Download Print this page

Kubota M8540 Workshop Manual

Kubota M8540 Workshop Manual

Hide thumbs Also See for M8540:

Operator's manual (168 pages)

,

Operator's manual (37 pages)

,

Operator's manual (111 pages)

Table of Contents

Advertisement

Quick Links

Download this manual See also: Operator's Manual

WORKSHOP MANUAL

TRACTOR

M8540,M9540

KiSC issued 09, 2008 A

Table of Contents

Advertisement

Chapters

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the M8540 and is the answer not in the manual?

Questions and answers

Summary of Contents for Kubota M8540

Page 1 WORKSHOP MANUAL TRACTOR M8540,M9540 KiSC issued 09, 2008 A...
Page 2 TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of M8540 and M9540. It is divided into three parts, “General”, “Mechanism” and “Servicing”. General Information on the tractor identification, the general precautions, maintenance check list, check and maintenance and special tools are described.
Page 3 SAFETY INSTRUCTIONS M8540, M9540, WSM SAFETY INSTRUCTIONS SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
Page 4 SAFETY INSTRUCTIONS M8540, M9540, WSM SAFETY STARTING • Do not start the engine by shorting across starter terminals or bypassing the safety start switch. • Do not alter or remove any part of machine safety system. • Before starting the engine, make sure that all shift levers are in neutral positions or in disengaged positions.
Page 5 SAFETY INSTRUCTIONS M8540, M9540, WSM AVOID FIRES • Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. • To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last.
Page 6 SAFETY INSTRUCTIONS M8540, M9540, WSM PREPARE FOR EMERGENCIES • Keep a first aid kit and fire extinguisher handy at all times. • Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. KiSC issued 09, 2008 A...
Page 7: Safety Decals
SAFETY INSTRUCTIONS M8540, M9540, WSM SAFETY DECALS The following safety decals (pictorial safety labels) 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.
Page 8 SAFETY INSTRUCTIONS M8540, M9540, WSM KiSC issued 09, 2008 A...
Page 9 SAFETY INSTRUCTIONS M8540, M9540, WSM KiSC issued 09, 2008 A...
Page 10 SAFETY INSTRUCTIONS M8540, M9540, WSM CABIN Model KiSC issued 09, 2008 A...
Page 11 SAFETY INSTRUCTIONS M8540, M9540, WSM KiSC issued 09, 2008 A...
Page 12 SAFETY INSTRUCTIONS M8540, M9540, WSM KiSC issued 09, 2008 A...
Page 13: Specifications
SPECIFICATIONS M8540, M9540, WSM SPECIFICATIONS M8540 M9540 Model Model V3800DI-TE3 Type Vertical, water-cooled, 4-cycle direct injection diesel engine Number of cylinders Total displacement 3769 cm (230.0 cu.in.) 100 × 120 mm (3.9 × 4.7 in.) Bore and stroke −1 Rated speed...
Page 14: Traveling Speeds
TRAVELING SPEEDS M8540, M9540, WSM TRAVELING SPEEDS (At rated engine rpm) Model M8540 / M9540 Tire size (Rear) 480/70R34 without Dual Transmission type with Dual speed speed Shuttle shift Range gear Main gear km/h (mph) lever shift lever shift lever...
Page 15 TRAVELING SPEEDS M8540, M9540, WSM (At rated engine rpm) Model M8540 / M9540 Tire size (Rear) 480/70R34 without Dual Transmission type with Dual speed speed Shuttle shift Range gear Main gear km/h (mph) lever shift lever shift lever km/h (mph) km/h (mph) 0.43 (0.27)
Page 16 DIMENSIONS M8540, M9540, WSM DIMENSIONS ROPS Model KiSC issued 09, 2008 A...
Page 17 DIMENSIONS M8540, M9540, WSM CABIN Model KiSC issued 09, 2008 A...
Page 18 GENERAL KiSC issued 09, 2008 A...
Page 19: Table Of Contents
GENERAL CONTENTS 1. TRACTOR IDENTIFICATION ................. G-1 [1] MODEL NAME AND SERIAL NUMBERS..........G-1 (1) Tractor Number ..................G-1 (2) Engine Number ..................G-1 [2] E3 ENGINE ....................G-3 [3] CYLINDER NUMBER ................G-3 2. GENERAL PRECAUTIONS ................G-4 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-5 [1] WIRING......................
Page 20: Tractor Identification
M8540, M9540, WSM 1. TRACTOR IDENTIFICATION [1] MODEL NAME AND SERIAL NUMBERS (1) Tractor Number When contacting your local KUBOTA distributor, always specify engine serial number, tractor serial number and hourmeter reading. (1) Tractor Identification Plate (4) ROPS Identification Plate...
Page 21: Engine Number
G GENERAL M8540, M9540, WSM (2) Engine Number Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows. • Year of manufacture...
Page 22: E3 Engine
Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the respective countries affected by Non-Road Emission regulations. For Kubota Engines, E3 will be the designation that identifies engine models affected by the next emission phase (See the table below).
Page 23: General Precautions
Screws, bolts and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
Page 24: Handling Precautions For Electrical Parts And Wiring
G GENERAL M8540, M9540, WSM 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring...
Page 25 G GENERAL M8540, M9540, WSM • Securely insert grommet. (1) Grommet (A) Correct (B) Incorrect W1011388 • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W1011458 •...
Page 26: Battery
G GENERAL M8540, M9540, WSM [2] BATTERY • Take care not to confuse positive and negative terminals. • When removing battery cable, disconnect negative wire first. When installing battery cable, check for polarity and connect positive wire first. • Do not install any battery with capacity other than is specified (Ah).
Page 27: Handling Of Circuit Tester
G GENERAL M8540, M9540, WSM • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust W1012346 • Make certain that there is no female connector being too open.
Page 28: Lubricants, Fuel And Coolant
6.3 U.S.qts. case oil 5.3 Imp.qts. KUBOTA UDT or SUPER UDT fluid* or SAE80, SAE90 gear oil Front axle gear 3.5 L case oil (one 3.7 U.S.qts. side) 3.1 Imp.qts. * KUBOTA original transmission hydraulic fluid. KiSC issued 09, 2008 A...
Page 29 G GENERAL M8540, M9540, WSM Greasing Place No. of greasing points Capacity Type of grease Front axle gear case support Front axle support Top link Multipurpose Top link bracket Until grease NLGI-2 or NLGI- overflows 1 (GC-LB) Lift rod grease...
Page 30 The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and to complete lubrication of the transmission, it is important that a multi-grade transmission fluid is used in this system. We recommend the use of KUBOTA UDT or SUPER UDT fluid for optimum protection and performance.
Page 31: Tightening Torques
G GENERAL M8540, M9540, WSM 5. TIGHTENING TORQUES Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. [1] GENERAL USE SCREWS, BOLTS AND NUTS Indication on top of...
Page 32: Hydraulic Fittings
G GENERAL M8540, M9540, WSM [3] HYDRAULIC FITTINGS Hydraulic Hose Fittings Tightening torque Hose size Thread size N·m kgf·m lbf·ft 13.7 to 15.7 1.4 to 1.6 10.1 to 11.6 22.6 to 27.5 2.3 to 2.8 16.6 to 20.3 45.1 to 53.0 4.6 to 5.4...
Page 33: Maintenance
G GENERAL M8540, M9540, WSM 6. MAINTENANCE Indication on hour meter Refe- Inter- Impor- Item rence 50 100 150 200 250 300 350 400 450 500 550 600 650 700 tant page every Engine start system Check G-22 50 Hr...
Page 34 G GENERAL M8540, M9540, WSM Service Interval Refe- Since Impor- Item rence 50 100 150 200 250 300 350 400 450 500 550 600 650 700 then tant page every Water separator Clean G-32 400 Hr every Fuel filter Replace...
Page 35 G GENERAL M8540, M9540, WSM Service Interval Refe- Since Impor- Item rence 50 100 150 200 250 300 350 400 450 500 550 600 650 700 then tant page every Inner air filter Clean G-30 200 Hr every Fresh air filter...
Page 36: Check And Maintenance
G GENERAL M8540, M9540, WSM 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the tractor on a flat place with engine shut off, the parking brake on and chock the wheels. [1] DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the tractor. Check the following items before starting.
Page 37: Check Points Of Initial 50 Hours
G GENERAL M8540, M9540, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Before changing oil, be sure to stop the engine. • Allow engine to cool down sufficiently, oil can be hot and can burn.
Page 38 9. Make sure that the transmission fluid doesn’t leak through the seal. IMPORTANT • To prevent serious damage to the hydraulic system, use only a KUBOTA genuine filter. (1) Drain Plug (A) Oil level is acceptable within this (2) Hydraulic Oil Filter range.
Page 39 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). 4. (Refer to “4. LUBRICANTS, FUEL AND COOLANT” in this section.)
Page 40 G GENERAL M8540, M9540, WSM Changing Front Axle Gear Case Oil 1. To drain the used oil, remove the right and left drain plugs (1) and filling plugs (2) at the front axle gear case and drain the oil completely into the oil pan.
Page 41: Check Points Of Every 50 Hours
G GENERAL M8540, M9540, WSM [3] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System CAUTION • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test, do not operate the tractor.
Page 42: Check Points Of Every 100 Hours
