brake pedal. Then, the trailer
brake valve (3) is operated with the pressurized brake
oil.
2. The trailer brake valve (3) switches the flow of oil from
hydraulic pump (7) and operates the brake system of
the trailer.
3. The trailer brake valve (3) controls the hydraulic oil
flow which operates the trailer brake from the
hydraulic pump (7) in proportion to the depressing
force of brake pedal (1).
(1)
(2)
(3)
(4)
(5)
(6)
Brake Pedal
Brake Master Cylinder
Trailer Brake Valve
Trailer Brake Cylinder
Control Spool
Flow Control Valve
(7) Hydraulic Pump
(8) Pilot Pipe
(a) To 3-Point Hydraulic
System
W1017472
8-M20
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[2] TRAILER BRAKE VALVE
■ Main Elements
• Flow control valve (10) with throttle (9) and restrictor
(11) : for controlling the delivery flow Qp and for
regulating the fluid flow for the trailer brake.
• Control spool (2) with piston surface (1) : for
controlling the flow control valve (10) and regulating
the trailer braking pressure.
• Check valve (13) : prevents oil from flowing back from
the brake line B to port N.
• Pressure relief element (3) with pre-loaded spring (4)
: for limiting the trailer braking pressure.
• Control head (6) with piston (7) and bleed valve (5) :
for operating the trailer brake valve through the tractor
brake line.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Piston Surface
Control Spool
Pressure Relief Element
Spring
Bleed Valve
Control Head
Piston
Bore
Throttle
Flow Control Valve
Restrictor
Bore
Check Valve
P : Port for 3P Hydraulic Pump
N : Port for 3P Control Valve
B : Port for Trailer Brake
(Connected to Coupler)
R : Port for Reservoir
(Transmission Case)
X : Port for Tractor Service
Brake (Connected to Pilot
Pipe)
Qp : Delivery Flow
Qx : Control Flow
W1017705
8-M21
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[3] OPERATION
■ Tractor Brake Released
The tractor service brake line X is pressureless. The
brake line B is relieved to the reservoir through the
control spool (2) and port R.
The delivery flow Qp of the pump flows from port P
past flow control valve (10), the flow Qp - Qx continues
through port N to the tractor hydraulics.
A small control oil flow Qx of approx. 0.6 L/min.
passes from port P to the reservoir through restrictor
(11), throttle (9), bore (8), control spool (2), and port R.
Thus the pressure drop at throttle (9) holds the flow
control valve (10) in the open flow position a. The flow
control valve (10) has no regulating function.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Piston Surface
Control Spool
Pressure Relief Element
Spring
Bleed Valve
Control Head
Piston
Bore
Throttle
Flow Control Valve
Restrictor
Bore
Check Valve
P:
N:
B:
R:
Port for 3P Hydraulic Pump
Port for 3P Control Valve
Port for Trailer Brake
Port for Reservoir
(Transmission Case)
X : Port for Tractor Service
Brake
Qp : Delivery Flow
Qx : Control Flow
W1018216
8-M22
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ Partial Braking of Trailer Brake - Initiation
Piston (7) of control head (6) is pressurized through
control line X from the tractor service brake. Control
spool (2) is thus shifted to the left and separates from the
reservoir first brake line B and then bore (8). The control
spool (2) is shifted from position c to position e. The
control oil flow is blocked and hence flow control valve
(10) is switched into the regulating function in position b.
A constant flow Qk (approx. 30 L/min.) passes from port
P to the trailer brake through restrictor (11), bore (12),
check valve (13) and port B.
The restrictor (11) is designed for the constant flow
Qk. A residual flow Qp-Qk bypasses the flow control
valve (10), and then passes to the tractor hydraulic
through port N.
The pressure in the trailer brake line B is built up and
it acts on surface (1) of control spool (2) in opposition to
the pressure on piston (7).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Piston Surface
Control Spool
Pressure Relief Element
Spring
Bleed Valve
Control Head
Piston
Bore
Throttle
Flow Control Valve
Restrictor
Bore
Check Valve
P:
N:
B:
R:
Port for 3P Hydraulic Pump
Port for 3P Control Valve
Port for Trailer Brake
Port for Reservoir
(Transmission Case)
X : Port for Tractor Service
Brake
Qk : Brake Oil Flow
Qp : Delivery Flow
W1018495
8-M23
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ Partial Braking of Trailer Brake
The trailer braking pressure Pb (acting on surface (1)
of control spool (2)) is in equilibrium with the tractor
braking pressure Px (acting on piston (7)).
The brake line B remains separated from the
reservoir and the oil in the trailer brake is thus enclosed.
Control spool (2) is shifted to the right after the
pressures have equalized and opens bore (8) to the
reservoir through port R. Control spool (2) is in position
d. Flow control valve (10) is thus switched into position
a and has no regulating function.
As in the case of the released trailer brake, the
delivery flow Qp from the pump passes through port N
and flows as Qp - Qx to the tractor hydraulic system. A
control flow Qx passes to the reservoir through control
spool (2).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Piston Surface
Control Spool
Pressure Relief Element
Spring
Bleed Valve
Control Head
Piston
Bore
Throttle
Flow Control Valve
Restrictor
Bore
Check Valve
P:
N:
B:
R:
Port for 3P Hydraulic Pump
Port for 3P Control Valve
Port for Trailer Brake
Port for Reservoir
(Transmission Case)
X : Port for Tractor Service
Brake
Qp : Delivery Flow
Qx : Control Flow
W1018858
8-M24
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ Maximum Braking of Trailer Brake - Braking
Pressure Limited
Flow control valve (10) and control spool (2) have the
same spool positions (a and d) as in the case of partial
braking.
The fluid flows Qp and Qx pass as with partial
braking.
The maximum permissible trailer braking pressure Pb
(e.g. 150 bar) has been reached. An even further
increase of the trailer braking pressure is prevented,
even if the tractor braking pressure rises further. The
pressure relief element (3) is now shifted to the left. The
springs (4), which are pre-loaded to the maximum
permissible trailer braking pressure Pb, are compressed.
If the trailer braking pressure Pb also rises, e.g. owing
to external factor, control spool (2) momentarily opens
brake line B to the reservoir and avoids further increasing
of the braking pressure.
In all control positions of the trailer brake valve, the
tractor hydraulics can be used and pressurized as
desired through port N. This does not have any
important effect on the trailer brake. The trailer brake
has precedence over the tractor hydraulics.
The
maximum pressure of the tractor hydraulics may be
higher than the maximum trailer braking pressure.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Piston Surface
Control Spool
Pressure Relief Element
Spring
Bleed Valve
Control Head
Piston
Bore
Throttle
Flow Control Valve
Restrictor
Bore
Check Valve
P:
N:
B:
R:
Port for 3P Hydraulic Pump
Port for 3P Control Valve
Port for Trailer Brake
Port for Reservoir
(Transmission Case)
X : Port for Tractor Service
Brake
Qp : Delivery Flow
Qx : Control Flow
W1019238
8-M25
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
8. POWER STEERING HYDRAULIC CIRCUIT
The power steering is hull hydraulic type (controller
code No. 3A111-63072).
When the engine starts, the hydraulic pump (1) of the
power steering system pressure-feeds the oil drawn from
the transmission case through the suction pipe.
Pressurizing and flowing quantity are controlled with
regulator valve (7), and oil from the pump is supplied by
the steering controller (2).
The oil which has entered steering controller (2) is
directed to control valve (6).
As the steering wheel is turned, control valve (6)
operates and the oil passes through gerotor (4) and into
steering cylinder (3). The cylinder rod then moves to
control the directional movement of the front wheels.
Return oil from steering cylinder (3) passes through
control valve (6) and oil cooler (10) is sent to the
hydraulic shuttle clutch pack and PTO clutch park for
lubrication.
When the engine is not operating, and the steering
wheel is turned, gerotor (4) rotates to supply oil to
steering cylinder (3). Thus the machine can be steered
manually.
Refer to Workshop Manual for Tractor Mechanism in
detail.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Hydraulic Pump
Steering Controller
Steering Cylinder
Gerotor
Check Valve
Control Valve
Regulator Valve
Relief Valve
(9) Steering Wheel
(10) Oil Cooler
(11) Double Acting Safety Valve
(a) To Shuttle Clutch Pack for
Lubrication
(b) To PTO Clutch Pack for
Lubrication
W1019633
8-M26
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
9. THREE-POINT HYDRAULIC SYSTEM
[1] HYDRAULIC CIRCUIT
(1) Oil Tank (Transmission
Case)
(2) Hydraulic Oil Filter Cartridge
(3) Hydraulic Pump
(4) Auxiliary Control Valve
(5) Control Valve
(6) Relief Valve
(7) Lowering Speed Adjusting
Valve
(8) Hydraulic Cylinder
(9) Cylinder Safety Valve
(10) Hydraulic Pump (for Power
Steering)
(a) To Regulator Valve
N : N Port
W1019991
1. When the engine is started, the hydraulic pump (3) is rotated to suck oil from transmission case (1) through the
suction pipe.
Supplied oil is filtered by the hydraulic oil filter cartridge (2).
2. Filtered oil is forced out by the hydraulic pump to the auxiliary control valve (4).
3. With the auxiliary control valve (4) in neutral position, oil is channeled from “N” port to the control valve (5).
4. The hydraulic system has a relief valve (6) which restricts the maximum pressure in the circuit.
The hydraulic cylinder (8) has a cylinder safety valve (9) to relieve shock pressure due to heavy implement bounce.
5. The control valve (5) is actuated by the mechanical linkage for “Position control” or “Draft control” or both “Mix
control” (combining position control with draft control).
6. Tractor has a single / double acting auxiliary control valve (4) as standard equipment.
8-M27
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[2] CONTROL VALVE
■ Neutral
Pressurized oil from the P port, pushes and opens
unload poppet 1 (4) and returns to tank from T1 port.
The oil in the chamber A behind the unload poppet 1
(4) returns to the tank through the E of spool (3) and
control valve body. The oil in the hydraulic cylinder does
not flow out because the circuit is cut off by the actions of
poppet 1 (1) and poppet 2.
This allows the implement to be kept at a steady
height.
(1)
(2)
(3)
(4)
Poppet 1
Poppet 2
Spool
Unload Poppet 1
P:
C:
T1 :
T2 :
T3 :
E:
A:
Pump Port
Cylinder Port
Tank Port 1
Tank Port 2
Tank Port 3
Groove
Chamber A
W1020421
■ Lifting
When the control lever is moved to “UP” position,
spool (3) is pulled by the spool operating lever, forming a
circuit with the P port and chamber A.
The pressurized oil thus flows into the chamber A and
closes unload poppet 1 (4).
The pressure in the circuit slowly rises, pushing open
poppet 1 (1), and the hydraulic oil flows into the hydraulic
cylinder from the C port, lifting the implement.
(1)
(2)
(3)
(4)
Poppet 1
Poppet 2
Spool
Unload Poppet 1
P:
C:
T1 :
T2 :
T3 :
A:
Pump Port
Cylinder Port
Tank Port 1
Tank Port 2
Tank Port 3
Chamber A
W1020747
8-M28
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
■ Lifting to Neutral (Acting the shockless
mechanism)
In returning from Lifting to Neutral, the spool (3) is
pushed back to the arrow-mark direction. When the
Neutral position comes near, the groove part D of the
spool (3) makes the pressure difference at the P port and
C port. Therefore, the poppet 1 (1) gradually closes, and
absorbs any shock at lifting stop. In that case, since oil
is remained in the chamber A of the unload poppet (4)
and closes. However, the unload poppet 2 (5) opens
because of low pressure in chamber B, and then the oil
from the pump returns to the transmission case through
T2 port until unload poppet 1 (4) opens.
(1)
(2)
(3)
(4)
(5)
Poppet 1
Poppet 2
Spool
Unload Poppet 1
Unload Poppet 2
P:
C:
A:
B:
D:
T1 :
T2 :
T3 :
Pump Port
Cylinder Port
Chamber A
Chamber B
Groove
Tank Port 1
Tank Port 2
Tank Port 3
W1020929
■ Lowering
When the control lever is moved to “DOWN” position,
spool (3) moves to arrow-mark direction, and pushes the
poppet 2 (2). If forms a circuit with the C port and T3 port.
The oil in the hydraulic cylinder is forced out by the
weight of the implement, and returns to the tank through
the C port and T3 port, lowering the implement. The
pressurized oil pushes open unload poppet (4) and
returns to the tank from T1 port.
■ Floating
When the control lever is kept at lowest position,
spool (3) and poppet 2 (2) keeps same as lowering
position. The hydraulic cylinder is unloading condition.
Therefore pressurized oil pushes open unload poppet (4)
and returns to tank.
(1)
(2)
(3)
(4)
(5)
Poppet 1
Poppet 2
Spool
Unload Poppet 1
Unload Poppet 2
P:
C:
T1 :
T2 :
T3 :
Pump Port
Cylinder Port
Tank Port 1
Tank Port 2
Tank Port 3
W1021318
8-M29
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[3] POSITION CONTROL
Position control is a system to raise and lower the implement proportionally to the movement of the position control
lever. With this system, the implement can be raised or lowered to any position desired by changing the position of
the control lever and fine adjustment is also easy. When using the position control, the draft control lever should be
set to the lowest position.
(1) Spool Retainer
(2) Position Control Shaft
(3) Position Connector
(4) Hydraulic Arm Shaft
(5) Spool
(6) Position Balancer
(7) Holder
(8) Connector
(9) Position Cam
(a) Motion for Raising
(b) Motion for Feed-back
■ Raising
1. When the position control lever is moved to the Raising direction, the position control shaft (2) rotates clockwise
to move the position connector (3) to the left.
2. Since the position balancer (6) is prevented by the position cam (9) from moving, the connector (8) rotates
clockwise as the position connector (3) moves. Thereby the holder (7) and spool retainer (1) are pushed against
the spool (5), and the spool (5) is forced in the control valve. As a result, a Raising circuit is formed.
3. When the lift arm moves upward, the hydraulic arm shaft (4) and position cam (9) rotate counterclockwise. As a
result, the position balancer (6) is also rotated counterclockwise. Accordingly, as the connector (8) does not press
the spool retainer (1), the spool (5) is forced out by the return spring in the control valve (feedback mechanism).
4. When the spool (5) returns to the neutral position, the lift arms stop rising. This results in raising of the lift arm in
proportion to the movement of the position control lever.
■ Lowering
1. When the control lever is moved to the Lowering direction, the position control shaft (2) rotates counterclockwise
to move the position connector (3) to the right.
2. As the position connector (3) moves, the connector (8) does not press the spool retainer (1) and the spool (5) is
forced out by the return spring in the control valve. As a result, a Lowering circuit is formed.
3. When the lift arms move downward, the hydraulic arm shaft (4) and position cam (9) rotate clockwise, causing the
position balancer (6) and connector (8) to press the holder (7) and spool retainer (1). Thereby, the spool (5) is
forced in (feedback mechanism).
4. When the spool (5) returns to the neutral position, the lift arms stop rising. This results in lowering of the lift arms
in proportion to the movement of the position control lever.
8-M30
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[4] DRAFT CONTROL
Draft control is a system in which the lift arms (implement) automatically rise when the implement's traction load is
increased and lower when the traction load is decreased. By maintaining a constant traction load, it prevents the
tractor from slipping and over-load.
There are two types of traction load sensing system: top link sensing system and lower link sensing system. These
tractor are equipped with the top link sensing type.
When using the draft control, the draft control lever should be set in the draft range, and the position control lever
should be set at the lowest position.
■ Draft Control System
(1)
(2)
(3)
(4)
Spool Retainer
Position Control Shaft
Draft Link
Draft Link 2
(5)
(6)
(7)
(8)
Torsion Bar
Top Link
Top Link Bracket
Spool
(9)
(10)
(11)
(12)
Holder
Connector
Draft Cam
Draft Control Rod
(a) Motion when traction load
increases
(b) Motion when traction load
decreases
1. When the draft control lever is moved to the draft range, the draft control shaft (2) rotates clockwise and draft link
2 (4) approaches to the draft cam (11).
(Reference)
• Draft control sensitivity can be regulated by changing the distance between draft link 2 (4) and the draft cam (11)
using the draft control lever.
2. Traction load of the implement acts as torsion force to the torsion bar (5) via the top link bracket (7).
When traction load increases, the torsion bar is twisted depending on the load, and this twist is transmitted to the
draft control rod (12), draft cam (11), draft link 2 (4), connector (10), holder (9), and spool holder (1), thereby
causing the spool (8) to be forced in.
As a result, a Raising circuit is formed.
3. As the lift arms (implement) are raised, traction load reduces. Therefore, the draft control rod (12) returns. As a
result of this, the spool (8) is forced out by the return spring which allows a Lowering circuit to be formed again,
thereby causing the lift arm to move downward.
(Reference)
• The spring installed inside the holder (9) is a safety device which functions when the draft control rod (12) is pushed
in excess of the specified spool stroke.
8-M31
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[5] MIXED CONTROL
Mixed control is a system combining position control
with draft control.
When traction load increases, the draft control
functions to raise the lift arms (implement). When
traction load reduces, the lift arms (implement) lower to
the height set by the position control only, when traction
load increases, slippage or engine stop may occur
unless the implement is raised.
With the draft control only, plowing depth cannot be
kept constant if soil hardness changes greatly.
The mixed control serves to eliminate such
disadvantages.
A : Position Controlled
B : Draft Controlled
C : Not Deep Even in Soft Soil
D : Shallow where Resistance
Occurs
W1022563
8-M32
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................8-S1
SERVICING SPECIFICATIONS ....................................................................8-S3
TIGHTENING TORQUES ..............................................................................8-S6
CHECKING, DISASSEMBLING AND SERVICING......................................8-S7
[1] CHECKING AND ADJUSTING ...............................................................8-S7
(1) Hydraulic Pump for Power Steering....................................................8-S7
(2) Hydraulic Pump for Three-Point Hitch ................................................8-S9
(3) Hydraulic Shuttle System Operating Pressure..................................8-S11
(4) PTO Clutch Operating Pressure .......................................................8-S12
(5) Dual Speed Operating Pressure .......................................................8-S13
(6) Trailer Brake Operating Pressure .....................................................8-S14
(7) Power Steering Operating Pressure .................................................8-S15
(8) Three-Point Hitch System (Relief Valve and Safety Valve)
Operating System .............................................................................8-S17
(9) Three-Point Hitch Control Linkage ...................................................8-S19
(10)Auxiliary Control Valve Wire .............................................................8-S23
[2] DISASSEMBLING AND ASSEMBLING................................................8-S24
(1) Hydraulic Pump (Power Steering and Three-Point Hitch).................8-S24
(2) Steering Controller Assembly ...........................................................8-S26
(3) Steering Cylinder ..............................................................................8-S28
(4) Relief Valve for Three-Point Hitch.....................................................8-S29
(5) Safety Valve for Three-Point Hitch....................................................8-S29
(6) Separating Three-Point Hitch Cylinder Assembly .............................8-S30
(7) Control Valve for Three-Point Hitch ..................................................8-S30
(8) Control Valve Linkage.......................................................................8-S32
(9) Cylinder Assembly ............................................................................8-S33
[3] SERVICING ............................................................................................8-S35
(1) Hydraulic Pump.................................................................................8-S35
(2) Power Steering Cylinder ...................................................................8-S35
(3) Three-Point Hitch Cylinder ................................................................8-S35
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
1. TROUBLESHOOTING
Symptom
Implement Does Not
Rise (Not Noise)
Implement Does Not
Rise (Noise)
Implement Does Not
Reach Maximum
Height
Implement Does Not
Lower
Implement Drops by
Weight
Probable Cause
Reference
Page
Solution
Control linkage improperly assembled or
damaged
Repair or replace
8-S19
Control valve malfunctioning (unload valve,
spool, check valve, poppet valve)
Repair or replace
8-S30
Control valve broken
Replace
8-S30
Control valve improperly adjusted
Adjust
8-S30
Relief valve spring damaged
Replace
8-S29
Hydraulic piston O-ring, cylinder damaged
Replace
8-S34
Safety valve damaged
Replace
8-S29
Transmission fluid improper or insufficient
Change or replenish
G-8
Oil filter clogged
Replace
G-17
Relief valve setting pressure too low
Adjust
8-S29
Relief valve spring weak or damaged
Replace
8-S29
Hydraulic pump malfunctioning
Repair or replace
8-S24
Position rod and control lever improperly
adjusted
Adjust
8-S19
Draft rod and draft control rod improperly
adjusted
Adjust
8-S19
Lever stopper position improper
Adjust
–
Control valve malfunctioning
Repair or replace
Spool damaged
Replace
8-S31
Poppet valve improperly adjusted (Adjusting
screw of poppet valve)
Adjust
8-S31
Lowering speed adjusting valve closed
Open
8-S34
Hydraulic cylinder worn or damaged
Replace
8-S34
Hydraulic piston O-ring worn or damaged
Replace
8-S34
Safety valve damaged
Replace
8-S29
Lowering speed adjusting valve damaged
Replace
8-S34
Check valve seat surface damaged
Replace
8-S31
Check valve O-ring damaged
Replace
8-S31
Poppet valve seat surface damaged
Replace
8-S31
Poppet valve O-ring damaged
Replace
8-S31
Poppet valve, poppet seat surface damaged
Replace
8-S31
Check valve, check valve seat surface damaged
Replace
8-S31
Control valve O-ring worn or damaged
Replace
8-S31
8-S30, 31
(Control valve malfunctioning)
Implement Hunts
(Moves Up and
Down)
W1014322
8-S1
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Symptom
Draft Control
Malfunctioning
Probable Cause
Solution
Reference
Page
Draft control linkage improperly adjusted
Adjust
8-S21
Torsion bar weak or broken
Replace
8-S22
W1010986
8-S2
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
2. SERVICING SPECIFICATIONS
HYDRAULIC PUMP FOR POWER STEERING
Item
Factory Specification
Allowable Limit
Above
48.9 L/min.
12.9 U.S.gals./min.
10.8 Imp.gals./min.
39.1 L/min.
10.3 U.S.gals./min.
8.6 Imp.gals./min.
Hydraulic Pump
Delivery
Housing Bore
Depth of Scratch
–
0.09 mm
0.0035 in.
Bushing to Gear Shaft
Clearance
–
0.15 mm
0.0059 in.
W1013874
HYDRAULIC PUMP FOR THREE-POINT HYDRAULIC SYSTEM
Hydraulic Pump
Delivery
Above
66.6 L/min.
17.6 U.S.gals/min.
14.7 Imp.gals/min.
53.2 L/min.
14.1 U.S.gals/min.
11.7 Imp.gals/min.
Housing Bore
Depth of Scratch
–
0.09 mm
0.0035 in.
Bushing to Gear Shaft
Clearance
–
0.15 mm
0.0059 in.
W1013973
REGULATOR VALVE (SHUTTLE CLUTCH, SWING SHIFT AND DUAL SPEED)
Relief Valve Setting Pressure at PTO
At Maximum
1.96 to 2.11 MPa
Clutch Valve
Engine Speed
20.0 to 21.5 kgf/cm2
284 to 306 psi
Charge Relief Setting Pressure at Steering
Controller
At Maximum
Engine Speed
2.78 to 2.79 MPa
28.3 to 28.5 kgf/cm2
403 to 405 psi
–
–
W1012742
8-S3
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
STEERING CONTROLLER
Item
Relief Valve Setting Pressure
Factory Specification
Allowable Limit
At Idling Engine
Speed
Above 15.5 MPa
158 kgf/cm2
2247 psi
–
At Maximum
Engine Speed
Below 16.5 MPa
168 kgf/cm2
2390 psi
–
W1012805
STEERING CYLINDER
Steering Cylinder
I.D.
60.000 to 60.074 mm
2.36220 to 2.36512 in.
60.100 mm
2.36614 in.
W1012932
POSITION CONTROL AND DRAFT CONTROL LINKAGE
Position Rod
Length
Approx. 369 mm
14.53 in.
–
Draft Rod
Length
Approx. 369 mm
14.53 in.
–
Stopper to Top Link Bracket
Clearance
7.5 to 8.5 mm
0.295 to 0.335 in.
–
W1012855
RELIEF VALVE FOR THREE-POINT HYDRAULIC SYSTEM
Relief Valve
Setting Pressure
18.6 to 19.1 MPa
190 to 195 kgf/cm2
2702 to 2773 psi
–
W1012969
POSITION CONTROL VALVE
Control Valve Spool Joint
Length
32.5 to 33.5 mm
1.28 to 1.32 in.
–
W1013006
8-S4
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
CYLINDER SAFETY VALVE
Item
Cylinder Safety Valve
Operating
Pressure
Factory Specification
Allowable Limit
23.1 to 24.5 MPa
235 to 250 kgf/cm2
3342 to 3356 psi
–
W1013973
HYDRAULIC CYLINDER
Cylinder Bore
Hydraulic Arm Shaft to Bushing
I.D.
100.036 to 100.071 mm
3.93843 to 3.93980 in.
100.15 mm
3.94291 in.
Clearance (Right)
0.140 to 0.250 mm
0.00551 to 0.00984 in.
0.50 mm
0.0197 in.
Clearance (Left)
0.140 to 0.250 mm
0.00551 to 0.00984 in.
0.50 mm
0.0197 in.
Hydraulic Arm
Shaft (O.D.)
(Right)
59.970 to 60.000 mm
2.36102 to 2.36220 in.
–
Hydraulic Arm
Shaft (O.D.) (Left)
64.970 to 65.000 mm
2.55787 to 2.55906 in.
–
Bushing (I.D.)
(Right)
60.140 to 60.220 mm
2.36772 to 2.37087 in.
–
Bushing (I.D.)
(Left)
65.140 to 65.220 mm
2.56457 to 2.56772 in.
–
W1013043
8-S5
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
Cylinder safety valve assembly
39.2 to 49.0
4.0 to 5.0
28.9 to 36.2
Cylinder safety valve lock nut
58.8 to 78.5
6.0 to 8.0
43.4 to 57.9
107.9 to 117.7
11.0 to 12.0
79.6 to 86.8
Pump base mounting nut
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Hydraulic pump mounting screw
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Housing cover mounting screw
88.2 to 93.1
9.0 to 9.5
65.1 to 68.7
Gerotor assembly mounting screw
25.5 to 28.4
2.6 to 2.9
18.8 to 21.0
Guide assembly
98.0 to 118
10.0 to 12.0
72.3 to 87.0
Relief valve for three point hydraulic system
34.3 to 39.2
3.5 to 4.0
25.3 to 28.9
Hydraulic cylinder assembly mounting screw and nut
77.5 to 90.2
7.9 to 9.2
57.1 to 66.5
Control valve mounting screw
19.6 to 23.5
2.0 to 2.4
14.5 to 17.4
Seat plug 1
39.2 to 58.8
4.0 to 6.0
28.9 to 43.4
Seat plug 2
39.2 to 58.8
4.0 to 6.0
28.9 to 43.4
Seat plug for poppet valve
39.2 to 58.8
4.0 to 6.0
28.9 to 43.4
Lock nut for spool
15.7 to 19.6
1.6 to 2.0
11.6 to 14.5
Seat plug for check valve
29.4 to 49.0
3.0 to 5.0
21.7 to 36.2
Bracket guide mounting screw
23.5 to 27.5
2.4 to 2.8
17.4 to 20.3
Hydraulic arm setting screw
39.2 to 45.0
4.0 to 4.6
29.0 to 33.3
123.6 to 147.1
4.0 to 4.6
28.9 to 33.3
197 to 225
20.0 to 23.0
145 to 166
Delivery pipe 1 and 2 retaining nut
Lift lever mounting screw
Cylinder cover mounting screw
W1012736
8-S6
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Hydraulic Pump for Power Steering
Hydraulic Flow Test
■ IMPORTANT
• When using flowmeter other than KUBOTA specified
flowmeter, be sure to use the instructions with the
flowmeter.
• Do not close the flowmeter loading valve completely, before
testing, because it has no relief valve.
1. Remove the delivery pipe (1).
2. Install the adaptor (4) (See page G-72) the pump discharge port
and regulator valve inlet port.
3. Connect the hydraulic test hose (5) to the adaptor at hydraulic
pump (3) and flowmeter inlet port.
4. Connect the other hydraulic test hose (6) to the flowmeter outlet
and adaptor (4) (see page G-72) at regulator valve (2).
5. Open the flowmeter loading valve completely.
(Turn
counterclockwise.)
6. Start the engine and set the engine speed at 2000 to 2200 min-1
(rpm).
7. Slowly close the loading valve to generate pressure approx. 9.8
MPa (100 kgf/cm2, 1422 psi). Hold this condition until oil
temperature reaches approx. 50 °C (122 °F).
8. Open the loading valve completely.
9. Set the engine speed. (Refer to Condition, next page.)
10.Read and note the pump delivery at no pressure.
11.Slowly close the loading valve to increase rated pressure. (Refer
to Condition, next page.) As the load is increased, engine speed
drops, therefore, reset the engine speed.
12.Read and note the pump delivery at rated pressure.
13.Open the loading valve completely and stop the engine.
14.If the pump delivery does not reach the allowable limit, check the
pump suction line, oil filter or hydraulic pump.
(1) Delivery Pipe
(2) Regulator Valve
(3) Pump (For Power Steering, PTO
Clutch)
(4)
(5)
(6)
(7)
Adaptor
Hydraulic Test Hose
Hydraulic Test Hose
Pump Flow Meter
W1014689
8-S7
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Hydraulic Flow Test (Continued)
Condition
• Engine speed : Approx. 2600 min-1 (rpm)
• Rated pressure : 16.5 MPa
168 kgf/cm2
2390 psi
• Oil temperature : 45 to 55 °C
113 to 131 °F
Factory spec.
48.9 L/min.
12.9 U.S.gals/min
10.8 Imp.gals/min
Allowable limit
39.1 L/min
10.3 U.S.gals/min
8.6 Imp.gals/min
Hydraulic pump delivery
at rated pressure
W1015188
8-S8
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(2) Hydraulic Pump for Three-Point Hitch
Hydraulic Flow Test
■ IMPORTANT
• When using flowmeter other than KUBOTA specified
flowmeter, be sure to use the instructions with the
flowmeter.
• Do not close the flowmeter loading valve completely, before
testing, because it has no relief valve.
1. Disconnect the delivery pipe (3) from hydraulic pump (1) to
hydraulic cylinder (4).
2. Install the adaptor (5) (See page G-72) to the pump discharge
port and hydraulic cylinder inlet port.
3. Connect the hydraulic test hose (7) to the adaptor (5) (see page
G-72) on the pump and flowmeter inlet port.
4. Connect the other hydraulic test hose (8) to the flowmeter outlet
port and hydraulic cylinder inlet port.
5. Open the flowmeter loading valve completely.
(Turn
counterclockwise.)
6. Start the engine and set the engine speed at 2000 to 2200 min-1
(rpm).
7. Slowly close the loading valve to generate pressure approx. 9.8
MPa (100 kgf/cm2, 1422 psi). Hold this condition until oil
temperature reaches approx. 50 °C (122 °F).
8. Open the loading valve completely.
9. Set the engine speed. (Refer to Condition, next page.)
10.Read and note the pump delivery at no pressure.
