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Kubota M105S, Workshop Manual

The Kubota M105S is a powerful agricultural tractor designed for heavy-duty tasks. To maintain and troubleshoot your M105S effectively, download the Workshop Manual for free from manualshive.com. This comprehensive manual provides step-by-step instructions and diagrams, ensuring your tractor operates at peak performance.

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10-M9

M105S, WSM

CABIN

[6] ELECTRICAL  SYSTEM

(1) Electrical Circuit

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/cm

2

, 30 psi) and 0.26 MPa (2.7 kgf/cm

2

, 38.4 psi) 

→

Compressor magnet clutch is engaged

(1) Mode Switch
(2) Temperature Control Dial
(3) Blower Switch
(4) 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) Blower Resistor

(12) Servo Motor (Mode)
(13) Servo Motor (Temperature)
(14) Temperature Control Resistor

KiSC issued 03, 2007 A

Summary of Contents for M105S

Page 1: ...M105S WORKSHOP MANUAL TRACTOR KiSC issued 03 2007 A...

Page 2: ...ism Workshop Manual Code No 97897 01872 97897 18200 for the one which has not been described to this workshop manual Servicing Information on the troubleshooting servicing specification lists tighteni...

Page 3: ...l 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 a...

Page 4: ...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 O...

Page 5: ...ep 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 grou...

Page 6: ...UCTIONS 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 SAFETY DECAL...

Page 7: ...5 M105S WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 8: ...6 M105S WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 9: ...7 M105S WSM SAFETY INSTRUCTIONS KiSC issued 03 2007 A...

Page 10: ...05 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 Traveling system Standard tire size 3 Front 340 85R24 13 6R24 Rear 460 85R34 18 4R34 Clu...

Page 11: ...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 L 1 2 02 1 26 1 67 1 04 2 2 57 1 60...

Page 12: ...9 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 L 1 2 04 1 27 1 68 1 04 2 2 59 1 61 2 14 1 3...

Page 13: ...11 M105S WSM DIMENSIONS DIMENSIONS KiSC issued 03 2007 A...

Page 14: ...G GENERAL KiSC issued 03 2007 A...

Page 15: ...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 C...

Page 16: ...ur local KUBOTA distributor always specify engine serial number tractor serial number and hour meter reading W1010602 1 Tractor Identification Plate 2 Tractor Serial Number 3 CABIN Identification Plat...

Page 17: ...y 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...

Page 18: ...eck 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 po...

Page 19: ...twist unnecessary sag or excessive tension except for movable part where sag be required W1011587 In installing a part take care not to get wiring caught by it W1011670 1 Grommet A Correct B Incorrect...

Page 20: ...ust 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...

Page 21: ...s to separate W1012272 Use sandpaper to remove rust from terminals Repair deformed terminal Make certain there is no terminal being exposed or displaced W1012346 Make certain that there is no female c...

Page 22: ...astic cover is large enough to cover whole connector W1012519 5 HANDLING OF CIRCUIT TESTER Use tester correctly following manual provided with tester Check for polarity and range W1012684 1 Cover A Co...

Page 23: ...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...

Page 24: ...s employed O Recommendable X Not Recommendable Transmission Oil The oil used to lubricate the transmission is also used as hydraulic fluid To insure proper operation of the hydraulic system and comple...

Page 25: ...o 33 2 31 4 to 34 3 3 2 to 3 5 23 2 to 25 3 48 1 to 55 8 4 9 to 5 7 35 5 to 41 2 39 3 to 44 1 4 0 to 4 5 29 0 to 32 5 60 9 to 70 6 6 2 to 7 2 44 9 to 52 1 M12 12 mm 0 47 in 62 8 to 72 5 6 4 to 7 4 46...

Page 26: ...0 36 1 to 50 6 15 t1 6 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 18 t1 6 107 9 to 117 7 11 0 to 12 0 79 6 to 86 8 Items Thread size Tightening torque N m kgf m ft lbs POA PF Nipple with O ring PF 1 8...

Page 27: ...place 200 hrs G 17 11 Toe in Adjust 200 hrs G 26 12 Fuel tank water Drain 200 hrs G 26 13 Power steering oil line Check 200 hrs G 25 Replace 2 years G 36 14 Radiator hose and clamp Check 200 hrs G 25...

Page 28: ...aster 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 Service as required G 38 34 Brake system Bleed G 39 35...

Page 29: ...eck 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...

Page 30: ...re 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 th...

Page 31: ...n 2 After draining reinstall the drain plug 3 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 4 After running the eng...

Page 32: ...el Top up if necessary IMPORTANT To prevent serious damage to the hydraulic system use only a KUBOTA genuine filter W1040732 Changing Front Differential Case Oil 1 To drain the used oil remove the dra...

Page 33: ...ctor Preparation before testing 1 Place all control levers in the NEUTRAL position 2 Set the parking brake and stop the engine Test Switch for the main gear shift lever 1 Sit on operator s seat 2 Shif...

Page 34: ...tery 1 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 2 Clean the battery surface with a clean cloth Keep...

Page 35: ...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 r...

Page 36: ...ut until the deflection of the belt falls within acceptable limits 4 Replace fan belt if it is damaged W1043886 Adjusting Brake Pedal 1 Brake Pedal Free Travel CAUTION When checking parking the tracto...

Page 37: ...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...

Page 38: ...nuts firmly 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 Shi...

Page 39: ...remely wet and muddy condition lubricate grease fittings more often W1045953 1 Grease Fitting Front Axle Support Front Rear 2 Grease Fitting Front Wheel Case Support RH LH 3 Grease Fitting Top Link 4...

Page 40: ...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...

Page 41: ...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 Adj...

Page 42: ...tach 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 counterc...

Page 43: ...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 th...

Page 44: ...ng W1048917 Adjusting Air Conditioner Belt Tension CAUTION Be sure to stop the engine before checking air conditioner belt tension 1 Stop the engine and remove the key 2 Apply 98 N 10 kgf 22 lbs press...

Page 45: ...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...

Page 46: ...fter installing the vinyl pipes 3 to the bleeder 2 loosen the bleeder a half turn 3 Move the brake pedal up and down Repeat this motion until fresh oil overflows W1050507 Adjusting Front Axle Pivot 1...

Page 47: ...d 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 W1051760 Checking Cabin Isolation Cushion...

Page 48: ...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 Se...

Page 49: ...e engine Check coolant level and add coolant if necessary 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 wa...

Page 50: ...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 sever...

Page 51: ...f 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...

Page 52: ...king brake cable 3 Refer to Adjusting Parking Brake Lever Free Play See page G 23 W1054811 Replacing Master Cylinder Kit and Equalizer Kit 1 Refer to Removing Master Cylinder and Equalizer See page 5...

Page 53: ...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...

Page 54: ...eders firmly 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 Accordin...

Page 55: ...es 1 and the rear window hinges 2 W1056309 Adding Washer Liquid 1 Add a proper amount of automobile washer liquid when it is necessary W1056398 1 Door Hinge 2 Rear Window Hinge Washer liquid tank Capa...

Page 56: ...rmation dealing with electrical problems W1056680 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 5 A Airco...