G GENERAL M8540, M9540, WSM [4] CHECK POINTS OF EVERY 100 HOURS Lubricating Grease Fittings 1. Apply a small amount of multipurpose grease to following points every 100 hours. 2. If you operated the machine in extremely wet and muddy condition, lubricate grease fittings more often.
Page 43 G GENERAL M8540, M9540, WSM (Continued) (5) Grease Fitting (Top Link Bracket) (9) Steering Joint Shaft (6) Grease Fitting (Lifting Rod) (7) Grease Fitting (Top Link) [A] CABIN Model (8) Grease Fitting (Hydraulic Lift Cylinders Pin) W1025259 KiSC issued 09, 2008 A...
Page 44 G GENERAL M8540, M9540, WSM Cleaning Air Cleaner Element 1. Remove the air cleaner cover (3) and primary element (2). 2. Clean the primary element if: - When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm...
Page 45 G GENERAL M8540, M9540, WSM Adjusting Fan Belt Tension CAUTION • Be sure to stop the engine before checking belt tension. 10 to 12 mm Belt tension Factory spec. 0.39 to 0.47 in. 1. Stop the engine and remove the key.
Page 46 G GENERAL M8540, M9540, WSM Checking Battery Condition CAUTION • Never remove the vent plugs while the engine is running. • Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention.
Page 47: Check Points Of Every 200 Hours
G GENERAL M8540, M9540, WSM [5] CHECK POINTS OF EVERY 200 HOURS Checking Radiator Hose and Hose Clamp Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first. 1. If hose clamps (2) are loose or water leaks, tighten bands (2) securely.
Page 48 G GENERAL M8540, M9540, WSM Adjusting Toe-in 1. Park tractor on a flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lower the implement, lock the park brake and stop the engine. 4. Measure distance between tire beads at front of tire, hub height.
Page 49 G GENERAL M8540, M9540, WSM Cleaning Inner Air Filter (CABIN Model) 1. Remove the knob bolt (2) and pull out the filter (1). 2. Blow air from the direction opposite to the filter’s normal air flow. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm 30 psi).
Page 50: Check Points Of Every 300 Hours
G GENERAL M8540, M9540, WSM Checking Air Conditioner Condenser (CABIN Model) 1. Release the air conditioner hoses off the hook (1). 2. Loosen the wing nut (2). 3. Hold the handle (3), slide out the air conditioner condenser (7). 4. Check air conditioner condenser (7) and air conditioner condenser screen (6) to be sure it is clean of debris.
Page 51: Check Points Of Every 400 Hours
G GENERAL M8540, M9540, WSM [7] CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter 1. Remove the fuel filter (1). 2. Put a film of clean fuel on rubber seal of new filter. 3. Tighten the filter until it contacts the mounting surface. Tighten filter by hand an additional 1/2 turn only.
Page 52: Check Points Of Every 600 Hours
G GENERAL M8540, M9540, WSM [8] CHECK POINTS OF EVERY 600 HOURS Replacing Engine Oil Filter 1. Refer to “[2] CHECK POINTS OF INITIAL 50 HOURS” in this section. W1074023 Changing Transmission Fluid 1. Refer to “[2] CHECK POINTS OF INITIAL 50 HOURS” in this section.
Page 53: Check Points Of Every 3000 Hours
G GENERAL M8540, M9540, WSM [11] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger 1. Refer to “[1] CHECKING AND ADJUSTING” at “1. ENGINE” section. W1075136 Checking Injection Pump 1. Refer to “[1] CHECKING AND ADJUSTING” at “1. ENGINE” section.
Page 54: Check Points Of Every 2 Years
G GENERAL M8540, M9540, WSM [13] CHECK POINTS OF EVERY 2 YEARS Flush Cooling System and Changing Coolant CAUTION • Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
Page 55 G GENERAL M8540, M9540, WSM Flush Cooling System and Changing Coolant (Continued) Anti-Freeze CAUTION • When using antifreeze, put on some protection such as rubber gloves (Antifreeze contains position). • If should drink antifreeze, throw up at once and take medical attention.
Page 56 The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. NOTE •...
Page 57 G GENERAL M8540, M9540, WSM Cleaning Master Cylinder Filter 1. Remove the master cylinder pipe (2) from the master cylinder assembly (1). 2. Remove the filter (3) using the screwdriver. 3. Clean the filer (3) with kerosene and blow with air.
Page 58: Others
G GENERAL M8540, M9540, WSM [14] OTHERS Bleeding Fuel System Air must be removed: 1. When the fuel filter or lines are removed. 2. When water is drained from water separator. 3. When tank is completely empty. 4. After the tractor has not been used for a long period of time.
Page 59 G GENERAL M8540, M9540, WSM Replacing Light Bulb CAUTION • Be careful not to drop the bulb, hit anything against the lamp, apply excess force, and get the lamp scratched. If broken, glass may cause injury. Pay more attention to halogen lamps in particular, which have high pressure inside.
Page 60 G GENERAL M8540, M9540, WSM Adding Washer Liquid (CABIN Model) 1. Add a proper amount of automobile washer liquid. 1.3 L Tank capacity 1.4 U.S.gals. 1.1 Imp.gals. (1) Washer Liquid Tank W1120170 Checking Refrigerant (Gas) (CABIN Model) CAUTION • Liquid contact with eyes or skin may cause frostbite.
Page 61: Special Tools
G GENERAL M8540, M9540, WSM 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Diesel Engine Compression Tester Code No.: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnostics of need for major overhaul.
Page 62 G GENERAL M8540, M9540, WSM NOTE • The following special tools are not provided, make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa...
Page 63 G GENERAL M8540, M9540, WSM Small End Bushing Replacing Tool Application: Use to press out and to press fit the small end bushing. [Press out] 157 mm (6.1811 in.) 14.5 mm (0.571 in.) 120 mm (4.7244 in.) 30.0 mm dia. (1.1811 in. dia.) 32.95 mm dia.
Page 64 G GENERAL M8540, M9540, WSM Gear Case Oil Seal Replacing Tool Application: Use to press fit the oil seal. 148.8 mm (5.8582 in.) 50 mm (1.9685 in.) 18.8 mm (0.7401 in.) 13.7 to 13.9 mm (0.5394 to 0.5472 in.) 11 mm (0.433 in.) 18 mm dia.
Page 65 G GENERAL M8540, M9540, WSM Auxiliary Socket for Fixing Crankshaft Sleeve Application: Use to fix the crankshaft sleeve of the diesel engine. Rmax = 12.5 S 94.5 to 95.0 mm dia. (3.7205 to 3.7402 in. dia.) 40 mm dia. (1.5748 in. dia.) 30 mm dia.
Page 66 G GENERAL M8540, M9540, WSM Balancer Bushing Replacing Tool 1 Components Parts 1) Shaft 498 mm (19.61 in.) 318.8 to 319.2 mm (12.5726 to 12.5669 in.) 102.8 to 103.2 mm (4.0472 to 4.0630 in.) 60 mm (2.36 in.) 8 mm (0.31 in.) 5 mm (0.20 in.)
Page 67 G GENERAL M8540, M9540, WSM 3) Piece 2 Chamfer 0.1 mm (0.004 in.) 1 mm (0.04 in.) Chamfer 1 mm (0.04 in.) 54.3 to 54.4 mm dia. (2.1378 to 2.1417 in. dia.) 34.025 to 34.05 mm dia. (1.3396 to 1.3406 in. dia.) 48.5 mm dia.
Page 68 G GENERAL M8540, M9540, WSM Balancer Replacing Tools 3, 4, 5 Application: Use to press fit the bushing. Name of Part Q’ty Bracket Flange Nut Washer Shaft Piece 1 Clevis Washer Cotter Pin Joint 1 Piece 2 Joint 2 Piece 3...
Page 69 G GENERAL M8540, M9540, WSM 2) Shaft 44 mm dia. (1.73 in. dia.) 12 mm (0.47 in.) Chamfer 1 mm (0.04 in.) 3 mm (0.12 in.) 3 mm (0.12 in.) 30 mm (1.18 in.) 38 mm (1.38 in.) 35 mm (1.38 in.) M12 ×...
Page 70 G GENERAL M8540, M9540, WSM 4) Joint 1 M12 × P1.25 Chamfer 1 mm (0.04 in.) 30 mm dia. (1.18 in. dia.) 13 mm dia. (0.51 in. dia.) Chamfer 3 mm (0.12 in.) R3 mm (0.12 in. radius) 45 mm (1.77 in.) 75 mm (2.95 in.)
Page 71 G GENERAL M8540, M9540, WSM 7) Piece 3 26 mm (1.02 in.) 18 mm (0.71 in.) 16.5 to 17.0 mm (0.6496 to 0.6693 in.) 1.5 mm (0.06 in.) 53.0 to 53.2 mm dia. (2.0866 to 2.0945 in. dia.) 49.55 to 49.75 mm dia. (1.9508 to 1.9587 in. dia.) 16 mm (0.63 in.)
Page 72 G GENERAL M8540, M9540, WSM Timer Gear Puller Application: Use for removing the timer gear from governor shaft. 27 mm (1.1 in.) 130 mm (5.12 in.) 15 mm (0.59 in.) 115 mm (4.53 in.) 26 mm dia. (1.0 in. dia.) 0.8 mm radius (0.03 in.
Page 73 G GENERAL M8540, M9540, WSM Nozzle Adaptor for Measuring Cylinder Compression Pressure Application: Use for measuring diesel engine compression pressure. 5 mm (0.1969 in.) 3 mm dia., 44.5 to 45 mm depth (0.1181 in. dia., 1.7520 to 1.7717 in. depth) 115.9 to 116.1 mm (4.5630 to 4.5709 in.)
Page 74 G GENERAL M8540, M9540, WSM Jig for Governor Connecting Rod Application: Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly. 1 mm (0.0394 in.) C0.2 mm (0.0079 in.) C2 mm (0.0787 in.) 35 mm dia.
Page 75 G GENERAL M8540, M9540, WSM Tool for Aligning the Crankcase 1 and 2 Application: Use for aligning the crankcase 1 and 2. 115 mm (4.53 in.) 56 mm (2.2 in.) 17 mm (0.67 in.) 20 mm (0.79 in.) 14 mm dia. (0.55 in. dia.) 11 mm dia.
Page 76: Special Tools For Tractor
G GENERAL M8540, M9540, WSM [2] SPECIAL TOOLS FOR TRACTOR Tie-rod End Lifter Code No.: 07909-39051 Application: Use for removing the tie-rod end with ease. W10264720 Steering Wheel Puller Code No.: 07916-51090 Application: Use for removing the steering wheel without damaging the steering shaft.
Page 77 G GENERAL M8540, M9540, WSM Toe-in Gauge Code No.: 07909-31681 Application: This allows easy measurement of toe-in for all machine models. W10266890 Injector CH3 Code No.: 07916-52501 Application: Use for injecting calcium chloride solution into, and removing it from, rear wheel.