11.Slowly close the loading valve to increase rated pressure. (Refer
to Condition, next page.) As the load is increased, engine speed
drops, therefore, reset the engine speed.
12.Read and note the pump delivery at rated pressure.
13.Open the loading valve completely and stop the engine.
14.If the pump delivery does not reach the allowable limit, check the
pump suction line, oil filter or hydraulic pump.
(1)
(2)
(3)
(4)
Pump (for 3P Hydraulic)
Pump (for Power Steering)
Delivery Pipe
Hydraulic Cylinder
(5)
(6)
(7)
(8)
Adaptor
Flow Meter
Hydraulic Test Hose
Hydraulic Test Hose
W1015845
8-S9
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Hydraulic Flow Test (Continued)
Condition
• Engine speed ............. Approx. 2600 min-1 (rpm)
• Rated pressure .......... 18.6 MPa (190 kgf/cm2, 2702 psi)
• Oil temperature .......... 45 to 55 °C
113 to 131 °F
Factory spec.
66.6 L/min
17.6 U.S.gals/min
14.7 Imp.gals/min
Allowable limit
53.2 L/min
14.1 U.S.gals/min
11.7 Imp.gals/min
Hydraulic pump delivery
at rated pressure
W1017146
8-S10
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(3) Hydraulic Shuttle System Operating Pressure
Checking of Shuttle Valve System Pressure
1. Remove the floor mat and inspection plate under the mat.
2. Remove the each plugs of F, R, M and set the adaptor D (1),
threaded joint (4), cable (3), and pressure gauge (Code No.:
07916-52961) (2).
3. Start the engine and measure the pressure of each port and each
shuttle lever position as the pressure table.
4. Operating oil is distributed from regulator valve to shuttle clutch
(M port pressure), PTO clutch, swing shift and dual speed.
Therefore, all the operating pressure are set with regulator valve
in the same pressure.
5. If the M port measurement is not within the factory specifications,
loosen the lock nut (5) and turn the screw (4) on the regulator
valve (6) to adjust.
Condition
• Engine speed ..... Maximum
• Oil temperature ... 45 to 55 °C (113 to 131 °F)
Shuttle
Lever
Clutch
Pedal
F Port pressure
R port pressure
Fully
pressed
0
0
Free
1.67 to 1.87 MPa
17 to 19 kgf/cm2
242 to 271 psi
0
Fully
pressed
0
0
Free
0
1.67 to 1.87 MPa
17 to 19 kgf/cm2
242 to 271 psi
Free
0
0
Forward
Reverse
Neutral
M port pressure
1.96 to 2.11 MPa
20.0 to 21.5
kgf/cm2
284 to 306 psi
0.26 to 0.28 MPa
2.7 to
2.9 kgf/cm2
38 to 41 psi
■ NOTE
• Use valve adaptor (see page G-67) to inspect the port F and
R.
• Pressure gauge is 5 MPa (50 kgf/cm2, 700 psi) full scale.
• Apply Three Bond 1324N or equivalent to the plugs F, R and
M, when install them.
• The supply oil to a shuttle clutch, a PTO clutch, a swing shift
and dual speed clutch has distributed the oil from regulator
valve. Check each system, when fault occurs using same
time with other systems.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Adaptor D
Pressure Gauge
Cable
Adjusting Screw
Lock Nut
Regulator Valve
Relief Valve
Plug F : Operation Oil Pressure (For
Forward)
Plug R : Operation Oil Pressure (For
Reverse)
Plug M : Operation Oil Pressure (For
Modulation Valve)
W1017491
8-S11
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(4) PTO Clutch Operating Pressure
Relief Valve Setting Pressure
1. Start the engine and warm up the transmission fluid, and then
stop the engine.
2. Remove the plug (4) (PT 1/8) on the PTO valve spool (5).
3. Set the adaptor (PT 1/8) (Use the oil pressure tester for diesel
engines, Code No. 07916-32032), threaded joint (3), cable (2)
and pressure gauge (1).
4. Start the engine and set the engine speed maximum.
5. Move the PTO clutch lever to the “ON” position, and measure
the pressure.
6. If only the pressure in the PTO clutch engaged position is low,
check the hydraulic PTO clutch system.
7. If the measurement is not within the factory specifications, loosen
the lock nut (7) and turn the screw (6) on the regulator valve (8)
to adjust.
■ IMPORTANT
• Do not connect the universal joint of the implement to the
tractor PTO shaft while testing.
■ NOTE
• The supply oil to a shuttle clutch, a PTO clutch, and a swing
shift has distributed the oil from regulator valve. Check
each system, when fault occurs using same time with other
systems.
PTO pressure (When
PTO clutch lever is
“Engaged” position)
Factory spec.
1.96 to 2.11 MPa
20.0 to 21.5 kgf/cm2
284 to 306 psi
PTO pressure (When
PTO clutch lever is
“Disengaged” position)
Factory spec.
No pressure
Condition
• Engine speed ......... Maximum
• Oil temperature ...... 45 to 55 °C
113 to 131 °F
(Reference)
• Turn the screw (6) to clockwise direction → Pressure increase
• Turn the screw (6) to counterclockwise direction → Pressure
decrease
(1)
(2)
(3)
(4)
(5)
(6)
Pressure Gauge
Cable
Threaded Joint
Plug (PT 1/8)
Spool
Adjusting Screw
(7)
(8)
(9)
(10)
(11)
Lock Nut
Regulator Valve
Valve Case
Spring
Relief Valve
W1021205
8-S12
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(5) Dual Speed Operating Pressure
Relief Valve Setting Pressure
1. Starting the engine and warm up the transmission fluid, and then
stop the engine.
2. Remove the each plugs of A, B, C, D and set the adaptor (PT 1/
8) (use the oil pressure tester for diesel engine : Code No. 0791632032) threaded joint, cable and pressure gauge.
3. Start the engine and set the engine speed maximum.
4. Measure the pressure of each port and each dual speed switch
as the pressure table.
5. Operating oil is distributed from regulator valve to dual speed
clutch (D port pressure), shuttle clutch, PTO clutch and swing
shift. Therefore, all operating pressure are set with regulator
valve in the same pressure.
6. If the D port measurement is not within the factory specifications,
loosen the lock nut (5) and turn the screw (2) on the regulator
valve (6) to adjust.
Condition
• Engine speed ..... Maximum
• Oil temperature ... 45 to 55 °C (113 to 131 °F)
(Reference)
• Turn the screw (2) to clockwise direction → Pressure increase
• Turn the screw (2) to counterclockwise direction → Pressure
decrease
Dual speed
(indicator)
A Port pressure
B port pressure
LO (ON)
0
1.96 to 2.11 MPa
20.0 to 21.5 kgf/cm2
284 to 306 psi
HI (OFF)
1.96 to 2.11 MPa
20.0 to 21.5 kgf/cm2
284 to 306 psi
0
C and D port
pressure
1.96 to 2.11 MPa
20.0 to 21.5 kgf/cm2
284 to 306 psi
■ NOTE
• The supply oil to a shuttle clutch, a PTO clutch, a swing shift
and dual speed clutch has distributed the oil from regulator
valve. Check each system, when fault occurs using same
time with other systems.
(1)
(2)
(3)
(4)
(5)
(6)
Dual Speed Valve
Adjusting Screw
Lock Nut
Spring
Relief Valve
Regulator Valve
Plug A : Operation Oil Pressure
(For HI)
Plug B : Operation Oil Pressure
(For LO)
Plug C, D : Operation Oil Pressure
(System)
W1022353
8-S13
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(6) Trailer Brake Operating Pressure
Checking Brake Pressure
1. Remove the trailer brake coupler (5), and set the hydraulic brake
adaptor (3), joint (Code No. 07616-50401), cable (2) (Code No.
07916-50331) and pressure gauge (1) (Code No. 07916-50321).
2. Interlock the left and right pedals.
3. Start the engine and fully depress the brake pedal to measure the
braking pressure.
4. If the measurement is not within the factory specifications, check
the pilot pipe (4) and braking system.
(Reference)
Braking pressure
Reference value
9.8 to 12.7 MPa
100 to 130 kgf/cm2
1422 to 1849 psi
Condition
• Oil temperature ...... 45 to 55 °C
113 to 131 °F
(1) Pressure Gauge
(2) Cable
(3) Hydraulic Brake Adaptor
(4) Pilot Pipe
(5) Brake Coupler
W1024436
8-S14
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(7) Power Steering Operating Pressure
Steering Regulator Valve Setting Pressure
1. Disconnect the power steering delivery hose (1) at P port (5) on
the steering controller (8) and set a pressure gauge (2) (Code No.
07916-50321) between them with using power steering adaptor
(3) (Code No. 07916-50401) and cable (Code No. 07916-50331).
2. Start the engine and set the engine at maximum speed.
3. Check the charge relief valve setting pressure.
4. If the measurement is not within the factory specifications, loosen
the lock nut (6) and turn the screw (7) on the regulator valve (4)
to adjust.
■ IMPORTANT
• Do not steer the steering wheel while checking the charge
relief valve setting pressure.
Steering regulator valve
setting pressure
Factory spec.
2.78 to 2.79 MPa
28.3 to 28.5 kgf/cm2
403 to 405 psi
Condition
• Engine speed .......... Maximum
• Oil temperature ....... 45 to 55 °C
113 to 131 °F
(Reference)
• Turn the screw (7) to clockwise direction → pressure increase.
• Turn the screw (7) to counter clockwise direction → pressure
decrease.
(1)
(2)
(3)
(4)
(5)
Power Steering Delivery Hose
Pressure Gauge
Power Steering Adaptor
Regulator Valve
Pump Port
(6)
(7)
(8)
(9)
(10)
Lock Nut
Adjusting Screw
Steering Controller
Spring
Relief Valve
W1025718
8-S15
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Power Steering Relief Valve Setting Pressure
1. Disconnect the power steering hose from P port (5) on the
steering controller (6) and set a pressure gauge (3) (Code No.
07916-50321) between them using power steering adaptor (1)
(Code No. 07916-50331), joint (Code No. 07916-50401) and
cable (2) (Code No. 07916-50331).
2. Start the engine and fully turn the steering wheel to the left or
right and read the pressure when the relief valve operates both
idling and maximum engine speed.
3. If the measurement is not within the factory specifications, adjust
the relief pressure by the adjusting plug (4).
■ IMPORTANT
• (Air Bleeding)
Start the engine, then turn the steering wheel slowly in both
directions all the way alternately a few times, and stop the
engine.
(Reference)
• One full turn of the adjusting screw changes the relief setting
pressure by approx. 2.9 MPa (30 kgf/cm2, 427 psi).
Relief valve setting
pressure
Factory
spec.
At idling
engine
speed
Above 15.5 MPa
158 kgf/cm2
2247 psi
At
maximum
engine
speed
Below 16.5 MPa
168 kgf/cm2
2390 psi
Condition
• Oil Temperature ......... 45 to 55 °C
113 to 131 °F
(1) Power Steering Adaptor
(2) Cable
(3) Pressure Gauge
(4) Adjusting Plug
(5) Pump Port
(6) Steering Controller
W1027018
8-S16
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(8) Three-Point Hitch System (Relief Valve and Safety Valve) Operating System
Relief Valve Setting Pressure Test Using Pressure Tester
(Coupler)
1. Set the relief valve set pressure adaptor G (Code No. 0791652751) to the half male of the quick coupler and then set a
pressure gauge (Code No. 07916-50321), cable (Code No.
07916-50331).
2. Start the engine, set at maximum speed.
3. Set the auxiliary control valve operation lever to the UP position
and read the pressure gauge when the relief valve is actuated.
4. If the pressure is not within the factory specification, adjust the
relief valve adjustor (3).
Condition
• Engine speed ............ Maximum
• Oil temperature ......... 45 to 55 °C
113 to 131 °F
Relief valve setting
pressure
(1) Relief Valve
(2) Lock Nut
Factory spec.
19.1 to 19.6 MPa
195 to 200 kgf/cm2
2773 to 2845 psi
(3) Adjustor
W1027885
8-S17
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Safety Valve Setting Pressure Test Using Injection Nozzle
Tester
1. Remove the cylinder safety valve assembly (1).
2. Attach the cylinder safety valve to an injection nozzle tester with
a safety valve setting adaptor. (See page G-68.)
3. Measure the operating pressure of the cylinder safety valve.
4. If the operating pressure is not within the factory specifications,
adjust by turning the adjusting screw (2).
5. After adjustment, tighten the lock nut (3) firmly.
(When reassembling)
• Install the cylinder safety valve to the hydraulic cylinder block,
taking care not to damage the O-ring.
Cylinder safety valve
assembly
39.2 to 49.0 N·m
4.0 to 5.0 kgf·m
28.9 to 36.2 ft-lbs
Cylinder safety valve lock
nut
58.8 to 78.5 N·m
6.0 to 8.0 kgf·m
43.4 to 57.9 ft-lbs
Tightening torque
Cylinder safety valve
operating pressure
23.1 to 24.5 MPa
235 to 250 kgf/cm2
3342 to 3556 psi
Factory spec.
■ NOTE
• Use specified transmission fluid (see page G-8) to test the
operating pressure of the cylinder safety valve.
(1)
(2)
(3)
(4)
Safety Valve Assembly
Adjusting Screw
Lock Nut
O-ring
(5)
(6)
(7)
(8)
Seat
Spring
Ball
Housing
W1028474
8-S18
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(9) Three-Point Hitch Control Linkage
Adjusting the Position Rod and Draft Rod
1. Be sure to adjust the position rod length A and draft rod length B.
Position rod length A
and draft rod length B
Factory spec.
369 mm
14.53 in.
W1028931
Adjusting the Uppermost Position of Lift Arm
1. Move the position and draft control levers all the way down.
2. Raise the lift arm (1) to the top dead center by hand, and mark
the hydraulic cylinder housing and the lift arm with S1 and S2
respectively.
3. Attach a weight of approx. 490 N (50 kgf, 110 lbs) to the end of
the lower links.
4. Start the engine and set the speed at 1000 min-1 (rpm).
5. Move the draft control lever all the way up, and measure the
offset which is the distance between S1 and S2.
6. If the offset is not within the factory specifications, remove the
plug (3) and adjust the distance A by adjusting screw (2).
■ NOTE
• When the offset is smaller, loosen the adjusting screw (2),
and when larger, tighten it.
Offset S1 and S2
Factory spec.
3.0 to 4.0 mm
0.118 to 0.157 in.
Reference value
34 to 35 mm
1.34 to 1.38 in.
(Reference)
Distance A
(1) Lift Arm
(2) Adjusting Screw
(3) Plug
W1029063
8-S19
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Adjusting Position Control Lever
1. Attach a weight of approx. 490 N (50 kgf, 110 lbs) to the end of
the lower links.
2. Start the engine and set the speed at 1000 min-1 (rpm).
3. Move the draft control lever (2) all the way down and shift the
position control lever (1) downward by approx. 20 mm (0.79 in.)
(A) from the lever guide upper end.
4. Loosen the lock nut (4), then turn the position control shaft (3)
with an open end wrench so as to adjust the offset within the
factory specifications (Refer to “Adjusting the Uppermost
Position of Lift Arm” on page 8-S19). Tighten the lock nut (4)
securely.
5. Secure the position control lever (1) all the way down position to
check that the floating range can be obtained.
(Reference)
• The specification of the floating range (a) is 20.0 to 40.0 mm
(0.79 to 1.57 in.) from lever guide lower end.
If the floating range (a) is not within the specification, readjust the
“Adjusting Position Control Lever”.
Length A
(1)
(2)
(3)
(4)
Position Control Lever
Draft Control Lever
Position Control Shaft
Lock Nut
Factory spec.
a:
b:
c:
d:
e:
f:
g:
20 to 30 mm
0.79 to 1.18 in.
Floating Range
Down
Deep
Position Range
Shallow
Draft Range
Up
W1029592
8-S20
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Adjusting Draft Control Rod
1. Attach a weight of approx. 490 N (50 kgf, 110 lbs) to the end of
the lower links.
2. Start the engine and set the speed at 1000 min-1 (rpm).
3. Move the position control lever and draft control lever (1) all the
way down.
4. Slowly shift the draft control lever (1) to lever guide upper end
and check the point where the lift arms begin to rise.
5. If the point of draft control lever (1) where the lift arms begin to
rise is not within the range A, adjust the length of the draft control
rod (2).
■ NOTE
• After adjusting the draft control rod (2), secure the
turnbuckle by the lock nuts.
Point A of draft control
lever from lever guide
upper end
Factory spec.
45 to 50 mm
1.77 to 1.97 in.
Draft control rod length
B
Reference value
Approx. 172.0 mm
6.77 in.
(1) Draft Control Lever
(2) Draft Control Rod
W1030151
Lifting Range Check
1. Attach the weight (4) of approx. 490 N (50 kgf, 110 lbs) to the end
of the lower links.
2. Attach the test bar (2) to the top link bracket (3).
3. Start the engine and set the speed at 1000 min-1 (rpm).
4. Move the position control lever all the way down.
5. Raise the test bar (2) until the top link bracket (3) comes in
contact with the bracket stopper.
6. Slowly shift the draft control lever (1) upward until the lift arms
begin to rise, and measure the lifting range A.
7. If the measurement is out of factory specifications, adjust the
length of the draft control rod.
Lifting range A
(1)
(2)
(3)
(4)
Draft Control Lever
Test Bar
Top Link Bracket
Weight
Factory spec.
35.0 to 45.0 mm
1.38 to 1.77 in.
A : Lifting Range
W1030781
8-S21
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Adjusting Top Link Bracket
1. Measure the clearance (A) between the stopper (3) and top link
bracket (1).
If the clearance is not within the factory specifications, adjust with
the shims (4) between the stopper (3) and top link bracket (1).
Clearance (A)
Factory spec.
7.5 to 8.5 mm
0.295 to 0.335 in.
(Reference)
• Thickness of shim (4) : 0.5 mm (0.020 in.), 1.0 mm (0.040 in.)
(1) Top Link Bracket
(2) Torsion Bar
(3) Stopper
(4) Shim
W1031081
Floating Range Check
1. Attach the weight (3) of approx. 490 N (50 kgf, 110 lbs) to the end
of the lower links.
2. Attach the test bar (1) to the top link bracket (2).
3. Start the engine and set the speed at 1000 min-1 (rpm).
4. Move the draft and position control lever all the way down.
5. Press the test bar (1) downward until the top link bracket (2)
comes in contact with the stopper.
6. Slowly shift the draft control lever (4) upward until the lift arms
begin to rise. Then slowly shift the draft control lever (4)
downward until the lift arms begin to down, measure the travel
distance L of the draft control lever (4) on the lever guide (5).
7. If L is shorter than 15 mm (0.591 in.), shorten the draft control
rod.
Floating range L
(1)
(2)
(3)
(4)
Test Bar
Top Link Bracket
Weight
Draft Control Lever
Factory spec.
More than 15.0 mm
0.59 in.
(5) Lever Guide
L : Floating Range
W1031315
8-S22
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(10) Auxiliary Control Valve Wire
Adjusting Wire of Auxiliary Control Valve
1. (Valve side) : Set the lock nut (2) at center of wire's threads.
2. (Lever side) : Screw in the wire (3) to the rod end (4) until 5 mm
(0.2 in.) of wire's threads remaining.
3. Shift the control lever (7) forward, and check the clearance
between the stopper and lever.
4. If the clearance is out of specified value, adjust by the nut (6).
Clearance between
stopper and lever
(1)
(2)
(3)
(4)
Auxiliary Control Valve
Lock Nut
Wire
Rod End
Factory spec.
0 to 1.0 mm
0 to 0.039 in.
(5) Threads
(6) Lock Nut
(7) Control Lever
W1031644
8-S23
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Hydraulic Pump (Power Steering and Three-Point Hitch)
Removing Hydraulic Pump
1. Remove the floor mat (1) and inspection plate under the mat.
2. Remove the seat (2) and floor cover (3).
3. Disconnect the delivery pipe 1 (4) and delivery pipe (5).
4. Remove the lowering speed adjusting rod (6).
5. Disconnect the parking brake cable (7).
6. Disconnect the PTO clutch cable (8).
7. Disconnect the suction pipes (11) and PTO pipe (12).
8. Remove the pump base (9) with gear pumps.
9. Remove the hydraulic pump (13) from pump base (9).
(When reassembling)
• Apply liquid gasket (Three Bond 1208D, 1216 or equivalent) to
joint face of transmission case and pump base, and pump base
and hydraulic pump.
• Replace the oil pipes (10) with new ones.
• Apply oil to oil pipes (10).
• Be sure to check the PTO clutch lever movement.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Delivery pipe 1 and 2
retaining nut
107.9 to 117.7 N·m
11 to 12 kgf·m
79.6 to 86.8 ft-lbs
Pump base mounting nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Hydraulic pump mounting
screw
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
Floor Mat
Seat
Floor Cover
Delivery Pipe 1
Delivery Pipe 2
Lowering Speed Adjusting Rod
Parking Brake Cable
(8)
(9)
(10)
(11)
(12)
(13)
(14)
PTO Clutch Cable
Pump Base
Pipe
Suction Pipe
PTO Pipe
Hydraulic Pump for Power Steering
Hydraulic Pump for Three-Point
Hitch
W1032179
8-S24
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Disassembling Hydraulic Pump
1. Put parting marks (A), (B) on the front cover (3), body (7) and
housing rear cover (9).
2. Remove the housing rear cover (9) and body (7).
3. Remove the side plate (5).
4. Take out the gears (6), (10).
(When reassembling)
• Take care not to damage the seal elements and O-rings.
• Fit the ellipse hole (12) of side plate (5) to the inlet side.
• When installing the drive gear (6) and driven gear (10) into front
cover and rear cover, apply clean transmission fluid to the
assemble.
• When installing the driven gear (10), be sure to reassembling it
to the original position.
• After reassembly, check the smooth rotation of the hydraulic
pump (for example, mount arm an approx. 100 mm (3.94 in.) long
to the drive gear and rotate its arm slowly for smooth rotation).
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Internal Snap Ring
Oil Seal
Front Cover
O-ring
Side Plate
Drive Gear
Body
O-ring
Rear Cover
Housing cover mounting
screw
(10)
(11)
(12)
(13)
A:
B:
(a)
(b)
88.2 to 93.1 N·m
9.0 to 9.5 kgf·m
65.1 to 68.7 ft-lbs
Driven Gear
Notching Circle Hole
Ellipse Hole
Seal Element
Parting Mark
Parting Mark
Inlet
Outlet
W1033284
8-S25
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(2) Steering Controller Assembly
Relief Valve Assembly
1. Remove the adjust plug (3) and draw out the spring (2) and
poppet (1).
(When reassembling)
• Take care not to damage the O-ring.
■ IMPORTANT
• After disassembling and assembling the relief valve, be sure
to adjust the relief valve setting pressure. (Refer to page 8S15.)
(1) Poppet
(2) Spring
(3) Adjust Plug
W1034252
Removing Gerotor
1. Secure the housing (3) in a vise and remove seven gerotor
mounting screws and gerotor assembly (1).
2. Remove the distributor plate (11) and drive shaft (2).
3. Remove the rotor (9), O-ring (5) between the distributor plate and
stator (6).
4. Take out the spacer ring (10) and spacer (7).
5. Remove the O-ring (8) from the rotor (9).
(When reassembling)
1. Fit an O-ring into the groove of the end cap (4), insert 2 or 3 bolts.
2. Fit an O-ring into the groove of the stator (6), and put it on the end
cap, with the O-ring upward.
3. Apply clean transmission fluid (specified fluid) to the rotor (9), fit
an O-ring (8) into the groove of the rotor and put the spacer on it.
Keeping the spacer on the rotor, fit it into the stator (6) with the
spline bevelled side upward.
4. After putting the spacer into the rotor (9) insert the splines of drive
shaft (2) into the rotor (9), aligning the direction of drive shaft pin
groove (12) with the rotor tooth bottom (13).
5. Fit an O-ring into the groove of the housing (3).
Fit the pin groove of the drive shaft (2) to the dowel pin inside the
housing.
■ IMPORTANT
• Be sure to align the direction of the drive shaft pin groove
(12) with the rotor tooth bottom (13).
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Gerotor Assembly
Driven Shaft
Housing
End Cap
O-ring
Stator
Spacer
Gerotor assembly
mounting screw (5/16')
(8)
(9)
(10)
(11)
(12)
(13)
(14)
22.6 to 28.4 N·m
2.6 to 2.9 kgf·m
18.8 to 21.0 ft-lbs
O-ring
Rotor
Spacer Ring
Distributor Plate
Direction of Pin Groove
Rotor Tooth Bottom
Ball
W1034410
8-S26
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Grand Seal, Needle Bearing, Sleeve and Spool
1. Remove the retaining ring (1) with a screw driver.
2. Hold the control valve unit vertically and spool and sleeve align
the cross pin parallels to flat side of housing (flow priority valve
mounting side), the cross pin is visible through open end of spool.
3. At this time, take care so as not to allow the cross pin to be caught
in the groove of the housing. If the cross pin is caught, adjust is
position with a fingertip.
4. Push the spool and sleeve to the allow direction and remove the
seal grand bushing (3) with dust seal (2) and quad ring seal (5).
5. Remove the O-ring (4) from the housing (12).
6. Remove the dust seal from the seal grand bushing (3).
7. Remove the O-ring (4).
(When reassembling)
• Replace O-ring with new one.
Apply transmission oil to the dust seal, quad ring seal and O-ring.
8. Remove the quad ring seal (5) from the sleeve (9).
9. Remove the bearing races and needle bearing from valve
assembly.
(When reassembling)
• Apply transmission oil to the bearing races and needle bearing.
10.Draw out the sleeve (9) and spool (11) assembly from the gerotor
side, with the port surface of the housing downward. At this time,
take care so as not to allow the dowel pin to be caught in the
groove of the housing (12). If the dowel pin is caught, adjust its
position with a fingertip and draw out the sleeve and spool
assembly slowly.
■ IMPORTANT
• As the clearance between the housing and sleeve is very
narrow, do not forcibly draw out the sleeve.
(When reassembling)
• When fitting the sleeve (9) and spool (11) assembly into the
housing (12), apply clean transmission fluid to the assembly and
then insert it while turning it slowly, taking care so that the parts
are not inclines. Also, pay attention to the dowel pin so that it is
not caught in the housing grooves. If the pin is caught, adjust its
position with a fingertip.
(1)
(2)
(3)
(4)
(5)
(6)
Retaining Ring
Dust Seal
Seal Grand Bushing
O-ring
Quad Ring Seal
Bearing Race
(7)
(8)
(9)
(10)
(11)
(12)
Needle Bearing
Pin
Sleeve
Centering Spring
Spool
Housing
W1035202
8-S27
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Sleeve and Spool
1. Draw out the dowel pin (1).
2. Draw out the spool (3) from the sleeve (2).
3. Push out the centering spring (4).
■ IMPORTANT
• As the clearance between the sleeve (2) and spool (3) is very
narrow, draw out the spool by turning it slowly with due
care.
(When reassembling)
• For easier assembly, first insert a couple of centering springs
assembled back to back and then fit springs in one after another.
• Align the centering spring notch with the sleeve notch.
(1) Dowel Pin
(2) Sleeve
(3) Spool
(4) Centering Spring
W1036839
(3) Steering Cylinder
Disassembling Steering Cylinder
1. Carefully clamp the cylinder in a vise.
2. Remove the guide assembly (1) and draw out the piston rod (4).
(When reassembling)
• Apply transmission fluid to the oil seal and O-ring.
• Apply molybdenum disulfide (Three Bond 1901 or equivalent) on
the screw of guide when tighten it.
• After tightening the guide assembly to the specified torque, stake
the cylinder firmly.
Tightening torque
(1) Guide Assembly
(2) O-ring
Guide assembly
98.0 to 118 N·m
10.0 to 12.0 kgf·m
72.3 to 87.0 ft-lbs
(3) Cylinder
(4) Piston Rod
W1037193
8-S28
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(4) Relief Valve for Three-Point Hitch
Relief Valve
1. Remove the lock nut (9).
2. Remove the adjuster (8), and draw out the spring (7) and pilot
valve (6).
3. Remove the valve seat (1), and draw out the valve seat (4), the
spring (3) and the main valve (2).
(When reassembling)
• Take care not to damage the O-rings.
Tightening torque
34.3 to 39.2 N·m
3.5 to 4.0 kgf·m
25.3 to 28.9 ft-lbs
Relief valve
■ IMPORTANT
• After disassembling and assembling the relief valve, be sure
to adjust the relief valve setting pressure. (See page 8-S17.)
(1)
(2)
(3)
(4)
(5)
Valve Seat
Main Valve
Spring
Valve Seat
Valve Body
(6)
(7)
(8)
(9)
(10)
Pilot Valve
Spring
Adjuster
Lock Nut
Relief Valve
W1038643
(5) Safety Valve for Three-Point Hitch
Cylinder Safety Valve
1. Remove the cylinder safety valve assembly (8).
2. Secure the cylinder safety valve assembly in a vise.
3. Loosen the lock nut (2), and remove the adjusting screw (1).
4. Draw out the spring (3), seat (4), and ball (5).
(When reassembling)
• Install the cylinder safety valve to the hydraulic cylinder block,
taking care not to damage the O-ring.
• Be sure to adjust the operating pressure of cylinder safety valve
after assembling. (See page 8-S18.)
Cylinder safety valve
assembly
39.2 to 49.0 N·m
4.0 to 5.0 kgf·m
28.9 to 36.2 ft-lbs
Cylinder safety valve lock
nut
58.8 to 78.5 N·m
6.0 to 8.0 kgf·m
43.4 to 57.9 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
Adjusting Screw
Lock Nut
Spring
Seat
(5)
(6)
(7)
(8)
Ball
Housing
O-ring
Safety Valve Assembly
W1039018
8-S29
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(6) Separating Three-Point Hitch Cylinder Assembly
Preparation
1. Remove the seat and floor seat cover.
2. Remove the delivery pipe (1).
3. Disconnect the auxiliary control wire (3) and position and draft
control rod (2).
4. Disconnect the lowering speed control rod (5).
5. Disconnect the ground cable (4).
(1) Delivery Pipe
(2) Draft Control Rod
(3) Auxiliary Control Wire
(4) Ground Cable
(5) Lowering Speed Control Rod
W1039396
Separating Hydraulic Cylinder Assembly
1. Remove the hydraulic cylinder mounting screws and nuts.
2. Set the lifting bar (1) (See page G-71) to the top link bracket.
3. Hoist the lifting bar (1) and separate the hydraulic cylinder
assembly.
(When reassembling)
Tightening torque
Hydraulic cylinder
assembly mounting screw
and nut
77.5 to 90.2 N·m
7.9 to 9.2 kgf·m
57.1 to 66.5 ft-lbs
■ NOTE
• After reassembling the hydraulic cylinder assembly to the
tractor, be sure to adjust the position control lever, draft
control lever and auxiliary control wire cable.
(1) Lifting Bar
W1039812
(7) Control Valve for Three-Point Hitch
Removing Control Valve
1. Remove the control valve mounting screws.
2. Remove the control valve (1).
■ NOTE
• Do not loosen adjusting section at the end of the spool
unless necessary.