Page 57: ...ine 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 flo...

Page 58: ...000 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...

Page 59: ...5 rad 45 0 262 rad 15 Diameter 28 6 mm 1 126 in 38 0 mm 1 496 in 31 6 mm 1 244 in 41 3 mm 1 626 in 35 0 mm 1 378 in 50 8 mm 2 000 in W10244580 Connecting Rod Alignment Tool Code No 07909 31661 Applica...

Page 60: ...eck 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 W102...

Page 61: ...1 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 m 250 in b 6 3 m 250 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm...

Page 62: ...8 075 to 48 100 mm dia 1 8927 to 1 8937 in dia F 20 mm dia 0 7874 in dia a 6 3 m 250 in b 6 3 m 250 in C1 Chamfer 1 0 mm 0 039 in C2 Chamfer 2 0 mm 0 079 in A 148 8 mm 5 8582 in B 50 mm 1 9685 in C 18...

Page 63: ...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 A Rmax 12 5 S B 94 5 to 95 0 mm dia 3 7205 to 3 7402 in dia C 40 mm d...

Page 64: ...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 Chamfe...

Page 65: ...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 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...

Page 66: ...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...

Page 67: ...ket W1037894 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...

Page 68: ...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 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 i...

Page 69: ...K 70 mm 2 76 in L 178 mm 7 01 in 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...

Page 70: ...K 70 mm 2 76 in L 394 mm 15 51 in 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...

Page 71: ...0 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...

Page 72: ...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...

Page 73: ...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...

Page 74: ...r removing the injection pump gear from injection pump shaft W1050836 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 i...

Page 75: ...ation This allows easy measurement of relief set pressure W10267410 Flow Meter Code No 07916 52791 Flow Meter 07916 52651 Hydraulic Test Hose Application This allows easy testing of hydraulic system W...

Page 76: ...ctor 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 a...

Page 77: ...clusively for pushing the thrust collar remove the external snap ring NOTE Replace the center guide 1 for shown in figure W1020107 A 20 mm dia 0 79 in dia B 11 5 mm dia 0 45 in dia C Chamfer 1 mm 0 04...

Page 78: ...om 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 W10520...

Page 79: ...ling 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 Cod...

Page 80: ...ng 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 W1013764 1 Manifold Gauge Assembly...

Page 81: ...hem referring to the figure Draft Control Test Bar Application Use for checking the lift range and floating range of hydraulic draft control W10625190 A 1045 mm 41 14 in B 1000 mm 29 37 in C 20 mm dia...

Page 82: ...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...

Page 83: ...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 2...

Page 84: ...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...

Page 85: ...the braking pressure in brake case W1069991 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 A 19 mm 0 74 in...

Page 86: ...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...

Page 87: ...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 A 70 mm 2 76 in B 67 5 mm 2 66 in C 56 mm 2 20 in...

Page 88: ...6 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...

Page 89: ...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 i...

Page 90: ...g 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 W1057295 A 5 mm 0 2 in Collar T...

Page 91: ...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 a...

Page 92: ...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...

Page 93: ...ll 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...

Page 94: ...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 07916 52501 W1033331 1 Injector 2 Ho...

Page 95: ...en 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 ti...

Page 96: ...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 07916 52501 and direc...

Page 97: ...NOTE Implement size may vary depending on soil operating conditions Tread max width Operating condition Lower link max lifting capacity W0 Front Rear IMPORTANT Tractor with front spacer option is not...

Page 98: ...idth 3050 mm 120 in 4 Sprayer Max Tank capacity Mid 1000 L 264 U S gals 220 Imp gals Rear 3P 1000 L 264 U S gals 220 Imp gals Drawbar 5500 L 1453 U S gals 1210 Imp gals 5 Rotary Tiller Max Tilling Wid...

Page 99: ...mm 102 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2842 psi 12 Rear Blade Max Cutting Width 2600 mm 102 in Max Oil Pressure 19 6 MPa 200 kgf cm2 2842 psi 13 Front Loader 1 2 Max Lifting Capacity 1300 kg...

Page 100: ...1 ENGINE KiSC issued 03 2007 A...

Page 101: ...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...

Page 102: ...he 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...

Page 103: ...ssemble disassemble it The cylinder is a linerless type which enables good cooling operation less strain and good abrasion resistance W1012734 2 HALF FLOATING HEAD COVER The rubber packing is fitting...

Page 104: ...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 mixe...

Page 105: ...enum disulfied serves as a solid lubricant like a Graphite or Teflon This material helps resist metal wears even with little lube oil W1013276 6 BUILT IN DYNAMIC BALANCER Engine are sure to vibrate by...

Page 106: ...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 coolin...

Page 107: ...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 undersh...

Page 108: ...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...

Page 109: ...ical 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 sh...

Page 110: ...e 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 overloade...

Page 111: ...ed 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...

Page 112: ...tly 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 idli...

Page 113: ...hese 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 functio...

Page 114: ...er 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 W1015595 1 Timing Flange 2 Fl...

Page 115: ...e 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 me...

Page 116: ...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 fue...

Page 117: ...ront 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 Injectio...

Page 118: ...n 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 c...

Page 119: ...ft bent Replace 1 S26 Turbocharger fin or other part damaged due to foreign matters Replace 1 S26 Either White or Blue Exhaust Gas Is Observed Excessive engine oil Reduce to specified level G 15 Pisto...

Page 120: ...ce 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 Fuel Mixed into...

Page 121: ...t 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 r...

Page 122: ...Intake 1 047 rad 60 Exhaust 0 785 rad 45 Valve Face Angle Intake 1 047 rad 60 Exhaust 0 785 rad 45 Valve Recessing 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...

Page 123: ...ing 1 0 mm 0 039 in Rocker Arm Shaft to Rocker Arm 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 f...

Page 124: ...4 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...

Page 125: ...8 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...

Page 126: ...otor 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 k...

Page 127: ...re T D C Fuel Injection Nozzle 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 V...

Page 128: ...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...

Page 129: ...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 a...

Page 130: ...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 spec...

Page 131: ...d 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...

Page 132: ...ature 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 th...

Page 133: ...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...

Page 134: ...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 inj...

Page 135: ...ctory 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 W1029881 Nozz...

Page 136: ...nt is drained reinstall the radiator drain plug 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...

Page 137: ...nect 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 Be sure to connect the p...

Page 138: ...aft Tap in the spring pins 2 as shown in figure 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 fr...

Page 139: ...sure hose 6 from receiver When reassembling Apply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1033120 Front Axle Support as a Unit 1 Check the front axle and clutc...

Page 140: ...ine 3 Disconnect the delivery hose 3 oil cooler hose 4 4 Remove the oil cooler pipe 5 When reassembling W1034340 Brake Oil Tank 1 Remove the brake oil tank 1 from the bonnet support 3 2 Remove the sta...

Page 141: ...sc boss Apply liquid gasket Three Bond 1141 1211 or equivalent to joint face of the engine and clutch housing W1035075 Tightening torque Engine and clutch housing mounting screw nut standard type 124...

Page 142: ...wheel 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 cen...

Page 143: ...tarting 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 pi...