Page 78 G GENERAL M8540, M9540, WSM Power Steering Adaptor Code No.: 07916-54021 Application: Use for measuring the relief valve setting pressure for power steering. W10442870 NOTE • The following special tools are not provided, make them referring to the figure. Front Axle Rocking Restrictor 120 mm (4.72 in.)
Page 79 G GENERAL M8540, M9540, WSM Sliding Hammer Application : Use to removing the bevel pinion shaft with adaptor for front axle. 120 mm (4.72 in.) 14.5 mm dia. (0.57 in. dia.) 60 mm dia. (2.36 in. dia.) Chamfer 5 mm (0.20 in.) M14 x P1.5...
Page 80 G GENERAL M8540, M9540, WSM Adaptor (M6) for Sliding Hammer Application : Use to removing the front axle bevel pinion shaft with sliding hammer. M6 x P1.0 25 mm (0.98 in.) 50 mm (1.97 in.) 23 mm (0.91 in.) 27 mm (1.06 in.) M14 x P1.5...
Page 81 G GENERAL M8540, M9540, WSM Hydraulic Clutch Spring Compressor Application: Use exclusively for pushing the spring, to remove the circlip for hydraulic clutch. (1) Tool 4 (Plate) (5) Nut (M x P1.5) (2) Tool 3 (Clow) (6) Screw (M5 x P1.0 - L10mm)
Page 82 G GENERAL M8540, M9540, WSM (3) Tool 1 (Body) 140 mm dia. (5.51 in. dia.) Radius 50 mm (2.0 in.) Radius 3 mm (0.1 in.) 30 mm dia. (1.2 in. dia.) 2.09 rad (120 °) 17 mm dia. (0.67 in. dia.) 60 mm (2.4 in.)
Page 83 G GENERAL M8540, M9540, WSM Locking Wrench Application : Use for locking pinion nut. 170 mm (6.69 in.) 130 mm (5.12 in.) 63.5 mm (2.5 in.) 40 mm radius (1.57 in. radius) 55 mm (2.17 in.) 15 mm (0.59 in.) 35 mm (1.38 in.)
Page 84 G GENERAL M8540, M9540, WSM Hydraulic Arm Shaft Bushing Press-Fitting Tool Application : Use for replacing the hydraulic arm shaft bushings in the hydraulic cylinder body. NOTE • Unless otherwise specified : All surface 12.5 μm (0.0005 in.) 54.85 to 54.95 mm (2.159 to 2.163 in.) 11 mm (0.43 in.)
Page 85 G GENERAL M8540, M9540, WSM Hydraulic Cylinder Piston Sealing Tool Application : Tool (a) : Use for installing the piston seals to the piston. Tool (b) : Use for installing the piston to the cylinder. Cylinder 60 mm (2.36 in.) 65 mm (2.56 in.)
Page 86 G GENERAL M8540, M9540, WSM Cylinder Safety Valve Setting Pressure Adaptor Application : Use to adapt the safety valve to the nozzle tester to measure cracking pressure and test the check valve on the safety valves. 45 mm (1.77 in.) 10 mm dia.
Page 87 G GENERAL M8540, M9540, WSM Oil Cooler Relief Valve Setting Pressure Adaptor Application: Use to adapt the oil cooler relief valve to the nozzle tester to measure cracking pressure and test check on the oil cooler relief valve. 50 mm (2.0 in.) 16.5 mm (0.650 in.)
Page 88 G GENERAL M8540, M9540, WSM Hydraulic Brake Adaptor Application: Use for testing the hydraulic brake oil linkage. 18 mm (0.71 in.) PS 1/4 4 mm (0.16 in.) 15 mm (0.59 in.) M7 x P1.0 2 mm (0.079 in.) ° 15 mm (0.59 in.) 0.79 rad (45...
Page 89: Special Tools For Air Conditioner Unit
G GENERAL M8540, M9540, WSM [3] SPECIAL TOOLS FOR AIR CONDITIONER UNIT NOTE • Special tools for R134a refrigerant air conditioning system introduced below are available from DENSO CO. LTD. Air Conditioner Service Tool Code No.: DENSO.CO. 95048-00061 Application: Use for charging, testing or discharging the air conditioning system.
Page 90 G GENERAL M8540, M9540, WSM NOTE • The following special tools are not provided, make them referring to the figure. Stopper Magnet Clutch (For A/C Compressor) Application: Use to loosen and tighten the magnet clutch mounting nut. (Use radius M) 125 mm (4.92 in.)
Page 91: Tires
• Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure show in the operator’s manual. IMPORTANT • Do not use tires other than those approved by KUBOTA. • Dual tires are not approved. NOTE • When optional different-diameter tires are fitted on the machine, the travel speed display mode must be changed.
Page 92: Tread Adjustment
G GENERAL M8540, M9540, WSM [2] TREAD ADJUSTMENT CAUTION • When working on slopes or when working with trailer, set the wheel tread as wide as practical for maximum stability. • Support tractor securely on stands before removing a wheel.
Page 93 G GENERAL M8540, M9540, WSM (Continued) Tread (a) 1569 mm 1656 mm 320/85R20 – – 61.77 in. 65.20 in. 1515 mm 1555 mm 1609 mm 320/70R24 – 59.65 in. 61.22 in. 63.35 in. 1566 mm 1652 mm 320/85R24 – –...
Page 94: Rear Wheels
G GENERAL M8540, M9540, WSM (2) Rear Wheels Rear tread width can be adjusted as shown with the standard equipped tires. To change the tread width 1. Remove the wheel rim and / or disc mounting bolts. 2. Change the position of the rim and disc (right and left) to the desired position, and tighten the bolts.
Page 95: Wheel Hub
G GENERAL M8540, M9540, WSM [3] WHEEL HUB Front wheel hub Rear wheel hub Screw circle diameter 203.2 mm (8 in.) 203.2 mm (8 in.) Number of screws M16 × P1.5 M18 × P1.5 Screws Hub pilot diameter (B) 152.4 mm (6 in.) 152.4 mm (6 in.)
Page 96: Tire Liquid Injection
G GENERAL M8540, M9540, WSM [4] TIRE LIQUID INJECTION Auxiliary weights can be used to increase traction force for plowing in fields or clayey ground. Another way is to inject water or another liquid, such as a calcium chloride solution in the tires. Water must not be used in winter since it freezes at 0 °C (32 °F).
Page 97 G GENERAL M8540, M9540, WSM Injection CAUTION • When a calcium chloride solution is used, cool it before pouring it into the tire. • Do not fill tires with water or solution more than 75 % of full capacity (to the valve stem level).
Page 98 G GENERAL M8540, M9540, WSM Draining Water or Solution 1. Lift the rear tires off the ground. 2. Turn the tire so that the air valve is at the bottom. 3. Remove the air valve, and drain liquid (liquid can only be drained to the level of the valve and liquid under that level remains inside).
Page 99: Implement Limitations
KUBOTA. Use with implements which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Tractor may result in malfunctions or failures of the tractor, damage to other property and injury to the operator or others. [Any malfunctions or failures of the tractor resulting from use with improper implements are not covered by the warranty.]...
Page 100: Implement Capacity
G GENERAL M8540, M9540, WSM [1] IMPLEMENT CAPACITY Implement Remarks M8540 M9540 Max. Tank 4000 L (1060 U.S.gals., 880 Imp.gals.) Capacity Slurry Tank Max. Load 5000 kg (11000 lbs) Capacity Max. Load Refer to the [2] TRAILER LOAD CAPACITY. Capacity Trailer Max.
Page 101 G GENERAL M8540, M9540, WSM Implement Remarks M8540 M9540 Numbers of Cultivating Tines Sub Soiler Cultivating Depth 500 mm (20 in.) 550 mm (22 in.) Max. Width 4880 mm (192 in.) 5490 mm (216 in.) Cultivator Number of Rows Max. Weight...
Page 102: Trailer Load Capacity
G GENERAL M8540, M9540, WSM [2] TRAILER LOAD CAPACITY Drawbar High-hitch Piton-fix Short Long Normal Automatic CUNA C CUNA D2 1500 kg 600 kg 580 kg 560 kg 590 kg 590 kg 1800 kg 3307 lbs 1320 lbs 1280 lbs...
Page 103 ENGINE KiSC issued 09, 2008 A...
Page 104 MECHANISM CONTENTS 1. FEATURE ...................... 1-M1 2. ENGINE BODY ..................... 1-M2 [1] CYLINDER BLOCK................. 1-M2 [2] HALF-FLOATING HEAD COVER ............1-M2 [3] CYLINDER HEAD ................... 1-M3 [4] CENTER DIRECT INJECTION SYSTEM (E-CDIS)......1-M3 [5] PISTON....................1-M4 [6] BUILT-IN DYNAMIC BALANCER ............1-M4 3.
Page 105: Feature
E-CDIS. Thus, this engine achieves high combustion efficiency and complies with various regulations of exhaust gas. Based upon the conventional model, Kubota developed a unique governor system and various new mechanisms which reduces exhaust emission, noise and vibration and realize durability and high torque.
Page 106: Engine Body
ENGINE M8540, M9540, WSM 2. ENGINE BODY [1] CYLINDER BLOCK This engine employs separate type crankcases - the crankcase 1 (1) with combustion part and the crankcase 2 (2) which supports the crankcase 1(1) and reduces noise. Since it is a hanger type, you can easily assemble / disassemble it.
Page 107: Cylinder Head
ENGINE M8540, M9540, WSM [3] CYLINDER HEAD This engine employs four valve system, the cylinder head is provided with double intake passenge in order to ensure appropriate air suction and give an optimum swirl. (1) Intake (2) Exhaust W1013336 [4] CENTER DIRECT INJECTION SYSTEM (E-CDIS)
Page 108: Piston
ENGINE M8540, M9540, WSM [5] PISTON Piston’s skirt is coated with molybdenum disulfide , which reduces the piston slap noise and thus the entire operating noise. Molybdenum disulfide (MoS The molybdenum disulfied serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil.
Page 109: Lubricating System
ENGINE M8540, M9540, WSM 3. LUBRICATING SYSTEM [1] OIL COOLER V3 series engine has a water-cooled oil cooler that not only cools hot oil, but also warms the cool engine oil shoftly after start up. As shown in the figure, the oil flows inside the...
Page 110: Cooling System
ENGINE M8540, M9540, WSM 4. COOLING SYSTEM [1] THERMOSTAT Conventional thermostatically-controlled valves (outlet water temperature control type) open against the flow of coolant. In this design, the pressure (steam pressure + water pump’s discharge pressure) affects the open/close performance of such valve. In other words,...