(When reassembling)
Tightening torque
Length A
Control valve mounting
screw
19.6 to 23.5 N·m
2.0 to 2.4 kgf·m
14.5 to 17.4 ft-lbs
Factory spec.
32.5 to 33.5 mm
1.28 to 1.32 in.
■ Adjusting Spool Joint
1. Measure the distance (A).
2. If the measurement is not within the factory specifications, loosen
the lock nut and adjust the distance (A) by the turnbuckle.
(1) Control Valve
(2) Lock Nut
(3) Turnbuckle
W1040322
8-S30
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Plug and Unload Valve
1. Secure the control valve with a vise.
2. Remove the seat plug 1 (1) for unload poppet 1 (3).
3. Draw out the spring (2) for unload poppet 1 (3).
4. Remove the seat plug 2 (4) for unload poppet 2 (6).
5. Draw out the spring (5) and unload poppet 2 (6).
(When reassembling)
• Install the plug, noting O-ring.
Seat plug 1
39.2 to 58.8 N·m
4.0 to 6.0 kgf·m
28.9 to 43.4 ft-lbs
Seat plug 2
39.2 to 58.8 N·m
4.0 to 6.0 kgf·m
28.9 to 43.4 ft-lbs
Tightening torque
(1) Seat Plug 1
(2) Spring
(3) Unload Poppet 1
(4) Seat Plug 2
(5) Spring
(6) Unload Poppet 2
W1040681
Spool and Poppet Valve
1. Remove the lock nut (1) for spool (5).
2. Draw out the spool (5).
3. Remove the seat plug (4) for poppet valve (2).
4. Draw out the spring (3), collar and poppet valve (2).
(When reassembling)
• Install the poppet valve, noting O-ring and backup ring.
Seat plug
39.2 to 58.8 N·m
4.0 to 6.0 kgf·m
28.9 to 43.4 ft-lbs
Lock nut
15.7 to 19.6 N·m
1.6 to 2.0 kgf·m
11.6 to 14.5 ft-lbs
Tightening torque
(1) Lock Nut
(2) Poppet Valve
(3) Spring
(4) Seat Plug
(5) Spool
(6) Spring
W1041830
Check Valve
1. Remove the seat plug (3).
2. Draw out the spring (2) and check valve (1).
(When reassembling)
• Install the plug, noting O-ring.
Tightening torque
(1) Check Valve
(2) Spring
Seat plug
29.4 to 49.0 N·m
3.0 to 5.0 kgf·m
21.7 to 36.2 ft-lbs
(3) Seat Plug
W1042131
8-S31
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(8) Control Valve Linkage
Position and Draft Linkage
1. Remove the clevis pin (2).
2. Remove the circlips (4), (5), (6), (7).
3. Remove the stopper and draw out the rod (3).
4. Remove the stopper and draw out the rod (8). To remove the Oring (22) and (23) order by c → b → a as shown in figure.
5. Remove the cotter pin (21).
6. Take out the linkage.
7. Remove the bracket guide assembly (20).
(When reassembling)
• When install the rods, noting O-ring.
• Apply transmission fluid to the O-ring.
• When installing the rod (8), a → b → c let the fix position of Oring (22) go to the outside of the hydraulic cylinder body (25) with
the process alternately, and O-ring (24) is assembled into the
rod. (As shown in figure.)
• When assemble the position connector (10) notched section (18)
downward.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clevis Pin
Clevis Pin
Rod
Circlip
Circlip
Circlip
Circlip
Rod
Spool Retainer
Position Connector
Draft Link 1
Draft Link 2
Position Balancer
Bracket guide mounting
screw
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
23.5 to 27.5 N·m
2.4 to 2.8 kgf·m
17.4 to 20.3 ft-lbs
Draft Cam
Connector
Feed Back Link
Holder Assembly
Notched Section
Screw
Bracket Guide Assembly
Cotter Pin
O-ring
Chamfer
O-ring
Hydraulic Cylinder Body
Stopper
W1042606
8-S32
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
(9) Cylinder Assembly
Lift Arm and Hydraulic Arm Shaft
1. Remove the wire and unscrew the setting screw (3).
2. Remove the screw (5) and lift arm L.H. (1).
3. Draw out the hydraulic arm shaft (2) and lift arm R.H. (4) as a unit.
4. Remove the collar (7) and O-ring (8).
(When reassembling)
• Align the alignment marks of the hydraulic arm and hydraulic arm
shaft.
• Align the alignment marks of the lift arm and hydraulic arm shaft.
• Apply grease to the right and left bushings of hydraulic cylinder
body and O-ring.
• Take care not to damage the O-ring.
• After tightening the hydraulic arm setting screw to the specified
torque, insert a wire through the holes of the screw head and
hydraulic arm.
Hydraulic arm setting
screw
39.2 to 45.1 N·m
4.0 to 4.6 kgf·m
28.9 to 33.3 ft-lbs
Lift lever mounting screw
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
Lift Arm L.H.
Hydraulic Arm Shaft
Setting Screw
Lift Arm R.H.
(5)
(6)
(7)
(8)
Screw
Alignment Mark
Collar
O-ring
W1044235
Hydraulic Arm and Hydraulic Rod
1. Remove the spring pin (2), and separate the hydraulic arm (3)
and the hydraulic rod (1).
(When reassembling)
• Apply grease to the joints of the hydraulic arm, hydraulic rod, set
pin and piston.
• Be sure to fix the spring pin (2), its split must face the direction A
as shown in figure.
(1) Hydraulic Rod
(2) Spring Pin
(3) Hydraulic Arm
W1045418
8-S33
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Hydraulic Cylinder Cover and Hydraulic Piston
1. Remove the hydraulic cylinder cover (1).
2. Push out the hydraulic piston (5) from the hydraulic cylinder.
(When reassembling)
• Install the hydraulic piston, noting O-ring (6) and backup ring (7).
• Install the hydraulic cylinder cover, noting O-ring (2), (4) and
backup ring (3).
• Apply grease to the hydraulic piston bottom contacts with
hydraulic rod.
Tightening torque
(1)
(2)
(3)
(4)
Cylinder cover mounting
screw
Hydraulic Cylinder Cover
O-ring
Backup Ring
O-ring
197 to 225 N·m
20.0 to 23.0 kgf·m
145 to 166 ft-lbs
(5) Hydraulic Piston
(6) O-ring
(7) Backup Ring
W1045626
Lowering Speed Adjusting Valve
1. Remove the internal snap ring (1) and adjusting screw (3).
2. Remove the internal snap ring (6), and draw out the poppet valve
(5).
(1) Internal Snap Ring
(2) Plane Washer
(3) Adjusting Screw
(4) Hydraulic Cylinder Cover
(5) Poppet Valve
(6) Internal Snap Ring
W1046076
8-S34
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
[3] SERVICING
(1) Hydraulic Pump
Housing Bore
1. Measure the housing I.D. where the interior surface is not
scratched, and measure the housing I.D. where the interior
surface is scratched.
2. If the values obtained in the two determinations differ by more
than the allowable limit, replace the hydraulic pump as a unit.
(Reference)
• Use a cylinder gauge to measure the housing I.D..
Depth of scratch
Allowable limit
0.09 mm
0.0035 in.
W1046268
Clearance between Bushing and Gear Shaft
1. Measure the gear shaft O.D. with an outside micrometer.
2. Measure the bushing I.D. with an inside micrometer, and
calculate the clearance.
3. If the clearance exceeds the allowable limit, replace the gear
shaft and the bushing as a unit.
Clearance between
bushing and gear shaft
Allowable limit
0.15 mm
0.0059 in.
W1046756
(2) Power Steering Cylinder
Steering Cylinder I.D.
1. Measure the steering cylinder I.D. with a cylinder gauge.
2. If the cylinder I.D. exceeds the allowable limit, replace the
cylinder barrel.
Factory spec.
60.000 to 60.074 mm
2.36220 to 2.36512 in.
Allowable limit
60.100 mm
2.36614 in.
Steering cylinder I.D.
W1046894
(3) Three-Point Hitch Cylinder
Hydraulic Cylinder Bore
1. Check the cylinder internal surface for scoring or damage.
2. Measure the cylinder I.D. with a cylinder gauge.
3. If the measurement exceeds the allowable limit, replace it.
Factory spec.
100.036 to 100.071 mm
3.93843 to 3.93980 in.
Allowable limit
100.15 mm
3.94291 in.
Cylinder I.D.
W1047035
8-S35
KiSC issued 03, 2007 A
HYDRAULIC SYSTEM
M105S, WSM
Clearance between Hydraulic Arm Shaft and Bushing
1. Measure the hydraulic arm shaft O.D. with an outside
micrometer.
2. Measure the bushing I.D. with a cylinder gauge, and calculate the
clearance.
3. If the clearance exceeds the allowable limit, replace the bushing.
(When reassembling)
• When press-fitting a new bushing with a press-fitting tool (see
page G-67), observe the dimensions described in the figure.
• When press-fitting a new bushing, apply transmission fluid to the
hydraulic cylinder liner boss and bushing.
• When press-fitting a new bushing, press-fit it so that each seam
faces up.
Factory spec.
0.140 to 0.250 mm
0.00551 to 0.00984 in.
Allowable limit
0.50 mm
0.0197 in.
Hydraulic arm shaft O.D.
(Right side)
Factory spec.
59.970 to 60.000 mm
2.36102 to 2.36220 in.
Bushing I.D. (After
press-fitted) (Right side)
Factory spec.
60.140 to 60.220 mm
3.36772 to 2.37087 in.
Factory spec.
0.140 to 0.250 mm
0.00551 to 0.00984 in.
Allowable limit
0.50 mm
0.0197 in.
Hydraulic arm shaft O.D.
(Left side)
Factory spec.
64.970 to 65.000 mm
2.55787 to 2.55906 in.
Bushing I.D. (After
press-fitted) (Left side)
Factory spec.
65.140 to 65.220 mm
2.56457 to 2.56772 in.
Press-fit location of
bushing (A)
Factory spec.
13.5 to 14.5 mm
0.5315 to 0.5709 in.
Press-fit location of
bushing (B)
Factory spec.
17.5 to 18.5 mm
0.6890 to 0.7283 in.
Clearance between
hydraulic arm shaft and
bushing (Right side)
Clearance between
hydraulic arm shaft and
bushing (Left side)
(1)
(2)
(3)
(4)
(5)
(6)
Collar (Left)
O-ring
Bushing (Left)
Bushing (Right)
O-ring
Collar (Right)
(a) Right Side
* Flush the end of collar with the
end of hydraulic cylinder body.
W1047185
8-S36
KiSC issued 03, 2007 A
9
ELECTRICAL SYSTEM
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. WIRING DIAGRAM ....................................................................................... 9-M1
[1] MAIN HARNESS..................................................................................... 9-M1
[2] CABIN HARNESS................................................................................... 9-M2
[3] ENGINE AND HEAD LAMP HARNESS............................................... 9-M3
2. ELECTRICAL CIRCUIT DETAILED CHART............................................... 9-M4
[1] STARTING, CHARGING SYSTEM, FUSE AND
SLOW-BLOW FUSE ............................................................................... 9-M4
[2] SWING SHIFT AND DUAL SPEED ..................................................... 9-M5
[3] LIGHTING SYSTEM ............................................................................... 9-M6
[4] INSTRUMENT PANEL BOARD ............................................................. 9-M7
[5] WORKING LIGHT, RADIO AND BEACON.......................................... 9-M8
[6] WIPER ..................................................................................................... 9-M9
[7] AIR CONDITIONER .............................................................................. 9-M10
[8] WIRING COLOR ................................................................................... 9-M11
3. STARTING SYSTEM .................................................................................. 9-M12
[1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT ............................ 9-M12
(1) System Outline................................................................................. 9-M12
[2] COMPONENTS ..................................................................................... 9-M13
(1) Air Heater ......................................................................................... 9-M13
(2) Air Heater Timer............................................................................... 9-M14
(3) Air Heater Relay............................................................................... 9-M14
4. CHARGING SYSTEM ................................................................................. 9-M15
[1] ELECTRICAL CIRCUIT ........................................................................ 9-M15
5. LIGHTING SYSTEM ................................................................................... 9-M16
[1] ELECTRICAL CIRCUIT ........................................................................ 9-M16
[2] COMPONENTS ..................................................................................... 9-M17
(1) Flasher Unit...................................................................................... 9-M17
6. EASY CHECKER ........................................................................................ 9-M18
[1] INDICATION ITEMS ............................................................................. 9-M18
[2] ELECTRICAL CIRCUIT ........................................................................ 9-M19
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
1. WIRING DIAGRAM
[1] MAIN HARNESS
1.25 W
Ground
0.5 B
0.5 B
0.5 Br/Y
1.25 B
0.85 Y
0.85 R
1.25 W
0.85 G
1.25 Br
0.5 W/L
0.5 L
0.5 R/B
0.5 B
0.85 Y
0.5 W/R
1.25 G/W
0.5 R/W
0.5 W
0.5 R/Y
0.5 Lg
0.5 Y
1.25 Br
0.5 B
1.25 G/W
0.85 Br
0.5 R
0.5 Y/G
0.5 Br/Y
0.5 B
0.5 B
0.85 B
0.85 B
0.85 B
0.5 B
0.5 Y
0.5 B
0.5 Y
0.5 Lg/R
0.5 B
0.5 B
Ground LH
Parking
Switch
Meter Panel
1.25 B
Trailer Connector
Ground RH
0.85 B
DS Lamp
0.5 R/L
DS Switch
0.5 B
0.85 B
0.5 B
0.5 B
0.85 L/R
Front Washer
Tank
0.85 B
0.85 L/W
Front Wiper Meter
0.85 B
1.25 L
0.85 L/Y
0.85 L
Rear Washer
Tank
0.5 B/Y
0.5 B/W
2 R/L
2 R/G
0.85 Y
3W
1.25 Lg/B
0.85 Lg/R
0.85 G
0.85 G
0.85 R/W
0.85 R/G
0.85 R/L
0.85 W/B
0.85 W/L
1.25 L
0.5 Y/B
0.5 L/Y
0.5 L
0.5 G/W
0.85 Br
0.85 B
0.5 R/W
0.85 G/R
0.5 R/Y
0.5 R/W
0.85 Lg/Y
PTO Switch
5A
5A
25A
25A
25A
5A
20A
15A
15A
10A
15A
15A
15A
15A
5A
5A
10A
5A
Flasher Unit
10A
0.5 R/L
0.85 G
0.5 R/W
0.5 R/W
Fuse
2 B/W
2 B/W
5R
2R
5 R/B
2Y
5W
0.5 R/Y
3 R/B
2 W/R
2Y
0.5 R
0.85 R/W
Buzzer
0.5 L/B
0.85 R/L
Cigar Lighter
0.85 B
2 R/W
1.25 L/W
Combination Switch
1.25 Br
0.5 G/W
1.25 B
1.25 Or
0.5 R
0.5 R/Y
Auxiliary Power
Connector
(Connector
for Seat Switch)
0.5 R/G
1.25 B
0.5 B
0.5 Lg
1.25 Lg/B
0.5 W/L
Diode
0.5 B/W
0.5 W/L
0.5 R
0.85 R
0.85 R/W
0.5 B/Y
0.5 B/L
0.5 B
0.85 G
0.85 B
0.85 G/R
0.85 G/R
2Y
2W
2 W/R
2 B/W
2 B/W
2 R/W
2 R/B
0.5 Lg
1.25 L/W
0.5 B/W
0.85 Y/L
0.5 W
0.5 R
0.5 Y/G
0.5 W/L
0.5 B/W
0.5 Y
1.25 Or
0.5 R/W
2W
0.5 B/Y
0.5 W/R
0.5 B/L
1.25 Br
2R
0.5 Br/L
0.5 Y
0.5 R/W
0.5 R/L
0.5 Br/W
5R
5 R/B
5W
0.85 L/W
0.85 B
0.85 L/B
0.85 L/Y
0.85 L/G
0.5 Br/Y
0.5 Or/B
Diode
0.5 B/Y
Cabin Harness
Key Switch
Wiper Relay
Hazard Switch
Heater Timer
Brake Switch
Diode
0.85 R/B
0.5 L/Y
0.85 L/B
0.85 Br
1.25 G/W
0.85 R/G
0.85 L/W
0.5 Y/B
0.85 Lg/Y
0.85 L/G
0.85 L/R
1.25 L
3W
0.85 W/L
0.85 Y/L
0.85 W/B
0.85 Y
2 R/G
0.5 L/B
0.5 B
(Connector
for OPC Unit)
0.5 R/Y
0.5 R/G
0.85 R/G
0.5 Br/L
0.85 Lg/R
H-L Switch
0.5 Br/W
0.5 R/W
0.5 Or
Diode
Working Light
Relay
PTO Relay
Key Stop Relay
Auxiliary
Power Relay
Buzzer Relay
1.25 B
0.85 R/W
1.25 Y/B
0.85 G
0.5 Or
0.5 B
0.5 L/B
0.5 B
2 R/W
0.5 L/Y
2 R/L
0.5 B
0.5 B
2 R/W
2 R/B
0.5 Or/B
0.5 B
0.5 B
0.5 R/B
0.5 B/W
0.5 R/L
3 R/B
0.5 L/Y
3 R/B
0.5 B
0.5 R/L
Rear Combination Rear Combination
Brake R
Turn R
Rear Combination
Rear Combination
Tail R
Ground R
3TMACAL9P009A
9-M1
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[2] CABIN HARNESS
2B
3 Y/B
2 L/Y
2 Y/G
3 Y/R
3 Y/R
3 Y/B
To Blower
Door
Switch
A/C Switch Mode Switch Temperature
Control
Resistor
Door
Switch
2B
Blower Switch
2 L/Y
2 Y/G
3 Y/R
0.5 B/Y
2 Y/G
2B
2 L/Y
0.5 Y/L
0.5 Br
0.5 G/W
0.5 G
0.5 B/Y
0.5 L/Or
0.5 Y
0.5 W/B
0.5 B/Y
0.5 Y/B
0.5 B/P
0.5 B/P
0.5 B/Y
0.5 Br
0.5 G/W
0.5 W/Y
0.5 Y/L
0.5 Y/B
0.5 G/Y
0.5 B/Y
0.5 L/G
Blower Meter
2B
2 L/Y
2 Y/G
To Blower
Temperature Control Amplifier
Blower
Resistor
0.5 Y/B
Mode Meter
0.85 B
0.5 L/Or
Front Work Lamp L
0.85 R/Y
0.5 Y
0.5 G
Thermo Switch
0.5 W
Thermo Switch
0.5 B/Y
0.5 G/Y
0.5 L/G
0.5 W/Y
Temperature
Meter
0.5 R
Pressure
Switch
0.5 G/W
0.5 W
0.5 Y/L
2 R/G
2 Y/B
Beacon Relay
Beacon
Lamp
2R
0.5 B
1.25 B
0.5 L/Y
1.25 B
Ground
2R
Beacon
Switch
2 Y/B
0.5 L/Y
0.5 Y
1.25 Y/B
0.5 R/G
0.5 W/B
0.5 Y/B
0.5 B
0.5 W
Radio
1.25 B
Ground
0.5 B
0.85 B
Front Work
Lamp R
0.85 R/Y
0.5 B/Y
3W
Blower Relay
3 Y/R
0.85 R/G
0.85 R/G
0.85 W/L
0.5 Y/B
0.85 B
0.85 R/Y
0.85 R/Y
0.85 W/B
0.5 R
0.85 Y
Compressor
Relay
Rear Work
Lamp Switch
Front Work
Lamp Switch
0.85 B
0.85 Y/L
0.5 W/B
0.85 L/B
0.85 L/R
0.85 R/W
Front Wiper Switch
1.25 L
0.5 L/Y
0.85 L/G
0.85 L/B
0.85 R/W
0.85 Lg/Y
1.25 L
1.25 Y/B
0.85 R/G
Rear Wiper Switch
0.85 Lg/W
0.85 B
0.85 G
0.5 Y/B
0.85 Lg/B
0.85 Lg/Y
0.85 L/G
0.85 L/R
1.25 L
0.5 B
3W
0.85 W/L
0.5 B
0.85 R/G
0.85 R/G
0.5 B/P
0.5 B/P
0.85 Y/L
0.85 W/B
0.85 Y
Room Lamp
Room Lamp
2 R/G
2B
2B
0.5 W
0.85 B
0.5 B
Speaker L
0.5 W/B
0.85 B
0.85 B
0.5 Y/B
Speaker R
1.25 B
0.5 Y
Front Combination
L Turn
0.85 R/W
Front Combination
L Position
1.25 Y/B
Front Combination
L Earth
1.25 B
Front Combination
R Turn
0.85 R/W
Front Combination
R Position
1.25 Y/B
Front Combination
R Earth
1.25 B
0.5 B
0.85 B
Rear Work
Lamp L
Rear Work
Lamp R
Rear Wiper Meter
Ground
Ground
Ground
Ground
Ground
0.85 B
Ground
0.85 B
Ground
1.25 B
1.25 Y/B
1.25 B
0.85 R/W
1.25 Y/B
0.85 G
1.25 B
1.25 B
0.85 Lg/B
1.25 L
0.85 Lg/W
0.85 B
0.85 B
0.85 R/G
0.85 B
0.85 R/G
0.85 B
Ground
Number Number
Ground Rear Combination
Rear Combination Lamp
Brake L
Lamp Ground
Turn L
Rear Combination Rear Combination
Tail L
Ground L
3TMACAL9P010A
9-M2
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[3] ENGINE AND HEAD LAMP HARNESS
1.25 B
1.25 Or
Head Lamp
RH
1.25 Br
1.25 B
1.25 Or
Head Lamp
LH
1.25 L/W
1.25 Br
1.25 L/W
Horn
1.25 B
1.25 Or
1.25 Br
1.25 B
Earth Horn
0.5 Br/W
Brake Oil
Switch
0.5 B
Air Cleaner
Sensor
Diode
0.5 Br/L
H-L Solenoid
0.5 Y/G
0.5 B
0.5 Y/G
0.5 W/L
0.5 B/W
0.5 Y
1.25 Or
0.5 R/W
2 R/W
2 R/B
0.5 L/G
1.25 L/W
0.5 B/W
0.85 Y/L
0.5 W
0.5 R
2W
0.5 Br/W
0.5 B/Y
0.5 W/R
0.5 B/L
1.25 Br
2R
0.5 Br/W
0.5 Br/L
0.5 Y
0.5 R/W
0.5 R/L
5R
5 R/B
5W
0.5 R
0.5 B
1.25 L/W
1.25 B
1.25 Or
1.25 Br
To Lamp
0.5 Br/L
0.5 Y
0.85 Y/L
Diode
0.5 Lg
0.5 B
15 R
Fuel
Tank
Key Stop Solenoid
5R
5R
2 R/B
2R
5R
5 R/B
5W
15 W
5R
5R
15 W
15 W
2W
120A 120A
60A
50A
Starter
Alternator
Starter
Relay
Compressor Oil
Switch
Water
Temperature
Sensor
0.5 B/P
Safety Switch 1-2
0.5 B/L
Safety Switch 1-2
0.5 B/W
Safety Switch 3-4
0.5 B/L
Safety Switch 3-4
0.5 Br/L
L Switch
0.5 R/L
L Switch
0.5 Br/W
H Switch
0.5 R/W
H Switch
0.5 Y
0.5 Y
0.5 W/R
0.5 W
0.85 Y/L
0.5 B/P
3 B/W
0.5 B/W
3 R/B
30A
3 B/W
60A
Slow Blow Fuse
0.5 W/L
30A
15 W
Ground
0.5 R/W
Heater Relay
15 W
0.5 B
0.5 B
5W
0.5 R/W
0.85 B
1.25 B
0.5 B/L
0.5 B/Y
15 R
15 W
0.85 B
2 R/W
Intake Air
Heater RH
Heater Relay
Fuel Unit
0.85 B
0.5 B
Diode
Lo Solenoid
3TMACAL9P011A
9-M3
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
2. ELECTRICAL CIRCUIT DETAILED CHART
[1] STARTING, CHARGING SYSTEM, FUSE AND SLOW-BLOW FUSE
Slow Blow Fuse Box 2
2R/B
5R
2R
60A
5R
2R
5R
Blower
5R
AC/Beacon
5R/B
Slow Blow Fuse Box 3
5R
2R
2
Auxiliary Power
0.5L/Y
2R/L
4
2R/W
Auxiliary
Power
Relay
3
2R/W
4
15A
Auxiliary
Power
Connector
1.25B
15A
Cigarette Lighter
15A
Seat Suspension
Compressor
Connector
2R/W
5
Working Light F
15A
5
0.5B
3R/B
1
0.5B
15A
3
0.85B
1.25B
2W/R
5A
To Radio Fuse 5A
Beacon
Compressor
Blower Fan Motor
Head Light, Horn
T/M Control
Turn Signal
5A
A/C Control
To Shift Buzzer Relay
Working
Light
Relay
2
Radio, ACC/Auxiliary Control
2R/W
1
2
Hold
㧹
Heater Timer Unit
3
0.5R/W
1
0.5B
3
12V2.5kW
3
2(F)R/W
5
PTO Safety
Relay
TIMER
M6
2R/B
0.5Or/B
0.5B
1
4
0.5B
S
Starter
Motor
M
4
Key Stop
Relay
Short Plate
0.5B
[F13]
Battery
6
4
Pull
0.5B/W
5
0.5R/L
0.5B/L
2
0.5R/B
15W
0.5B/L
0.5B/W
M8
B
To Meter Panel
(PTO)
Heater
Relay
2
15R
3
0.5B/W
3B/W
60B/Y(EB)
60B/Y(EB)
4
M6
2
1
0.5B/Y
0.5B/Y
1
0.5B/P
3R/B
15(F)W
Starter
Relay
M6
0.5B/Y
0.5B
0.5Or/B
0.5B/W
1
2
3R/B
Diode
0.5B/Y
Safety Switch
(1-2 Speed
Change
Monitor)
25A
0.85R/B
0.5L/B
0.85R/B
Buzzer
25A
0.85R
0.5B/Y
0.5R/W
Safety Switch
(3-4 Speed
Change
Monitor)
BZ
2
5A
To Radio Fuse 5A
PTO
Switch
5A
1
25A
0.5L/Y
5A
0.5B/W
0.5B/W
0.5B/W
0.5B/L
To Meter Panel
(Charge)
E
Working Light R
0.5W/L
0.5W/L
Alternator
B
20A
Brake Lamp, Dome Lamp, Radio Backup
Main Key Switch
15A
Flasher (Hazard)
0.5R/W
L
0.5R/Y
0.5R/W
R
15A
0.5L/B
M6
B
0.5R/Y
M5
10A
0.5R/G
M5
OFF
ACC
ON
GL
ST
15(F)W(AVX)
10A
0.5R/Y
15(F)W
M6
120A
10A
Meter Panel
M5
Charge
5A
A C D
AM ACC M GL ST
15W
Engine, PTO
120A
Heater
Key IG
5R/B
5W
0.5R/W
Flasher/Main
5W
2Y
0.5R/Y
60A
Key ACC
2Y
5R/B
0.5R/W
Head/ACC
5R/B
Flasher
2W/R
2W
2B/W
50A
2W
2B/W
Main Key
30A
To Meter Panel
(Power)
Slow Blow Fuse Box 1
Head/ACC
5W
Wiper
Blower/Fuel
Auxiliary Power
Compressor
2R/B
30A
Key Stop
Solenoid
Intake Air
Heater
3TMACAL9P012A
9-M4
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[2] SWING SHIFT AND DUAL SPEED
Key IG
10A
3
0.5Lg/R
0.5Y
0.5Y
0.5Y
0.5B
0.5Y
2
0.5B
4
E
0.5Y
Shift
Buzzer
Relay
5
0.5B
1
0.5B
To Meter Panel
To Meter Panel
0.5Br/L
0.5R/W
0.5Br/W
0.5R/W
Dual Shift
Pilot Lamp
0.5Br/L
Dual Shift
Solenoid
0.5B
Diode
L Shift
Solenoid
Diode
0.5B
0.5W
0.5Br/W
0.5Y
H Shift
Solenoid
0.5R/L
0.5Or
Shift HI Switch
BZ
2
Diode
0.5R/L
0.5Br/W
Dual Shift
Switch
1
0.5L/B
0.5Br/L
0.5Br/W
0.5Br/L
2
B
12V1.7W B
Shift LO Switch
1
R
FREE
LOCK
0.5Br/L
0.5Br/W
Shift HI-LO
Switch
0.5L/B
3
To Meter
Panel
2
Buzzer
1
HI
LO
To Meter
Panel
5A Fuse
0.85Lg/R
0.5Lg/R
3TMACAL9P013A
9-M5
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[3] LIGHTING SYSTEM
Head/ACC
Flasher
Key IG
1.25B
0.85R/G
0.5R/G
0.85R/W
0.85R
1.25Br
0.5B
1.25Or
1.25Br
1.25Or
M5 ON OFF
DOOR
D
55W
60W
55W
E
Head Light LH
H4 12V55/60W
1.25B
60W
E
Head Light RH
H4 12V55/60W
0.5B/P
Horn
1.25B
1.25G/W
Flasher Unit
1.25G/W
To Meter Panel (Illumination RH)
To Meter Panel (Illumination LH)
Door Switch LH
1.25B
0.85R/W
0.85Br
0.85B
H
H4
5
0.85Br
L
H4
2
7
H
Dome (Room)
Light
0.5B/P
13
0.5B
L
12V10W
0.5B
3
10
8
B
1.25B
1
To Radio (Back Up)
1.25Or
1.25B
9
0.85R/G
Brake Switch
1.25L/W
6
Flasher Circuit
To Meter Panel (Turn LH)
To Meter Panel (Turn RH)
2
1.25Br
1.25L/W
4
0.5G/W
0.5B
0.5R
0.5R/W
0.85G
0.85B
0.85G/R
0.85G/R
12
11
0.5L
1
OFF
1(H)
2(L)
FREE
PUSH
To Meter Panel
(Hi Beem)
Light Switch
0.85G/R
To Meter Panel
(Trailer)
B1 T
B1 H
1.25Br
0.85Or
1.25Or
Turn Switch
B2 R L
1(R)
OFF
2(L)
FREE
LOCK
0.85Br
1.25Br
Combination Light
Switch
14V2W
1 (2) 3 4 5
15A
0.85R/W
1.25Lg/B
0.85G
1.25L/W
Hazard Switch
20A
0.5R/W
10A
0.85G
15A
Door Switch RH
0.85Y
0.85R/B
0.85R/W
1.25G/W
1.25Y/B
1.25Y/B
0.85Y
To Radio
(Illumination)
0.85G
1.25B
0.85R/W
0.85L/W
1.25Y/B
0.85L/W
E
E
Front
Combination
Lamp RH
0.85Y
1.25B
1.25W
POSI
TURN
TURN
0.85R
10W
21W
Rear
Combination
Lamp RH
1.25Br
0.85G
1.25Y/B
0.85R/W
0.85R/W
21W
21/10W
P
F
F
TAIL
STOP
T
1.25B
10/21W
E
Rear
Combination
Lamp LH
1.25Y/B
0.85G
0.85G
B
STOP
1.25Y/B
21W
B
1.25B
1.25B
E
Front
Combination
Lamp LH
TAIL
0.85R/W
21W
T
1.25B
10W
1.25B
F
TURN
POSI
Licence Light
F
TURN
P
12V10W
0.85R/W
1.25Y/B
0.85G
Trailer Socket
Assembly
0.85G/R
1 /
0.85B
2 5
0.85G/Y
6
0.85G/L
3 6
0.85GY
2
0.85G/B
4 7
0.85G/W
4
7
1
3
5
3TMACAL9P014A
9-M6
KiSC issued 03, 2007 A
0.5B
0.85B
Fuel Sensor
1
9-M7
Parking
Switch
2
To Alternator L
0.5W/L
2
0.5Br/Y
0.5Y/G
Brake Oil Switch
1
0.5Lg
Diode
Engine Oil
Pressure
Switch
0.5W/L
0.5B
Air Cleaner Switch
7
0.5R
0.5L
18
0.5R
To Flasher Unit
0.5R/W
1.25Br
1
To Light Comb Switch
2
0.5R/L
28
To Shift Switch HI
22
To Shift Switch LO
21
0.5W
0.5Lg
8
0.5W
0.5Lg
11
0.5Lg
0.5R/B
0.5Y/G
9
0.5W/L
0.85Br
12
0.5Br/Y
15
To PTO Safety Relay
0.5B
To Flasher Unit
16
1.25G/W
5
To Light
Combination Switch
6
0.5B
PTO
14V3.4W
Air Cleaner
14V3.4W
Trailer
14V3.4W
HI Beam
14V1.4W
Shift HI
14V1.4W
Shift LO
14V1.4W
Engine Oil Press
14V3W
Fuel Limit
14V3.78W
14V3.4W
Brake Oil
14V3.4W
Charge
14V3.4W
Parking
14V3.4W
Turn Signal LH
14V3.4W
Illumination LH
14V3.4W
Turn Signal RH
14V3.4W
Temperature
Gauge
0.5W/L
Engine
Coolant
Temperature
Sensor
4
0.85Y
Illumination RH
Fuel Gauge
To Flasher Unit
3
1.25G/W
0.5W/R
0.5W/R
19
To Light
Combination Switch
0.5Y
17
0.5Y
0.5R/Y
0.5R/Y
Thermistor
0.5Y
0.5R/Y
Sender
0.5B
0.5R/Y
M105S, WSM
ELECTRICAL SYSTEM
[4] INSTRUMENT PANEL BOARD
Key IG
10A
To OPC Unit
To Buzzer
To Seat Switch
20
Meter Panel
14
13
Diode
0.5R
M5
3TMACAL9P015A
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[5] WORKING LIGHT, RADIO AND BEACON
AC/Beacon
Head/ACC
3R/L
Key ACC
25A
5A
0.5L/Y
0.5L/Y
0.5L/Y
0.85R/G
IG
12V55W
12V55W
2R/G
3
0.5B
0.5Y/B
4
2
SR+SR-
Beacon
Switch
14V1.12W
R E
OFF
ON
6
1.25Y/B
1.25B
2R
5
0.5W
1
0.5B
0.85B
SL- SL+
1.25B
0.85B
0.85B
To Tail Lamp
0.85B
0.85B
E ILL+
12V55W
12V55W
Working Lamp
Front RH
Beacon
Relay
-
Radio/CD Unit
Cigarette
Lighter
Working
Lamp
Rear RH
Working Lamp
Rear LH
Working Lamp
Front LH
B
9
0.85R/G
0.85R/Y
0.85R/G
0.85B
Working Light
Rear Switch
4
B
OFF
ON
Working Light
Front Switch
7
5
2
0.5L/Y
8
14V1.12W
R E
1
0.5W/B
B
+
0.5Y
0.85R/L
0.85W/L
14V1.12W
R E
OFF
ON
0.85R/Y
Antenna
0.85W/L
0.85W/B
B
15A
2Y/B
0.5L/Y
3R/B
0.85W/B
15A
Speaker RH
0.5L/Y
0.5L/Y
To Dome Light
15A
0.85B
2R/G
4
0.5B
5
-
2
To Auxiliary Power Relay
Beacon Power Outlet
+
Working Light
Relay
3
0.5L/Y
1
Speaker LH
(Beacon Lamp)
Option
3TMACAL9P016A
9-M8
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[6] WIPER
Key ACC
15A
1.25L
0.85L/Y
Y
1.25L
L
M
1.25L
Front Wiper Motor
1.25L
B
1.25L
E
0.85L
+1
0.85Lg/B
S
M
0.85Lg/W
1.25L
(-)
0.85Lg/B
0.85B
0.85L/R
INT +1 E WV WM
B +1 -S
0.85B
WASH
OFF
ON
WASH
Rear Wiper Switch
(If equipped)
0.85L/R
Front Wiper Switch
0.85Lg/W
(-) W
WASH
ON
OFF
INT
WASH
+B
0.85B
Washer Motor
1.25L
Rear
Front
0.85L/B
1.25L
0.85L/B
Intermittent
Wiper Unit
0.85L/G
0.85B
A
M
(-) (-)
Timer
Circuit
0.85L/G
0.85L/W
C
B
0.85Lg/W
+ +
M
0.85Lg/Y
D
0.85L/R
0.85L/Y
0.85L/W
Rear Wiper Motor
(If equipped)
1.25L
0.85B
W
3TMACAL9P017A
9-M9
KiSC issued 03, 2007 A
M105S, WSM
ELECTRICAL SYSTEM
[7] AIR CONDITIONER
Blower
B/Def
Key ACC
5A
0.5Y/B
25A
0.5Y/B
3
3W
0.85Y
1.25Y
0.5Y/B
0.5Y/B
0.5Y/B
5A
2
M
5
1
3Y/R
0.5B/Y
0.5R
3Y/B
2
3
M2
2L/Y
M1
4
1
L
Blower
Resistor
2
OFF(F/D)
1(Lo)
2(Me)
3(Hi)
2B(AVSSF)
Surge Cut
Diode
0.5B
2Y/G
2B
4
0.5B/Y
0.5B/Y
0.5B/Y
0.5B/Y
0.5B/Y
2Y/G
10
Thermostat
1.00ǡ 0.47ǡ 0.22ǡ
221͠
0.5W
DEF
H
2B
0.5Y/B
0.85Y/L
0.5B/Y
0.5L/Or
0.5G
0.5Y
0.5Y
0.5G
4
0.85Y/L
Temperature Control
Volume
(-)
F/D
Temperature
Control
Amplifier Unit
Blower
Motor
M
2L/Y
Hot
3
3
(+)
0.5B/Y
3Kǡ
0.5G/W
2
Dual
Pressure
Switch
0.5B/Y
Cool
3
1
1
0.5B/Y
2
Mode Select
Switch
2
0.85Y/L
3
7
2
Compressor
Relay
FACE
2
0.5Br
1
1
8
4
Blower
Relay
0.85Y/L
0.5Y/L
6
9
1 2 3 4 5 6
0.5B/Y
5
0.5W/L
0.5Y/B
0.5L/G
7
0.5G/Y
0.5L/G
0.5W/L
0.5Y/L
0.5G/W
3
6
5
1
M
1 2 3 4 5
1
0.5B/Y
4
3W
0.5W/B
A/C Switch
3Y/R
Servomotor Temperature Control
0.5Y/B
Servomotor Mode
12V35W
Magnet Clutch