Page 144: ...SM ENGINE Turbocharger 1 Remove the screw 1 and bolt 2 2 Take off the turbocharger assembly 3 When reassembling Replace the gasket with new one W1036884 1 Screw 2 Bolt 3 Turbocharger Assembly KiSC iss...

Page 145: ...ighten the head cover mounting bolts to specified torque Mount the check valve with the mark toward the tank W1037062 Tightening torque Nozzle holder clamp nut 17 7 to 20 6 N m 1 8 to 2 1 kgf m 13 0 t...

Page 146: ...ssembling the rocker arm be sure to adjust the valve clearance W1037771 Injection Nozzle Oil Seal if necessary 1 Remove the injection nozzle oil seal 1 from cylinder head cover 2 When reassembling Whe...

Page 147: ...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 val...

Page 148: ...ownward 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 h...

Page 149: ...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...

Page 150: ...ting 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 sid...

Page 151: ...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 mo...

Page 152: ...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 inj...

Page 153: ...e 1 S17 W1044005 Tightening torque 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...

Page 154: ...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...

Page 155: ...overnor 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 assembl...

Page 156: ...e governor housing 3 Remove the start spring 4 and the stop spring 5 W1046875 Stop Lever 1 Remove the stop lever 1 and the return spring 2 2 Remove the stop lever shaft 3 W1047173 1 Speed Control Leve...

Page 157: ...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 fue...

Page 158: ...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 W1048682 Tightenin...

Page 159: ...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...

Page 160: ...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 an...

Page 161: ...50946 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 W1051452 Tightening torque Anti rotation nut 2 8 to 4 0 N m...

Page 162: ...the O ring and not to let it out of position 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 W1051821 1 Wat...

Page 163: ...4 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...

Page 164: ...5 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 wil...

Page 165: ...irm 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...

Page 166: ...necting 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...

Page 167: ...en 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 pisto...

Page 168: ...o 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...

Page 169: ...bling 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...

Page 170: ...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 screw...

Page 171: ...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 ca...

Page 172: ...correcting 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 re...

Page 173: ...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...

Page 174: ...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 th...

Page 175: ...tool 4 Check the valve seating with prussian blue The valve seating surface should show good contact all the way around W1060921 Free Length and Tilt of Valve Spring 1 Measure the free length A with v...

Page 176: ...ft 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 W1062712 Setting load Setting len...

Page 177: ...clearance 3 If the oil clearance exceeds the allowable limit or the tappet is damaged replace the tappet W1062838 Oil clearance between tappet and tappet guide bore Factory spec 0 020 to 0 062 mm 0 0...

Page 178: ...49 to 0 193 mm 0 0019 to 0 0076 in Allowable limit 0 22 mm 0 0087 in Backlash between idle gear 1 and cam gear Factory spec 0 049 to 0 189 mm 0 0019 to 0 0074 in Allowable limit 0 22 mm 0 0087 in Back...

Page 179: ...he misalignment half of the measurement 3 If the misalignment exceeds the allowable limit replace the camshaft W1064033 Cam Height 1 Measure the height of the cam at its highest point with an outside...

Page 180: ...l clearance 3 If the oil clearance exceeds the allowable limit replace the bushing W1064798 Oil clearance of camshaft journal Factory spec 0 050 to 0 091 mm 0 00197 to 0 00358 in Allowable limit 0 15...

Page 181: ...ncer shaft to the front and rear 3 If the measurement exceeds the allowable limit replace the balancer shaft W1065170 Balancer shaft Alignment 1 Support the balancer shaft with V blocks on the surface...

Page 182: ...oth the horizontal and vertical directions with a cylinder gauge 2 If the measurement exceeds the allowable limit replace the piston W1066065 Oil clearance of balancer shaft journal Factory spec 0 070...

Page 183: ...ower 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 W1066469 Factory spec Top rin...

Page 184: ...ut 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...

Page 185: ...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...

Page 186: ...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...

Page 187: ...ithout color 56 00 to 56 01 mm 2 2047 to 2 2051 in S 1C020 22331 1 491 to 1 496 mm 0 0587 to 0 0589 in Undersize 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 ra...

Page 188: ...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 W1070...

Page 189: ...When the cylinder is worn beyond the allowable limit bore and hone it to the specified dimension 2 Replace the piston and piston rings with oversize 0 5 mm ones NOTE When the oversize cylinder is wor...

Page 190: ...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 clearanc...

Page 191: ...2 CLUTCH KiSC issued 03 2007 A...

Page 192: ...CONTENTS MECHANISM 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...

Page 193: ...utch 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 p...

Page 194: ...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 condi...

Page 195: ...h 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 lev...

Page 196: ...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...

Page 197: ...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...

Page 198: ...plate Replace 3 S38 Tractor Does Not Keep in Neutral Shuttle linkage defective or deformed Adjust or replace 3 S6 PTO Clutch Slip Operating pressure is low Adjust 8 S12 PTO clutch valve malfunctioning...

Page 199: ...s 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 Drive...

Page 200: ...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...

Page 201: ...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 NOTE Be sure to fix the coil spring 4 in o...

Page 202: ...e 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 W1012725 Proper c...

Page 203: ...int 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...

Page 204: ...coolant is drained reinstall the radiator drain plug 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 d...

Page 205: ...shown in figure Apply liquid gasket Three Bond 1208D 1206D or equivalent to joint face of under cover and clutch housing case W1019942 Differential Lock Spring 1 Loosen the lock nut 1 and disconnect...

Page 206: ...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 W1014586 1 Side Panel LH 2 Side Panel RH 3 Shield Weather...

Page 207: ...ply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1014957 Steering Joint Hose Meter Cable Oil Cooler Pipe and Hose 1 Remove the steering joint 1 2 Disconnect the met...

Page 208: ...n 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 s...

Page 209: ...gine 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 jo...

Page 210: ...lve Shuttle Clutch Valve 1 Remove the floor mat 1 and inspection plate 2 2 Remove the shuttle valve 3 When reassembling W1016768 Tightening torque Damper disc mounting screw 48 1 to 55 9 N m 4 9 to 5...

Page 211: ...ee 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 2 S6 W1017134 Tigh...

Page 212: ...g 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 j...

Page 213: ...x difference brands oil together 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 dr...

Page 214: ...nes and apply oil to them Apply liquid gasket Three Bond 1208D 1216 or equivalent to joint face of pump base and transmission case W1021905 Tightening torque Tank stay mounting screw 196 1 to 225 6 N...

Page 215: ...e 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 tr...

Page 216: ...ond 1208D 1216 or equivalent to joint face of the rear axle case and transmission case after eliminate the water oil and stuck liquid gasket W1023029 Rear Cover Assembly 1 Remove the rear cover and PT...

Page 217: ...o 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...

Page 218: ...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 W1029591 1 Brake Ring 2 Return Spring 3...

Page 219: ...plate 3 and driven plate 4 with vernier calipers 2 If the thickness is less than the allowable limit replace it W1030468 Displacement around disc edge Allowable limit 2 0 mm 0 079 in Thickness of clut...