Page 111: Bottom Bypass System
ENGINE M8540, M9540, WSM [2] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in V3 series for improving the cooling performance of the radiator. While the temperature of coolant in the engine is low, the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.
Page 112: Fuel System
M8540, M9540, WSM 5. FUEL SYSTEM [1] GOVERNOR The engine employs the separated fuel injection pump in combination with Kubota’s own small multi- function mechanical governor, which enables more dependability. It also employs the torque limiting mechanism to control the maximum peak torque so that it complies with the regulations of exhaust gas.
Page 113 ENGINE M8540, M9540, WSM At Idling Turn the speed control lever (3) clockwise to idle the engine. It tensions the governor spring (4) to pull the fork lever 2 (5). When the fork lever 2 is pulled, it moves the torque spring pin (6) and the fork lever 1 (7) in the direction of the arrow A to restrain the weight.
Page 114 ENGINE M8540, M9540, WSM To stop engine When the stop solenoid is turned off, the spring tension of the solenoid is released, the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine.
Page 115: Mechanical Timer With Cold Start Advance Function
ENGINE M8540, M9540, WSM [2] MECHANICAL TIMER WITH COLD START ADVANCE FUNCTION This device makes the fuel injection timing advanced by engine oil temperature and engine rpm in order to improve the engine cold start-ability and reduce the blue white smoke.
Page 116 ENGINE M8540, M9540, WSM Speed control If the engine rpm is higher than a certain rpm, the fuel injection timing advance by engine oil temperature does not work. At that time, the quantity of advance timing is variably changed by centrifugal force of the timer flyweights which meets engine rpm.
Page 117: Stage Di Nozzle
ENGINE M8540, M9540, WSM [3] 2 STAGE DI NOZZLE Exhaust and noise regulations are becoming increasingly strict, particularly in regard to the reduction of NOx (nitrogen oxides) and particulates. The two-spring nozzle holder has been developed to reduce NOx (nitrogen oxides) and particulates from direct injection diesel engine exhaust.
Page 118: Injection Pump With F.s.p
ENGINE M8540, M9540, WSM A-B : First Spring’s Set Force B-C-D : Combined Force of First and Second Springs P1 : First Opening Pressure P2 : Second Opening Pressure L : Full Needle Valve Lift I : Needle Valve Pre-lift X1 : Cam Angle (°)
Page 119: Intake System
ENGINE M8540, M9540, WSM 6. INTAKE SYSTEM [1] INTAKE AIR HEATER The intake air heater is introduced in order to further improve the starting performance and to reduce the white smoke at cold starting. The intake air heater is mounted on the intake manifold.
Page 120: Exhaust Gas Recirculation (Egr) System
[1] GENERAL In order to meet with the strict emission regulations, Kubota has adopted the EGR on the V3800DI-T-E3. The nitrogen oxide (NOx) which is a hazardous component in exhaust gas is generated by oxidation of nitrogen in the air, due to rise of the combustion temperature in cylinders.
Page 121 ENGINE M8540, M9540, WSM (A) EGR Cooler The EGR (Exhaust Gas Recirculation) cooler is used to lower combustion temperature and efficiently cool EGR gas, with the aim of reducing the NOx that is in the exhaist das of diesel engine.
Page 122 ENGINE M8540, M9540, WSM (C) Mechanical EGR Valve Mechanical EGR valve controls the flow of cooled EGR gas to the intake manifold. If the boost pressure is low, EGR valve is closed, so cooled EGR gas does not flow to the intake manifold.
Page 123 SERVICING CONTENTS 1. TROUBLESHOOTING ..................1-S1 2. SERVICING SPECIFICATIONS ..............1-S5 3. TIGHTENING TORQUES ................1-S12 4. CHECKING, DISASSEMBLING AND SERVICING........1-S14 [1] CHECKING AND ADJUSTING .............1-S14 (1) Engine Body..................1-S14 (2) Lubricating System ................1-S16 (3) Cooling System .................1-S16 (4) Fuel System ..................1-S19 (5) EGR System ..................1-S22 (6) Turbocharger ..................1-S24 [2] PREPARATION ..................1-S25 (1) Lubricant and Coolant...............1-S25...
Page 124: Troubleshooting
ENGINE M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel Start Air in the fuel system Vent air G-39 Water in the fuel system Change fuel and G-9, 29 repair or replace fuel...
Page 125 ENGINE M8540, M9540, WSM Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-32 Not Smooth Air cleaner clogged Clean or replace G-25 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut...
Page 126 ENGINE M8540, M9540, WSM Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust 1-S19 Engine’s moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace 1-S19, 52 Deficient nozzle injection Repair or replace...
Page 127 ENGINE M8540, M9540, WSM Reference Symptom Probable Cause Solution Page High Oil Pressure Different type of oil Use specified type of Relief valve defective Replace 1-S55 Engine Overheated Engine oil insufficient Replenish Fan belt broken or elongated Replace or adjust...
Page 128: Servicing Specifications
ENGINE M8540, M9540, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.701 to 0.930 mm – 0.0276 to 0.0366 in. Compression Pressure 3.47 MPa / 2.56 MPa / −1...
Page 129 ENGINE M8540, M9540, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Stem to Valve Guide Clearance (Intake) 0.055 to 0.085 mm 0.1 mm 0.0022 to 0.0033 in. 0.0039 in. Valve Stem O.D. (Intake) 6.960 to 6.975 mm –...
Page 130 ENGINE M8540, M9540, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.15 mm 0.00063 to 0.0017 in. 0.0059 in. Rocker Arm Shaft O.D. 15.973 to 15.984 mm –...
Page 131 ENGINE M8540, M9540, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Idle Gear 1 to Crank Gear Backlash 0.0490 to 0.193 mm 0.22 mm 0.00193 to 0.00759 in. 0.0087 in. Idle Gear 1 to Cam Gear Backlash 0.0490 to 0.189 mm...
Page 132 ENGINE M8540, M9540, WSM ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Ring Gap Top Ring 0.30 to 0.45 mm 1.25 mm 0.012 to 0.017 in. 0.0492 in. Second Ring 0.30 to 0.45 mm 1.25 mm 0.012 to 0.017 in.
Page 133 ENGINE M8540, M9540, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed – 50 kPa 0.5 kgf/cm 7 psi At Rated Speed 200 to 390 kPa 150 kPa 2.0 to 4.0 kgf/cm 1.5 kgf/cm 29 to 56 psi...
Page 134 ENGINE M8540, M9540, WSM FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing 0.0917 to 0.117 rad – (5.25 to 6.75 °) before T.D.C. Pump Element Fuel Tightness – 18.63 MPa 190.0 kgf/cm 2702 psi Delivery Valve Fuel Tightness 10 seconds 5 seconds 18.63 →...
Page 135: Tightening Torques
ENGINE M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m kgf·m...
Page 136 ENGINE M8540, M9540, WSM Item N·m kgf·m lbf·ft Plate mounting screw 24 to 27 2.4 to 2.8 18 to 20 Oil pan mounting screw (Length : 165 mm (6.5 in.)) 74 to 78 7.5 to 8.0 55 to 57 Oil pan mounting screw (Length : 25 mm (1.0 in.)) 49 to 55 5.0 to 5.7...
Page 137: Checking, Disassembling And Servicing
ENGINE M8540, M9540, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. After warming up the engine, stop it and remove the air cleaner, the muffler, high pressure pipes, cylinder head cover, overflow pipe, all nozzle holders and all nozzle gaskets.
Page 138 ENGINE M8540, M9540, WSM Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the high pressure pipes and the head cover. 2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (gear case side) comes to the compression top dead center.
Page 139: Lubricating System
ENGINE M8540, M9540, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the oil switch and set a pressure tester (Code No. 07916-32031). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 140 ENGINE M8540, M9540, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
Page 141 ENGINE M8540, M9540, WSM Thermostat Valve Opening Temperature 1. Push down the thermostat valve and insert a string between the valve and the valve seat. 2. Place the thermostat and a thermostat in a container with water and gradually heat the water.
Page 142: Fuel System
ENGINE M8540, M9540, WSM (4) Fuel System Injection Timing 1. Remove the timer gear lubricating pipe (1). 2. Remove the gear case cover (2). 3. Set the timer 0 ° restoring jig (4) to the timer gear(3). 4. Make sure of matching the injection timing align mark (5) of the injection pump unit and the plate (gearcase), as shown in the illustration.
Page 143 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 18.63 MPa...
Page 144 ENGINE M8540, M9540, WSM CAUTION • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 145: Egr System
ENGINE M8540, M9540, WSM (5) EGR System (A) Checking the function of EGR system 1. Check the coolant temperature and monitor the coolant temperature while checking 1) and 2). 2. If the coolant temperature is already 55 °C (131 °F), cool down the engine.
Page 146 ENGINE M8540, M9540, WSM 2) If the coolant temperature is over 70 °C (158 °F), the surface temperature of EGR pipe must be over 100 °C (212 °F). KiSC issued 09, 2008 A 1-S23...
Page 147: Turbocharger