Compressor
Blower Motor
Switch
3TMACAL9P018A
9-M10
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
[8] WIRING COLOR
B ........... Black
B/Y ......... Black / Yellow
Lg/Y ......... Light Green / Yellow
G .......... Green
Br/B ........ Brown / Black
Or/W ......... Orange / White
L ........... Blue
Br/Y ........ Brown / Yellow
R/B ............ Red / Black
P ........... Pink
G/B ......... Green / Black
R/G ............ Red / Green
R ........... Red
G/L ......... Green / Blue
R/L ............. Red / Blue
W .......... White
G/R ......... Green / Red
R/W ............ Red / White
Y .......... Yellow
G/W ........ Green / White
R/Y ............. Red / Yellow
Br .......... Brown
G/Y ......... Green / Yellow
W/B ............ White / Black
Lg .......... Light Green
L/B .......... Blue / Black
W/G ........... White / Green
Or .......... Orange
L/G .......... Blue / Green
W/L ............ White / Blue
Sb ......... Sky Blue
L/Or ......... Blue / Orange
W/R ........... White / Red
B/G ......... Black / Green
L/R .......... Blue / Red
W/Y ........... White / Yellow
B/L .......... Black / Blue
L/W ......... Blue / White
Y/B ............ Yellow / Black
B/P .......... Black / Pink
L/Y .......... Blue / Yellow
Y/G ............ Yellow / Green
B/Pu ........ Black / Violet
Lg/B ........ Light Green / Blue
Y/L ............. Yellow / Blue
B/R .......... Black / Red
Lg/R ....... Light Green / Red
Y/R ............. Yellow / Red
B/W ......... Black / White
Lg/W ....... Light Green / White
W1019456
9-M11
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
3. STARTING SYSTEM
[1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT
(1) System Outline
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Battery
Main Switch
Starter Motor
Starter Relay
Safety Switch (1-2 Speed
Change Monitor)
Safety Switch (3-4 Speed
Change Monitor)
Alternator
Air Heater Relay
Air Heater
Air Heater Timer
PTO Safety Switch
PTO Relay
Key Stop Relay
Engine Stop Solenoid
(A) To Meter Panel (PTO)
(B) To Meter Panel (Charge
Lamp)
W1013561
There are five key positions, OFF, ACC, ON, PREHEAT (GL) and START (ST) on the main switch as shown
above.
When the main switch (2) is set to ACC (Accessory), in case of cabin, the radio, windshield wipers (front and rear),
work lights (front and rear), cigar lighter and blower fan can be used.
When the main switch (2) is set “ON”, AM terminal of the main switch is connected to ACC and M terminals.
As a result, the battery current flows to the key stop relay (13), and the contact points of relay turned to “ON”
position, and the key stop solenoid (14) is actuating for opening the fuel supply line.
When the main switch is set to “START” under the condition that the main gear shift lever is neutral position and
safety switches (5), (6) is turned ON and PTO lever is in neutral (PTO safety switch (11) is pushed to ON).
AM terminal of the main switch is connected to M and ST terminals.
Consequently, battery current flows to safety switches (5), (6) coil of starter relay (4), PTO relay (12) (When the
PTO safety switch is set to ON, battery current flows PTO safety switch (11) and coil of PTO relay (12)).
This actuates starter motor (3).
When the main switch is released after starting the engine, the main switch returns to ON automatically.
This stops the starter motor.
Fuel supply and fuel stop to and from then injection pump are carried out by the key stop relay (13) and engine
stop solenoid (14).
In case of the hydraulic clutch operation type, the tractor is kept in safety even if the can not be disengaged.
9-M12
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
[2] COMPONENTS
(1) Air Heater
The PTC intake air heater is introduced in order to
further improve the starting performance in cold regions.
The intake air heater is mounted on the air inlet manifold,
while the conventional glow plug on the cylinder head.
This means that a multi-valve design can be
implemented and that the starting performance and
serviceability are enhanced.
The PTC intake air heater features temperature
control function. As the climate gets colder, the heater
gives a greater output without little white plume and odor.
What's more, this self-control of its own temperature
makes the heater protective against overheat and easy
to control.
[STRUCTURE]
The 12 V battery's positive terminal is connected with
the main terminal. When the key switch is set to the ON
position, the current starts flowing in this routes as
indicated with the arrow marks : main terminal → lead
bar → inner fin → PTC element → outer fin → housing →
battery's negative terminal. The four PTC elements are
heated up to 160 °C or so in order to raise the
temperature of air that passes through the air inlet
manifold.
The preheating time is also automatically controlled to
meet the intake air temperature.
(1) Body
(2) PTC Element
(3) Terminal
(4) Insulator
(5) Insulation Plate
W1014259
9-M13
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(2) Air Heater Timer
The current flowing time to the air heater is controlled
and the heater element is prevented being damaged by
burning off.
When the battery current flows to 4 terminal, the
current flowing time between 6 terminal and 3 terminal
(body earth of the timer relay) is controlled.
The current flow time is controlled 12 to 18 seconds.
(1)
(2)
(3)
(4)
(5)
Air Heater Timer
Battery
Main Switch
Air Heater Relay
Air Heater
A:
B:
C:
D:
OFF Position
ON Position
PREHEAT Position
START Position
W1014601
(3) Air Heater Relay
In some cases, the air heater relay is mounting on air
heating system to prevent the contact of the main switch
burning out when the main switch is switched.
Current from the main switch flows only the air heater
relay coil (6), and the relay contact (5) is pulled to ON
position by electromagnetic force.
Therefore, current from the battery flows directly to
the pull-in coil and holding coil of the air heater.
(1) From Battery
(2) To Air Heater
(3) To Ground
(4) From Main Switch
(5) Relay Contact
(6) Relay Coil
W1015058
9-M14
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
4. CHARGING SYSTEM
[1] ELECTRICAL CIRCUIT
(1)
(2)
(3)
(4)
Battery
Main Switch
Slow Blow Fuse
Alternator
(A) To Charging Lamp
(Meter Panel)
W1015223
9-M15
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
5. LIGHTING SYSTEM
[1] ELECTRICAL CIRCUIT
(1)
(2)
(3)
(4)
(5)
Hazard Switch
Combination Switch
Flasher Unit
Horn
Head Lamp LH
(6)
(7)
(8)
(9)
(10)
Head Lamp RH
Dome Lamp
Door Switch LH
Door Switch RH
Licence Light
(11)
(12)
(13)
(14)
9-M16
Front Combination Lamp LH
Rear Combination Lamp LH
Front Combination Lamp RH
Rear Combination Lamp RH
(a) From main switch ACC
terminal
(b) From 50A slow blow fuse
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
[2] COMPONENTS
(1) Flasher Unit
■ Hazard / Flasher Unit
This hazard / flasher unit is a summary to one as for
past hazard / flasher unit, hazard relay, and charge relay.
(1)
(2)
(3)
(4)
(5)
Battery
Main Switch
AC Terminal
B Terminal
Turn Signal Switch
(6)
(7)
(8)
(9)
(10)
Hazard Switch
Trailer Indicator Lamp
Turning Lamp RH
Turning Lamp LH
Ground
W1015651
9-M17
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
6. EASY CHECKER
[1] INDICATION ITEMS
The operator must check the conditions of the tractor before and during operations.
To facilitate checking, the Easy-Checker (TM) lamps on the panel board is provided.
■ Parking brake
The warning lamp (3) comes ON if the parking brake
is applied.
If the lamp is on during operation, release the parking
brake lever immediately.
■ Brake oil level
If the brake oil goes below the prescribed level, the
warning lamp (4) will come ON.
If this should happen during operation, check to see
that there is no oil leak in the brake system, and then add
oil.
■ Electrical charge
If the alternator is not charging the battery, the lamp
(5) will come ON.
If this should happen during operation, check the
electrical charging system.
■ PTO operation lamp
When the PTO lever is set ON position, the lamp (7)
comes ON.
If the lamp does not come ON during PTO clutch
operation, check the relative parts.
■ Fuel level
If the fuel in the tank goes below the prescribed level,
the warning lamp (11) will come ON. (less than 11.8 L
(3.1 gals)).
If this should happen during operation, refuel as soon
as possible.
■ Engine oil pressure
If the oil pressure in the engine goes below the
prescribed level, the warning lamp (10) will come ON.
If this should happen during operation, and it does not
go off when the engine is accelerated to more than 1000
rpm, check level of engine oil.
■ Swing shift turtle (LO) and rabbit (HI)
When move the main shift lever against the left side
face, and the speed change each between Low speed
lamp (9) and High speed lamp (8).
The lamps (9) and (8) indicate that the shift is
changed between Low speed lamp (9) and High speed
lamp.
■ Air Cleaner
If the air cleaner is clogged, the warning lamp (2) in
the Easy Checker (TM) will come on. If this should
happen during operation, clean the air cleaner element.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
High Beam Lamp
Air Cleaner Indicator
Parking Brake Lamp
Brake Oil Lamp
Electrical Charge Lamp
Trailer Indicator
PTO Operation Lamp
(8) High Speed Lamp
(Swing Shift)
(9) Low Speed Lamp
(Swing Shift)
(10) Engine Oil Lamp
(11) Fuel Level Lamp
W1015889
9-M18
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
[2] ELECTRICAL CIRCUIT
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Parking Brake Lamp
Brake Oil Lamp
Electrical Charging Lamp
PTO Operation Lamp
Fuel Level Lamp
Engine Oil Pressure Lamp
Parking Brake Switch
Brake Oil Switch
Engine Oil Pressure Switch
Fuel Unit
Low Speed Lamp
High Speed Lamp
(13)
(14)
(15)
(16)
(A)
(B)
(C)
(D)
(E)
(F)
High Beam Lamp
Trailer Indicator Lamp
Air Cleaner Lamp
Air Cleaner Switch
To Alternator L Terminal
To PTO Relay
To Swing Shift Switch (LO)
To Swing Shift Switch (HI)
To Combination Switch
To Flasher Unit
W1016495
9-M19
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ....................................................................................9-S1
SERVICING SPECIFICATIONS ....................................................................9-S7
TIGHTENING TORQUES ..............................................................................9-S8
CHECKING, DISASSEMBLING AND SERVICING......................................9-S9
[1] CHECKING AND ADJUSTING ...............................................................9-S9
(1) Battery.................................................................................................9-S9
(2) Main Switch.......................................................................................9-S11
(3) Air Heater Relay................................................................................9-S13
(4) Air Heater Timer................................................................................9-S14
(5) Air Heater ..........................................................................................9-S14
(6) Starter Relay .....................................................................................9-S16
(7) Starter Motor .....................................................................................9-S17
(8) Relays [PTO Clutch Safety, Key Stop, Work Light, Aux. Power,
A/C Compressor, A/C Main, Buzzer and Beacon Relay] ..................9-S18
(9) Engine Stop Solenoid .......................................................................9-S19
(10)Safety Start System ..........................................................................9-S20
(11)Swing Shift........................................................................................9-S21
(12)Dual Speed .......................................................................................9-S25
(13)Alternator ..........................................................................................9-S27
(14)Lighting Combination Switch ............................................................9-S28
(15)Hazard Switch...................................................................................9-S30
(16)Flasher Unit ......................................................................................9-S31
(17)Working Light Switch ........................................................................9-S31
(18)Beacon Switch ..................................................................................9-S32
(19)Panel Board ......................................................................................9-S33
(20)Easy Checker ...................................................................................9-S36
(21)Parking Brake Switch........................................................................9-S37
(22)Brake Oil Switch ...............................................................................9-S38
(23)Brake Switch.....................................................................................9-S39
(24)Fuel Limit Sensor..............................................................................9-S39
(25)Fuel Level Sensor.............................................................................9-S40
(26)Coolant Temperature Sensor ...........................................................9-S41
[2] DISASSEMBLING AND ASSEMBLING................................................9-S41
(1) Starter ...............................................................................................9-S41
(2) Alternator ..........................................................................................9-S42
[3] SERVICING ............................................................................................9-S44
(1) Starter ...............................................................................................9-S44
(2) Alternator ..........................................................................................9-S46
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
1. TROUBLESHOOTING
Solution
Reference
Page
Battery discharged or defective
Recharge or replace
9-S10
Battery positive cable disconnected or
improperly connected
Repair or replace
9-S9
Battery negative cable disconnected or
improperly connected
Repair or replace
9-S9
Slow blow fuse blown
Replace
G-41
Short-circuited
Repair or replace
Symptom
All Electrical
Equipments Do Not
Operate
Fuse Blown
Frequently
Probable Cause
–
W1014322
BATTERY
Battery Discharges
Too Quickly
Battery defective
Replace
9-S10
Alternator defective
Repair or replace
9-S27
Wiring harness disconnected or improperly
connected (between battery positive terminal
and alternator B terminal)
Repair or replace
–
Cooling fan belt slipping
Adjust tension
G-21
W1013580
STARTING SYSTEM
Starter Motor Does
Not Operate
Battery discharged or defective
Recharge or replace
9-S10
Slow blow fuse blown
Replace
G-41
Starter relay defective
Replace
9-S16
Monitor switch defective (swing shift)
Replace
9-S21
PTO switch improperly adjusted or defective
Repair or replace
9-S21
Wiring harness disconnected or improperly
connected (between main switch ST terminal
and PTO switch, between PTO switch and safety
switch, between safety switch and starter relay,
between starter relay and ground, between main
switch B terminal and starter relay, between
starter relay and starter motor S terminal,
between battery positive terminal and starter
motor B terminal)
Repair or replace
–
Starter motor defective
Repair or replace
9-S17
Main switch defective
Replace
9-S11
W1011018
9-S1
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
AIR HEATER
Symptom
Air Heater Does Not
Heat
Probable Cause
Solution
Reference
Page
Slow blow fuse blown
Replace
G-41
Air heater relay defective
Replace
9-S13
Air heater defective
Replace
9-S14
Air heater timer defective
Replace
9-S14
W1010808
CHARGING SYSTEM
Charging Lamp Does
Not Light When Main
Switch Is Turned ON
Charging Lamp Does
Not Go Off When
Engine Is Running
Fuse blown
Replace
G-41
Wiring harness disconnected or improperly
connected (between main switch AC terminal
and panel board, between panel board and
alternator L terminal)
Repair or replace
–
Short circuit between alternator L terminal lead
and chassis
Repair or replace
–
Alternator defective
Repair or replace
9-S27
W1011159
SWING SHIFT SYSTEM
Hi-Lo Shift Monitor
Fuse blown
Not Indicate
Monitor switch defective (swing shift)
Buzzer Always Buzz
Swing Shift Does Not
Act
Replace
G-41
Replace
9-S21
Solenoid valve defective
Replace
9-S24
Swing shift switch defective
Replace
9-S22
Fuse blown
Replace
G-41
Swing shift switch defective
Replace
9-S22
Solenoid valve defective
Replace
9-S24
Buzzer relay defective
Replace
9-S18
Wiring harness disconnected or improperly
connected (between swing shift switch and
solenoid valve, monitor switch and buzzer relay)
Replace
–
W1011249
9-S2
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Dual Speed
Symptom
Dual Speed Monitor
Not Indicate
Probable Cause
Solution
Reference
Page
Fuse blown
Replace
G-41
Dual speed switch defective
Replace
9-S25
Dual speed indicator bulb blown
Replace
9-S25
Wiring harness disconnected or improperly
connected (between DS switch and DS lamp)
Repair or replace
–
W1011406
9-S3
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
LIGHTING SYSTEM
Symptom
Head Light Does Not
Light
Probable Cause
Solution
Reference
Page
Fuse blown
Replace
G-41
Bulb blown
Replace
G-39
Wiring harness disconnected or improperly
connected (between main switch B terminal and
combination switch B1 terminal, between
combination switch 1 terminal and head light,
between combination switch 2 terminal and head
light)
Repair or replace
Fuse blown
Replace
G-41
Bulb blown
Replace
G-39
Wiring harness disconnected or improperly
connected (between combination switch T
terminal and panel board)
Repair or replace
Fuse blown
Replace
Wiring harness disconnected or improperly
connected (between combination switch T
terminal and tail light)
Repair or replace
Fuse blown
Replace
G-41
Bulb blown
Replace
–
Flasher unit defective
Replace
9-S31
Hazard switch defective
Replace
9-S30
Turn signal switch defective
Replace
9-S29
Hazard and Turn
Signal Indicator
Lamp Does Not Light
Bulb blown
Replace
–
Wiring harness disconnected or improperly
connected
Repair or replace
–
Hazard and Turn
Signal Light Does
Not Go ON and OFF
Flasher unit defective
Replace
9-S31
Work Light Does Not
Light
Fuse blown
Replace
G-41
Bulb blown
Replace
–
Wiring harness disconnected or improperly
connected (between starter motor B terminal
and work light)
Repair or replace
–
Illumination Light
Does Not Light
Tail Light Does Not
Light
Hazard Light Does
Not Light
9-S28, 29
–
G-41
–
W1011496
9-S4
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
EASY CHECKER
Symptom
Probable Cause
Solution
Reference
Page
Brake Oil Level /
Parking Brake
Indicator Lamp Does
Not Light When Main
Switch Is Turned ON
and Pull Parking
Brake Lever
Bulb blown
Replace
Brake oil level too low
Supply oil
5-S6
Brake oil level switch defective
Replace
9-S38
Parking brake switch defective
Replace
9-S37
Engine Oil Pressure
Lamp Lights Up
When Engine Is
Running
Engine oil pressure too low
Repair engine
1-S14
Engine oil insufficient
Replenish
Engine oil pressure switch defective
Replace
9-S36
Short circuit between engine oil pressure switch
lead and chassis
Repair
9-S36
Circuit in panel board defective
Replace
9-S33
Bulb blown
Replace
–
Engine oil pressure switch defective
Replace
9-S36
Wiring harness disconnected or improperly
connected (between panel board and engine oil
pressure switch)
Repair or replace
Circuit in panel board defective
Replace
Engine Oil Pressure
Lamp Does Not Light
When Main Switch Is
Turned ON and
Engine Is Not
Running
–
G-8
–
9-S33
W1011794
ENGINE KEY SWITCH SHUT-OFF SYSTEM
Engine Does Not
Fuse blown
Stop When Main
Key stop relay defective
Switch Is Turned
Wiring harness disconnected or improperly
OFF
connected
Engine Does Not
Start
Replace
G-41
Replace
9-S18
Repair or replace
–
Fuse blown
Replace
G-41
Engine stop solenoid defective
Replace
9-S19
Key stop relay defective
Replace
9-S18
PTO switch defective
Replace
9-S21
Safety switch defective (1-2, 3-4 speed range
monitor)
Replace
9-S22
W1011890
9-S5
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
GAUGES
Symptom
Fuel Gauge Does Not
Function
Coolant Temperature
Gauge Does Not
Function
Probable Cause
Solution
Reference
Page
Fuel gauge defective
Replace
9-S34
Fuel level sensor (tank unit) defective
Replace
9-S40
Wiring harness disconnected or improperly
connected (between panel board and fuel level
sensor)
Repair or replace
–
Circuit in panel board defective
Replace
–
Coolant temperature gauge defective
Replace
9-S35
Coolant temperature sensor defective
Replace
9-S41
Wiring harness disconnected or improperly
connected (between panel board and coolant
temperature sensor)
Repair or replace
–
Circuit in panel board defective
Replace
–
W1011980
9-S6
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
2. SERVICING SPECIFICATIONS
STARTER MOTOR
Item
Commutator
O.D.
Mica
Undercut
Brush
Length
Factory Specification
Allowable Limit
32.0 mm
1.2598 in.
31.4 mm
1.2362 in.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
0.2 mm
0.0079 in.
18.0 mm
0.7086 in.
11.0 mm
0.4331 in.
W1013874
ALTERNATOR
Brush
Slip Ring
Length
18.5 mm
0.728 in.
5.0 mm
0.197 in.
O.D.
22.7 mm
0.894 in.
22.1 mm
0.870 in.
W1013973
FUEL LEVEL SENSOR
Float at Uppermost Position
Resistance
1.0 to 5.0 Ω
–
Float at Lowermost Position
Resistance
108 to 112 Ω
–
W1014788
COOLANT TEMPERATURE SENSOR
Coolant Temperature at 120 °C (248 °F)
Resistance
Approx. 14.9 to 17.3 Ω
–
Coolant Temperature at 100 °C (212 °F)
Resistance
Approx. 26.2 to 29.3 Ω
–
Coolant Temperature at 80 °C (176 °F)
Resistance
Approx. 47.7 to 56.8 Ω
–
Coolant Temperature at 50 °C (122 °F)
Resistance
Approx. 133.9 to 178.9
Ω
–
W1014851
SWING SHIFT VALVE SOLENOID / DS VALVE SOLENOID
Solenoid valve
Resistance
10 to 12 Ω
–
W1014914
FLASHER UNIT
Flasher Blinking
Times
60 to 120 times /
minutes
–
W1014977
9-S7
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10)
Item
N·m
kgf·m
ft-lbs
Pulley nut (Alternator)
58.3 to 78.9
5.95 to 8.05
43.0 to 58.2
Air heater lead terminal nut
3.43 to 5.39
0.35 to 0.55
2.53 to 3.98
Air heater terminal nut
6.37 to 8.33
0.65 to 0.85
4.70 to 6.14
Starter B terminal nut
9.8 to 11.8
1.0 to 1.2
7.2 to 8.7
W1012736
9-S8
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
4. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
•
•
•
•
■
•
CAUTION
To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
Never remove the battery cap while the engine is running.
Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
IMPORTANT
If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
(1) Battery
Battery Voltage
1. Stop the engine and turn the main switch off.
2. Connect the COM (−) lead of the voltmeter to the battery's
negative terminal post and the (+) lead to the positive terminal
post, and measure the battery voltage.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage
Factory spec.
More than 12 V
W1015899
Battery Terminal Connection
1. Turn the main switch on, and turn on the head light.
2. Measure the voltage with a voltmeter across the battery's positive
terminal post and the cable terminal, and the voltage across the
battery's negative terminal post and the chassis.
3. If the measurement exceeds the factory specification, clean the
battery terminal posts and cable clamps, and tighten them firmly.
Potential difference
Factory spec.
Less than 0.1 V
W1016279
9-S9
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Battery Condition Indicator
1. Check the battery condition by reading the indicator (2).
State of indicator display
Green
Specific gravity of electrolyte and quality of
electrolyte are both in good condition.
Black
Needs charging battery
White
Needs changing battery
■ IMPORTANT
• The factory installed battery is of non-refillable type. If the
indicator turns white, do not charge the battery but replace
it with new one.
(1) Battery
(2) Indicator
W1016405
Recharging
•
•
•
1.
2.
3.
4.
CAUTION
When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
When disconnecting the cable from the battery, start with
the negative terminal first.
When connecting the cable to the battery, start with the
positive terminal first.
Never check battery charge by placing a metal object across
the posts.
Use a voltmeter or hydrometer.
To slow charge the battery (1), connect the battery positive
terminal (2) to the charge positive terminal and the negative (3)
to the negative, then recharge in the standard fashion.
A boost charge is only for emergencies. It will partially charge the
battery at a high rate and in a short time.
When using a boost-charged battery, it is necessary to recharge
the battery as early as possible.
Failure to do this will shorten the battery's service life.
The battery is charge if the indicator display turns green from
black.
When exchanging an old battery for a new one, use battery of
equal specification shown in table.
Table
Battery Type
Volts (V)
Capacity at 5H.R. (A.H.)
GP31 (105E41R)
12
85.3
Reserve Capacity (min)
Cold Cranking Amps
Normal Charging Rate (A)
160
900
11
(1) Battery
(2) Positive Terminal
(3) Negative Terminal
(4) Indicator
W1016725
9-S10
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
■ Battery Storage
1. When shutting down the tractor for long periods of time, remove
the battery from the tractor, store the battery in a well ventilated
placed where it is not exposed to direct sunlight.
2. Since the battery self-discharges by approx. 0.5 % per day even
in storage, it must be once every two months in cold season.
3. When storaging the battery mounted on the tractor, disconnect
the ground cable from the battery's negative terminal post.