Page 220: ...t 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 W1031235 Flatness of PTO piston Allowable limit 0 15 mm 0 006 in Flatnes...

Page 221: ...3 TRANSMISSION KiSC issued 03 2007 A...

Page 222: ...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 SHI...

Page 223: ...Section 2 Main Gear Shift Section 3 Range Gear Shift Section 4 Four Wheel Drive Section 5 PTO Gear Section 6 PTO Clutch Section 7 Hydraulic Pump Drive Gear 8 Swing Shift HI LO 9 Dual Speed Section HI...

Page 224: ...huttle shift lever 1 forward speeds and reverse speeds in the table below are obtained 1 Hydraulic Shuttle Shift Lever 2 Main Gear Shift Lever 3 Range Gear Shift Lever 4 Pilot Lamp LOW 5 Pilot Lamp HI...

Page 225: ...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 wh...

Page 226: ...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 1 3rd 4th Shift Fork Rod 2 1st 2nd Shift Fork Rod 3 Shaft 4 3rd 4...

Page 227: ...he 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 turtl...

Page 228: ...Swing Shift Switch 2 LO Solenoid Valve 3 HI Solenoid Valve 4 LO Motion Switch 5 HI Motion Switch 6 Buzzer Relay 7 Buzzer A To Meter Panel 10A Fuse B To OPC Unit C To Meter Panel Swing Shift HI D To M...

Page 229: ...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 W1014355 1 Shift Fo...

Page 230: ...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 I...

Page 231: ...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 W1015037 1 Flywheel 2 Damper Disc 3 Input Shaft 4 Reverse Clu...

Page 232: ...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...

Page 233: ...lutch 8 Clutch Body 6 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 op...

Page 234: ...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...

Page 235: ...d 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 Shi...

Page 236: ...n 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 Ca...

Page 237: ...r 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...

Page 238: ...erential 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...

Page 239: ...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 t...

Page 240: ...0665 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...

Page 241: ...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...

Page 242: ...ear 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 W1013598 Shuttle Cable 1 The movement of shuttle le...

Page 243: ...s for the shuttle lever 3 In this adjustment procedure make alignment between the shuttle valve N detent and shuttle lever guide n groove W1013805 Checking Shuttle Lever Free Play How to Check and Adj...

Page 244: ...o 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 W1014688 1 Shuttle Lever 2 Shuttle...

Page 245: ...e 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 thes...

Page 246: ...event 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...

Page 247: ...h 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 Check and adjust points of the select cable 3 A Tighten until the bottoms up thread...

Page 248: ...ion of the range gear shift Hi and Lo position 2 If feeling abnormal shifting check the length of range gear shift rod 2 W1018307 Length of range gear shift rod L Initial adjustment 285 mm 11 22 in 1...

Page 249: ...FUEL AND COOLANT See page G 8 Do not mix difference brands oil together 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 ta...

Page 250: ...2 as shown in figure Apply liquid gasket Three Bond 1208D 1206D or equivalent to joint face of under cover and clutch housing case W1019942 Differential Lock Spring 1 Loosen the lock nut 1 and disconn...

Page 251: ...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...

Page 252: ...quid gasket Three Bond 1208D 1216 or equivalent to joint face of pump base and transmission case W1019997 Tightening torque Delivery pipe 1 and 2 retaining nut 107 9 to 117 7 N m 11 0 to 12 0 kgf m 79...

Page 253: ...ing Apply liquid gasket Three Bond 1208D 1216 or equivalent to joint face of mid case and clutch housing W1021161 Tightening torque Transmission case and mid case mounting screw and nut 77 5 to 90 2 N...

Page 254: ...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 Rep...

Page 255: ...g 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 sh...

Page 256: ...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 r...

Page 257: ...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 s...

Page 258: ...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 l...

Page 259: ...sing 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 s...

Page 260: ...ving 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...

Page 261: ...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 s...

Page 262: ...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 W1028579 Front Drive Shaft 1 Remove the bearing ret...

Page 263: ...ure 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 W1029698 Bearing Support 1 Remove the external snap ring 1 2 Remove the feather key...

Page 264: ...ut 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 th...

Page 265: ...ar shaft 3 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...

Page 266: ...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 disul...

Page 267: ...16 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 r...

Page 268: ...ing 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 W1036548 Differential Lock Fork 1 Remove the clevis pin 3 and the plug 6 2 Draw out...

Page 269: ...al 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 shaf...

Page 270: ...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 pinio...

Page 271: ...djust the turning torque of spiral bevel pinion shaft only See page 3 S41 There staking groove 4 and lubrication groove 5 on the pinion shaft 3 be sure to stake the nut on right side groove Reference...

Page 272: ...ssembling Apply liquid gasket Three Bond 1208D 1216 or equivalent to joint face of transmission case and parking brake case W1040231 Tightening torque Parking brake case mounting screw 77 5 to 90 1 N...

Page 273: ...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 t...

Page 274: ...t 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 c...

Page 275: ...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...

Page 276: ...ct 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...

Page 277: ...tory specifications adjust the tightening torque of staking nut 2 When reassembling 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...

Page 278: ...ning 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 t...

Page 279: ...ally 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 ac...

Page 280: ...rightward Repeat above until the proper tooth contact and backlash are achieved W1049426 Deep or Toe contact Replace the adjusting collar 5 with a thinner one to move the spiral bevel pinion shaft fo...

Page 281: ...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...

Page 282: ...in 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 measurem...

Page 283: ...4 REAR AXLE KiSC issued 03 2007 A...

Page 284: ...CONTENTS MECHANISM 1 STRUCTURE 4 M1 KiSC issued 03 2007 A...

Page 285: ...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 RE...

Page 286: ...SPECIFICATIONS 4 S2 3 TIGHTENING TORQUES 4 S3 4 CHECKING DISASSEMBLING AND SERVICING 4 S4 1 DISASSEMBLING AND ASSEMBLING 4 S4 1 Separating Rear Axle Case from Transmission 4 S4 2 Disassembling Rear A...

Page 287: ...ear 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...

Page 288: ...lanetary 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 Pla...

Page 289: ...to 41 0 254 to 297 Cabin mounting bolt and nut 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 12...

Page 290: ...orrect level 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...

Page 291: ...e lower link 4 with the stabilizer 5 When reassembling 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 W101238...

Page 292: ...assembling Apply liquid gasket Three Bond 1208D 1216 or equivalent to the seam of brake case and transmission case Apply grease to the O ring W1013184 Tightening torque Cabin mounting bolt and nut 123...

Page 293: ...nsmission fluid to the inner surface of planetary gear 2 and bearing Tap in the spring pin 1 as shown in the figure W1013638 Rear Axle 1 Remove the rear axle cover mounting screw 2 Hammer out the rear...

Page 294: ...t wrench 98 Code No 07916 52521 When reassembling 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...

Page 295: ...e 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...

Page 296: ...5 BRAKES KiSC issued 03 2007 A...

Page 297: ...CONTENTS MECHANISM 1 FEATURE 5 M1 1 TRAVELING AND PARKING BRAKE 5 M1 KiSC issued 03 2007 A...

Page 298: ...essure 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 corres...

Page 299: ...5 S4 4 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 Removi...