ENGINE M8540, M9540, WSM (6) Turbocharger Turbine Side 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one.
Page 148: Preparation
ENGINE M8540, M9540, WSM [2] PREPARATION (1) Lubricant and Coolant Draining Coolant and Engine Oil 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL” section. W1051987 (2) 4WD Propeller Shaft and Power Steering Hose Propeller Shaft 1.
Page 149: Separating Engine (Rops Model)
ENGINE M8540, M9540, WSM Front Axle Support as a Unit 1. Install the front axle rocking restrictor (1) (refer to “8. SPECIAL TOOL” at “G. GENERAL” section) to the front axle bracket. (1) Front Axle Rocking Restrictor W1063409 [3] SEPARATING ENGINE (ROPS MODEL)
Page 150 ENGINE M8540, M9540, WSM Cover, Oil Cooler Pipe, Fuel Hoses, Accelerator Wire and Wire Harness for R.H. Side 1. Disconnect the fuel hose (2) from separator and fuel overflow hose (6). 2. Disconnect the oil cooler pipe retaining nut (3).
Page 151: Removing Engine From Tractor
ENGINE M8540, M9540, WSM Front Axle Support as a Unit 1. Make sure the clutch housing case and front frame are securely mounted on the disassembling stands. 2. Remove the front frame mounting screws and separate the front axle as a unit from the engine.
Page 152: Separating Engine (Cabin Model)
ENGINE M8540, M9540, WSM [4] SEPARATING ENGINE (CABIN MODEL) (1) Separating Front Axle and Front Frame as a Unit Bonnet 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the connector (3) for head lights. 3. Disconnect the dampers (4).
Page 153 ENGINE M8540, M9540, WSM Muffler Pipe 1. Remove the muffler pipe (1). (1) Muffler Pipe W1095571 Hydraulic Pipes, Hoses and Heater Hoses 1. Disconnect the power steering delivery hose 1 (3) and 2 (1) from controller (4). 2. Disconnect the master cylinder hose (7) and master cylinder return hose (5) from the brake master cylinder (6).
Page 154 ENGINE M8540, M9540, WSM Wire Harness, Heater Hoses and Tool Box 1. Remove the fuse box (1) and (5) from stay. 2. Remove the relay (3) and (4) from stay. 3. Disconnect the compressor switch 1P connector (2). 4. Remove the 3P connector from stop solenoid (6) and remove the connector from engine speed sensor (8).
Page 155 ENGINE M8540, M9540, WSM Compressor, Condenser and Receiver Drier 1. Remove the air intake hose. 2. Remove the air conditioner belt. 3. Remove the compressor with stay, condenser and receiver drier without removing the air conditioner hoses. (When reassembling) • Take care not to damage the air condenser fin.
Page 156 ENGINE M8540, M9540, WSM (2) Separating Engine Fuel Filling Port, Floor Mat and Floor Cover 1. Remove the fuel filling port (1) mounting screw. 2. Remove the floor mat 1 (2) and 2 (3). 3. Remove the floor cover (4).
Page 157: Separating Engine From Clutch Housing Case
ENGINE M8540, M9540, WSM Duct 1. Remove the duct retainer (1). 2. Remove the seat under cover 2 (3) and remove the duct mounting screw (4). 3. Remove the duct (2). (1) Duct Retainer (3) Seat Under Cover 2 (2) Duct...
Page 158: Removing External Components
ENGINE M8540, M9540, WSM [5] REMOVING EXTERNAL COMPONENTS (1) Damper Disc Damper Disc (Hydraulic Shuttle Model) 1. Remove the damper disc (1). (When reassembling) • Direct the shorter end of the damper disc boss toward the flywheel. • Apply molybdenum disulphide (Three Bond 1901 or equivalent) to the spline.
Page 159: Turbocharger
ENGINE M8540, M9540, WSM (3) Turbocharger CAUTION • While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger. NOTE • When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matter in the oil pipes.
Page 160: Exhaust Gas Recirculation (Egr)
ENGINE M8540, M9540, WSM (4) Exhaust Gas Recirculation (EGR) EGR Pipe 1. Remove the EGR pipe (1). (When reassembling) • Replace the gaskets with new ones. (1) EGR Pipe W1184151 EGR Cooler 1. Remove the EGR cooler (1). (When reassembling) •...
Page 161 ENGINE M8540, M9540, WSM Thermo Valve (If necessary) 1. Disconnect hoses (1), (2). 2. Remove the thermo valve (3). NOTE • If you drop the thermo valve (3), replace the thermo valve (3) with new one. (When reassembling) • Securely connect the hoses (1), (2).
Page 162: Disassembling And Assembling
ENGINE M8540, M9540, WSM [6] DISASSEMBLING AND ASSEMBLING (1) Cylinder Head and Valves Cylinder Head Cover and Nozzle Holder 1. Remove the injection pipes (1). 2. Remove the cylinder head cover (2). 3. Remove the over flow pipe (3). 4. Remove the nozzle holder clamps (4), nozzle holder assembly (5) and nozzle gaskets.
Page 163 ENGINE M8540, M9540, WSM Rocker Arm and Push Rod 1. Remove the rocker arm (1) as a unit. 2. Remove the push rods (2). 3. Remove the bridge arm (4). (When reassembling) • When putting the push rods onto the tappets, check to see if their ends are properly engaged with the grooves.
Page 164 ENGINE M8540, M9540, WSM Cylinder Head and Tappet 1. Loosen the pipe band, and remove the water return pipe (1). 2. Disconnect the fuel pipe (3) first and then the fuel filter (2). 3. Remove the IN. / EX. Manifold.
Page 165 ENGINE M8540, M9540, WSM Selecting Cylinder Head Gasket Replacing the Cylinder Head Gasket 1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket (1) in advance. 2. Replace the same notch (a), (b) or (c) as the original cylinder head gasket (1).
Page 166: Thermostat
ENGINE M8540, M9540, WSM (2) Thermostat Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
Page 167: Injection Pump Unit
ENGINE M8540, M9540, WSM (3) Injection Pump Unit Injection Pump Unit (Removing the fuel injection pump unit) 1. Remove the timer lubricating pipe (1). 2. Remove the gear cover (2) for the fuel injection pump unit from the gearcase. 3. Set the timer 0 ° restoring jig (4) to the timer gear (3).
Page 168 ENGINE M8540, M9540, WSM (Continued) 8. Remove the timer gear mounting nut and washer. 9. Set the timer gear puller (10). 10.Remove the timer gear (3). NOTE • Be careful not to drop the key. 11.Disconnect the lubricating oil pipe (8).
Page 169 ENGINE M8540, M9540, WSM (Continued) (Reassembling the fuel injection pump unit) 1. Place the piston of the 4th cylinder at the top dead center in the compression stroke. Fix the flywheel with the flywheel stopper. 2. Set the timer 0 ° restoring jig (3) to the timer gear (2).
Page 170 ENGINE M8540, M9540, WSM Governor Housing Assembly 1. Remove the injection pump unit from the engine. (See the “Injection Pump Unit”.) 2. Remove the governor lubricating pipe (3). 3. Remove the stop solenoid (3). 4. Detach the sight cover (2) from the injection pump unit.
Page 171 ENGINE M8540, M9540, WSM Governor Fork Lever Assembly 1. Pull off the governor fork lever shaft (1) with the extra bolt (Dia : 4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2). 2. Unhook the governor spring (3) at the governor fork lever (4) side.
Page 172 ENGINE M8540, M9540, WSM Governor Lever 1. Remove the speed control lever (1) and the return spring (2). 2. Remove the governor lever assembly (3) from the governor housing. 3. Remove the start spring (4) and the stop spring (5).
Page 173 ENGINE M8540, M9540, WSM Fuel Camshaft and Governor Weight 1. Separate the governor housing assembly from the injection pump unit. (See the “Injection Pump Unit”.) 2. Remove the governor sleeve (1). 3. Remove the injection pump assembly (2). 4. Remove the fuel camshaft lock screws.
Page 174 ENGINE M8540, M9540, WSM (Continued) (When reassembling) • Fix the fuel camshaft with lock bolts as the key way of fuel camshaft (9) is upward. • Install the injection pump assembly to the injection pump housing. • Attach the O-ring and the cover and tighten the cover mounting bolts.
Page 175 ENGINE M8540, M9540, WSM Replacing Injection Pump Assembly (If necessary) • The injection pump can be replaced with the crankshaft in whatever position. 1. Disconnect all injection pipes (1). 2. Disconnect the fuel pipe (6) and fuel overflow pipe (4).
Page 176 ENGINE M8540, M9540, WSM Installing Procedure of Injection Pump Assembly 1. Install the fuel injection pump assembly (1) in its unit (2), and tighten the mounting screws and nuts like the figure, which the injection pump assembly (1) keeps tilted.
Page 177: Water Pump And Oil Cooler
ENGINE M8540, M9540, WSM Installing Procedure of Injection Pump Assembly (Continued) 1. Move the stop lever (8) and visually check to see if the fuel injection pump control rack comes smoothly back to the start position by the counter force of the start spring.
Page 178: Gear Case
ENGINE M8540, M9540, WSM 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). 40 to 44 N·m Tightening torque Oil cooler joint screw 4.0 to 4.5 kgf·m...
Page 179 ENGINE M8540, M9540, WSM 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...
Page 180 ENGINE M8540, M9540, WSM Plate (Gear Case) 1. Remove the three plate mounting screws. Detach the plate (1). (When reassembling) • Apply Three Bond 1217D adhesive or equivalent over the shaded zones on both sides of the gasket that will be sandwiched between the crankcase and plate.
Page 181: Piston And Connecting Rod