(Reference)
• Self-discharge Rate
Temperature
Self-discharge rate
30 °C (86 °F)
Approx. 1.0 % per day
20 °C (68 °F)
Approx. 0.5 % per day
10 °C (50 °F)
Approx. 0.25 % per day
W1017453
(2) Main Switch
Preparation
1. Remove the meter panel, and disconnect the hourmeter cable
and the main switch connectors after turning the main switch off.
2. Perform the following checking.
(1) Main Switch
W1017794
Connector Voltage
1. Measure the voltage with a voltmeter across the connector 3
terminal and chassis.
2. If the voltage differs from the battery voltage (11 to 14 V), the
wiring harness is faulty.
Voltage
Connector 3 terminal Chassis
(1) Main Switch (Switch Side)
Approx. battery voltage
(2) Main Switch Connector
(Wire Harness Side)
W1018057
9-S11
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Main Switch at ON Position
1. Turn the main switch on.
2. Measure the resistance with an ohmmeter across the 3 terminal
and the 1 terminal, and across the 3 terminal and the 6 terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance
3 terminal –
1 terminal
0Ω
3 terminal –
6 terminal
0Ω
(1) Main Switch Connector
W1018249
Main Switch at START Position
1. Turn and hold the main switch key at the START position.
2. Measure the resistances with an ohmmeter across the 3 terminal
and 5 terminal, and across the 3 terminal and the 6 terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance
3 terminal –
5 terminal
0Ω
3 terminal –
6 terminal
0Ω
(1) Main Switch Connector
W1018482
Main Switch at PREHEAT Position
1. Turn and hold the main switch key at the PREHEAT position.
2. Measure the resistances with an ohmmeter across the 3 terminal
and 2 terminal, and the 3 terminal and the 6 terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance
3 terminal –
2 terminal
0Ω
3 terminal –
6 terminal
0Ω
(1) Main Switch Connector
W1018647
Main Switch at ACC Position
1. Turn the main switch key at the ACC position.
2. Measure the resistances with an ohmmeter across the 3 terminal
and the 1 terminal.
3. If 0 ohm is not indicated, these contacts of the main switch are
faulty.
Resistance
3 terminal –
1 terminal
0Ω
(1) Main Switch Connector
W1018807
9-S12
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(3) Air Heater Relay
Connector Voltage
1. Turn off the main switch.
2. Disconnect the 2P connector (3) and both white color lead and
red color lead from relay (1).
3. Measure the voltage with a voltmeter across white color lead and
chassis.
4. If the voltage differs from battery voltage the wiring harness or
slow blow fuse is faulty.
5. Turn on the main switch to the PREHEAT position.
6. Measure the voltage a voltmeter across 2P connector's (4) 1
terminal and chassis.
7. If the voltage differs from the battery voltage, the wiring harness
or slow blow fuse is faulty.
Voltage
Main switch at
“OFF”
White color lead –
chassis
Main switch at
“PREHEAT”
1 terminal – chassis
(1) Air Heater Relay
(2) Terminal
(3) 2P Connector (Relay Side)
Approx. battery voltage
(4) 2P Connector (Wire Harness Side)
1 and 2 : Terminal
W1019485
Functional Check
1. Remove the air heater relay.
2. Apply battery voltage across the 1 and 2 terminals, check
continuity across 3 terminal and 4 terminal as shown in figure.
3. If continuity is not established across 3 terminal and 4 terminal,
air heater relay is faulty.
(1) Air Heater Relay
(2) Relay Connector
1 to 4 : Terminal
W1020202
9-S13
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(4) Air Heater Timer
Function Check
1. Remove the air heater timer (1).
2. Connect the jumper leads with switch (3) across the battery.
3. Connect the jumper leads across the battery negative terminal
and 3 terminal.
4. Connect the jumper leads across the 6 terminal and bulb (4) as
shown in figure.
5. The bulb (4) lights up when switch (3) goes on and bulb goes off
between 12 to 18 seconds late, air heater timer is proper.
(1) Air Heater Timer
(2) Battery
(3) Switch
(4) Bulb
W1020533
(5) Air Heater
Connector Voltage
1. Disconnect the wiring white color lead (2) from air heater (1) after
turning the main switch OFF.
2. Make sure that the shuttle shift lever is in the NEUTRAL position
and the PTO control lever to OFF position.
3. Turn the main switch to the PREHEAT position, and measure the
voltage with a voltmeter across the white color lead terminal and
the chassis.
4. Turn the main switch to the START position, and measure the
voltage with a voltmeter across the white color lead terminal and
the chassis.
5. If the voltage at either position differs from the battery voltage, the
wiring harness or main switch is faulty.
Voltage
Main switch at
“PREHEAT”
Main switch at
“START”
(1) Air Heater
White color lead –
Chassis
Approx. battery voltage
(2) Wiring Lead
W1020752
9-S14
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Functional Check
1. Disconnect the leads from air heater (1).
2. Check the continuity across the lead 1 (2), and the ground, and
the lead 2 (3) and the ground with an ohmmeter.
3. If these do not conduct, replace the air heater (1).
Resistance
Lead 1 - Ground
Lead 2 - Ground
Approx. 0 Ω
(When reassembling)
Lead terminal nut
tightening torque
Factory spec.
Terminal nut tightening
torque
(1)
(2)
(3)
(4)
Air Heater
Lead 1
Lead 2
Body
3.43 to 5.39 N·m
0.35 to 0.55 kgf·m
2.53 to 3.98 ft-lbs
6.37 to 8.33 N·m
0.65 to 0.85 kgf·m
4.70 to 6.14 ft-lbs
(5) Lead Terminal Nut
(6) Heater Element
(7) Terminal Nut
W1021112
9-S15
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(6) Starter Relay
Functional Check
1. Remove the starter relay (1).
2. Apply battery voltage across the 3 and 4 terminals, and check for
continuity across the 1 and 2 terminals.
3. If continuity is not established across the 1 and 2 terminals,
replace it.
(1) Starter Relay
W1021736
Connector Voltage
1. Disconnect the engine wire harness connector (1) from starter
relay.
2. Turn the main switch to the START position, and measure the
voltage across the 4 terminal on connector (1) and chassis.
3. If the voltage differs from the battery voltage, the wiring harness
or main switch is faulty.
(1) Connector (Wire Harness Side)
W1022158
9-S16
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(7) Starter Motor
Starter Motor B Terminal Voltage
1. Measure the voltage with a voltmeter across the B terminal and
chassis.
2. If the voltage differs from the battery voltage, the battery's
positive cable or the battery negative cable is faulty.
Voltage
Factory spec.
Approx. battery voltage
W1022522
Motor Test
CAUTION
• Secure the starter to prevent it from jumping up and down
while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable and the leads from the
starter C terminal (1).
3. Remove the starter from the engine.
4. Disconnect the connecting lead (2) from the starter C terminal
(1).
5. Connect a jumper lead from the connecting lead (2) to the battery
positive terminal post.
6. Connect a jumper lead momentarily between the starter motor
housing and the battery negative terminal post.
7. If the motor does not run, check the motor.
(1) C Terminal
(2) Connecting Lead
W1022645
Magnet Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable and the leads from the
starter B terminal (4).
3. Remove the starter from the engine.
4. Disconnect the connecting lead (3) from the starter C terminal
(2).
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal post.
6. Connect a jumper lead momentarily between the starter C
terminal (2) and the battery negative terminal post.
7. If the pinion gear does not pop out, check the magnetic switch.
■ NOTE
• This test should be carried out for a short time, about 3 to 5
seconds.
(1) S Terminal
(2) C Terminal
(3) Connecting Lead
(4) B Terminal
W1023186
9-S17
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(8) Relays [PTO Clutch Safety, Key Stop, Work Light, Aux. Power, A/C Compressor, A/C
Main, Buzzer and Beacon Relay]
Functional Check
■ NOTE
• The relays described here are used same ones so that these
are interchangeable.
1. Remove the relative relays.
2. Connect the battery (11) and bulb (10) with the relay (9) as shown
in the figure.
3. If the bulb goes on when disconnecting the jumper lead (A) from
the relay terminal and if the bulb goes OFF when connecting the
jumper lead (A) to the relay 2 terminal, the relay is proper.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
PTO Clutch Safety Relay
Key Stop Relay
Work Light Relay
Aux. Power Relay
A/C Compressor Relay
A/C Main Relay
Beacon Relay
(8)
(9)
(10)
(11)
Buzzer Relay
Relay
Bulb
Battery
A : Jumper Lead
W1023448
9-S18
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(9) Engine Stop Solenoid
Functional Check
1. Remove the engine stop solenoid (5) from the injection pump.
2. Connect the leads as shown in the figure.
- Connect the jumper leads from P terminal through the switch
(4) to the battery positive terminal
- Connect the jumper leads from H terminal through the switch
(3) to the battery positive terminal
- Connect the jumper leads from the negative terminal to the
engine stop solenoid body
3. When switch (4) is turn ON, the plunger is pulled into the solenoid
body and then turn OFF the switch (4), the plunger comes out.
4. Turn on the switch (3) then turn ON the switch (4), the plunger is
pulled into the solenoid body and it is kept in HOLDING position
after turning OFF the switch (4).
5. If the plunger is not attracted, the engine stop solenoid is faulty.
■ IMPORTANT
• Never apply the current for pulling coil more than two
seconds when inspecting.
(1)
(2)
(3)
(4)
(5)
Connector
Battery
Switch for Holding Coil
Switch for Pulling Coil
Engine Stop Solenoid
P : Terminal for Pulling Coil
H : Terminal for Holding Coil
W1024150
9-S19
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(10) Safety Start System
Preparation
1. Place all control levers to the “NEUTRAL” position.
2. Set the parking brake and stop the engine.
■ Test 1 : Switch for the Main Gear Shift Lever
1. Sit on operator's seat.
2. Shift the main gear shift lever (1) to the desire position.
3. Depress the clutch pedal fully.
4. Disengage the PTO clutch control lever (3).
5. Turn the key to “START” position.
6. The engine must not crank.
7. If it cranks, check the safety switches (4), (5). (See page 9-S22.)
■ Test 2 : Switch for the PTO Clutch Control Lever
1. Sit on operator's seat.
2. Engage the PTO clutch control lever (3).
3. Depress the clutch pedal (2) fully.
4. Turn the key to “START” position.
5. The engine must not crank.
6. If it cranks, check the PTO switch (6). (See page 9-S21.)
(1)
(2)
(3)
(4)
Main Gear Shift Lever
Clutch Pedal
PTO Clutch Control Lever
Safety Switch (1-2 Speed Range
Monitor)
(5) Safety Switch (3-4 Speed Range
Monitor)
(6) PTO Switch
W1024916
9-S20
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
PTO Switch
1) Wiring Harness
1. Disconnect the leads from the PTO switch (1).
2. Connect the wiring harness lead terminals to each other and turn
the main switch ON.
3. If the indicator do not light, the fuse, wiring harness or bulb is
faulty.
2) PTO Switch Continuity
1. Check the continuity with an ohmmeter across the switch
terminals.
2. If it does not conduct or any value is indicated when the switch is
pushed, the switch is faulty.
3. If infinity is not indicated when the switch is released, the switch
is faulty.
Resistance
(Across switch
terminals)
Reference
value
(1) PTO Switch
When switch is pushed (P)
0Ω
When switch is released
(R)
Infinity
P : Pushed
R : Released
W1025931
(11) Swing Shift
Monitor Switch (LO and HI)
1. Remove the monitor switch (1), (2).
2. Check the continuity with an ohmmeter across switch terminals.
3. If it does not conduct or any value is indicated when the switch is
pushed, the switch is faulty.
4. If infinity is not indicated when the switch is released, the switch
is faulty.
Resistance (Across
switch terminals)
(1) LO Monitor Switch
(2) HI Monitor Switch
(3) Monitor Switch
When switch is
pushed (P)
0Ω
When switch is
released (R)
Infinity
P : Pushed
R : Released
W1026655
9-S21
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Safety Switch (1-2, 3-4 Speed Range Monitor)
1. Remove the safety switch leads.
2. Check the continuity with an ohmmeter across switch terminals.
3. If it does not conduct or any value is indicated when the switch is
released, the switch is faulty.
4. If infinity is not indicated when the switch is pushed, the switch is
faulty.
Resistance
(Across switch
terminals)
When operate main
shift lever to the 1st
or 2nd range
Resistance
(Across switch
terminals)
When operate main
shift lever to the 3rd
or 4th range
Resistance
(Across switch
terminals)
When main shift
lever on neutral
position
(1) 3-4 Safety Switch
(2) 1-2 Safety Switch
1-2 safety switch
(P)
Infinity
3-4 safety switch
(R)
0Ω
1-2 safety switch
(R)
0Ω
3-4 safety switch
(P)
3-4 safety
switch (P)
Both safety
switch (Both
switch released)
0Ω
P : Pushed
R : Released
W1027086
Swing Shift Switch
1. Remove the Hi-Lo touch shift switch (1) connector.
2. Check the continuity with a ohmmeter across the 2 terminal to the
1 terminal, and across the 2 terminal to the 3 terminal.
3. Whenever swing shift switch is pushed each time, the connection
change to 2-1 terminals and 2-3 terminals repeatedly.
4. If the connection does not change, shift switch is faulty.
Condition
2 terminal - 1 terminal
2 terminal - 3 terminal
1
0Ω
Infinity
2
Infinity
0Ω
(1) Swing Shift Switch
W1027541
9-S22
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Buzzer
1. Remove the buzzer (1).
2. Connect the jumper lead across the battery positive terminal and
1 terminal of connector.
3. Connect the jumper lead across the battery negative terminal and
2 terminal of connector.
4. If the buzzer does not whistle, replace it.
(1) Buzzer
W1028046
9-S23
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
HI-LO Shift Solenoid Valve
1. Disconnect the connector (1).
2. Measure the resistance with an ohmmeter across the 1 terminal
to the chassis, and the 2 terminal to the chassis.
3. If infinity is indicated, the solenoid valve is faulty.
Resistance
(1) Connector
(2) Yellow Lead (LO Side)
HI solenoid valve
1 terminal to chassis
LO solenoid valve
2 terminal to chassis
10 to 12 Ω
(3) White Lead (HI Side)
(4) Solenoid Valve
W1028218
9-S24
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(12) Dual Speed
Dual Speed Indicator
1. Remove the indicator (1) from the side panel.
2. Check the continuity with an ohmmeter across the indicator
terminals.
3. If value is indicated, the bulb is faulty.
(1) Indicator
W1028688
Dual Speed Switch
1. Remove the dual speed switch connector (2).
2. Check the continuity with an ohmmeter across the switch
terminals.
3. If it does not conduct or any value is indicated when the switch is
pushed, the switch is faulty.
Whenever the DS switch button is pushed, the switch repeats
turning ON and turning OFF.
4. If infinity is not indicated when switch is pushed on the turning
OFF position, the switch is faulty.
Resistance
(Across switch terminal)
(1) Dual Speed Switch
Resistance
ON
condition
0Ω
OFF
condition
Infinity
(2) Connector
W1029124
Connector Voltage
1. Disconnect the dual speed valve wire harness connector (1).
2. Turn the main switch to the ON position.
3. Measure the voltage with a voltmeter across the yellow color lead
with wire harness and chassis when DS switch button is pushed
ON position.
4. If the voltage differs from the battery voltage, the wiring harness
or fuse is faulty.
Voltage
(1) Connector
DS switch at ON (LO)
Approx. battery voltage
DS switch at OFF (HI)
0V
(2) DS Valve
W1029532
9-S25
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Dual Speed Solenoid Valve
1. Disconnect the wire harness connector (1).
2. Measure the resistance with an ohmmeter across the 1 terminal
on the connector (2) and chassis.
3. If infinity is indicated, the solenoid valve is faulty.
Resistance
(1) Wire Harness Connector
(2) Connector
Solenoid valve 1
terminal to chassis
10 to 12 Ω
(3) Solenoid Valve
W1030117
9-S26
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(13) Alternator
Preparation
1. Disconnect the 2P connector (3) from alternator after turning the
main switch OFF.
2. Perform the following checkings.
(1) B Terminal
(2) Alternator
(3) 2P Connector
W1030485
Connector Voltage
1. Turn off the main switch. Measure the voltage between the B
terminal (1) and the chassis.
2. Turn on the main switch. Measure the voltage between the IG
terminal (3) and the chassis.
Voltage
(Main switch at OFF)
B terminal - Chassis
Approx. battery voltage
Voltage
(Main switch at ON)
IG terminal - Chassis
Approx. battery voltage
(1) B Terminal
(2) Alternator
(3) IG Terminal
(4) L Terminal
W1030607
No-Load Test
1. Connect the 2P connector (6) to previous positions of the
alternator after turning off the main switch.
2. Connect the jumper lead (3) between IG terminal (4) and B
terminal (2).
3. Start the engine and then set at idling speed.
4. Disconnect the negative cable from the battery.
5. Measure the voltage between the B terminal (2) and the chassis.
6. If the measurement is less than the factory specifications,
disassemble the alternator and check the IC regulator.
Voltage
Factory spec.
More than 14 V
(Reference)
• Once the engine has started, the alternator temperature rises
quickly up to an ambient temperature of 70 to 90 °C (158 to 194
°F). As the temperature goes higher than 50 °C (122 °F), the
alternator voltage slowly drops; at higher than 100 °C (212 °F), it
drops by about 1 V.
(1) Voltmeter
(2) B Terminal
(3) Jumper Lead
(4) IG Terminal
(5) L Terminal
(6) 2P Connector
W1030850
9-S27
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(14) Lighting Combination Switch
Preparation
1. Remove the switch board, and disconnect the combination
switch connector after turning off the main switch.
2. Perform the following checkings.
(1) Light Switch
(2) Turn Signal Light Switch
(3) Horn Switch
W1032506
Connector Voltage
1. Disconnect the 8P connector from the combination switch.
2. Measure the voltage with a voltmeter across the connector B1
terminal to chassis and the B2 terminal to chassis when the main
switch is “OFF” position.
3. If the voltage differs from the battery voltage, the wiring harness
is faulty.
Voltage
Main switch at
“OFF” position
B1 terminal –
Chassis
Battery voltage
B2 terminal –
Chassis
W1033198
Light Switch Continuity When Setting Switch at OFF Position
1. Disconnect the combination switch connector.
2. Set the light switch to the OFF position.
3. Measure the resistance with an ohmmeter across the B1 terminal
to the T terminal, the B1 terminal to the 1 terminal and the B1
terminal to the 2 terminal.
4. If infinity is not indicated, the head light switch is faulty.
B1 terminal – T terminal
Resistance (Switch at
OFF position)
B1 terminal – 1 terminal
Infinity
B1 terminal – 2 terminal
W1033535
Light Switch Continuity When Setting Switch at HIGH-BEAM
1. Measure the resistance with an ohmmeter across the B1 terminal
to the T terminal and the B1 terminal to the 1 terminal.
2. If 0 ohm is not indicated, the head light switch is faulty.
Resistance (Switch at
HIGH-BEAM position)
B1 terminal – T terminal
B1 terminal – 1 terminal
0Ω
W1033679
9-S28
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Light Switch Continuity When Setting Switch at LOW-BEAM
Position
1. Measure the resistance with an ohmmeter across the B1 terminal
to the T terminal and the B1 terminal to the 2 terminal.
2. If 0 ohm is not indicated, the head light switch is faulty.
Resistance (Switch at
LOW-BEAM position)
B1 terminal - T terminal
B1 terminal - 2 terminal
0Ω
W1033803
Turn Signal Light Switch When Setting Switch Knob at OFF
Position
1. Set the turn signal light switch to the OFF position.
2. Measure the resistance with an ohmmeter across the B2 terminal
to the R terminal and the B2 terminal to the L terminal.
3. If infinity is not indicated, the turn signal light switch is faulty.
Resistance (Switch at
OFF position)
B2 terminal - R terminal
B2 terminal - L terminal
Infinity
W1033897
Turn Signal Light Switch When Setting Switch Knob at R
Position
1. Set the turn signal light switch to the R position.
2. Measure the resistance with an ohmmeter across the B2 terminal
to the R terminal.
3. If 0 ohm is not indicated, the turn signal light switch is faulty.
Resistance (Switch at R
position)
B2 terminal - R terminal
0Ω
W1034004
Turn Signal Light Switch When Setting Switch Knob at L
Position
1. Set the turn signal light switch to the L position.
2. Measure the resistance with an ohmmeter across the B2 terminal
to the L terminal.
3. If 0 ohm is not indicated, the turn signal light switch is faulty.
Resistance (Switch at L
position)
B2 terminal - L terminal
0Ω
W1034162
9-S29
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Horn Switch Continuity
1. Measure the resistance with an ohmmeter across the B2 terminal
to the H terminal.
2. If measurement is not following below, the horn switch is faulty.
Resistance
(Switch at OFF)
B2 terminal - T terminal
Infinity
Resistance
(Switch at ON)
B2 terminal - 2 terminal
0Ω
W1034280
(15) Hazard Switch
Preparation
1. Remove the meter panel and disconnect the 6P connector from
hazard switch (1) after disconnecting the battery negative code.
2. Remove the hazard switch (1).
3. Perform the following checking.
(1) Hazard Switch
W1035265
Connector Voltage
1. Connect the battery negative code, then measure the voltage
with a voltmeter across the a terminal and chassis.
2. If the voltage differs from the battery voltage, the wiring harness
is faulty.
Voltage
a terminal - Chassis
Approx. battery voltage
(1) 6P Connector
W1035451
Hazard Switch Continuity
1. Measure the resistance with ohmmeter across the a terminal and
c terminal, and across the d terminal and e terminal.
2. If the measurement is not following values below, the hazard
switch or the bulb are faulty.
Resistance
(Switch at OFF)
a terminal c terminal
Infinity
Resistance
(Switch at ON)
a terminal c terminal
0Ω
Resistance (Bulb)
d terminal e terminal
Approx. 13 Ω
(1)
(2)
(3)
(4)
Hazard Switch
Bulb
a Terminal
b Terminal
(5) d Terminal
(6) c Terminal
(7) e Terminal
W1036339
9-S30
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(16) Flasher Unit
Flasher Unit
1. Disconnect the connector from the flasher unit.
2. Turn the main switch at ON position.
3. Measure the voltage between the terminal 12 and chassis.
4. If the voltage differ from the battery voltage, the wiring harness is
faulty.
Voltage
Terminal 12 – Chassis
Approx. battery voltage
(1) Flasher Unit
W1047788
Flasher Unit Actuation Test
1. Set the hazard switch to the ON position, and make sure the
hazard light gives 60 to 85 flashes for a minute.
2. Set the main switch to the ON position and move the turn signal
switch to the left. Make sure the left-hand light gives flashes.
Then move the turn signal switch to the right and make sure the
right-hand light gives flashes. Make sure the same actions as
above result.
3. If both the hazard switch and the turn signal switch function but
the above actions do not take place, replace the flasher unit with
new one.
(1) Hazard Switch
(2) Turn Signal Switch
(3) Flasher Unit
W1048275
(17) Working Light Switch
Preparation
1. Remove the outer roof, and disconnect the working light switch
connector (1) from the switch (2) connector.
2. Perform the following checkings “Connector Voltage” and
“Working Light Switch”.
(1) Working Light Switch Connector
(Front)
(2) Working Light Switch (Front)
(3) Working Light Switch Connector
(Rear)
(4) Working Light Switch (Rear)
W1037853
9-S31
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Connector Voltage
1. Turn on the main switch.
2. Measure the voltage with a voltmeter across the connector 1
terminal and chassis.
3. If the voltage differs from the battery voltage, the wiring harness,
fuse or main switch is faulty.
Voltage
1 terminal - Chassis
(1) Working Light Switch
(2) Working Light Switch Connector
(Switch Side)
(3) Working Light Switch Connector
(Wiring Harness Side)
Approx. battery voltage
W/B :Front Work Light
W/L :Rear Work Light
W1038200
Working Light Switch
1. Check the continuity through the switch with an ohmmeter.
2. If continuity specified below is not indicated, replace it.
Terminal
Position
Working light
switch
1
OFF
●
ON
(1) Working Light Switch
2
3
●
●
●
●
(2) Working Light Switch Connector
(Switch Side)
W1038414
(18) Beacon Switch
Preparation
1. Remove the outer roof, and disconnect the beacon switch from
the connector.
2. Perform the following checkings “Connector Voltage” and
“Beacon Switch”.
(1) Beacon Switch
W1049216
Connector Voltage
1. Turn on the main switch.
2. Measure the voltage with a voltmeter across the connector 1
terminal and chassis.
3. If the voltage differs from the battery voltage, the wiring harness,
fuse or main switch is faulty.
Voltage
1 terminal - Chassis
(1) Beacon Switch
(2) Beacon Switch Connector (Switch
Side)
Approx. battery voltage
(3) Beacon Switch Connector (Wiring
Harness Side)
W1049502
9-S32
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Beacon Switch
1. Check the continuity through the switch with an ohmmeter.
2. If continuity specified below is not indicated, replace it.
Terminal
Position
Beacon
switch
(1) Beacon Switch
1
OFF
ON
●
2
3
●
●
●
●
(2) Beacon Switch Connector (Switch
Side)
W1049824
(19) Panel Board
Preparation
1. Remove the panel board (1) after disconnecting battery negative
code.
2. Perform following checking.
(1) Panel Board
W1038729
Connector Voltage
1. Turn on the main switch.
2. Measure the voltage with a voltmeter across the T terminal on the
12P connector (b) and chassis.
3. If the voltage differs from the battery voltage, the wiring harness,
fuse or main switch is faulty.
Voltage
(a) 10P Connector
T terminal to chassis
Approx. battery voltage
(b) 12P Connector
W1038833
9-S33
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Functional Check of Fuel Gauge
1. Check the continuity with an ohmmeter across the S terminal to
T terminal and the S terminal to Q terminal on panel board.
2. If infinity is indicated, the fuel gauge is faulty.
Item
Item
A
Shift L (Turtle)
L
Parking Brake Indicator
B
Shift H (Rabbit)
M
–
C
Temperature Unit
N
Air Cleaner Indicator
D
Illumination
O
Turn Signal LH
E
GND
P
Illumination
F
Turn Signal RH
Q
GND
G
Trailer Indicator
R
High Beam Indicator
H
PTO Clutch
S
Fuel Unit
I
Electrical Charge
T
IG+
J
–
U
Fuel Level
K
Brake Oil Level
V
Engine Oil Pressure
(1) Meter Panel
(a) 10P Connector
(b) 12P Connector
W1039199
9-S34
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Functional Check of Coolant Temperature Gauge
1. Check the continuity with an ohmmeter across the C terminal to
T terminal and the C terminal to Q terminal on the panel board.
2. If infinity is indicated, the coolant temperature gauge is faulty.
Item
Item
A
Shift L (Turtle)
L
Parking Brake Indicator
B
Shift H (Rabbit)
M
–
C
Temperature Unit
N
Air Cleaner Indicator
D
Illumination
O
Turn Signal LH
E
GND
P
Illumination
F
Turn Signal RH
Q
GND
G
Trailer Indicator
R
High Beam Indicator
H
PTO Clutch
S
Fuel Unit
I
Electrical Charge
T
IG+
J
–
U
Fuel Level
K
Brake Oil Level
V
Engine Oil Pressure
(1) Meter Panel
(a) 10P Connector
(b) 12P Connector
W1039964
9-S35
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(20) Easy Checker
Engine Oil Pressure Switch Panel Board and Wiring Harness
1. Disconnect the lead (2) from the engine oil pressure switch (1)
after turning off the main switch.
2. Turn on the main switch and connect a jumper lead from the lead
to the chassis.
3. If the engine oil pressure indicator lamp does not light, the panel
board circuit or the wiring harness is faulty.
(1) Engine Oil Pressure Switch
(2) Lead
(a) From Oil Pressure Lamp
W1040320
Engine Oil Pressure Switch Continuity
1. Measure the resistance with an ohmmeter across the switch
terminal and the chassis.
2. If 0 ohm is not indicated in the normal state, the switch is faulty.
3. If infinity is not indicated at pressure over 4.9 kPa (0.5 kgf/cm2, 7
psi), the switch is faulty.
Resistance (Switch
terminal - Chassis)
In normal state
0Ω
At pressure over
approx. 4.9 kPa (0.5
kgf/cm2, 7 psi)
Infinity
(1) Engine Oil Pressure Switch
W1040687
Air Cleaner Sensor Panel Board and Wiring Harness
1. Disconnect the leads from the air cleaner sensor (1) after turning
the main switch OFF.
2. Turn the main switch ON and connect a jumper lead between the
leads.
3. If the air cleaner clogged lamp does not light, the panel board
circuit or wiring harness is faulty.
(1) Air Cleaner Sensor
W1050130
9-S36
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Air Cleaner Sensor Continuity
1. Disconnect the leads from the air cleaner sensor (1) after turning
the main switch OFF.
2. Measure the resistance with an ohmmeter across the air cleaner
sensor terminals.
3. If infinity is not indicated, the sensor is faulty.
Resistance (Across
sensor terminals)
In normal state
Infinity
(1) Air Cleaner Sensor
W1052230
Charging Circuit (Panel Board and Wiring Harness)
1. Disconnect the 2P connector from the alternator after turning off
the main switch.
2. Turn on the main switch.
3. Connect a jumper lead from L terminal on the connector (5) to the
chassis.
4. If the charge lamp (1) does not light, the panel board circuit,
alternator, wiring harness, or fuse is fault.
(1) Charge Lamp
(2) Alternator
(3) IG Terminal
(4) L Terminal
(5) Connector (Wire Harness)
W1041413
(21) Parking Brake Switch
Wiring Harness
1. Disconnect the leads from the parking brake switch (1).
2. Connect the wiring harness lead terminals to each other and turn
on the main switch.
3. If the indicator do not light, the fuse, wiring harness or bulb is
faulty.
Resistance
(Across switch
terminals)
Reference
value
When switch is pushed
0Ω
When switch is released
Infinity
(1) Parking Brake Switch
W1041733
9-S37
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Parking Brake Switch Continuity
1. Check the continuity with an ohmmeter across the switch
terminals.
2. If it does not conduct or any value is indicated when the switch is
pushed, the switch is faulty.
3. If infinity is not indicated when the switch is released, the switch
is faulty.
Resistance
(Across switch
terminals)
Reference
value
When switch is pushed (P)
0Ω
When switch is released
(R)
Infinity
(1) Parking Brake Switch
P : Pushed
R : Released
W1041960
(22) Brake Oil Switch
Panel Board and Wiring Harness
1. Start the engine and check the easy checker.
2. Disconnect the 2P connector from the brake oil level switch.
3. Connect the 2P connector of the wiring harness side to each
other by using the lead.
4. If the parking brake / brake oil level indicator lamp does not light
on, the panel board circuit or the wiring harness is faulty.
Resistance
Factory
spec.
Across 2P
connector
Brake oil level
below MIN mark
0Ω
Brake oil level
above MIN mark
Infinity
(1) Brake Oil Reservoir
W1042861
Brake Oil Level Switch Continuity
1. Check the continuity between the 1 and 2 terminals with an
ohmmeter.