Page 300: ...nder 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...

Page 301: ...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 Brake Piston Flatness 0 3 mm 0 012 in Brake Disc Thickness 4 15 to 4 35 mm 0 1634 to 0 1713 in 3...

Page 302: ...er 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...

Page 303: ...eel mounting nut 343 to 401 35 to 41 254 to 297 Cabin mounting bolt and nut 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...

Page 304: ...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...

Page 305: ...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 chemi...

Page 306: ...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 p...

Page 307: ...ling 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 f...

Page 308: ...he engine is not stopped check the parking brake pad and brake plate See page 5 S17 to 18 W1014561 Checking Brake Pressure 1 Remove the trailer brake coupler 5 and set the hydraulic brake adaptor 3 jo...

Page 309: ...r 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 be...

Page 310: ...r 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 bon...

Page 311: ...zer 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 Reference W1017215 Master cylinder return spring Free l...

Page 312: ...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 W1020945 Draining Fuel When remov...

Page 313: ...lower link 4 with stabilizer 5 When reassembling 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 W1021560 Tig...

Page 314: ...ssembling Apply liquid gasket Three Bond 1208D 1216 or equivalent to the seam of brake case and transmission case Apply grease to the O ring W1021861 Tightening torque Cabin mounting bolt and nut 123...

Page 315: ...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 bra...

Page 316: ...ng 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 g...

Page 317: ...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...

Page 318: ...f the thickness is less than the allowable limit replace it W1021315 Brake disc wear Factory spec 4 15 to 4 35 mm 0 1634 to 0 1713 in Allowable limit 3 3 mm 0 130 in Brake plate wear Factory spec 2 25...

Page 319: ...6 FRONT AXLE KiSC issued 03 2007 A...

Page 320: ...CONTENTS MECHANISM 1 STRUCTURE 6 M1 1 4 WHEEL DRIVE TYPE 6 M2 KiSC issued 03 2007 A...

Page 321: ...ft 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 a...

Page 322: ...ECIFICATIONS 6 S2 3 TIGHTENING TORQUES 6 S4 4 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 F...

Page 323: ...t 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 Front Wheels Can Not...

Page 324: ...9 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...

Page 325: ...6 S3 M105S WSM FRONT AXLE W1011456 Item Factory Specification Allowable Limit Thrust Collar Thickness 1 55 to 1 65 mm 0 0610 to 0 0650 in 1 0 mm 0 039 in KiSC issued 03 2007 A...

Page 326: ...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 l...

Page 327: ...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 W1018163 Axial Sway of Front Wheel 1 Jac...

Page 328: ...re 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 W1013116 Tighteni...

Page 329: ...in 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...

Page 330: ...fter filling reinstall the filling plugs 1 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...

Page 331: ...he cylinder cover 3 5 Disconnect the power steering hoses 1 2 When reassembling W1013932 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 Cylin...

Page 332: ...ock cable 4 at the center of thread 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 diffe...

Page 333: ...Install the bevel gear case to the front differential case noting the O ring W1016047 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 lo...

Page 334: ...y gear oil to the bearing IMPORTANT Be sure to adjust the kingpin pivot See page 6 S6 W1016334 Front Wheel Case Cover 1 Remove the front wheel case cover from the front wheel case by screwing M10 scre...

Page 335: ...ing 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...

Page 336: ...y 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 W1018079 Front Axle 1 Tap out the front axle from front wheel case cover Whe...

Page 337: ...ply liquid gasket Three Bond 1208D 1216 or equivalent to the front differential case 1 W1018729 Pinion Bearing Case 1 Remove the pinion bearing case mounting screws 2 Remove the pinion bearing case W1...

Page 338: ...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 pini...

Page 339: ...1324B or equivalent to the spiral bevel gear UBS screws W1020208 Tightening torque Spiral bevel gear UBS screw 29 4 to 34 3 N m 3 0 to 3 5 kgf m 21 7 to 25 3 ft lbs 1 Bearing 2 27T Spiral Bevel Gear 3...

Page 340: ...side in the standard Thickness of adjusting shims 6 The 0 4 mm 0 012 in shim is built in the standard Backlash changes per 0 1 mm 0 004 in shim Approx 0 05 mm 0 002 in IMPORTANT Adjust the tooth conta...

Page 341: ...e between differential case and differential side gear 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 m...

Page 342: ...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 W1022243 Front bracket and rear bracket bushing Alloy thickness A 0 5...

Page 343: ...the shaft diameter to the gear diameter 4 If the backlash exceeds the allowable limit adjust with the shims 1 Reference Thickness of adjusting shim 1 The 1 0 mm 0 039 in shim is built in the standard...

Page 344: ...e allowable limit replace them W1023313 Thrust Collar Thickness 1 Measure the thickness of the thrust collar 2 If the measurement is less than the allowable limit replace it W1023552 Backlash between...

Page 345: ...ter 4 If the backlash exceeds the allowable limit adjust with the shims 1 Reference Thickness of adjusting shim 1 The 2 0 mm 0 078 in shim is built in the standard W1023691 Backlash Play x 2 Backlash...

Page 346: ...7 STEERING KiSC issued 03 2007 A...

Page 347: ...CONTENTS MECHANISM 1 STRUCTURE 7 M1 1 STEERING MECHANISM 7 M1 KiSC issued 03 2007 A...

Page 348: ...e 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...

Page 349: ...G 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 C...

Page 350: ...ioning Repair or replace 8 S26 Steering Wheel Turns SpontaneouslyWhen Released Control valve malfunctioning Repair or replace 8 S26 Front Wheels Wander to Right and Left Control valve malfunctioning R...

Page 351: ...o 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...

Page 352: ...ntroller joint 4 5 Remove the steering controller bracket 5 6 Remove the steering controller 6 When reassembling W1012259 1 Bonnet 2 Muffler Pipe Tightening torque Main delivery pipe and return pipe r...

Page 353: ...linder When reassembling W1013465 Tightening torque 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...

Page 354: ...8 HYDRAULIC SYSTEM KiSC issued 03 2007 A...

Page 355: ...OW 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 T...

Page 356: ...s 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 p...

Page 357: ...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...

Page 358: ...artridge 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 Hydraulic Cylinder 14 Regulator Valve 15 Swing Sh...

Page 359: ...Inching Valve Spool 8 Modulating Valve a Clutch Pedal Released Position b Clutch Pedal Depressed Position c Shuttle Forward Position d Shuttle Neutral Position e Shuttle Reverse Position f Oil from R...

Page 360: ...component parts 1 Power Steering Controller 2 Modulation Valve 3 Shuttle Shift Spool Forward Reverse 4 Proportionally Reducing Valve 5 Accumulate Valve 6 Shuttle Valve 7 PTO Clutch Control Valve 8 Oil...

Page 361: ...8 M6 M105S WSM HYDRAULIC SYSTEM 2 OPERATION Shuttle Lever at Neutral Position KiSC issued 03 2007 A...

Page 362: ...not engage 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 Modu...

Page 363: ...8 M8 M105S WSM HYDRAULIC SYSTEM When Shuttle Lever is Shifting Neutral to Reverse or Forward Position Clutch Pedal is Released KiSC issued 03 2007 A...