ENGINE M8540, M9540, WSM (6) Piston and Connecting Rod Oil Pan and Oil Strainer 1. Unscrew the oil pan mounting screws and remove the oil pan (1). 2. Unscrew the oil strainer mounting screw, and remove the oil strainer (2).
Page 182 ENGINE M8540, M9540, WSM Connecting Rod Cap 1. Remove the connecting rod screws (1) from connecting rod cap. 2. Remove the connecting rod caps. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.) •...
Page 183 ENGINE M8540, M9540, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (1), and separate the connecting rod (7) from the piston (2). (When reassembling) • Be sure to fix the crankpin bearing and the connecting rod are same I.D.
Page 184: Flywheel And Crankshaft
ENGINE M8540, M9540, WSM (7) Flywheel and Crankshaft Flywheel 1. Install the stopper to the flywheel so that the flywheel does not turn. NOTE • Do not use an impact wrench. Serious damage will occur. 2. Detach the flywheel screws.
Page 185 ENGINE M8540, M9540, WSM Crankcase 2 1. Remove the crankcase 2 (1). (When reassembling) IMPORTANT • Make sure the crankcase 1 and 2 are clean. • Apply liquid gasket (Three Bond 1217D) to the crankcase 2 as shown in the figure.
Page 186 ENGINE M8540, M9540, WSM Crankshaft 1. Remove the main bearing case. 2. Remove the crankshaft. (When reassembling) • Reassemble the main bearing case having the same number as the one engraved on the crankcase, and set the casting mark “F/ W SIDE”...
Page 187: Servicing
ENGINE M8540, M9540, WSM [7] SERVICING (1) Cylinder Head Top Clearance 1. Remove the cylinder head (remove the cylinder head gasket completely). 2. Set the piston to its top dead center, set 1.5 mm (0.059 in.) dia. 5.0 to 7.0 mm (0.20 to 0.27 in.) long fuse wires to 3 or 4 spots on the piston top with grease so as to avoid the intake and exhaust valves.
Page 188 ENGINE M8540, M9540, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
Page 189 ENGINE M8540, M9540, WSM Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of the cylinder head at the most wear part as shown in the figure below with a small hole gauge.
Page 190 ENGINE M8540, M9540, WSM Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
Page 191 ENGINE M8540, M9540, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (A) with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the spring on a surface plate, place a square on the side of the spring, and check to see if the entire side is contact with the square.
Page 192 ENGINE M8540, M9540, WSM 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. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
Page 193: Idle Gar And Camshaft
ENGINE M8540, M9540, WSM (2) Idle Gar and Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
Page 194 ENGINE M8540, M9540, WSM Camshaft Alignment 1. Support the camshaft with V block on the surface plate and set a dial indicator with its tip on the intermediate journal at right angle. 2. Rotate the camshaft on the V blocks and get the misalignment (half of the measurement).
Page 195 ENGINE M8540, M9540, WSM Oil Clearance between Idle Gear Shaft 1, 2 and Idle Gear 1, 2 Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushings I.D. with an inside micrometer, and calculate the oil clearance.
Page 196: Piston And Connecting Rod
ENGINE M8540, M9540, WSM Oil Clearance of Balancer Shaft Journal 1. Measure the balancer shaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. (A), (B) for balancer shaft with an inside micrometer. 3. If the clearance exceeds the allowable limit, replace the balancer shaft.
Page 197 ENGINE M8540, M9540, WSM Piston Ring Gap 1. Insert the piston ring into the lower part of the liner (the least worn out part) with the piston. 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the piston ring.
Page 198: Crankshaft
ENGINE M8540, M9540, WSM Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check the bushing for wear beforehand. 1. Remove the piston pin in the connecting rod.
Page 199 ENGINE M8540, M9540, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
Page 200 ENGINE M8540, M9540, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1. Clean the crankshaft journal and crankshaft bearing. 2. Put a strip of press gauge on the center of the journal. IMPORTANT • Never insert the press gauge into the oil hole of the journal.
Page 201: Cylinder
ENGINE M8540, M9540, WSM (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s.
Page 202 ENGINE M8540, M9540, WSM Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 2. If the clearance exceeds the allowable limit, replace the oil pump rotor assembly.
Page 203 CLUTCH KiSC issued 09, 2008 A...
Page 204 MECHANISM CONTENTS 1. PTO CLUTCH ....................2-M1 [1] STRUCTURE ................... 2-M1 [2] PTO SOLENOID VALVE, RELIEF VALVE AND OIL FLOW..... 2-M2 KiSC issued 09, 2008 A...
Page 205 CLUTCH M8540, M9540, WSM 1. PTO CLUTCH [1] STRUCTURE As shown in the figure above, the PTO propeller shaft 1 (3) is splined to the input shaft (2) and is always rotating while the engine is running. The PTO clutch pack (4) has three clutch discs (8), three drive plates (9), a belleville washer (cupped spring washer) (11) and one pressure plate (7).
Page 206 CLUTCH M8540, M9540, WSM [2] PTO SOLENOID VALVE, RELIEF VALVE AND OIL FLOW When the PTO switch is at the OFF position, the oil flows is stopped by the PTO solenoid valve (3). When the PTO switch is at ON position, the solenoid valve (3) is operated and the oil flows through the PTO solenoid valve (3) to the PTO clutch pack (5) to engage it.
Page 207 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 2. SERVICING SPECIFICATIONS ..............2-S2 3. TIGHTENING TORQUES ................2-S3 4. CHECKING AND ADJUSTING ..............2-S4 [1] CLUTCH PEDAL FREE TRAVEL ............2-S4 (1) ROPS Model ..................2-S4 (2) CABIN Model ..................2-S4 [2] PTO CLUTCH ..................2-S5 5. DISASSEMBLING AND ASSEMBLING ............2-S6 [1] REMOVING PTO CLUTCH PACK AND HOLDER ......2-S6 (1) Separating Transmission Case and Clutch Housing Case ....2-S6 (2) PTO Clutch Pack and Holder..............2-S6...
Page 208: Troubleshooting
CLUTCH M8540, M9540, WSM 1. TROUBLESHOOTING PTO CLUTCH Reference Symptom Probable Cause Solution Page PTO Clutch Slip Operating pressure is low Adjust 2-S5 PTO solenoid valve malfunctioning Replace 9-S43 Clutch disc or drive plate excessively worn Replace 2-S8, 10 Deformation of piston or return plate...
Page 209: Servicing Specifications
CLUTCH M8540, M9540, WSM 2. SERVICING SPECIFICATIONS TRAVELING CLUTCH (HYDRAULIC SHUTTLE MODEL) Item Factory Specification Allowable Limit Clutch Pedal (ROPS Model) Free Travel 15 to 20 mm – 0.59 to 0.79 in. Total Stroke 145 to 155 mm – 5.71 to 6.10 in.
Page 210: Tightening Torques
CLUTCH M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G.GENERAL” section.) Item N·m kgf·m lbf·ft...
Page 211: Checking And Adjusting
CLUTCH M8540, M9540, WSM 4. CHECKING AND ADJUSTING [1] CLUTCH PEDAL FREE TRAVEL (1) ROPS Model Clutch Pedal Free Travel (Hydraulic Shuttle Model) 1. Measure the clutch pedal free travel (L). 2. If adjustment is needed, change with clutch wire cable (3) retaining nut (2) so that the free travel becomes 15.0 to 20.0 mm...
Page 212: Pto Clutch
CLUTCH M8540, M9540, WSM [2] PTO CLUTCH PTO Clutch Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the main shift lever and shuttle lever in Neutral position.
Page 213: Removing Pto Clutch Pack And Holder
CLUTCH M8540, M9540, WSM 5. DISASSEMBLING AND ASSEMBLING [1] REMOVING PTO CLUTCH PACK AND HOLDER (1) Separating Transmission Case and Clutch Housing Case Separating Transmission Case 1. Refer to “5. DISASSEMBLING ASSEMLBING” at “3. TRANSMISSION” section. 2. Refer to “6.-[2] DISASSEMBLING AND ASSEMBLING” at “10.
Page 214: Solenoid Valve (Pto)
CLUTCH M8540, M9540, WSM Removing PTO Clutch Pack and Holder 1. Remove the pipes (3). 2. Remove the PTO clutch holder mounting screws. 3. Remove the PTO clutch (5) with holder (1). (When reassembling) • Apply transmission fluid to the O-rings (4).
Page 215 CLUTCH M8540, M9540, WSM (2) PTO Clutch Pack Clutch Hub and Clutch Discs 1. Remove the internal circlip (6), and then take out the clutch discs (3), belleville washer (cupped spring washer) (5), back plate (4), steel plates (7), (8), (9), (10), and the hub (2).
Page 216 CLUTCH M8540, M9540, WSM Clutch Case 1. Remove the external circlip (7). 2. Remove the clutch case (5), brake disc (3) and brake plate (2). (When reassembling) • Direct the contact part of the brake disc (3) to the brake plate (2).
Page 217 CLUTCH M8540, M9540, WSM 6. SERVICING [1] PTO CLUTCH PACK PTO Clutch Disc Wear 1. Measure the thickness of PTO clutch disc with vernier calipers. 2. If the thickness is less than the allowable limit, replace it. 2.5 to 2.7 mm Factory spec.
Page 218 CLUTCH M8540, M9540, WSM Thickness of Seal Ring 1. Measure the thickness of seal rings (1) with an outside micrometer. 2. If the measurement is less than the allowable limit, replace it. 2.45 to 2.50 mm Factory spec. 0.096 to 0.098 in.
Page 219 TRANSMISSION KiSC issued 09, 2008 A...