2. If the factory specification is not indicated, replace the brake oil
tank assembly.
Resistance
Factory
spec.
(1) 2P Connector
1 and 2
terminals
Brake oil level
below MIN mark
0Ω
Brake oil level
above MIN mark
Infinity
A : Max Level
B : Low Level
W1042188
9-S38
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(23) Brake Switch
Brake Switch
1) Wiring Harness
1. Disconnect the leads from the brake switch (1).
2. Connect the wiring harness lead terminals to each other and turn
the main switch on.
3. If the stop lights do not light, the fuse, wiring harness or bulb is
faulty.
2) Brake Switch Continuity
1. Remove the brake switch (1).
2. Check the continuity with an ohmmeter across the switch
terminals.
3. If it does not conduct or any value is indicated when the switch is
pulled, the switch is faulty.
4. If infinity is not indicated when the switch is released, the switch
is faulty.
Resistance
(Across switch
terminals)
Reference
value
When switch is pulled
Infinity
When switch is released
0Ω
(1) Brake Switch
W1050616
(24) Fuel Limit Sensor
Panel Board and Wiring Harness
1. Start the engine and check the easy checker.
2. Disconnect the 2P connector (2) from the fuel limit sensor.
3. If the fuel limit indicator lamp does not light on when 2 terminal is
connected to the chassis, the panel board circuit or wiring
harness is faulty.
(1) Fuel Unit
(2) 2P Connector (Wire Harness Side)
Y : Yellow Lead
Lg : Light Green Lead
W1044369
9-S39
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Sensor Continuity
1. Check the continuity with an ohmmeter across the 2 terminal and
ground.
2. If a certain value is not indicated, the thermistor of the fuel limit
sensor is faulty.
Resistance
Factory
spec.
Across 2 terminal and
chassis
A certain value is indicated.
Its value depends on fuel
quantity.
(1) Fuel Unit
W1044554
Sensor Performance
1. Start the engine.
2. Connect the ammeter COM (−) lead to the sensor terminal and
the (+) lead to the coupler terminal, and measure the thermistor
amperage with an ammeter.
3. If the measurement is less than 80 mA when the thermistor is in
fuel and more than 135 mA when it is in the air, the thermistor is
working properly.
Thermistor
amperage
Factory
spec.
When thermistor is in
fuel
Less than 80 mA
When thermistor is in
the air
More than 135 mA
■ NOTE
• The thermistor must be in the air for more than 7 minutes, in
order to adjust to the atmospheric temperature, before the
in-air amperage is measured.
(1) Fuel Unit
W1044958
(25) Fuel Level Sensor
Functional Check
1. Remove the fuel level sensor from the fuel tank.
2. Measure the resistance with an ohmmeter across the 1 terminal
and its body.
3. If the measurement is not indicated, the fuel level sensor is faulty.
Resistance (Sensor
terminal - Its body)
(1) Fuel Unit
Factory
spec.
Float at uppermost
position
1.0 to 5.0 Ω
Float at lowermost
position
108 to 112 Ω
(a) Float at Uppermost Position
(b) Float at Lowermost Position
W1045226
9-S40
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(26) Coolant Temperature Sensor
Functional Check
1. Disconnect the connector from the coolant temperature sensor.
2. Measure the resistance with an ohmmeter across the terminal of
coolant temperature sensor (1) and the chassis.
3. If the measurement is not indicated, the coolant temperature
sensor is faulty.
Resistance (Sensor
terminal - Chassis)
Reference
value
Approx. 14.9 to 17.3 Ω at 120 °C (248 °F)
Approx. 26.2 to 29.3 Ω at 100 °C (212 °F)
Approx. 47.5 to 56.8 Ω at 80 °C (176 °F)
Approx. 133.9 to 178.9 Ω at 50 °C (122 °F)
(1) Coolant Temperature Sensor
W1045476
[2] DISASSEMBLING AND ASSEMBLING
(1) Starter
Disassembling Motor
1. Disconnect the solenoid switch (3).
2. Remove the two through screws (9) and the two brush holder
lock screws. Take out the rear end frame (13) and the brush
holder (12).
3. Disconnect the armature (10) and the yoke (11). Remove also
the ball (7) from the tip of the armature.
4. Remove the set of packings (8), the four planetary gears and
another packing.
5. Take out the shaft assembly. Take note of the position of the
lever.
■ IMPORTANT
• Before disconnecting the yoke, put tally marks on the yoke
and the front bracket.
• Take note of the positions of the set of packings and the
setup bolt.
• Apply grease to the gears, bearings, shaft's sliding part and
ball.
■ NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO.CO. No. 50 or equivalent) to the parts
indicated in the figure.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Gear
Front Bracket
Solenoid Switch
Overrunning Clutch
Internal Gear
Planetary Gear
Ball
(8)
(9)
(10)
(11)
(12)
(13)
Set of Packings
Through Screw
Armature
Yoke
Brush Holder
Rear End Frame
W1046358
9-S41
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
(2) Alternator
Front Bracket
1. Remove the four screws (3).
2. Separate the front bracket (1) and the rear bracket (2) from each
other.
■ IMPORTANT
• Put a tally line on the front bracket and the rear bracket for
reassembling them later.
(1) Front Bracket
(2) Rear Bracket
(3) Screw
W1047457
Pulley
1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut
using a M24 box wrench.
Tightening torque
Pulley nut
58.3 to 78.9 N·m
5.95 to 8.05 kgf·m
43.0 to 58.2 ft-lbs
W1047823
Rotor
1. Remove the four screws and detach the bearing retainer.
2. Temporarily install the nut on the pulley screw, and detach the
rotor.
W1047952
Brush
1. When the rotor is detached, the two brushes are found to stretch
out of the shaft hole.
W1048533
9-S42
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Reassembling the Brush
1. Fit the brush with its sliding face in the clockwise direction when
viewed from front.
■ IMPORTANT
• Be sure to keep the two brushes deep in the brush holder.
Otherwise the rotor and the rear section can not be fitted
into position.
• Use a 4 mm hex. wrench to push the brushes into place.
• Using a pin-pointed (2 mm) punch, keep the brushes from
popping out.
2. Match the tally line of the front section with that of the rear
section.
3. Tighten the four screws, and draw out the pin-pointed punch out
of the brush holder.
(1) Marking
W1049086
Bearing at Slip Ring Side
1. Lightly secure the rotor (1) with a vise to prevent damage, and
remove the bearing (2) with a puller (3).
(1) Rotor
(2) Bearing
(3) Puller
W1049437
9-S43
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
[3] SERVICING
(1) Starter
Commutator and Mica
1. Check the contact face of the commutator for wear, and grind the
commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a saw
blade and chamfer the segment edges.
Factory spec.
32 mm
1.2598 in.
Allowable limit
31.4 mm
1.2362 in.
Factory spec.
0.50 to 0.80 mm
0.0197 to 0.0315 in.
Allowable limit
0.20 mm
0.0079 in.
Commutator O.D.
Mica undercut
(1) Segment
(2) Depth of Mica
(3) Mica
(a) Good
(b) Bad
W1049581
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with emery
paper.
2. Measure the brush length (A) with a vernier caliper.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
Factory spec.
18.0 mm
0.7086 in.
Allowable limit
11.0 mm
0.4331 in.
Brush length (A)
W1050080
9-S44
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Armature Coil
1. Check the continuity across the commutator and armature coil
core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
an ohmmeter.
4. If it does not conduct, replace the armature.
Resistance
Commutator Armature coil core
Infinity
Commutator segment
0Ω
W1050238
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
4. If the pinion slips or does not rotate in the both directions, replace
the overrunning clutch assembly.
W1050563
Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
Resistance
Brush holder -Holder
support
Infinity
W1050680
9-S45
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
Resistance
(1) Lead
(2) Brush
Lead (1) - Brush (2)
0Ω
Brush (2) - Yoke (3)
Infinity
(3) Yoke
W1050789
(2) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1051135
Stator
1. Measure the resistance across each lead of the stator coil with an
ohmmeter.
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with an
ohmmeter.
4. If infinity is not indicated, replace it.
Resistance
Factory spec.
Less than 1.0 Ω
W1051214
9-S46
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Rotor
1. Measure the resistance across the slip rings with an ohmmeter.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with an
ohmmeter.
4. If infinity is not indicated, replace it.
Resistance
Factory spec.
2.8 to 3.3 Ω
W1051368
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
Factory spec.
22.7 mm
0.894 in.
Allowable limit
22.1 mm
0.870 in.
Resistance
W1051525
Brush Wear
1. Measure the brush length with a vernier caliper.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
Factory spec.
18.5 mm
0.728 in.
Allowable limit
5.0 mm
0.197 in.
Resistance
W1052337
9-S47
KiSC issued 03, 2007 A
ELECTRICAL SYSTEM
M105S, WSM
Rectifier
1. Check the continuity across each diode of rectifier with an
ohmmeter.
2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.
W1052515
9-S48
KiSC issued 03, 2007 A
10
CABIN
KiSC issued 03, 2007 A
MECHANISM
CONTENTS
1. AIR CONDITIONING SYSTEM .................................................................. 10-M1
[1] STRUCTURE ......................................................................................... 10-M1
[2] AIR FLOW............................................................................................. 10-M3
[3] AIR CONTROL VENT .......................................................................... 10-M3
[4] CONTROL PANEL................................................................................ 10-M5
[5] OPERATION .......................................................................................... 10-M6
[6] ELECTRICAL SYSTEM ........................................................................ 10-M9
(1) Electrical Circuit ............................................................................... 10-M9
(2) Air Conditioner Main Relay and Compressor Relay ...................... 10-M10
(3) Blower Switch ................................................................................ 10-M11
KiSC issued 03, 2007 A
CABIN
M105S, WSM
1. AIR CONDITIONING SYSTEM
[1] STRUCTURE
(1) Heater Hose
(2) Air Conditioner Unit
(3) Control Unit
(4) Outer Roof
(5) Inner Air Filter
(6) Fresh Air Filter
(7) High Pressure Pipe and Low
Pressure Pipe
(8) Receiver
10-M1
(9) Condenser
(10) Compressor
KiSC issued 03, 2007 A
CABIN
M105S, WSM
The machine is equipped with a thin large-capacity air
conditioner with outside air intake. The air through the
inside air filter (9) as well as the outside air filter (4) and
the roof (8) reaches the air conditioner unit (1). The air is
cooled and dehumidified by this unit.
The resulting air is heated to a comfortable level. In
this way, the air being blown via the blow port can be kept
at comfortable temperature and humidity.
The three front blow ports (5) can be opened and
closed using the center knob of each port. The four side
blow ports (7) are opened and closed using the mode
lever on the control panel (6). With these ports open or
closed, you can feel your head cool and your feet warm.
Capacity (Cooling)
Factory
spec.
3.95 kW
Capacity (Warming)
Factory
spec.
4.30 kW
Kinds of refrigerant
(Charge amount)
Factory
spec.
R134a
0.95 to 1.05 kg
2.09 to 2.31 lbs
Pressure sensor (Low)
Factory
spec.
0.196 MPa
2.0 kgf/cm2
28.4 psi
Pressure sensor (High)
Factory
spec.
3.14 MPa
32.0 kgf/cm2
455 psi
(1) Air Conditioner Unit
(2) Outer Roof
(3) Inside / Outside Air Selection
Damper
(4) Outside Air Filter
(5)
(6)
(7)
(8)
(9)
Front Blow Port
Control Panel
Side Blow Port
Inner Roof
Inside Air Filter
W1014918
■
•
•
■
NOTE
Refer to “10. CABIN” section in the workshop manual of tractor mechanism (Code No. 97897-18200).
The type of the compressor is scroll type.
Compressor Oil
The compressor oil dissolves in the refrigerant, circulates through the air-conditioning cycle, and functions to
lubricate the compressor. But the conventional compressor oil for R12 doesn't dissolve in R134a, so it doesn’t
circulate through the cycle, and the lifespan of the compressor is considerably shortened.
It is still essential to ensure that the correct refrigerant oil is used. R12 systems were lubricated with mineral oil,
which is totally unsuitable for R134a systems. The letter require PAG oil, which mixes very well with the refrigerant
and provides ideal lubrication throughout the system.
Quantity (Total)
60 to 100 cc
0.063 to 0.106 U.S.qts.
0.053 to 0.088 Imp.qts.
Brand Name
ND-OIL 8 <PAG* oil>
*PAG : Polyalkyleneglycol (Synthetic oil)
10-M2
KiSC issued 03, 2007 A
CABIN
M105S, WSM
[2] AIR FLOW
Air in the CAB and fresh air introduced into CAB flow
as shown below. Adjust the nine air ports to obtain the
desired condition.
■ IMPORTANT
• Do not pour water directly into the fresh air port
while washing the vehicle.
(1)
(2)
(3)
(4)
(5)
Control Panel
Door Air Outlet
Face Air Outlet
Front Air Outlet
Fresh Air Filter
(A) Inner Air Recirculation
(B) Fresh Air Inlet
W1013503
[3] AIR CONTROL VENT
■ Front air outlet
The front air outlets can be independently adjusted as
required. To defrost the windshield, rotate the outlets
toward the windshield.
(1) Front Air Outlet
(A) Windshield
(B) Closed
(C) Chest Area
W1013733
10-M3
KiSC issued 03, 2007 A
CABIN
M105S, WSM
■ Face air outlet
The face air outlets can be adjusted to direct air on to
the operator or the rear of the CAB.
(1) Face Air Outlet
(A)
(B)
(C)
(D)
Open
Shut
Back Area
Face Area
W1013834
■ Door air outlet
The door air outlets can be adjusted to direct air on to
the door window or the foot area.
(1) Door Air Outlet
(A)
(B)
(C)
(D)
Open
Shut
Door Window
Foot Area
W1013941
■ Recirculation / fresh air selection lever
Fresh Air:
Set the lever to the “FRESH” (in figure) position, and
fresh air will flow into the CAB. This is helpful when you
work in dusty conditions or if the glass windows get
foggy.
Recirculation:
Set the lever to the “RECIRC” (in figure) position,
and the in-CAB air will be recirculated. This is useful for
cooling or heating the CAB quickly or keeping it extra
cool or warm.
■ NOTE
• When heating, do not keep the lever at the
“RECIRCULATION” position for a long time. The
windshield easily gets foggy.
• While working in a dusty conditions, keep the
lever at the “FRESH AIR” position. This increases
the pressure in the CAB, which helps prevent
dust from coming into the CAB.
(1) Recirculation / Fresh Air
Selection Lever
(a) FRESH (Fresh Air)
(b) RECIRC (Recirculation)
W1014057
10-M4
KiSC issued 03, 2007 A
CABIN
M105S, WSM
[4] CONTROL PANEL
■ Control panel switch
• Mode Switch (1)
(a): Air is blown from only the face air outlets.
(b): Air is blown from the front, face and door air
outlets.
(c): Air is blown from the front and door air outlets.
• Set this dial at the desired position to obtain the
optimum air temperature. Turn the dial in the
“Warm” direction to obtain warmer air. Turn it in the
“Cool” direction to obtain cooler air.
• Blower Switch (3)
Air volume can be changed in three steps. At the “3”
position, the largest air volume is obtained.
• Air Conditioner Switch (4)
Push this switch to activate the air conditioner. An
indicator light will light up when the switch is set to
“ON”. Push switch again to turn air conditioner off, in
which case the indicator light will be off.
(1)
(2)
(3)
(4)
Mode Switch
Temperature Control Dial
Blower Switch
Air Conditioner Switch with
Indicator Light
(A) Warm
(B) Cool
W1014273
10-M5
KiSC issued 03, 2007 A
CABIN
M105S, WSM
[5] OPERATION
■ Cooling or dehumidifying-heating
1. Set the mode switch to the (a) or (b) position.
2. Set the recirculation / fresh air selection lever to the
“FRESH AIR” position. To fall the temperature in the
CAB
quickly,
set
this
lever
to
the
“RECIRCULATION” position.
3. Press and turn on the air-conditioner switch (4) with
indicator.
4. Turn on the blower (1 / 2 / 3) switch (3).
5. Adjust the temperature control dial (2) to the “Cool”
(end of counterclockwise) position. Otherwise, hot air
will raise the temperature in the CAB.
(1)
(2)
(3)
(4)
Mode Switch
Temperature Control Dial
Blower Switch
Air Conditioner Switch with
Indicator Light
(A) Warm
(B) Cool
W1014533
10-M6
KiSC issued 03, 2007 A
CABIN
M105S, WSM
■ Foot warming and head cooling
1. Set the mode switch (2) to the (b) position.
2. In the cooling or dehumidifying-heating mode, set the
temperature control dial (1) at the center position
area.
3. Open the front air outlet and the door air outlet direct
it to your feet.
4. You can feel your head cool and your feet warm.
(1) Temperature Control Dial
(2) Mode Switch
(A) Center Position Area
W1014813
10-M7
KiSC issued 03, 2007 A
CABIN
M105S, WSM
■ Defrosting or demisting
To defrost or demist the windshield, take the following
steps.
1. Set the mode switch (1) to the (c) position.
2. Open the front air outlet, door air outlet direct it to the
windshield.
3. Set the recirculation / fresh air selection lever to the
“FRESH AIR” position.
4. Set the blower switch (4) and the temperature control
dial to the “3” and max “Warm” (end of clockwise)
position, respectively.
■ NOTE
• If you set the temperature control dial (2) to
“Cool” side position at (c) position, cool air will
not come out from the face air outlets.
(1)
(2)
(3)
(4)
Mode Switch
Temperature Control Dial
Door Air Outlet
Blower Switch
(A) Warm
(B) Open
(C) Shut
W1014984
10-M8
KiSC issued 03, 2007 A
CABIN
M105S, WSM
[6] ELECTRICAL SYSTEM
(1) Electrical Circuit
(1)
(2)
(3)
(4)
Mode Switch
Temperature Control Dial
Blower Switch
Air Conditioner Switch with
Indicator Light
(5) Compressor Relay
(6) Thermo Switch
(7) A/C Pressure Switch
(8) Compressor Magnet Clutch
(9) Blower Motor
(10) Blower Relay
(11)
(12)
(13)
(14)
Blower Resistor
Servo Motor (Mode)
Servo Motor (Temperature)
Temperature Control Resistor
The process of compressor magnet clutch begin engaged is shown below.
Main switch ON → A/C switch (4) ON → Blower switch (3) ON (Low, Medium or High) → Compressor Relay (5)
ON → Thermo switch (6) ON (the thermostat temperature is more than 4 °C (39.2 °F)) → A/C pressure switch (7) ON
→ (if refrigerant pressure is between 0.21 MPa (2.1 kgf/cm2, 30 psi) and 0.26 MPa (2.7 kgf/cm2, 38.4 psi) →
Compressor magnet clutch is engaged
10-M9
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(2) Air Conditioner Main Relay and Compressor Relay
(1) Battery
(2) Slow Blow Fuse
(3) Main Switch
(4) A/C Switch (Air Conditioner)
(5) Compressor Relay
(6) Thermo Switch
(7) A/C Pressure Switch
(8) Magnetic Clutch
(9) Blower Relay
(10) Blower Motor
(11) Blower Resistor
(12) Blower Switch
Remove the outer roof and the relays are visible at the ceiling center of the cabin : compressor relay (5) and blower
relay (9). The blower fan is adjusted for the air flow rate by a signal from the blower switch on the control panel.
Among the air conditioner components, current flows to the blower motor (10) and magnetic clutch (8). If all of
these current were to be passed through the main switch (3) and supplied, the current would be too large for the main
switch (3) so that there will be danger or burning out the main switch contact. If the current were to be passed directly
from the battery (1), forgetting to turn off the blower motor could result in a discharged battery.
To protect against such trouble, compressor relay (5) and blower relay (9) have been provided. The compressor
relays have been made so that when current flows through its coil, the contact close to supply the power from the
battery. By employing compressor relays, the current flowing through the main switch (3) has been decreased as only
a small current is required to actuate the relay. Thus there will be no danger of burning out the switch contact will open
at the same time. This action stops the current flow in the air conditioner circuit so that there will also be no chance
of the battery discharging.
10-M10
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(3) Blower Switch
(1)
(2)
(3)
(4)
Blower Switch
Battery
Main Switch
A/C Switch
(5) Compressor Relay
(6) Thermo Switch
(7) A/C Pressure Switch
(8) Magnetic Clutch
(9) Blower Relay
(10) Blower Motor
10-M11
(11) Blower Resistor
(12) Slow Blow Fuse
(13) Fuse
KiSC issued 03, 2007 A
CABIN
M105S, WSM
The wind of blower can be changed in 3 position (1Low, 2-Medium and 3-High) by changing the blower
switch (1) position.
■ Blower switch is “OFF” position
When the blower switch (1) is in OFF position, even if
the main switch (3) is turned to ON position, the blower
relay (9) does not operate.
■ When Blower switch is in 1 (Low), 2 (Medium) or 3
(High) position.
When the main switch (3) and blower switch (1) is
turned ON, the current flows from battery (2) to blower
relay is turned ON.
As the blower relay (9) is turned ON, the current from
battery (2) flows to the blower switch (1) through the
blower motor (10) and blower resistor (11) as follows.
● 1 (Low) Position
Battery (2) → Slow Blow Fuse (12) → Fuse (13) →
Blower Relay (9) → Blower Motor (10) → Blower
Resistor (11) → Blower Switch (1) → Ground.
● 2 (Medium) Position
Battery (2) → Slow Blow Fuse (12) → Fuse (13) →
Blower Relay (9) → Blower Motor (10) → Blower
Resistor (11) → Blower Switch (1) → Ground.
● 3 (High) Position
Battery (2) → Slow Blow Fuse (12) → Fuse (13) →
Blower Relay (9) → Blower Motor (10) → Blower
Resistor (11) → Blower Switch (1) → Ground.
W1016667
10-M12
KiSC issued 03, 2007 A
SERVICING
CONTENTS
1.
2.
3.
4.
TROUBLESHOOTING ..................................................................................10-S1
SERVICING SPECIFICATIONS ..................................................................10-S7
TIGHTENING TORQUES ............................................................................10-S8
PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE ......................10-S9
[1] HANDLING OF SERVICE TOOLS.....................................................10-S10
(1) Manifold Gauge Set ........................................................................10-S10
(2) Refrigerant Charging Hose .............................................................10-S12
(3) Vacuum Pump Adaptor...................................................................10-S13
(4) Electric Gas Leak Tester.................................................................10-S13
(5) Can Tap Valve ................................................................................10-S14
(6) T-joint ..............................................................................................10-S14
(7) R134a Refrigerant Recover and Recycling Machine ......................10-S14
5. CHECKING AND CHARGING REFRIGERANT CYCLE.........................10-S15
[1] CHECKING WITH MANIFOLD GAUGE ............................................10-S15
[2] DISCHARGING EVACUATING AND CHARGING ............................10-S19
(1) Discharging the Refrigerant ............................................................10-S19
(2) Evacuating the System ...................................................................10-S20
(3) Charging the Refrigerant.................................................................10-S21
(4) Checking Charge Refrigerant Amount ............................................10-S23
6. CHECKING, DISASSEMBLING AND SERVICING..................................10-S24
[1] CHECKING AND ADJUSTING ...........................................................10-S24
(1) Compressor ....................................................................................10-S24
(2) Air Conditioner Unit.........................................................................10-S25
(3) Blower Switch .................................................................................10-S26
(4) Blower Motor ...................................................................................10-S27
(5) Blower Resistor...............................................................................10-S27
(6) A/C Switch ......................................................................................10-S28
(7) Mode Switch ...................................................................................10-S29
(8) Temperature Control Dial................................................................10-S29
(9) Temperature Motor .........................................................................10-S30
(10)Mode Motor.....................................................................................10-S30
(11)A/C Pressure Switch.......................................................................10-S31
(12)Front Wiper Switch .........................................................................10-S32
(13)Wiper Motor Relay ..........................................................................10-S34
(14)Front Wiper Motor...........................................................................10-S34
[2] DISASSEMBLING AND ASSEMBLING..............................................10-S35
(1) Separating Cabin from Tractor........................................................10-S35
(2) Removing Compressor Assembly...................................................10-S42
(3) Removing Air Conditioner Unit........................................................10-S45
(4) Removing Air Conditioner Pipes .....................................................10-S45
(5) Removing Heater Hoses .................................................................10-S47
(6) Cab Windshield...............................................................................10-S49
(7) Wiper Motor ....................................................................................10-S50
[3] SERVICING ..........................................................................................10-S51
KiSC issued 03, 2007 A
CABIN
M105S, WSM
1. TROUBLESHOOTING
COMPRESSOR
Symptom
Noisy (Compressor
ON
Noisy (Compressor
OFF)
Probable Cause
Reference
Page
Solution
Bearing of compressor worn or damaged
Replace
10-S42
Valves in compressor damaged
Replace
10-S42
Belt slipping
Adjust or replace
Compressor mounting screws loosen
Tighten
Piping resonant
Tighten or add clamp
Blower motor defective
Repair or replace
10-S45
Bearings of magnetic clutch, idle pulley or crank
pulley worn or damaged
Replace
10-S43
G-29
10-S42
–
W1013580
AIR CONDITIONING SYSTEM
Does Not Cool (No
Fuse blown
Air Flow)
A/C main relay defective
Does Not Cool
(Compressor Does
Not Rotate)
Does Not Cool
(Others)
Insufficient Cooling
(Insufficient Air
Flow)
Replace
–
Repair or replace
10-S25
Compressor relay detective
Replace
10-S25
Blower motor defective
Replace
10-S45
Blower switch defective
Replace
10-S26
Wiring harness disconnected or improperly
connected
Repair
–
Fuse blown
Replace
–
Magnetic clutch defective
Repair or replace
10-S43
A/C switch defective
Replace
10-S28
Pressure switch defective
Replace
10-S31
Belt slipping
Adjust or replace
Insufficient refrigerant
Check with manifold
gauge
10-S23
Expansion valve defective
Replace
10-S45
Compressor defective
Replace
10-S42
Air filter clogged
Clean or replace
G-27, 28
Evaporator frosted
Clean or replace
thermo switch
10-S51
Blower motor defective
Replace
10-S45
Blower resistor defective
Replace
10-S27
Mode Switch defective
Replace
10-S29
Temperature control dial defective
Replace
10-S29
Temperature motor defective
Replace
10-S30
Mode motor defective
Replace
10-S30
G-29
W1013580
10-S1
KiSC issued 03, 2007 A
CABIN
M105S, WSM
AIR CONDITIONING SYSTEM
Symptom
Insufficient Cooling
(Many Bubbles in
Sight Glass)
Probable Cause
Solution
Reference
Page
Insufficient refrigerant
Check with manifold
gauge
Refrigerant leaking from some place in
refrigerating cycle
Repair and charge
refrigerant
Air mixed in
Check with manifold
gauge
10-S23
Insufficient Cooling
(No Bubbles in Sight
Glass)
Too much refrigerant
Check with manifold
gauge
10-S23
Insufficient Cooling
(Compressor Does
Not Rotate Properly)
Belt slipping
Adjust or replace
G-29
Magnetic clutch defective
Repair or replace
10-S24, 44
Compressor defective
Replace
10-S42
Insufficient Cooling
(Others)
Thermostat defective
Replace
10-S45
Water valve defective
Replace
10-S45
Condenser fin clogged with dust
Clean
Expansion valve defective
Replace
10-S45
Water valve defective
Replace
10-S45
Temperature control dial defective
Replace
10-S29
Temperature motor defective
Replace
10-S30
Mode motor defective
Replace
10-S30
Insufficient coolant
Replenish
Insufficient Heating
10-S23
–
G-29
G-9
W1010722
10-S2
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Air Conditioning System (Continued)
10-S3
KiSC issued 03, 2007 A
CABIN
M105S, WSM
10-S4
KiSC issued 03, 2007 A
CABIN
M105S, WSM
10-S5
KiSC issued 03, 2007 A
CABIN
M105S, WSM
WINDSHIELD WIPER
Symptom
Windshield Wiper
Does Not Operate
Windshield Wiper
Operating Speed Is
Too Low
Windshield Wiper
Does Not Stop
Correctly
Probable Cause
Solution
Reference
Page
Wiring defective
Check and repair
–
Fuse blown (Short-circuit, burnt component
inside motor or other part for operation)
Correct cause and
replace
G-41
Wiper motor defective (Broken armature, worn
motor brush or seized motor shaft)
Replace
10-S50
Wiper switch defective
Replace
10-S33
Foreign material interrupts movement of link
mechanism
Repair
Wiper arm seized or rusted
Lubricate or replace
10-S50
Wiper motor relay defective
Replace
10-S34
Wiper motor defective (Short-circuit of motor
armature, worn motor brush or seized motor
shaft)
Replace
10-S50
Low battery voltage
Recharge or replace
9-S9
Humming occurs on motor in arm operating
cycle due to seized arm shaft
Lubricate or replace
–
Wiper switch contact improper
Replace
10-S32
Wiper motor relay defective
Replace
10-S34
Wiper motor defective (Contaminated autoreturn contacts or improper contact due to
foreign matter)
Replace
10-S50
–
W1010876
WASHER MOTOR
Washer Motor Does
Not Operate
Washer Motor
Operates but Washer
Fluid Is Not Ejected
Fuse blown
Correct cause and
replace
G-41
Washer switch defective
Replace
10-S32
Washer motor defective
Replace
–
Wiring defective
Repair
–
No washer fluid
Replenish
–
Clogged washer nozzle
Clean or replace
–
W1010953
10-S6
KiSC issued 03, 2007 A
CABIN
M105S, WSM
2. SERVICING SPECIFICATIONS
Item
Factory Specification
Allowable Limit
0.25 to 0.50 mm
0.01 to 0.02 in.
–
3.0 to 4.0 Ω
–
A/C Compressor Magnet Clutch
Airgap
Magnet Clutch Stator Coil
Resistance
Refrigerating Cycle
(Refrigerating Cycle is Normal Operating)
Pressure
(LO Pressure Side)
0.15 to 0.20 MPa
1.5 to 2.0 kgf/cm2
21 to 28 psi
–
Pressure
(HI Pressure Side)
1.27 to 1.66 MPa
13 to 17 kgf/cm2
185 to 242 psi
–
Setting Pressure
(LO Pressure Side)
Less than
approx. 0.196 MPa
2.0 kgf/cm2
28.4 psi
–
Setting Pressure
(HI Pressure Side)
More than
approx. 3.14 MPa
32 kgf/cm2
455 psi
–
10 to 12 mm
(de 0.39 to 0.47 in.)
deflection at 98 N
(10 kgf, 22 lbs) of force
–
33 to 43 times/min.
–
Pressure Switch (Dual Type)
(When pressure switch is turned OFF)
Air Conditioner Drive Belt
Tension
Front Wiper
Rotating Speed
Hydraulic Control Rod
Position and Draft Rod
Length
Approx. 264 mm
10.39 in.
–
Main Shift Rod 1
Length
369 mm
14.53 in.
–
Main Shift Rod 2
Length
Approx. 120 mm
4.72 in.
–
Range Gear Shift Rod
Length
369 mm
14.53 in.
–
W1013874
10-S7
KiSC issued 03, 2007 A
CABIN
M105S, WSM
3. TIGHTENING TORQUES
Tightening torques of screws, bolts and nuts on the table below are especially specified.