Page 364: ...alve 4 assists the operation of modulating valve 1 to reduce a shock 1 Modulating Valve 2 Proportionally Reducing Valve 3 Shuttle Shift Spool Forward Reverse 4 Accumulate Valve 5 Shuttle Valve 6 Inchi...

Page 365: ...8 M10 M105S WSM HYDRAULIC SYSTEM Shuttle Lever at Reverse Position Clutch Pedal is Released KiSC issued 03 2007 A...

Page 366: ...ugh F port and shuttle shift spool 3 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 Clutc...

Page 367: ...8 M12 M105S WSM HYDRAULIC SYSTEM Shuttle Lever at Forward Position Clutch Pedal is Released KiSC issued 03 2007 A...

Page 368: ...ugh R port and shuttle shift spool 3 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 Clutc...

Page 369: ...8 M14 M105S WSM HYDRAULIC SYSTEM When Clutch Pedal is Depressed with Shuttle Lever at Reverse or Forward Position KiSC issued 03 2007 A...

Page 370: ...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 no...

Page 371: ...huttle 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 Lubricatio...

Page 372: ...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...

Page 373: ...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 ac...

Page 374: ...eed 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 W1017062 1 Valve Body 2 Line Filter 3 Connect...

Page 375: ...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...

Page 376: ...lement 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 W1017705...

Page 377: ...rvoir 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...

Page 378: ...ictor 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 thro...

Page 379: ...e 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 tra...

Page 380: ...ernal 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 hydra...

Page 381: ...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...

Page 382: ...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 b...

Page 383: ...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 u...

Page 384: ...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 t...

Page 385: ...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...

Page 386: ...ng 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 t...

Page 387: ...s 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...

Page 388: ...int 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 P...

Page 389: ...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 Implement Does Not Lower Control...

Page 390: ...DRAULIC SYSTEM W1010986 Symptom Probable Cause Solution Reference Page Draft Control Malfunctioning Draft control linkage improperly adjusted Adjust 8 S21 Torsion bar weak or broken Replace 8 S22 KiSC...

Page 391: ...ing Bore Depth of Scratch 0 09 mm 0 0035 in Bushing to Gear Shaft Clearance 0 15 mm 0 0059 in 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...

Page 392: ...ine Speed Above 15 5 MPa 158 kgf cm2 2247 psi At Maximum Engine Speed Below 16 5 MPa 168 kgf cm2 2390 psi Steering Cylinder I D 60 000 to 60 074 mm 2 36220 to 2 36512 in 60 100 mm 2 36614 in Position...

Page 393: ...in 100 15 mm 3 94291 in Hydraulic Arm Shaft to Bushing 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...

Page 394: ...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 scre...

Page 395: ...n 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 u...

Page 396: ...600 min 1 rpm Rated pressure 16 5 MPa 168 kgf cm2 2390 psi Oil temperature 45 to 55 C 113 to 131 F W1015188 Hydraulic pump delivery at rated pressure Factory spec 48 9 L min 12 9 U S gals min 10 8 Imp...

Page 397: ...clockwise 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...

Page 398: ...600 min 1 rpm Rated pressure 18 6 MPa 190 kgf cm2 2702 psi Oil temperature 45 to 55 C 113 to 131 F W1017146 Hydraulic pump delivery at rated pressure Factory spec 66 6 L min 17 6 U S gals min 14 7 Imp...

Page 399: ...3 to 131 F 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 insta...

Page 400: ...egulator 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 h...

Page 401: ...sen 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 Pres...

Page 402: ...k 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 an...

Page 403: ...ations 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 Condition Engine...

Page 404: ...nt 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 wa...

Page 405: ...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...

Page 406: ...nut 3 firmly When reassembling Install the cylinder safety valve to the hydraulic cylinder block taking care not to damage the O ring NOTE Use specified transmission fluid see page G 8 to test the ope...

Page 407: ...0 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...

Page 408: ...y 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 f...

Page 409: ...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 d...

Page 410: ...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...

Page 411: ...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...

Page 412: ...ree 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 th...

Page 413: ...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 m...

Page 414: ...ap 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 i...

Page 415: ...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 p...

Page 416: ...tch with the sleeve notch 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 reassem...

Page 417: ...e 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 th...

Page 418: ...and auxiliary control wire cable 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 adjust...

Page 419: ...ve noting O ring and backup ring 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 W1042131 Tightening torque Sea...

Page 420: ...on of O ring 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 notc...

Page 421: ...tting screw to the specified torque insert a wire through the holes of the screw head and hydraulic arm W1044235 Hydraulic Arm and Hydraulic Rod 1 Remove the spring pin 2 and separate the hydraulic ar...

Page 422: ...aulic piston bottom contacts with hydraulic rod 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 poppe...

Page 423: ...he gear shaft and the bushing as a unit 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 l...

Page 424: ...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 6...

Page 425: ...9 ELECTRICAL SYSTEM KiSC issued 03 2007 A...

Page 426: ...ING 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 M1...

Page 427: ...R 0 85 Br 0 85 Br 0 85 R W 0 85 R W 0 85 G 1 25 Y B Front Wiper Meter 0 5 R 0 5 G W 0 5 G W 0 85 G R 0 85 G R 0 85 G R 0 85 G 0 85 G 0 85 G Heater Timer Hazard Switch 2 W R 0 5 B L 0 5 Lg 0 5 Lg 0 5 Y...

Page 428: ...G 0 5 G 0 5 Y 0 5 Y 0 5 L Or 0 5 L Or 0 5 B Y 0 5 Y B 0 5 B Y 0 5 W 0 5 R 0 5 W 0 5 R 0 5 W B 0 5 W B 2 B 2 B 2 B 0 5 B Y 0 5 Y B 2 B 2 Y G 2 Y G 2 L Y 2 L Y 0 5 B Y 2 B 3 Y B Blower Meter Blower Resi...

Page 429: ...R 5 R 5 R 0 5 B 0 5 B 5 R 5 R 5 R 0 5 W L 0 85 Y L 0 85 B 0 85 B Diode 0 5 B 0 5 L G 0 5 Lg 0 5 Y 0 85 B 0 5 Y Fuel Unit Fuel Tank 0 5 B W H Switch 0 5 R W H Switch 0 5 Br W L Switch 0 5 R L L Switch...

Page 430: ...ate TIMER Safety Switch 3 4 Speed Change Monitor Safety Switch 1 2 Speed Change Monitor Starter Relay To Meter Panel Charge 5A PTO Safety Relay Slow Blow Fuse Box 3 30A Meter Panel 2R W 2R W 1 25B 0 8...

Page 431: ...5Br L 0 5Br W 0 5R W 0 5R L 0 5R W 0 5R L 0 5W 0 5Y 0 5B 0 5Br L 0 5Br W 0 5Br W 0 5Br L 0 5Br L 0 5Br W 0 5Br L 0 5Br W Diode 10A Buzzer Diode 2 1 Diode Dual Shift Solenoid Dual Shift Switch B R LOC...