Page 220 MECHANISM CONTENTS 1. STRUCTURE ....................3-M1 [1] F18/R18 SPEED TRANSMISSION MODEL ......... 3-M1 [2] F36/R36 SPEED TRANSMISSION MODEL ......... 3-M2 2. POWER TRAIN FOR TRAVELING GEAR..........3-M3 [1] SHUTTLE SHIFT SECTION ..............3-M3 (1) Structure .................... 3-M3 (2) Oil Flow ....................3-M4 (3) Hydraulic Clutch Pack................
Page 221: Structure
M8540, M9540, WSM TRANSMISSION 1. STRUCTURE [1] F18/R18 SPEED TRANSMISSION MODEL 3TMACBH3P001A (1) Hydraulic Shuttle Section (3) Hydraulic Pump Drive Section (5) PTO Gear Section (6) Parking Brake Section (7) Four Wheel Drive Clutch Section (8) Creep Gear Section (9) Auxiliary Gear Shift Section...
Page 222: F36/R36 Speed Transmission Model
M8540, M9540, WSM TRANSMISSION [2] F36/R36 SPEED TRANSMISSION MODEL (11) (10) 3TMACBH3P002A (1) HI-LO Dual Speed Section (3) Hydraulic Pump Drive Section (5) PTO Gear Section (6) Interchange Type PTO Gear (7) Parking Brake Section (9) Creep Gear Section (10) Auxiliary Gear Shift Section...
Page 223: Power Train For Traveling Gear
TRANSMISSION M8540, M9540, WSM 2. POWER TRAIN FOR TRAVELING GEAR [1] SHUTTLE SHIFT SECTION (1) Structure (1) Return Spring (4) Belleville Washer (6) Reverse Side Clutch (8) Hydraulic Shuttle Valve (2) Clutch Pedal (Cupped Spring Washer) (7) Clutch Spool (9) Clutch Cable...
Page 224: Oil Flow
TRANSMISSION M8540, M9540, WSM (2) Oil Flow (1) Shuttle Valve (3) Forward Clutch (5) Clutch Pedal (A) Pump (2) Reverse Clutch (4) Shuttle Lever (6) Spool (B) Power Steering Controller (C) Oil Cooler (D) PTO Clutch and Other Clutches When the shuttle lever (4) shifts to the forward or reverse, the oil flows to the forward or reverse clutch (2), (3) respectively.
Page 225: Hydraulic Clutch Pack
TRANSMISSION M8540, M9540, WSM (3) Hydraulic Clutch Pack Shuttle Shift Section The shuttle shift section allows the operators to change forward and reverse with a shuttle lever. It is using hydraulic clutch shifting. When the shuttle lever is move to the F or R position, clutch is engaged to the front or rear by the hydraulic.
Page 226: Hydraulic Shuttle Valve
TRANSMISSION M8540, M9540, WSM [2] HYDRAULIC SHUTTLE VALVE (1) Structure (1) Shuttle Shift Spool (7) Line Filter (e) Clutch Pedal Released C : Pressure Check Port (Forward, Reverse) (8) Accumulate Valve Position (Forward) (2) Inching Valve Spool F : To Clutch Body (Forward)
Page 227: Operation
TRANSMISSION M8540, M9540, WSM (2) Operation Shuttle Lever at Neutral Position (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever (8) Clutch Pedal A : Check Port (Modulation)
Page 228 TRANSMISSION M8540, M9540, WSM When Shuttle Lever is Shifting Neutral to Reverse or Forward Position (Clutch Pedal is Released) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve...
Page 229 TRANSMISSION M8540, M9540, WSM When Lever at Forward Position (Clutch Pedal is Released) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever (8) Clutch Pedal...
Page 230 TRANSMISSION M8540, M9540, WSM When Lever at Reverse Position (Clutch Pedal is Released) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever (8) Clutch Pedal...
Page 231 TRANSMISSION M8540, M9540, WSM When Clutch Pedal is Depressed (with Shuttle Lever at Reverse or Forward Position) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever...
Page 232: Main Gear Shift Section
TRANSMISSION M8540, M9540, WSM [3] MAIN GEAR SHIFT SECTION (1) 1st Shaft (6) 32T Gear (11) Coupling (16) 27T Gear (2) 26T Gear (7) Coupling (12) Shifter (17) 14T Gear Shaft (3) Shifter (8) Shifter (13) 16T Gear (18) 24T Gear...
Page 233: Hi-Lo/Creep Shift Section
TRANSMISSION M8540, M9540, WSM [4] HI-LO/CREEP SHIFT SECTION (1) 30T Gear (2) 14T Gear Shaft (2nd Shaft) (3) 25T Gear (4) 3rd Shaft (5) Coupling (6) Shifter (7) 45T-23T Gear (8) 44T-21T Gear (9) 40T Gear (10) 17T Gear (11) 26T Gear...
Page 234: Shift Fork Rod And Fork
TRANSMISSION M8540, M9540, WSM [5] SHIFT FORK ROD AND FORK (1) 3rd-4th Shift Fork (6) H-L-C Rod (11) 5th-6th Shift Fork Rod (A) Engage to 1st-2nd Shift Fork (2) Select Arm (7) H-L-C Arm (12) Select Lever (3) 3rd-4th Shift Fork Rod...
Page 235: Hi-Lo Dual Speed Shift Section (F36/R36 Transmission Model)
TRANSMISSION M8540, M9540, WSM [6] HI-LO DUAL SPEED SHIFT SECTION (F36/R36 TRANSMISSION MODEL) (1) Hydraulic Clutch Pack Hi-Lo Dual Speed Section The hi-Lo dual speed section is operated hydraulic clutch, solenoid valve and dual speed switch. When operate the lo to hi position, travelling speed increase approx.
Page 236: Dual Speed Valve
TRANSMISSION M8540, M9540, WSM (2) Dual Speed Valve This valve change the oil flow to the dual speed HI clutch or LO clutch. As the pilot valve DS (solenoid valve) (5) operates by energizing the solenoid, the flow of oil is switched to the HI side (B) or LO (C) side of dual speed clutch with DS spool (2).
Page 237: Lubrication For Transmission
TRANSMISSION M8540, M9540, WSM 3. LUBRICATION FOR TRANSMISSION [1] F18/R18 SPEED TRANSMISSION Hydraulic shuttle section, main shift change synchromesh gears, hydraulic pump drive / driven gear, PTO hydraulic pack and PTO brake are forcibly lubricated. The lubrication oil from the PTO valve lubricates to PTO clutch holder and the each sections through PTO propeller shaft and 1st shaft.
Page 238: Power Train For Pto System
TRANSMISSION M8540, M9540, WSM 4. POWER TRAIN FOR PTO SYSTEM [1] PTO GEAR SECTION (1) PTO Propeller Shaft 1 (8) 45T Gear (14) 49T Gear [A] 540-540E Shift Type (2) PTO Clutch (9) Hub (15) 43T Gear [B] 540-1000 Interchange Type...
Page 239: Power Train For 4Wd
TRANSMISSION M8540, M9540, WSM 5. POWER TRAIN FOR 4WD [1] 4WD HYDRAULIC CLUTCH SECTION (1) DT Propeller Shaft (2) 33T Gear (3) Neutral Cover (4) 4WD Piston (5) Spring (6) Clutch Body (7) 4WD Shaft (8) 35T Gear A : 4WD W1019299 The 4WD clutch is controlled by the solenoid valve and the hydraulic flow.
Page 240: 4Wd Oil Flow
TRANSMISSION M8540, M9540, WSM [2] 4WD OIL FLOW Oil pressure-fed from the power steering hydraulic pump is flowed to the 4WD solenoid valve (1) through the steering controller and oil cooler. The system hydraulic pressure-fed to disengaged position for 4WD clutch (6) when 4WD switch at 2WD position.
Page 241: Differential Lock
TRANSMISSION M8540, M9540, WSM 6. DIFFERENTIAL LOCK [1] HYDRAULIC ACTUATED TYPE (1) Shaft L.H. (2) Piston (3) Differential Lock Pin (4) Shaft R.H. (5) Differential Case (6) Spring (7) Pin (8) Piston Support W1020080 The differential lock can be operated easily with an electric switch.
Page 242: Oil Flow
TRANSMISSION M8540, M9540, WSM [2] OIL FLOW Oil pressure-fed from the power steering hydraulic pump is flowed to the differential lock solenoid valve (3) through the steering controller and oil cooler. When the differential lock switch turned on, the differential lock solenoid valve is electrified, the oil flow is switched and engage the differential lock pin to lock position.
Page 243 SERVICING CONTENTS 1. TROUBLESHOOTING ..................3-S1 2. SERVICING SPECIFICATIONS ..............3-S3 3. TIGHTENING TORQUES ................3-S5 4. CHECKING AND ADJUSTING ..............3-S6 [1] SHUTTLE LEVER ..................3-S6 (1) Hydraulic Shuttle Model ..............3-S6 (2) Engine Start Condition ................3-S8 [2] GEAR SHIFTING LINKAGE..............3-S9 (1) Main Gear Shift ...................3-S9 (2) Range Gear Shift ................3-S11 [3] SHUTTLE VALVE ..................3-S12 [4] 2WD-4WD CLUTCH ................3-S13...
Page 244 [9] DISASSEMBLING CLUTCH HOUSING CASE ........3-S51 (1) Removing 1st Shaft, 2nd Shaft and 3rd Shaft ........3-S51 (2) 1st Shaft Assembly................3-S53 (3) 2nd Shaft ..................3-S54 (4) 3rd Shaft................... 3-S55 (5) DT Propeller Shaft................3-S55 (6) Creep Gear..................3-S55 [10]DISASSEMBLING TRANSMISSION CASE .........
Page 245: Troubleshooting
TRANSMISSION M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Shuttle Clutch Slip Operating pressure is low Adjust 3-S12 Shuttle clutch valve malfunctioning Replace 3-S17 Clutch disc or steel plate excessively worn Replace 3-S33, 67 Deformation of piston or steel plate Replace –...
Page 246 TRANSMISSION M8540, M9540, WSM Reference Symptom Probable Cause Solution Page 4WD Clutch Slip Operating pressure is low Adjust 2-S5 4WD solenoid valve malfunctioning Repair or replace 3-S17, 9-S43 Clutch disc or drive plate excessively worn Replace 3-S58, 70 Deformation of piston, steel plate or pressure...
Page 247: Servicing Specifications
TRANSMISSION M8540, M9540, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit [ROPS Model] Main Shift Rod 1 Length 364 mm – 14.33 in. Main Shift Rod 2 Length 178 mm – 7.008 in. [CABIN Model] Main Shift Rod 1...
Page 248 TRANSMISSION M8540, M9540, WSM Item Factory Specification Allowable Limit Spiral Bevel Pinion Shaft Only Turning Torque 3.138 to 3.628 N·m – 0.32 to 0.37 kgf·m 2.314 to 2.676 lbf·ft Spiral Bevel Gear to Spiral Bevel Pinion Backlash 0.2 to 0.3 mm 0.4 mm...
Page 249: Tightening Torques
TRANSMISSION M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” Section.) Item N·m kgf·m...
Page 250: Checking And Adjusting