(For general use screws, bolts and nuts : See page G-10.)
Item
N·m
kgf·m
ft-lbs
Oil cooler pipe nut
49.0 to 68.6
5.7 to 7.0
36.1 to 50.6
Oil cooler hose retaining nut
45.1 to 53.0
4.6 to 5.4
33.3 to 39.0
7.8 to 11.8
0.8 to 1.2
5.8 to 8.7
High pressure pipe 1
between compressor and condenser (High pressure
pipe 1) retaining nut
19.6 to 24.5
2.0 to 2.5
14.5 to 18.1
High pressure pipe 2
(between receiver and A/C unit) retaining nut
11.8 to 14.7
1.2 to 1.5
8.7 to 10.8
Low pressure pipe (between A/C unit and compressor)
mounting screw
7.8 to 11.8
0.8 to 1.2
5.8 to 8.7
Low pressure pipe (between A/C unit and compressor)
retaining nut
29.4 to 34.3
3.0 to 3.5
21.7 to 25.3
123.6 to 147.1
12.6 to 15.0
91.1 to 108.5
Compressor mounting screw
24.5 to 29.4
2.5 to 3.0
18.1 to 21.7
Clutch mounting screw
10.8 to 16.2
1.10 to 1.65
8.0 to 11.9
A/C unit mounting screws (M6)
3.9 to 6.9
0.4 to 0.7
2.9 to 5.1
A/C unit mounting screws (M8)
9.8 to 15.7
1.0 to 1.6
7.2 to 11.6
Rear wiper motor mounting screw
7.8 to 9.3
0.8 to 0.95
5.79 to 6.87
Wiper arm mounting nut (Front)
6.37 to 9.32
0.65 to 0.95
4.7 to 6.9
Wiper arm mounting nut (Rear)
7.8 to 9.3
0.8 to 0.95
5.79 to 6.87
High pressure pipe 1
(between compressor and condenser) mounting screw
Cabin mounting screws and nuts
W1012736
10-S8
KiSC issued 03, 2007 A
CABIN
M105S, WSM
4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE
When checking or repairing the air conditioning system, the following precautions and rules must be observed.
And it is of first importance that no other personnel than a well-trained serviceman should be allow to handle the
refrigerant.
•
•
•
•
•
•
•
■
•
•
•
•
•
•
•
•
•
•
•
•
CAUTION
Since direct contact of the liquid refrigerant with your skin will cause frostbite, always be careful when
handling the refrigerant. Always wear goggles to protect your eyes when working around the system.
The refrigerant service container has a safe strength. However, if handled incorrectly, it will explode.
Therefore, always follow the instructions on the label. In particular, never heat the refrigerant container
above 40 °C (104 °F) or drop it from a high height.
Do not steam clean on the system, especially condenser since excessively high pressure will build up in
the system, resulting in explosion of the system.
If you improperly connect the hose between the service valve of compressor and gauge manifold, or
incorrectly handle the valves, the refrigerant service container or charging hose will explode. When
connecting the hose or handling the valve, be sure to check the high pressure side or low pressure side.
In case the refrigerant is charged while the compressor is operated, do not open the high pressure valve
of the gauge manifold.
Beware of the toxicity of the gas. The gas is harmless and nontoxic in its original state, however it
produces a toxic substance when it comes in contact with high temperature parts and decomposes.
Do not heat the service can unless necessary. When it has to be heated, use warm water of 40 °C (104 °F)
or lower. Do not heat using boiling water.
IMPORTANT
If the refrigerant, O-rings, etc. for R12 are used in the R134a air conditioner system, problems such as
refrigerant leakage or cloudiness in the sight glass may occur. Therefore, in order to prevent charging of
refrigerant or erroneous connections, the shapes of the piping joint as well as the shapes of the service
valve and the service tools have been changed.
Always keep the working place clean and dry and free from dirt and dust. Wipe off water from the line
fittings with a clean cloth before disconnecting.
Use only for R134a refrigerant service tool.
Use for R134a refrigerant recovery and recycling machine when discharging the refrigerant.
Before attaching the charging hose to the can tap valve of the refrigerant container, check each packing
for clogging.
When disconnecting the charging hose from the charging valve of compressor and receiver, remove it as
quick as possible so that gas leakage can be minimized.
Be sure to charge the specified amount of refrigerant, but not excessively. Over-charging of the refrigerant
in particular may cause insufficient cooling, etc..
Since the charging hose can be connected to can tap valve by hand, do not use a pliers for tightening it.
Keep refrigerant containers in a cool and dark place avoiding such place which are subject to strong
sunlight or high temperature.
R134a compressor oil absorbs moisture easily, so that be sure to seal after disconnecting the each parts.
Do not use old-type refrigerant R12a or compressor oil for old-type refrigerant.
When replacing the condenser, evaporator and receiver, etc., replenish the compressor oil to compressor
according to the table below.
10-S9
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(Reference)
Replacing Parts
Condenser
Evaporator
Receiver
Replenish Quantity
20 cc
0.021 U.S.qts
0.018 Imp.qts
20 cc
0.021 U.S.qts
0.018 Imp.qts
10 cc
0.011 U.S.qts
0.009 Imp.qts
Brand Name
ND-ACEITE 8<PÁG* oil>
*PAG : Polyalkyleneglycol (Synthetic oil)
W1012709
[1] HANDLING OF SERVICE TOOLS
(1) Manifold Gauge Set
The hand valves on the manifold gauge set are used to open and
close the valve. The hand valve inscribed LO is for the low pressure
side valve (3) and HI is for the high pressure side valve (4). By
opening or closing the high and low pressure hand valves, the
following circuits are established.
(1) LO Pressure Gauge
(2) HI Pressure Gauge
(3) LO Pressure Side Valve
(4) HI Pressure Side Valve
(5) Schrader Valve
W1013107
■ When LO Pressure Side Valve and HI Pressure Side Valve
are Closed
Two circuits are established.
Port (C) → LO pressure gauge (1)
Port (A) → HI pressure gauge (2)
■ NOTE
• Schrader valve (D) must be opened.
W1013376
■ When LO Valve is Opened and HI Valve is Closed
Two circuits are established.
Port (C) → LO pressure gauge (1)
→ Port (B)
→ Port (D)
Port (A) → HI pressure gauge (2)
■ NOTE
• Schrader valve (D) must be opened.
W1013454
10-S10
KiSC issued 03, 2007 A
CABIN
M105S, WSM
■ When LO Valve is Closed and HI Valve is Opened
Two circuits are established.
Port (C) → HI pressure gauge (2)
→ Port (B)
→ Port (D) (Schrader valve must be opened)
Port (A) → LO pressure gauge (1)
■ NOTE
• Schrader valve (D) must be opened.
W1013304
■ When LO and HI Valve is Opened
Two circuits are established.
Port (A) → HI pressure gauge (2)
→ LO pressure gauge (1)
→ Port (B)
→ Port (C)
→ Port (D) (Schrader valve must be opened)
■ NOTE
• Schrader valve (D) must be opened.
W1013864
10-S11
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(2) Refrigerant Charging Hose
The charging hoses are classified into three colors. Each
charging hose must be handled as follows :
• The air conditioner manufacture recommends that the blue hose
(3) is used for the LO pressure side (suction side), the green
hose (5) for refrigeration side (center connecting port) and the red
hose (4) for HI pressure side (discharged side).
(When connecting)
• Push the quick disconnect adaptor (6) into the charging valve,
and push on part A until a click is heard.
■ NOTE
• When connecting, push carefully so the pipe doesn't bend.
• When connecting the quick disconnect connector, should
the sleeve (7) move before the quick link connector can be
connected to the charging valve, move the quick sleeve to
its original position and try again.
• When some refrigerant remains in the charging hose at the
time of connections, it may be difficult to connect the quick
link connector. In this case, perform the operation after
removing any residual pressure in the hose. (Remove the
residual pressure by pushing the pusher (8).)
(When reassembling)
• While holding on to part A of the quick disconnect adaptor, slide
part B up.
■ NOTE
• After removing the adaptor, ensure to cap the quick
disconnect adaptor service valve.
(1)
(2)
(3)
(4)
(5)
(6)
LO Pressure Side Valve
HI Pressure Side Valve
Blue Hose
Red Hose
Green Hose
Quick Disconnect Adaptor
(7) Sleeve
(8) Pusher
(9) Sleeve
a : CLICK
W1014039
10-S12
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(3) Vacuum Pump Adaptor
Objective of the Vacuum Pump Adaptor
1. After vacuum has been created in the air conditioning cycle,
when the vacuum pump is stopped, since there is vacuum in
hoses within the gauge manifold, the vacuum pump oil flows back
into the charging hose. If the refrigerant is refilled with the system
still in this state, the vacuum pump oil left in the charging hose
enters the air conditioner cycle together with the refrigerant.
Vacuum pump adaptor with a solenoid valve is used to prevent
this back-flow of oil from the vacuum pump. The role of the
solenoid valve is that when the current passes through the
solenoid valve, the valve closes to keep out the outside air and
allow the vacuum to build up, but when the current stops, the
valve opens to allow in air and end the vacuum.
2. Attaching this adaptor to the R12 vacuum pump currently being
used allows the pump to be used with both R134a and R12.
(1)
(2)
(3)
(4)
Vacuum Pump Adaptor
Vacuum Pump
Magnetic Valve
Blind Cap
(5) Air
(6) For R134a
(7) For R12
W1014539
(4) Electric Gas Leak Tester
The current R12 gas leak tester has poor sensitivity for R134a
and cannot be used. Therefore, a new electric gas leak tester with
greater sensitivity has been designed and can be used with both
R134a and R12.
(Reference)
Leak tester with halide torch
• Since the reaction with chlorine within the refrigerant is used to
detect gas leaks, R134a, which contains no chlorine, cannot be
detected.
(1) Electric Gas Leak Tester
W1014905
10-S13
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(5) Can Tap Valve
The can tap valve that is used to charge the refrigerant into the
air conditioning system, should be used as follows :
1. Before putting the can tap valve on the refrigerant container, turn
the handle (1) counterclockwise till the valve needle is fully
retracted.
2. Turn the plate nut (disc) (4) counterclockwise till it reaches its
highest position, then screw down the can tap valve into the
sealed tap.
3. Turn the place nut clockwise fully, and fix the center charging
hose to the valve.
4. Tighten the place nut firmly by hand.
5. Turn the handle (1) clockwise, thus making a hole in the sealed
tap.
6. To charge the refrigerant into the system, turn the handle (1)
counterclockwise. To stop charging, turn it clockwise.
(1) Butterfly Handle
(2) Connection
(3) Needle
(4) Disc
W1015014
(6) T-joint
T-joint (2) is used to increase efficiency of gas charging using two
refrigerant containers (4) at a time.
1. Install two refrigerant container service valves to T-joint (2) sides
and connect the charging hose (1) to it.
(1) Charging Hose (Green)
(2) T-joint
(3) Can Tap Valve
(4) Refrigerant Container
W1015169
(7) R134a Refrigerant Recover and Recycling Machine
When there is necessity of discharging the refrigerant on
repairing the tractor, it should use recovery and recycling machine.
(Don't release the refrigerant into the atmosphere.)
■ IMPORTANT
• Use only R134a refrigerant recovery and recycling machine,
eliminate mixing R134a equipment, refrigerant and
refrigerant oils with R12 systems to prevent compressor
damage.
W1015488
10-S14
KiSC issued 03, 2007 A
CABIN
M105S, WSM
5. CHECKING AND CHARGING REFRIGERANT CYCLE
[1] CHECKING WITH MANIFOLD GAUGE
■ IMPORTANT
• The gauge indications described in the following testing are those taken under the same condition, so it
should be noted that the gauge readings will differs somewhat with the ambient conditions.
Condition
• Ambient temperature : 30 to 35 °C (86 to 95 °F)
• Engine speed : Approx. 1500 min−1 (rpm)
• Temperature control lever : Maximum cooling position
• Blower switch : HI position
Manifold Gauge Connecting and Test Preparation
1. Close the manifold gauge HI and LO pressure side valve (3), (4)
tightly.
2. Connect the charging hose (7) (red) to the HI pressure side
charging valve (1) and connect the charging hose (6) (blue) to the
LO pressure side charging valve (2).
■ NOTE
• Be sure to drive out the air in the charging hoses at the
manifold gauge connection end by utilizing the refrigerant
pressure in the refrigerating cycle.
3. Start the engine and set at approx. 1500 min-1 (rpm).
4. Turn on the A/C switch and set the temperature control dial to
maximum cooling position.
5. Set the blower switch to HI position.
(1)
(2)
(3)
(4)
HI Pressure Side Charging Valve
LO Pressure Side Charging Valve
HI Pressure Side Valve
LO Pressure Side Valve
(5) Manifold Gauge
(6) Charging Hose (Blue)
(7) Charging Hose (Red)
W1015662
Normal Operating
If the refrigerating cycle is operating normally, the reading at the
LO pressure side (1) should be generally by around 0.15 to 0.2 MPa
(1.5 to 2.0 kgf/cm2, 21 to 28 psi) and that at the HI pressure side (2)
around 1.27 to 1.66 MPa (13 to 17 kgf/cm2, 185 to 242 psi).
Gas pressure
(1) LO Pressure Side
Factory
spec.
Low
pressure
side
0.15 to 0.20 MPa
1.5 to 2.0 kgf/cm2
21 to 28 psi
High
pressure
side
1.27 to 1.66 MPa
13 to 17 kgf/cm2
185 to 242 psi
(2) HI Pressure Side
W1015870
10-S15
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Insufficient Refrigerant
1. Symptoms seen in refrigerating cycle
- Both LO and HI pressure side (1), (2) pressures too low.
LO pressure side (1) : 0.05 to 0.1 MPa
(0.5 to 1.0 kgf/cm2, 7.1 to 14.2 psi)
HI pressure side (2) : 0.69 to 0.98 MPa
(7 to 10 kgf/cm2, 99.6 to 142.2 psi)
- Bubbles seen in sight glass.
- Air discharged from air conditioner sightly cold.
2. Probable cause
- Gas leaking from some place in refrigerant cycle.
3. Solution
- Check for leakage with electric gas leak tester (see page 10S13) and repair.
- Recharge refrigerant to the proper level. (See page 10-S23.)
(1) LO Pressure Side
(2) HI Pressure Side
W1016070
Excessive Refrigerant or Insufficient Condenser Cooling
1. Symptoms seen in refrigerating cycle
- Both LO and HI pressure side (1), (2) pressures too high.
LO pressure side (1) : 0.2 to 0.35 MPa
(2.0 to 3.5 kgf/cm2, 28 to 49.8 psi)
HI pressure side (2) : 1.96 to 2.45 MPa
(20 to 25 kgf/cm2, 284.5 to 355.6 psi)
2. Probable cause
- Overcharging refrigerant into cycle.
- Condenser cooling faulty.
3. Solution
- Clean condenser. (See page G-29.)
- Adjust air conditioner belt to proper tension. (See page G-29.)
- If the above two items are in normal condition, check refrigerant
quantity. (See page 10-S23.)
■ NOTE
• If excessive refrigerant is to be discharged, loosen manifold
gauge LO pressure side valve and vent out slowly.
(1) LO Pressure Side
(2) HI Pressure Side
W1016402
10-S16
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Air Entered in the Cycle
1. Symptoms seen in refrigerating cycle
- Both LO and HI pressure side (1), (2) pressures too high.
LO pressure side (1) : 0.2 to 0.35 MPa
(2.0 to 3.5 kgf/cm2, 28 to 49.8 psi)
HI pressure side (2) : 1.96 to 2.45 MPa
(20 to 25 kgf/cm2, 284.5 to 355.6 psi)
- LO pressure side (1) piping not cold when touched.
2. Probable cause
- Air entered in refrigerating cycle.
3. Solution
- Replace receiver.
- Check compressor oil contamination and quantity.
- Evacuate and recharge new refrigerant. (See page 10-S20,
21.)
■ NOTE
• The above cycle can be seen when the cycle is charged
without evacuation.
(1) LO Pressure Side
(2) HI Pressure Side
W1016771
Moisture Entered in the Cycle
1. Symptoms seen in refrigerating cycle
- The air conditioner operates normally at the beginning, but over
time, LO pressure side (1) pressure is vacuum and HI
pressure side (2) is low pressure.
LO pressure side (1) : Vacuum
HI pressure side (2) : 0.69 to 0.98 MPa
(7 to 10 kgf/cm2, 99.6 to 142.2 psi)
2. Probable cause
- The moisture in the refrigerating cycle freezes in the expansion
valve orifice and causes temporary blocking. After a time, the
ice melts and condition returns to normal.
3. Solution
- Replace receiver.
- Remove moisture in cycle by means of repeated evacuation.
(See page 10-S20.)
- Recharge new refrigerant to the proper level. (See page 10S21.)
(1) LO Pressure Side
(2) HI Pressure Side
W1017013
10-S17
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Refrigerant Fails to Circulate
1. Symptoms seen in refrigerating cycle
- LO pressure side (1) pressure is vacuum and, HI pressure side
(2) is low pressure.
LO pressure side (1) : Vacuum
HI pressure side (2) : 0.49 to 0.59 MPa
(5 to 6 kgf/cm2, 71.2 to 85.3 psi)
2. Probable cause
- Refrigerant flow obstructed by moisture or dirt in the
refrigerating cycle freezing or sticking on the expansion valve
orifice.
3. Solution
Allow to stand for same time and then resume operation to
decide whether the plugging is due to moisture or dirt.
- If caused by moisture, correct by referring to instructions in
previous.
- If caused by dirt, remove the expansion valve and blow out the
dirt with compressed air.
- If unable to remove the dirt, replace the expansion valve.
Replace the receiver. Evacuate and charge in proper amount
of new refrigerant. (See page 10-S20, 21.)
- If caused by gas leakage in heat sensitizing tube, replace the
expansion valve.
(1) LO Pressure Side
(2) HI Pressure Side
W1017346
Expansion Valve Opens Too Far or Improper Installation of
Heat Sensitizing Tube
1. Symptoms seen in refrigerating cycle
- Both LO and HI pressure side (1), (2) pressures too high.
LO pressure side (1) : 0.29 to 0.39 MPa
(3.0 to 4.0 kgf/cm2, 42.71 to 56.9 psi)
HI pressure side (2) : 1.96 to 2.45 MPa
(20 to 25 kgf/cm2, 284.5 to 355.6 psi)
- Frost or heavy dew on low pressure side piping.
2. Probable cause
- Expansion valve trouble or heat sensitizing tube improperly
installed.
- Flow adjustment not properly done.
3. Solution
- Check installed condition of heat sensitizing tube.
- If installation of heat sensitizing tube is correct, replace the
expansion valve.
(1) LO Pressure Side
(2) HI Pressure Side
W1017612
10-S18
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Faulty Compression of Compressor
1. Symptoms seen in refrigerating cycle
- LO pressure side (1) : 0.39 to 0.59 MPa
(4 to 6 kgf/cm2, 56.9 to 85.3 psi)
- HI pressure side (2) : 0.69 to 0.98 MPa
(7 to 10 kgf/cm2, 99.6 to 142.2 psi)
2. Probable cause
- Leak in compressor.
3. Solution
- Replace compressor. (See page 10-S42.)
■ NOTE
• Manifold gauge indications (left side figure) at faulty
compressing by compressor.
(1) LO Pressure Side
(2) HI Pressure Side
W1017960
[2] DISCHARGING EVACUATING AND CHARGING
■ IMPORTANT
• When discharging, evacuating or charging the refrigerating system, be sure to observe the “PRECAUTION
AT REPAIRING REFRIGERANT CYCLE”. (See page 10-S9.)
(1) Discharging the Refrigerant
Prepare for the R134a refrigerant recovery and recycling
machine.
1. Connect low pressure side hose (blue) (6) from the recovery and
recycling machine to LO pressure side charging valve (2).
Connect high pressure side hose (red) (7) to HI pressure side
charging valve (1).
2. Follow the manufacturers instructions and discharge the system.
■ IMPORTANT
• Use only R134a refrigerant recovery and recycling machine.
Eliminate mixing R134a equipment, refrigerant, and
refrigerant oils with R12 systems to prevent compressor
damage.
CAUTION
• Protect fingers with cloth against frostbite by refrigerant
when disconnecting the hose to the charging valve.
(1)
(2)
(3)
(4)
HI Pressure Side Charging Valve
LO Pressure Side Charging Valve
Compressor
LO Pressure Side Valve
(5) HI Pressure Side Valve
(6) Blue Hose
(7) Red Hose
W1018328
10-S19
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(2) Evacuating the System
Evacuating the System
1. Discharge refrigerant from the system by R134a refrigerant
recovery and recycling machine. (Refer to “Discharging the
Refrigerant”. (See page 10-S19.))
2. Connect the charging hose (4) (red) to the HI pressure side
charging valve and connect the charging hose (5) (blue) to the
LO pressure side charging valve.
3. Connect the center charging hose (6) (green) to a vacuum pump
inlet.
4. Open both valves (3), (9) of manifold gauge fully. Then run the
vacuum pump (7) to evacuate the refrigerant cycle. (For approx.
15 minutes.)
5. When LO pressure gauge (1) reading is more than 750 mmHg
(299 in.Hg), stop the vacuum pump (7) and close both valves (3),
(9) of manifold gauge fully.
6. Wait for over 5 minutes with the HI and LO pressure side valves
(3), (9) of gauge manifold closed, and then check that gauge
indicator does not return to 0.
7. If the gauge indicator is going to approach to 0, check whether
there is a leaking point and repair if it is, and then evacuate it
again.
(1)
(2)
(3)
(4)
(5)
LO Pressure Gauge
HI Pressure Gauge
HI Pressure Side Valve (Open)
Red Hose
Blue Hose
(6)
(7)
(8)
(9)
Green Hose
Vacuum Pump (Running)
Vacuum Pump Adaptor
LO Pressure Side Valve (Close)
W1018495
10-S20
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(3) Charging the Refrigerant
Charging an Empty System (Liquid)
This procedure is for charging an empty system through the HI
pressure side with the refrigerant in the liquid state.
CAUTION
• Never run the engine when charging the system through the
HI pressure side.
• Do not open the LO pressure valve when refrigerant R134a
is being charged in the liquid state (refrigerant container is
placed upside-down).
■ IMPORTANT
• After charging the refrigerant in the liquid state with approx.
500 g (1.1 lbs) through the HI pressure side, be sure to
recharge the refrigerant in the vapor state to specified
amount through the LO pressure side.
1. Close the HI and LO pressure side valves (1), (2) of manifold
gauge after the system is evacuated completely.
2. Connect the center charging hose (5) to the can tap valve (7)
fitting, and then loosen the center charging hose at the center
fitting of manifold gauge until hiss can be heard.
Allow the air to escape for few seconds and tighten the nut.
3. Open the HI pressure side valve (2) fully, and keep the container
upside-down to charge the refrigerant in the liquid state from the
HI pressure side.
4. Charge the refrigerant in the liquid state with approx. 500 g (1.1
lbs) from the HI pressure side.
■ NOTE
• If LO pressure gauge does not show a reading, the system
is clogged and must be repaired.
5. Close the HI pressure side valve (2) of manifold gauge and can
tap valve of refrigerant container.
(1)
(2)
(3)
(4)
(5)
(6)
LO Pressure Side Valve (Close)
HI Pressure Side Valve (Open)
Red Hose
Blue Hose
Green Hose
Refrigerant Container (R134a)
(7) Can Tap Valve (Open)
[A] Refrigerant Container “Upside”
[B] Refrigerant Container “Down
Side”
W1018931
10-S21
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Charging an Empty or Partially Charged System (Vapor)
This procedure is to charge the system through the LO pressure
side with refrigerant in the vapor state. When the refrigerant
container is placed right side up, refrigerant will enter the system as
a vapor.
CAUTION
• Never open the HI pressure side valve of manifold gauge
while the engine is running.
■ NOTE
• Do not turn the refrigerant container upside-down when
charging the system by running the engine.
• Put refrigerant container into a pan of warm water (maximum
temperature 40 °C (104 °F)) to keep the vapor pressure in the
container slightly higher than vapor pressure in the system.
1. Check that the HI pressure side valve (4) is closed.
2. Start the engine and set an approx. 1500 min-1 (rpm).
3. Turn on the A/C switch.
Set the temperature control lever to maximum cooling position
and the blower switch to HI position.
4. Open the LO pressure side valve (5) of manifold gauge and the
can tap valve (1) on refrigerant container and charge the
refrigerant until air bubbles in the sight glass of the receiver
vanish.
5. After charging the specified amount of refrigerant into the system,
close the LO pressure side valve (5) of manifold gauge and can
tap valve (1), then stop the engine.
6. Check for gas leak with an electric gas leak tester (see page 10S13).
(Reference)
• Specified amount of refrigerant (total) :
• Manifold gauge indication at fully charged system (at ambient
temperature: 30 °C (86 °F))
HI pressure side : 1.27 to 1.66 MPa
13 to 17 kgf/cm2
185 to 242 psi
LO pressure side : 0.15 to 0.20 MPa
1.5 to 2.0 kgf/cm2
21 to 28 psi
(1) Can Tap Valve
(2) LO Pressure Gauge
(3) HI Pressure Gauge
(4) HI Pressure Side Valve (Close)
(5) LO Pressure Side Valve (Open)
W1019245
10-S22
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(4) Checking Charge Refrigerant Amount
After charging the refrigerant, check for amount of charging
refrigerant as follows.
■ NOTE
• The pressure on the following checking is the gauge
indications at ambient temperature 30 °C (86 °F), so it should
be noted that the pressure will differ some what with the
ambient temperature.
1. Disconnect the 1P connector (3) of magnetic clutch.
2. Start the engine and set a approx. 1500 min-1 (rpm).
3. Connect the 1P connector (3) of magnetic clutch to battery
directly, and then set the blower switch to HI position.
4. Leave the system for approx. 5 minutes until the refrigerant cycle
becomes stable, keeping pressure on the HI pressure side from
1.27 to 1.66 MPa (13 to 17 kgf/cm2, 185 to 242 psi).
5. When the refrigerant cycle is stabilizer, turn off the blower switch
and let the compressor alone to run. Then pressure on the LO
pressure side gradually drops. At this time, if pressure on the HI
pressure side is maintained from 1.27 to 1.66 MPa (13 to 17 kgf/
cm2, 185 to 242 psi), air bubbles which pass through the sight
glass (7) becomes as stated below depending on refrigerant
charged amount.
■ Insufficient refrigerant charge
Air bubbles pass continuously the sight glass when pressure on
the LO pressure side is over 99.0 kPa (1.01 kgf/cm2, 14.4 psi). In
this case, charge the refrigerant from the LO pressure side.
■ Properly refrigerant charge
Air bubbles pass through the sight glass continuously when
pressure on the LO pressure side is within 59 to 98 kPa (0.6 to 1.0
kgf/cm2, 9 to 14 psi).
If the charge refrigerant amount is proper, no air bubble is
observed on the sight glass at pressure on the LO pressure side
over 99.0 kPa (1.01 kgf/cm2, 14.4 psi) when the blower switch is
turned on. When the blower switch is turned off, bubbles pass
through the sight glass in case pressure on the LO pressure side is
within 59 to 98 kPa (0.6 to 1.0 kgf/cm2, 9 to 14 psi).
■ Excessive refrigerant charge
Air bubbles pass through the sight glass time to time or no air
bubble is observed when pressure on the LO pressure side is under
59 kPa (0.6 kgf/cm2, 9 psi).
In this case, discharge excessive refrigerant gradually from the
LO pressure side.
(1)
(2)
(3)
(4)
LO Pressure Gauge
HI Pressure Gauge
1P Connector
To Battery
(5) HI Pressure Side Valve (Close)
(6) LO Pressure Side Valve (Close)
(7) Sight Glass
W1019604
10-S23
KiSC issued 03, 2007 A
CABIN
M105S, WSM
6. CHECKING, DISASSEMBLING AND SERVICING
[1] CHECKING AND ADJUSTING
(1) Compressor
Operation of Magnetic Clutch
1. Start the engine.
2. Check whether abrasion of abnormal noise is heard when only
the magnetic clutch pulley is running while the A/C switch is
turned off.
3. Check that the magnetic clutch (1) does not slip when the A/C
switch and blower switch are turned on (when the air conditioner
is in operation).
4. If anything abnormal is found, repair or replace.
(1) Magnetic Clutch
W1014211
Stator Coil
1. Measure the resistance of the stator coil with an ohmmeter
across the 1P connector (1) of magnetic clutch and compressor
body.
2. If the measurement is not within the factory specifications,
replace the stator coil.
Stator coil resistance
Factory spec.
3.0 to 3.4 Ω
(1) 1P Connector
W1014331
Air Gap
1. Check the air gap with feeler gauge.
2. If the measurement is not within the factory specifications, adjust
it. (See page 10-S51.)
Air gap
Factory spec.
0.20 to 0.45 mm
0.0079 to 0.0177 in.
W1018230
10-S24
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(2) Air Conditioner Unit
Connector Voltage (A/C Main Relay, Compressor Relay)
1. When turning on the main switch, voltage across the 1 terminal
and chassis should be approx. battery voltage.
2. The voltage across the 4 terminal and chassis should be approx.
battery voltage.
(1) Connector
W1036697
Relay Test (A/C Main Relay, Compressor Relay)
■ NOTE
• A/C main relay and compressor relay are used same ones so
that these are interchangeable.
1. Remove the A/C main relay (4) and compressor relay (5).
2. Connect the battery (2) and bulb (3) with the relay (1) as shown
in the figure left.
3. If the bulb on when disconnecting the jumper lead (A) from the
relay terminal and if the bulb off when connecting the jumper lead
(A) to the relay 2 terminal, the relay is proper.
(1)
(2)
(3)
(4)
(5)
Relay
Battery
Bulb
A/C Main Relay
Compressor Relay
A : Jumper Lead
W1037726
10-S25
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(3) Blower Switch
Connector Voltage
1. Disconnect the blower switch 4P connector.
2. Turn the main switch “ON” position.
3. Measure the voltage with a voltmeter across the connector 3
terminal and 4 terminal.
4. If the voltage differs from the battery voltage, the wiring harness,
A/C relay, fuse or main switch is faulty.
Voltage
3 terminal - 4 terminal
(1) 4P Connector
Approx. battery voltage
A : 4P Connector
(Wire Harness Side)
W1019240
Blower Switch Test
1. Check the continuity through the switch with an ohmmeter.
2. If the continuity specified below are not indicated, the switch is
faulty.
Terminal
Position
Blower switch
(1) Blower Switch
4
3
OFF
●
1: Low
●
●
2: Medium
●
●
3: High
●
●
2
1
●
●
A : Switch Side
W1019735
10-S26
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(4) Blower Motor
Blower Motor Test
1. Remove the outer roof.
2. Turn the blower motor (1) by hand and check whether it turns
smoothly.
3. Disconnect the connector (2) of blower motor (1).
4. Connect a jumper lead from battery (3) positive terminal to
connector B terminal.
5. Connect a jumper lead from battery negative terminal to
connector L, M and H terminal momentarily.