Page 432: ...PUSH R L OFF Turn Switch 4 12 6 Flasher Circuit To Meter Panel Trailer 11 10 Flasher Unit 1 3 2 13 0 85G 0 85G 0 85G R 0 85G R 0 85B 0 5R W 0 5R W 0 85G R 0 5B 0 85B 0 5B 0 5L 0 5R 0 5G W 0 85Br 0 85...

Page 433: ...OPC Unit 0 5R Y 0 5R Y 0 5R Y Engine Coolant Temperature Sensor 0 5W R 2 1 M5 0 5B 0 85B Sender Thermistor Fuel Sensor 3 4 6 5 16 15 0 5W R 19 17 0 5B Turn Signal LH Illumination LH Turn Signal RH Il...

Page 434: ...Power Outlet Beacon Lamp Option 2R 2R G 1 25B 1 25B Beacon Switch OFF ON E R B 14V1 12W 2R G Beacon Relay 3 2 1 5 4 25A To Auxiliary Power Relay 5A Speaker LH Antenna Radio CD Unit Speaker RH To Dome...

Page 435: ...25L 1 25L 0 85Lg W 1 25L 0 85Lg W 0 85Lg B 1 25L 0 85Lg W 0 85Lg Y Washer Motor 0 85B 0 85B Rear Front Front Wiper Motor Front Wiper Switch WASH INT OFF ON WASH WV WM E 1 INT C E D 0 85B A B Timer Cir...

Page 436: ...or 0 47 1 00 5A 25A 0 5Y B 3W Blower Relay 4 5 1 2 3 3W 0 5Y B 3Y R 3Y B 2B 2B 2Y G 2L Y 0 5B Y 0 5B Y 0 5B Y 0 5B Y 0 5B Y Blower Motor Switch 3 4 1 2 OFF F D 1 Lo 2 Me 3 Hi 0 5B Y 2L Y 2Y G 2B AVSSF...

Page 437: ...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...

Page 438: ...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 Wh...

Page 439: ...e 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...

Page 440: ...elay 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 th...

Page 441: ...9 M15 M105S WSM ELECTRICAL SYSTEM 4 CHARGING SYSTEM 1 ELECTRICAL CIRCUIT W1015223 1 Battery 2 Main Switch 3 Slow Blow Fuse 4 Alternator A To Charging Lamp Meter Panel KiSC issued 03 2007 A...

Page 442: ...3 Flasher Unit 4 Horn 5 Head Lamp LH 6 Head Lamp RH 7 Dome Lamp 8 Door Switch LH 9 Door Switch RH 10 Licence Light 11 Front Combination Lamp LH 12 Rear Combination Lamp LH 13 Front Combination Lamp R...

Page 443: ...zard flasher unit is a summary to one as for past hazard flasher unit hazard relay and charge relay W1015651 1 Battery 2 Main Switch 3 AC Terminal 4 B Terminal 5 Turn Signal Switch 6 Hazard Switch 7 T...

Page 444: ...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...

Page 445: ...Pressure Lamp 7 Parking Brake Switch 8 Brake Oil Switch 9 Engine Oil Pressure Switch 10 Fuel Unit 11 Low Speed Lamp 12 High Speed Lamp 13 High Beam Lamp 14 Trailer Indicator Lamp 15 Air Cleaner Lamp 1...

Page 446: ...elay 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...

Page 447: ...sitive terminal and alternator B terminal Repair or replace Cooling fan belt slipping Adjust tension G 21 Starter Motor Does Not Operate Battery discharged or defective Recharge or replace 9 S10 Slow...

Page 448: ...r L terminal Repair or replace Charging Lamp Does Not Go Off When Engine Is Running Short circuit between alternator L terminal lead and chassis Repair or replace Alternator defective Repair or replac...

Page 449: ...n Reference Page Dual Speed Monitor Not Indicate Fuse blown Replace G 41 Dual speed switch defective Replace 9 S25 Dual speed indicator bulb blown Replace 9 S25 Wiring harness disconnected or improper...

Page 450: ...epair or replace Tail Light Does Not Light Fuse blown Replace G 41 Wiring harness disconnected or improperly connected between combination switch T terminal and tail light Repair or replace Hazard Lig...

Page 451: ...itch lead and chassis Repair 9 S36 Circuit in panel board defective Replace 9 S33 Engine Oil Pressure Lamp Does Not Light When Main Switch Is Turned ON and Engine Is Not Running Bulb blown Replace Eng...

Page 452: ...operly connected between panel board and fuel level sensor Repair or replace Circuit in panel board defective Replace Coolant Temperature Gauge Does Not Function Coolant temperature gauge defective Re...

Page 453: ...h Length 18 0 mm 0 7086 in 11 0 mm 0 4331 in Brush Length 18 5 mm 0 728 in 5 0 mm 0 197 in Slip Ring O D 22 7 mm 0 894 in 22 1 mm 0 870 in Float at Uppermost Position Resistance 1 0 to 5 0 Float at Lo...

Page 454: ...neral use screws bolts and nuts See page G 10 W1012736 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...

Page 455: ...ery 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...

Page 456: ...battery positive terminal 2 to the charge positive terminal and the negative 3 to the negative then recharge in the standard fashion 2 A boost charge is only for emergencies It will partially charge t...

Page 457: ...harge Rate 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 check...

Page 458: ...urn 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 indicat...

Page 459: ...ssis 7 If the voltage differs from the battery voltage the wiring harness or slow blow fuse is faulty W1019485 Functional Check 1 Remove the air heater relay 2 Apply battery voltage across the 1 and 2...

Page 460: ...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 measu...

Page 461: ...ot conduct replace the air heater 1 When reassembling W1021112 Resistance Lead 1 Ground Lead 2 Ground Approx 0 Lead terminal nut tightening torque Factory spec 3 43 to 5 39 N m 0 35 to 0 55 kgf m 2 53...

Page 462: ...lished across the 1 and 2 terminals replace it 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 t...

Page 463: ...nnect 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 W1022645 Magnet Switch Test 1 Disconnect the batter...

Page 464: ...t 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 jum...

Page 465: ...olenoid 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 i...

Page 466: ...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...

Page 467: ...is released the switch is faulty 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 condu...

Page 468: ...ing 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 W1027541 Resistance Across switch te...

Page 469: ...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 doe...

Page 470: ...across the 1 terminal to the chassis and the 2 terminal to the chassis 3 If infinity is indicated the solenoid valve is faulty W1028218 Resistance HI solenoid valve 1 terminal to chassis 10 to 12 LO...

Page 471: ...N and turning OFF 4 If infinity is not indicated when switch is pushed on the turning OFF position the switch is faulty W1029124 Connector Voltage 1 Disconnect the dual speed valve wire harness connec...

Page 472: ...or 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 W1030117 Resistance Solenoid valve 1 termina...

Page 473: ...able 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...

Page 474: ...tch 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...

Page 475: ...en 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...

Page 476: ...the voltage differs from the battery voltage the wiring harness is faulty W1035451 Hazard Switch Continuity 1 Measure the resistance with ohmmeter across the a terminal and c terminal and across the d...

Page 477: ...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 abo...

Page 478: ...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...

Page 479: ...ng checking 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 batte...

Page 480: ...ge is faulty W1039199 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 Sig...

Page 481: ...t temperature gauge is faulty W1039964 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 Illumi...

Page 482: ...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 W1040687 Air Cleaner Sensor Panel Boa...

Page 483: ...5 to the chassis 4 If the charge lamp 1 does not light the panel board circuit alternator wiring harness or fuse is fault W1041413 21 Parking Brake Switch Wiring Harness 1 Disconnect the leads from t...

Page 484: ...ake brake oil level indicator lamp does not light on the panel board circuit or the wiring harness is faulty W1042861 Brake Oil Level Switch Continuity 1 Check the continuity between the 1 and 2 termi...

Page 485: ...he switch is pulled the switch is faulty 4 If infinity is not indicated when the switch is released the switch is faulty W1050616 24 Fuel Limit Sensor Panel Board and Wiring Harness 1 Start the engine...

Page 486: ...er to adjust to the atmospheric temperature before the in air amperage is measured W1044958 25 Fuel Level Sensor Functional Check 1 Remove the fuel level sensor from the fuel tank 2 Measure the resist...

Page 487: ...ary 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 o...

Page 488: ...he rotor base of the claw in a vise Loosen the lock nut using a M24 box wrench W1047823 Rotor 1 Remove the four screws and detach the bearing retainer 2 Temporarily install the nut on the pulley screw...

Page 489: ...on 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 Tig...

Page 490: ...rcut 6 If the undercut is less than the allowable limit correct it with a saw blade and chamfer the segment edges W1049581 Brush Wear 1 If the contact face of the brush is dirty or dusty clean it with...

Page 491: ...ny 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 do...

Page 492: ...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 i...

Page 493: ...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 W1051525 Brush Wear 1 Measure the brush length with a vernier...

Page 494: ...tifier 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 dire...

Page 495: ...10 CABIN KiSC issued 03 2007 A...

Page 496: ...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...

Page 497: ...ITIONING 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 9 Condenser 10...

Page 498: ...oning 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...

Page 499: ...while washing the vehicle 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 windshiel...

Page 500: ...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 k...

Page 501: ...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 Pus...

Page 502: ...et 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...

Page 503: ...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 an...

Page 504: ...tion 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 tem...

Page 505: ...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 1 Mode Switch 2 Temperature Control Dial 3...

Page 506: ...e 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 f...

Page 507: ...Switch 1 Blower Switch 2 Battery 3 Main Switch 4 A C Switch 5 Compressor Relay 6 Thermo Switch 7 A C Pressure Switch 8 Magnetic Clutch 9 Blower Relay 10 Blower Motor 11 Blower Resistor 12 Slow Blow Fu...

Page 508: ...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...

Page 509: ...ging 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...

Page 510: ...ace 10 S45 Blower switch defective Replace 10 S26 Wiring harness disconnected or improperly connected Repair Does Not Cool Compressor Does Not Rotate Fuse blown Replace Magnetic clutch defective Repai...

Page 511: ...ld 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...

Page 512: ...10 S3 M105S WSM CABIN Air Conditioning System Continued KiSC issued 03 2007 A...

Page 513: ...10 S4 M105S WSM CABIN KiSC issued 03 2007 A...

Page 514: ...10 S5 M105S WSM CABIN KiSC issued 03 2007 A...

Page 515: ...g Speed Is Too Low 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 a...

Page 516: ...to 242 psi Pressure Switch Dual Type When pressure switch is turned OFF 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 a...

Page 517: ...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 an...

Page 518: ...n 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...

Page 519: ...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 T...

Page 520: ...ort 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 p...

Page 521: ...nnector 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 th...

Page 522: ...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 va...

Page 523: ...turn the handle 1 counterclockwise To stop charging turn it clockwise 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...

Page 524: ...ng 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...

Page 525: ...essive 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...

Page 526: ...acuation 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...

Page 527: ...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 W1017346 E...

Page 528: ...re 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 s...

Page 529: ...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...

Page 530: ...ated 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 a...

Page 531: ...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...

Page 532: ...comes 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...

Page 533: ...is in operation 4 If anything abnormal is found repair or replace W1014211 Stator Coil 1 Measure the resistance of the stator coil with an ohmmeter across the 1P connector 1 of magnetic clutch and com...

Page 534: ...or 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...

Page 535: ...ery voltage the wiring harness A C relay fuse or main switch is faulty W1019240 Blower Switch Test 1 Check the continuity through the switch with an ohmmeter 2 If the continuity specified below are no...

Page 536: ...nal momentarily 6 If the blower motor does not run check the motor W1020120 5 Blower Resistor Blower Resistor Check 1 Disconnect the 4P connector for blower resistor 1 2 Measure each resistance from B...

Page 537: ...ness A C relay or fuse is faulty 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 1 Push the...

Page 538: ...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 W1022044 Terminal Po...

Page 539: ...eck 1 Confirm whether the mode switch 3 is defective See page 10 S29 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...

Page 540: ...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 act...

Page 541: ...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...

Page 542: ...the continuity through the switch with an ohmmeter 2 If the continuity specified below are not indicated the switch is faulty W1046557 Terminal Position IN 1 E WY WM WASH I ON OFF INT WASH II 1 Front...

Page 543: ...e 1 terminal under B condition Bulb lights up and an intermittent sound is heard from relay 6 If any defective is found replace it W1046930 14 Front Wiper Motor Front Wiper Motor 1 Raise up the front...

Page 544: ...drain plug 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 bonne...

Page 545: ...er hose 8 When reassembling Be sure to connect the power steering turning hoses to original positions W1050711 Tightening torque Oil cooler pipe nut 49 0 to 68 6 N m 5 0 to 7 0 kgf m 36 1 to 50 6 ft l...

Page 546: ...ling 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 Disconnec...

Page 547: ...e 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 W1055474 Preparation 5 1 Disconnect the connecto...

Page 548: ...0 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 clut...

Page 549: ...e 3 See page 2 S6 Be sure to adjust the length of main shift rod 1 9 See page 3 S11 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 p...

Page 550: ...mounting bolts and nuts 3 Dismounting the cabin from tractor body When reassembling W1062418 Tightening torque Cabin mounting screws and nuts 123 6 to 147 1 N m 12 6 to 15 0 kgf m 91 1 to 108 5 ft lbs...

Page 551: ...gerant 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 suc...

Page 552: ...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 W1059166 Rotor 1 Remove the ex...

Page 553: ...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 o...

Page 554: ...erant 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 W1066...

Page 555: ...ing Apply compressor oil DENSO CO ND OIL8 to the O rings and take care not to damage them W1067402 Inner Covers 1 Remove the inner covers 1 2 2 Remove the seat 3 W1067892 Tightening torque Low pressur...

Page 556: ...ses 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...

Page 557: ...moving 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 connec...

Page 558: ...ternately 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...

Page 559: ...nect 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 b...

Page 560: ...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 W1071460 Tightening torque Wiper arm mounting nut 7 8 t...

Page 561: ...de No 9Y011 13350 2004 12 S EI EI e KUBOTA Corporation 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 2...

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