6. If the blower motor does not run, check the motor.
(1) Blower Motor
(2) Blower Motor and Blower Resistor
Connector
(3) Battery (12 V)
(4) Resistor
W1020120
(5) Blower Resistor
Blower Resistor Check
1. Disconnect the 4P connector for blower resistor (1).
2. Measure each resistance from B terminal.
3. If the factory specifications are not indicated, renew blower
resistor.
Resistance
Factory
spec.
(1) Blower Resistor
B terminal –
Hi terminal
Approx. 0.22 Ω
B terminal –
Me terminal
Approx. 0.69 Ω
B terminal –
Lo terminal
Approx. 1.69 Ω
A : Resistor Side
W1020387
10-S27
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(6) A/C Switch
Connector Voltage
1. Disconnect the A/C switch 3P connector.
2. Turn the main switch “ON” position.
3. Measure the voltage with a voltmeter across the connector 1
terminal and terminal.
4. If the voltage differs from the battery voltage, the wiring harness,
A/C relay or fuse is faulty.
Voltage
1 terminal – 3 terminal
Approx. battery voltage
A : 3P Connector (Wire Harness Side)
W1020794
A/C Switch Check
1. Check the continuity through the switch with an ohmmeter.
2. If the continuity specified below are not indicated, check the
switch.
Terminal
Position
A/C switch
1
2
3
●
●
●
OFF (*2)
ON (*1)
*1 : Push the A/C switch button on ON position.
*2 : Push again the A/C switch button to OFF position.
(1) A/C Switch
A : A/C Switch Side
W1020998
10-S28
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(7) Mode Switch
Mode Switch Check
1. Disconnect the mode switch 4P connector.
2. Check the continuity through the switch with an ohmmeter.
3. If the continuity specified below is not indicated, check the switch.
Terminal
1
2
FACE
●
●
FACE / DEF
●
●
Position
Mode switch
DEF
(1) Mode Switch
●
3
4
●
●
A : Mode Switch Side
W1042432
(8) Temperature Control Dial
Temperature Control Dial
1. Disconnect the temperature control dial 3P connector.
2. Check the continuity through the dial with an ohmmeter.
3. If the continuity specified below is not indicated, check the dial.
Resistance
Factory
spec.
(1) Temperature Control Dial
1 terminal – 3 terminal
Approx. 3 kΩ
1 terminal – 2 terminal
2 terminal – 3 terminal
Resistance changes by
the position of the dial
A : Dial Side
W1022044
10-S29
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(9) Temperature Motor
Temperature Motor Check
1. Confirm whether the temperature control dial (3) is defective.
(See page 10-S29.)
2. Turn the main switch “ACC” position.
3. Turn the blower switch (2) at 1 position.
4. Turn the temperature control dial from COOL (a) position to
WARM (b). At the time, confirm the motor is operating.
5. If the motor does not operate, replace it.
(1) Temperature Motor
(2) Blower Switch
(3) Temperature Control Dial
(a) COOL
(b) WARM
W1023638
(10) Mode Motor
Mode Motor Check
1. Confirm whether the mode switch (3) is defective. (See page 10S29.)
2. Turn the main switch “ACC” position.
3. Turn the blower switch at 1 position.
4. Turn the mode switch each (a), (b) and (c).
5. Confirm whether the position where the mode motor (1) is
stopped synchronize with mode switch (3).
6. If the motor does not move, replace it.
(1) Mode Motor
(2) Blower Switch
(3) Mode Switch
(a) Air is blown from only the face air
outlets
(b) Air is blown the foot, face and
door air outlets
(c) Air is blown the front and door air
outlets
W1044370
10-S30
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(11) A/C Pressure Switch
HI Pressure Side
1. Connect the manifold gauge (5) to compressor as following
procedure.
Close the HI and LO pressure valves (3), (4) of manifold gauge
tightly, and connect the charging hoses (red and blue) (6), (7) to
the respective compressor service valves. (Refer to HANDLING
OF SERVICE TOOLS : See page 10-S13.)
■ NOTE
• Be sure to blow out the air in the charging hoses at the
manifold gauge connection end by utilizing the refrigerant
pressure in the refrigerant cycle.
2. Start the engine and set at approx. 1500 min−1 (rpm). Turn on
the A/C switch, then set the blower switch to HI position.
3. Raise pressure on the HI pressure side of the refrigerant cycle by
covering the condenser front with a corrugated carboard, and the
pressure switch (8) is activated and the compressor magnetic
clutch is turned off. At this time, read the HI pressure gauge of
the manifold gauge. If this pressure reading differs largely with
the setting pressure, replace the pressure switch with a new one.
Setting Pressure
Factory
spec.
(1) HI (High Pressure Side) Charging
Valve
(2) LO (Low Pressure Side) Charging
Valve
(3) HI Pressure Valve
(4) LO Pressure Valve
Pressure
switch
OFF
(5)
(6)
(7)
(8)
(9)
More than
approx. 3.14 MPa
32 kgf/cm2
455 psi
Manifold Gauge
Charging Hose (Blue)
Charging Hose (Red)
Pressure Switch
Air Conditioner Unit
W1044875
10-S31
KiSC issued 03, 2007 A
CABIN
M105S, WSM
LO Pressure Side
1. Disconnect 2P connector of pressure switch.
2. Measure the resistance with an ohmmeter across the connector
terminals.
3. If 0 ohm is not indicated at normal condition, there is no
refrigerant in the refrigerating cycle because gas leaks or
pressure switch is defective.
(Reference)
Setting Pressure
Factory
spec.
Pressure
switch
OFF
More than
approx. 0.196 MPa
2.0 kgf/cm2
28.4 psi
• The resistance of dual switch is 0 ohm in normal condition, but it
becomes infinity when the pressure is abnormal (out of factory
spec.). Because the dual switch starts to work.
(1) HI (High Pressure Side) Charging
Valve
(2) LO (Low Pressure Side) Charging
Valve
(3) HI Pressure Valve
(4) LO Pressure Valve
(5)
(6)
(7)
(8)
(9)
Manifold Gauge
Charging Hose (Blue)
Charging Hose (Red)
Pressure Switch
Air Conditioner Unit
W1045680
(12) Front Wiper Switch
Connector Voltage
1. Turn on the main switch.
2. Disconnect the wiper motor connector (1).
3. Measure the voltage with a voltmeter across the connector 4
terminal and chassis.
4. If the voltage differs from the battery voltage (11 to 14 V), the
wiring harness, fuse or main switch is faulty.
Voltage
(1) Front Wiper Connector
(2) Front Wiper Motor
(3) Wiper Motor Relay
4 terminal - Chassis
Approx. battery voltage
A : Wire Harness Side
W1046134
10-S32
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Wiper Switch
1. Check the continuity through the switch with an ohmmeter.
2. If the continuity specified below are not indicated, the switch is
faulty.
Terminal
IN
+1
E
WY
WM
WASH I
●
●
●
●
ON
●
●
●
●
Position
OFF
INT
●
●
WASH II
●
●
(1) Front Wiper Switch Connector
W1046557
10-S33
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(13) Wiper Motor Relay
Wiper Motor Relay
1. Remove the wiper motor relay (1).
2. Connect jumper leads across the 4 terminal and the bulb
terminal, and across the 5 terminal and the bulb terminal.
3. Connect jumper leads across the battery negative terminal and
the 3 terminal.
4. Connect jumper leads across the battery positive terminal and
the 2 terminal.
Bulb lights up continuously (under A condition).
5. Connect jumper lead across the battery positive terminal and the
1 terminal (under B condition).
Bulb lights up and an intermittent sound is heard from relay.
6. If any defective is found, replace it.
(1)
(2)
(3)
(4)
(5)
Wiper Motor Relay
Battery
Bulb
Wiper Motor
Wiper Switch
(6) Switch on "INT."
(7) Switch on "ON."
A : Wiper Switch ON Condition
B : Wiper Switch INT. Condition
W1046930
(14) Front Wiper Motor
Front Wiper Motor
1. Raise up the front wiper arm (1).
2. Turn on the main switch.
3. Push the front wiper switch to ON position.
4. Count the number of wiper arm moving per minutes.
5. If the number differs from the factory specifications, replace the
wiper motor assembly.
Wiper arm moving at no
load
Factory spec.
33 to 43 times / min.
(1) Wiper Arm
W1047741
10-S34
KiSC issued 03, 2007 A
CABIN
M105S, WSM
[2] DISASSEMBLING AND ASSEMBLING
(1) Separating Cabin from Tractor
Draining Coolant
•
1.
2.
3.
4.
CAUTION
Never remove the radiator cap until coolant temperature is
well below its boiling point. Then loosen cap slightly to the
stop to relieve any excess pressure before removing cap
completely.
Stop the engine and let cool down.
To drain the coolant, open the radiator drain plug (1). When
opening the drain plug set the hose to drain port (2).
Remove the radiator cap to completely drain the coolant.
After all coolant is drained, reinstall the radiator drain plug.
Coolant
(1) Drain Plug
9.1 L
9.6 U.S.qts
8.0 Imp.qts
Capacity
(2) Drain Port
W1024819
Preparation 1
1. Open the bonnet (1) and disconnect the battery (2) negative
terminal and head light 4P connector (9).
2. Remove the bonnet dampers (3) and close the bonnet.
3. Remove the bonnet hinge mounting screws (4) from the holes (5)
in the upper part of the bonnet.
4. Remove the bonnet (1) and muffler (6).
5. Remove the side cover (7) LH and RH.
6. Install the front axle rocking restrictor (8) (see page G-72) to the
front axle bracket.
■ IMPORTANT
• When disconnecting the battery cords, disconnect the
grounding cord first. When connecting, positive cord first.
(1)
(2)
(3)
(4)
(5)
Bonnet
Battery
Damper
Screw
Hole
(6)
(7)
(8)
(9)
Muffler
Side Cover
Rocking Restrictor
4P Connector
W1049203
10-S35
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Preparation 2
1. Remove the side panel LH (1) and side panel RH (2).
2. Disconnect the radiator hose (3).
3. Remove the shield weather strip (4) and radiator plate (5).
4. Remove the air cleaner hoses (6).
5. Disconnect oil cooler pipe (7) and oil cooler hose (8).
(When reassembling)
Oil cooler pipe nut
49.0 to 68.6 N·m
5.0 to 7.0 kgf·m
36.1 to 50.6 ft-lbs
Oil cooler hose retaining
nut
45.1 to 53.0 N·m
4.6 to 5.4 kgf·m
33.3 to 39.0 ft-lbs
Tightening torque
• Be sure to connect the power steering turning hoses to original
positions.
(1)
(2)
(3)
(4)
Side Panel LH
Side Panel RH
Radiator Hose
Shield Weather Strip
(5)
(6)
(7)
(8)
Radiator Plate
Air Cleaner Hose
Oil Cooler Pipe
Oil Cooler Hose
W1050711
10-S36
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Preparation 3
■ Without discharging the refrigerant from system
1. Remove the air condenser slide stopper (1) and slide out the
condenser (2).
2. Remove the compressor (3) with hoses.
(When reassembling)
• Take care not damage the air condenser fin.
• After reassembling the compressor, be sure to adjust the air
conditioner belt tension.
(Refer to “Adjusting Air Conditioner Belt Tension” : See page G29.)
■ With discharge the refrigerant from system
1. Refer to “Discharging the Refrigerant” (See page 10-S19).
(When reassembling)
• Charge the refrigerator to the air conditioner system, refer to
“Charging the Refrigerant”. (See page 10-S21.)
2. Disconnect the low pressure hose (5) and high pressure hose (4)
from compressor (3).
3. Disconnect the high pressure hose (6) from receiver.
(When reassembling)
• Apply compressor oil (DENSO CO. ND-OIL8) to the O-rings and
take care not to damage them.
High pressure hose
retaining nut
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 ft-lbs
Low pressure pipe
mounting screw
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
Condenser Slide Stopper
Condenser
Compressor
High Pressure Hose
(5) Low Pressure Hose
(6) High Pressure Hose
[A] Without discharging the
refrigerant
W1052713
10-S37
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Preparation 4
1. Disconnect the heater hoses (2).
2. Disconnect the accelerator wire (3).
3. Remove the steering controller support (6) and bonnet stay (1).
4. Disconnect the hour meter cable (5) from engine side.
5. Remove the screw (7) and pull out the steering joint (4).
(When reassembling)
• Be sure to connect the heater hoses to original positions.
(1)
(2)
(3)
(4)
Bonnet Stay
Heater Hose
Accelerator Wire
Steering Joint
(5) Hour Meter Cable
(6) Steering Controller Support
(7) Screw
W1055474
Preparation 5
1. Disconnect the connectors (1) and pull out them from cabin.
(1) Connector
W1056786
10-S38
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Preparation 6
1. Remove the seat (1) and floor seat cover (2).
2. Remove the floor mat (3) and inspection plate under the floor
mat.
3. Disconnect the main shift rod 2 (5).
4. Disconnect the select wire (4).
5. Disconnect the lowering speed adjusting rod (6).
6. Disconnect the rear differential lock rod (7).
7. Disconnect the clutch cable (8) and shuttle cable (9).
8. Disconnect the all connector of wire harness (10).
(When reassembling)
• Be sure to adjust the select wire at A part. (See page 3-S11.)
• Be sure to adjust the shuttle cable the shuttle lever neutral
position at B part. (See page 3-S6.)
• Be sure to adjust the clutch cable for the clutch pedal free play at
C part. (See page 2-S5.)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Seat
Floor Seat Cover
Floor Mat
Select Wire
Main Shift Rod 2
Lowering Speed Adjusting Rod
Differential Lock Rod
Clutch Cable
(9) Shuttle Cable
(10) Wire Harness
(A) Adjusting for the Main Shift Lever
Movement
(B) Adjusting for the Shuttle Lever
Neutral Position
(C) Adjusting for the Clutch Pedal
Free Play
W1057237
10-S39
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Preparation 7
1. Disconnect the PTO clutch cable (3).
2. Disconnect the parking brake wire (2).
3. Disconnect the brake hose LH, RH (4).
4. Remove the auxiliary control valve wire (1).
5. Disconnect the ground cable (5).
6. Disconnect the range gear shift rod (8).
7. Disconnect the position control rod (6) and draft control rod (7).
8. Remove the front drive lever grip and range gear shift lever grip.
(When reassembling)
• Be sure to adjust the PTO clutch lever movement by the PTO
clutch cable (3). (See page 2-S6.)
• Be sure to adjust the length of main shift rod 1 (9). (See page 3S11.)
• Be sure to adjust the range gear shift rod (8). (See page 3-S12.)
• Be sure to adjust the parking brake lever free play by parking
brake wire (2). (See page 5-S9.)
• Be sure to bleed air from brake system. (See page 5-S8.)
• Be sure to adjust the length of position rod and draft rod (6), (7).
(See page 8-S19.)
• Be sure to adjust the auxiliary control lever movement by
auxiliary control valve wire (1). (See page 8-S23.)
(1)
(2)
(3)
(4)
(5)
Auxiliary Control Valve Wire
Parking Brake Wire
PTO Clutch Cable
Brake Hose
Ground Cable
(6)
(7)
(8)
(9)
Position Control Rod
Draft Control Rod
Range Gear Shift Rod
Main Shift Rod 1
W1059688
10-S40
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Dismounting Cabin
1. Set the cabin dismounting tool (1).
2. Remove the cabin mounting bolts and nuts.
3. Dismounting the cabin from tractor body.
(When reassembling)
Tightening torque
Cabin mounting screws
and nuts
(1) Dismounting Tool
(2) Mounting Screw and Nut (Front)
123.6 to 147.1 N·m
12.6 to 15.0 kgf·m
91.1 to 108.5 ft-lbs
(3) Mounting Screw (Rear)
W1062418
10-S41
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(2) Removing Compressor Assembly
Compressor Assembly
1. Discharge the refrigerant from the system.
(Refer to
“Discharging the Refrigerant” : See page 10-S19.)
2. Disconnect the low pressure pipe (suction) (4) and high pressure
pipe (discharge) (3) from the compressor, then cap the open
fitting immediately to keep moisture out of the system.
3. Disconnect the 2P connector (2) of magnetic clutch.
4. Remove the air conditioner belt (5) and remove the compressor
(1).
(When reassembling)
• After reassembling the compressor, be sure to adjust the air
conditioner belt tension and recharge the refrigerant to the
system. (Refer to “Charging the Refrigerant” : See page 10-S21.)
• Apply compressor oil (DENSO CO. ND-OIL8 or equivalent) to
the O-rings and take care not to damage them.
• “S” letter is marked on the compressor for connecting the low
pressure pipe (suction side).
• “D” letter is marked on the compressor for connecting the high
pressure pipe (discharge side).
• When replacing the compressor with a new one, meet the oil
amount with old one.
Tightening torque
(1)
(2)
(3)
(4)
(5)
(6)
High pressure pipe and
low pressure pipe
mounting screw
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 ft-lbs
Compressor mounting
screws
24.5 to 29.4 N·m
2.5 to 3.0 kgf·m
18.1 to 21.7 ft-lbs
Compressor
2P Connector Harness
High Pressure Pipe
Low Pressure Pipe
Air Conditioner Belt
New Compressor
(7) Old Compressor
(8) Remove the Excess Oil (A-B)
A : Oil Flow New Compressor
B : Oil Flow Replace Compressor
W1014469
10-S42
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Hub Plate
1. Three stopper bolts (1) are set in stopper magnetic clutch (2) at
the position corresponding to the shape of compressor. (See
page G-69, 70.)
2. The stopper magnetic clutch (2) is hung on hub plate (3) and it is
fixed that the compressor rotates.
3. Remove the magnet clutch mounting screw.
4. Remove the hub plate (3) and air gap adjustment shim (4).
(When reassembling)
• Do not apply grease or oil on the hub plate facing.
• Do not use the magnet clutch mounting screw again.
• It is confirmed to turn rotor by hand after assembling and not
contact with stator and hub plate.
• Check and adjust the air gap before tight the magnetic clutch
mounting screw to the specified torque. (See page 10-S51.)
Tightening torque
Clutch mounting screw
(1) Stopper Bolt
(2) Stopper Magnetic Clutch
10.8 to 16.2 N·m
1.10 to 1.65 kgf·m
8.0 to 11.9 ft-lbs
(3) Hub Plate
(4) Shim
W1059166
Rotor
1. Remove the external snap ring (1).
2. Remove the rotor (2).
(When reassembling)
• Do not use the external snap ring again.
• Assemble the external snap ring for the tapered side to become
outside of rotor.
• The width of expanding of external snap ring is set in boss of
shaft as a minimum.
(Reference)
• Code No. for external snap ring : T1065-87450
(1) External Snap Ring
(2) Rotor
W1059753
10-S43
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Stator
1. Remove the lead wire from compressor body.
2. Remove the external snap ring (1).
3. Remove the stator (2).
(When reassembling)
• Do not use the external snap ring again.
• Assemble the external snap ring for the tapered side to become
outside of front housing.
• The width of expanding of external snap ring is set is boss of shaft
as a minimum.
• Match and assemble the concave part (3) of the front housing (5)
and the pin (4) of stator.
(Reference)
• Code No. for external snap ring : T1065-87440
(1) External Snap Ring
(2) Stator
(3) Concave Part
(4) Pin
(5) Front Housing
W1059953
10-S44
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(3) Removing Air Conditioner Unit
Air Conditioning Unit
1. Remove the unit cover (1).
2. Disconnect the heater hoses (6).
3. Disconnect the cooler pipe (liquid) (2) and cooler pipe (suction
side) (3).
4. Remove the five screws and take off the air conditioning unit.
5. Remove the duct hoses.
(When reassembling)
• When reconnecting the cooler pipes with the unit, apply
compressor oil (DENSO CO. ND-OIL8) to O-rings.
• When remounting the unit, tighten five screws by hand and finally
retighten them after aligning the inner roof duct with the unit duct.
Tightening torque
A/C unit mounting screw
(M6)
3.9 to 6.9 N·m
0.4 to 0.7 kgf·m
2.9 to 5.1 ft-lbs
A/C unit mounting screw
(M8)
9.8 to 15.7 N·m
1.0 to 1.6 kgf·m
7.2 to 11.6 ft-lbs
Low pressure pipe (Cooler
pipe (suction)) retaining
nut
29.4 to 34.3 N·m
3.0 to 3.5 kgf·m
21.7 to 25.3 ft-lbs
High pressure pipe 2
(Cooler pipe (liquid))
retaining nut
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 ft-lbs
(1) Unit Cover
(2) High Pressure Pipe 2 (Cooler Pipe
(Liquid))
(3) Low Pressure Pipe (Cooler Pipe
(Suction Side))
(4) Heater Core
(5) Evaporator
(6) Heater Hose
W1025169
(4) Removing Air Conditioner Pipes
Discharging Refrigerant
1. Refer to “Discharging the Refrigerant”. (See page 10-S19.)
W1029483
Muffler and Bonnet
1. Disconnect the battery's cable (4).
2. Remove the muffler (1).
3. Remove the bonnet (2).
4. Remove the side cover (3).
(1) Muffler
(2) Bonnet
(3) Side Cover
(4) Battery Cable
W1066653
10-S45
KiSC issued 03, 2007 A
CABIN
M105S, WSM
High Pressure Pipe 1 and Low Pressure Pipe
1. Disconnect the low pressure pipe (3) from the compressor (2)
and cap the open fittings immediately to keep moisture out of the
system.
2. Disconnect the high pressure pipe 1 (1) from the compressor (2)
and condenser.
(When reassembling)
• Apply compressor oil (DENSO CO. ND-OIL8) to the O-rings and
take care not to damage them.
Tightening torque
Low pressure pipe
mounting screw
(compressor side)
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 ft-lbs
High pressure pipe 1
mounting screw
(compressor side)
7.8 to 11.8 N·m
0.8 to 1.2 kgf·m
5.8 to 8.7 ft-lbs
High pressure pipe 1
retaining nut
(condenser side)
19.6 to 24.5 N·m
2.0 to 2.5 kgf·m
14.5 to 18.1 ft-lbs
(1) High Pressure Pipe 1
(2) Compressor
(3) Low Pressure Pipe
W1029528
High Pressure Pipe 2
1. Remove the pipe clamps (3).
2. Disconnect the high pressure hose 2 (1) from the receiver (2) and
cap the open fittings immediately to keep moisture out of the
system.
(When reassembling)
• Apply compressor oil (DENSO CO. ND-OIL8) to the O-rings and
take care not to damage them.
Tightening torque
High pressure pipe 2
retaining nut
(Receiver side)
(1) High Pressure Hose 2
(2) Receiver
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 ft-lbs
(3) Clamp
W1067402
Inner Covers
1. Remove the inner covers (1), (2).
2. Remove the seat (3).
(1) Inner Cover (Upper)
(2) Inner Cover (Lower)
(3) Seat
W1067892
10-S46
KiSC issued 03, 2007 A
CABIN
M105S, WSM
High Pressure and Low Pressure Pipes
1. Remove the outer roof.
2. Disconnect the pressure switch (1) connector.
3. Disconnect the high pressure pipe 2 (2), then cap the open fitting
immediately to keep moisture out of the system.
4. Remove the rubber (3) and disconnect the low pressure pipe (4),
then cap the open fittings immediately to keep moisture out of the
system.
5. Pull out the pressure pipes (2) and (4) from the bottom of the
cabin.
6. Take out the pressure pipes (2) and (4).
(When reassembling)
• Replace the rubber (3) with a new one.
• Apply compressor oil (DENSO CO. ND-OIL8) to the O-rings and
take care not to damage them.
High pressure pipe 2
retaining nut
11.8 to 14.7 N·m
1.2 to 1.5 kgf·m
8.7 to 10.8 ft-lbs
Low pressure pipe
retaining nut
29.4 to 34.3 N·m
3.0 to 3.5 kgf·m
21.7 to 25.3 ft-lbs
Tightening torque
(1) Pressure Switch
(2) High Pressure Pipe 2
(3) Rubber
(4) Low Pressure Pipe
W1029826
(5) Removing Heater Hoses
Draining Coolant
CAUTION
• Never remove the radiator cap until coolant temperature is
well below its boiling point. Then loosen cap slightly to the
stop to relieve any excess pressure before removing cap
completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (1). When
opening the drain plug set the hose to drain port (2).
3. Remove the radiator cap to completely drain the coolant.
4. After all coolant is drained, reinstall the radiator drain plug.
Coolant
(1) Drain Plug
Capacity
9.1 L
9.6 U.S.qts
8.0 Imp.qts
(2) Drain Port
W1049566
10-S47
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Muffler and Bonnet
1. Disconnect the battery cable.
2. Remove the muffler (1).
3. Remove the bonnet (2). (See page 10-S35.)
4. Remove the side cover (3).
(1) Muffler
(2) Bonnet
(3) Side Cover
(4) Battery
W1068475
Heater Hoses
1. Disconnect the heater hoses (1), (2), and take out them under the
cabin.
(When reassembling)
• Note the inlet hose and outlet hose.
(1) Heater Hose 1
(2) Heater Hose 2
W1030123
Inner Covers
1. Remove the inner covers (1) and (2).
(1) Inner Cover (Upper)
(2) Inner Cover (Lower)
W1069032
Removing Heater Hoses
1. Remove the outer roof.
2. Disconnect the heater hoses (1), (2).
3. Pull out the heater hoses (1), (2) from the bottom of the cabin.
4. Take out the heater hoses (1), (2).
(When reassembling)
• When connecting the heater hose with A/C unit, hose should be
put into the A/C unit pipe more than 30 mm (1.2 in.).
• Be sure to fix the heater hose (2) to the original position.
• Note the inlet hose and outlet hoses.
(1) Heater Hose 1
(2) Heater Hose 2
W1030250
10-S48
KiSC issued 03, 2007 A
CABIN
M105S, WSM
(6) Cab Windshield
Preparation
1. Prepare the followings.
- Cutter knife
1 piece
- Scraper
1 piece
- Gun for coating
1 piece
- Sika Tack-Ultrafast or equivalent
- Sika-cleaner No. 1
- Gummed tape
■ NOTE
• Sika Tack-Ultrafast and cleaner No. 1 are made by Sika
Corporation.
• These materials can't be provided by Kubota Corporation.
• Therefore, please find the local made equivalent materials in
your country and use them when you need.
W1053361
Before Replacing Windshields (1)
[In case of using piano wire (When glass is cracked)]
1. Thread the piano wire from the inside of cabin. Tie its both ends
to a wooden blocks or the like. (See the left figure.)
2. Pull the piano wire inward/outward alternately to cut the adhered
part.
■ NOTE
• Do not let the piano wire make sliding contact with the edge
of glass plate forcibly.
[In case of using cutter knife (When glass is totally crushed
finely)]
1. Insert the knife (3) into the adhered part.
2. Keep the edge of knife blade square to the glass edge at the part
(a). Slide the knife blade along the glass surface and the edge.
Pull the part (b) in the direction parallel to the glass edge to cut
them off.
■ NOTE
• Find a wider gap between the glass and body.
• Take care of handling the cutter knife not to damage your
hands.
(1) Piano Wire
(2) Wood Peace
(3) Cutter Knife
(4) Pulling
W1035600
Before Replacing Windshields (2)
1. When the Sika Tack-Ultrafast or equivalent attached to the cabin
frame and the glass are reused, remove the bond clearly.
2. Clean the frame surface with Sika-cleaner No. 1.
■ NOTE
• Remove the bond completely.
W1035852
10-S49
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Before Replacing Windshields (3)
1. Check that the glasses are not damaged and cracked.
2. Turn over the glass and clean this surface of the glass by Sikacleaner No. 1.
3. The cleaning area of the rear surface is indicated “A” in the
figure left.
■ NOTE
• If not cleaning the glass, it may result in adhesive failure.
(1) Upper Windshield
(2) Lower Windshield (Left)
(3) Lower Windshield (Right)
A : 25 mm (1.0 in.)
W1035931
(7) Wiper Motor
Front Wiper Motor
1. Remove the steering wheel and steering post under covers.
2. Remove the meter panel.
3. Remove the panel under cover.
4. Disconnect the front wiper motor 4P connector (2).
5. Remove the wiper arm mounting nut (4) and wiper arm (5).
6. Remove the wiper link cap (3).
7. Disconnect the earth lead setting screw.
8. Remove the front wiper motor bracket (7) mounting screw (8),
then take out the front wiper motor (1).
(When reassembling)
Tightening torque
(1)
(2)
(3)
(4)
(5)
Wiper arm mounting nut
Front Wiper Motor
Front Wiper Motor Connector 4P
Wiper Link Cap
Nut
Wiper Arm
6.37 to 9.32 N·m
0.65 to 0.95 kgf·m
4.7 to 6.9 ft-lbs
(6) Wiper Blade
(7) Wiper Motor Mounting Bracket
(8) Wiper Motor Bracket Mounting
Screw
(9) Ground Wire Mounting Screw
W1031321
10-S50
KiSC issued 03, 2007 A
CABIN
M105S, WSM
Rear Wiper Motor
1. Remove the wiper motor cover (5).
2. Disconnect the rear wiper motor 4P connector (2).
3. Remove the wiper arm mounting nut (4) and wiper arm (6).
4. Remove the wiper link cap (3) and nut.
5. Remove the rear wiper motor mounting screws, then take out the
rear wiper motor (1).
Wiper arm mounting nut
7.8 to 9.3 N·m
0.8 to 0.95 kgf·m
5.79 to 6.87 ft-lbs
Wiper motor mounting
screw
7.8 to 9.3 N·m
0.8 to 0.95 kgf·m
5.79 to 6.87 ft-lbs
Tightening torque
(1)
(2)
(3)
(4)
Rear Wiper Motor
Rear Wiper Motor 4P Connector
Wiper Link Cap
Nut
(5) Wiper Motor Cover
(6) Wiper Arm
(7) Wiper Blade
W1031819
[3] SERVICING
Adjustment of Air-gap
1. Measure the air-gap with a feeler gauge.
2. When the measurement value comes off from factory
specification, adjustment shim (3) is added or deleted.
Air-gap (A)
0.20 to 0.45 mm
0.0079 to 0.0177 in.
Factory spec.
(Reference)
Adjusting Shim Size
Code No.
0.10 mm (0.0039 in.)
T1065-87340
0.15 mm (0.0059 in.)
T1065-87350
0.40 mm (0.016 in.)
T1065-87360
0.60 mm (0.024 in.)
T1065-87370
1.0 mm (0.0394 in.)
T1065-87380
(1)
(2)
(3)
(4)
(5)
Magnet Clutch Mounting Screw
Hub Plate
Shim
External Snap Ring
Rotor
(6) External Snap Ring
(7) Stator
(8) Compressor Body
A : Air-Gap
W1060178
Cleaning Evaporator
1. Check whether white powder or dust is attached to the
evaporator (1). If they are attached, wash them off with warm
water and blow them off with compressed air.
■ NOTE
• In case the evaporator is cleaned with warm water, cap the
evaporator pipe ends so that water does not enter it.
(1) Evaporator
W1071460
10-S51
KiSC issued 03, 2007 A
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX
: (81)72-245-2484
E-mail : ksos-pub@kubota.co.jp
KUBOTA Corporation
Printed in Japan 2007. 03, S, EI, EI, e
2004. 12, S, EI, EI, e
Code No.9Y011-13350