TRANSMISSION M8540, M9540, WSM 4. CHECKING AND ADJUSTING [1] SHUTTLE LEVER (1) Hydraulic Shuttle Model CAUTION • Park the machine on a firm, flat and level surface, set the parking brake and place the gear shift in neutral. • Stop the engine and remove the key before checking and adjusting.
Page 251 TRANSMISSION M8540, M9540, WSM Adjusting Shuttle Valve Neutral Position and Lever Guide Neutral Position (Continued) 7. Shift the free play “D” toward the forward direction and slowly lower the shuttle lever as shown in the figure. And visually inspect the clearance “X”.
Page 252: Engine Start Condition
TRANSMISSION M8540, M9540, WSM (2) Engine Start Condition Engine Start Condition IMPORTANT • Before starting the engine, make sure the gear shift lever at the neutral position. • Place the PTO lever to the OFF position. • Apply the parking brake.
Page 253: Gear Shifting Linkage
TRANSMISSION M8540, M9540, WSM [2] GEAR SHIFTING LINKAGE (1) Main Gear Shift Checking Function of Main Gear Shift (ROPS Model) 1. Check the function of the main gear shift. - Neutral position to 1st gear position. - Neutral position to 2nd gear position.
Page 254 TRANSMISSION M8540, M9540, WSM Checking Function of Main Gear Shift (CABIN Model) 1. Check the function of the main gear shift. - Neutral position to 1st gear position. - Neutral position to 2nd gear position. - Neutral position to 3rd gear position.
Page 255: Range Gear Shift
TRANSMISSION M8540, M9540, WSM (2) Range Gear Shift Checking Function of Range Shift (CABIN Model Only) 1. Check the function of the range gear shift. - Hi and Lo position. 2. If feeling abnormal shifting, check the length of range gear shift rod 1 (3) and 2 (1).
Page 256: Shuttle Valve
TRANSMISSION M8540, M9540, WSM [3] SHUTTLE VALVE Checking of Shuttle Valve System Pressure 1. Prepare a can (3) for fuel and put in the fuel hose (1) and fuel return hose (2). 2. Remove the each plugs of F, R, M and install the adaptor (4) (refer to “8.
Page 257: 2Wd-4Wd Clutch
TRANSMISSION M8540, M9540, WSM [4] 2WD-4WD CLUTCH Clutch Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the main shift lever and shuttle lever in Neutral position.
Page 258: Hi-Low Dual Speed Clutch (F36/R36 Speed Transmission Model)
TRANSMISSION M8540, M9540, WSM [5] HI-LOW DUAL SPEED CLUTCH (F36/R36 SPEED TRANSMISSION MODEL) Dual Speed Clutch Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the main shift lever and shuttle lever in Neutral position.
Page 259: Disassembling And Assembling
TRANSMISSION M8540, M9540, WSM 5. DISASSEMBLING AND ASSEMBLING [1] HYDRAULIC SHUTTLE VALVE AND SOLENOID VALVE ASSEMBLY (1) Removing Fuel Tank (ROPS Model) Draining Transmission Fluid and Fuel 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL”...
Page 260 TRANSMISSION M8540, M9540, WSM Fuel Tank Under Cover 1. Remove the fuel tank mounting screws (1) and under cover mounting screws (2). (1) Fuel Tank Mounting Screw (2) Under Cover Mounting Screw W1015206 Rear Wheel and Fuel Tank 1. Place the disassembling stand under the transmission case.
Page 261: Hydraulic Shuttle Valve
TRANSMISSION M8540, M9540, WSM (3) Hydraulic Shuttle Valve Shuttle Valve Assembly 1. Disconnect the shuttle cable (1). 2. Disconnect the clutch cable (2) and spring (3). 3. Remove the shuttle valve pipe (6). 4. Remove the external circlip (5) and plate (4).
Page 262: Dual Speed Solenoid Valve (F36/R36 Speed Transmission Model)
TRANSMISSION M8540, M9540, WSM (5) Dual Speed Solenoid Valve (F36/R36 Speed Transmission Model) Dial Speed Valve Solenoid Assembly 1. Disconnect the harness coupler (2). 2. Remove the dual speed valve delivery pipe (1). 3. Remove the dual speed solenoid valve (3).
Page 263: Preparation For Separating Each Block
TRANSMISSION M8540, M9540, WSM [2] PREPARATION FOR SEPARATING EACH BLOCK (1) Lubricant and Coolant Draining Transmission Fluid and Fuel 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL” section. W1016839 (2) 4WD Propeller Shaft and Power Steering Hose Propeller Shaft 1.
Page 264: Front Axle Rocking Restrictor
TRANSMISSION M8540, M9540, WSM (3) Front Axle Rocking Restrictor Front Axle Rocking Rectrictor 1. Install the front axle rocking restrictor (1) (refer to “8. SPECIAL TOOL” at “G. GENERAL” section) to the front axle bracket on both side. (1) Front Axle Rocking Restrictor...
Page 265: Bonnet (Cabin Model)
TRANSMISSION M8540, M9540, WSM (5) Bonnet (CABIN Model) Bonnet 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the connector (3) for head lights. 3. Disconnect the dampers (4). 4. Remove the bonnet (1). 5. Remove the both side covers (2).
Page 266: Separating Engine And Clutch Housing Case
TRANSMISSION M8540, M9540, WSM [3] SEPARATING ENGINE AND CLUTCH HOUSING CASE (1) ROPS Model Cover, Oil Cooler Pipe, Fuel Hoses, Accelerator Wire and Wire Harness for R.H. Side 1. Disconnect the fuel hose (2) from separator and fuel overflow hose (6).
Page 267: Cabin Model
TRANSMISSION M8540, M9540, WSM Steering Support Under Cover and Rear Bonnet 1. Remove the steering support under cover (1). 2. Remove the rubber sheet (3) and disconnect the 3-1P connectors (2). 3. Remove the shield assembly (6). 4. Loosen the rear bonnet mounting screws (8).
Page 268 TRANSMISSION M8540, M9540, WSM Condenser and Compressor Without discharging the refrigerant from system 1. Detach the air conditioner hoses from the hose retainer (1) and slide out the condenser (2). 2. Remove the hose clamps (3). 3. Remove the slow blow fuse boxes (4) and relays (6).
Page 269 TRANSMISSION M8540, M9540, WSM Preparation 3 (Continued) 1. Remove the compressor (1) with hoses and compressor bracket. (When reassembling) • Take care not damage the air condenser fin. • After reassembling the compressor, be sure to adjust the air conditioner belt tension.
Page 270 TRANSMISSION M8540, M9540, WSM Steering Joint and Wire Harness 1. Remove the steering joint shaft mounting screw (2) then remove the steering joint shaft (1). 2. Remove the retaining nut for hydraulic hose (3). 3. Remove the connectors (4). 4. Remove the harness connectors for the engine oil pressure switch (7), alternator (5) and starter (6).
Page 271: Separating Clutch Housing Case From Transmission Case
TRANSMISSION M8540, M9540, WSM [4] SEPARATING CLUTCH HOUSING CASE FROM TRANSMISSION CASE (1) Preparation for CABIN Model Removing Cabin from Body 1. Refer to “10. CABIN” section. W1020843 Fuel Tank 1. Remove the auxiliary step (1) both side. 2. Remove the fuel tank (2).
Page 272: Preparation For Rops Model
TRANSMISSION M8540, M9540, WSM (2) Preparation for ROPS Model ROPS Upper 1. Hook the ROPS upper frame (2) and remove the damper (1). 2. Remove the set bolt (3). 3. Remove the ROPS upper frame (2). (When reassembling) • Confirm the ROPS upper frame (2) slide smoothly.
Page 273 TRANSMISSION M8540, M9540, WSM Remote Control Valve Cable and Lowering Speed Rod 1. Remove the cables (1) for remote control valves. 2. Remove the lowering speed rod (2). (When reassembling) • Adjust the remote control valve cable position. (Refer to “8.
Page 274 TRANSMISSION M8540, M9540, WSM Seat, Parking Brake Lever, Fuel Tank and Center Frame 1. Remove the seat (1). 2. Remove the seat stay. 3. Remove the parking brake rod 1 (3). 4. Remove the parking brake lever (2). 5. Disconnect the connector (4) from the fuel tank.
Page 275 TRANSMISSION M8540, M9540, WSM Shuttle Wire Cable 1. Remove the shuttle wire cable (1). 2. Remove the clutch wire cable (2). (1) Shuttle Wire Cable (2) Clutch Wire Cable W1026838 Steering Support Unit 1. Unscrew the steering support screws (1).
Page 276: Separating Transmission Case
TRANSMISSION M8540, M9540, WSM [5] SEPARATING TRANSMISSION CASE 3-Point Linkage and Hydraulic Cylinder 1. Remove the lower link (6) and lift rod (5). 2. Remove the cylinder cover (1). 3. Disconnect the cylinder hose (3) and return hose. 4. Remove the hydraulic cylinder (2).
Page 277: Damper Disc
TRANSMISSION M8540, M9540, WSM [6] DAMPER DISC Damper Disc 1. Remove the damper disc (1). (When reassembling) • Direct the shorter end of the damper disc boss toward the flywheel. • Apply molybdenum disulphide (Three Bond 1901 or equivalent) to the spline.
Page 278 TRANSMISSION M8540, M9540, WSM Disassembling Shuttle Case Assembly 1. Remove the oil seal (1). 2. Remove the external circlip (2). 3. Tap out the input shaft (3) with shuttle clutch and 26T, 24T gear with shuttle shaft (4) together. (When reassembling) •...
Page 279: Removing Hydraulic Shuttle / Dual Speed Clutch (F36/R36 Speed Transmission Model)
TRANSMISSION M8540, M9540, WSM (2) Removing Hydraulic Shuttle / Dual Speed Clutch (F36/R36 Speed Transmission Model) Shuttle / Dual Case CAUTION • The shuttle case assembly is heavy, so that take care it when handling. 1. Remove the shuttle holder (1).
Page 280 TRANSMISSION M8540, M9540, WSM Removing Shuttle Clutch Pack 1. Remove the external circlip (2) and 30T gear (1). 2. Remove the spacer (4), collar (5) and 28T gear (3). 3. Pull the shuttle clutch pack (7) and lower the shuttle clutch pack (7) in the housing case.
Page 281: Shuttle Clutch Assembly
TRANSMISSION M8540, M9540, WSM (3) Shuttle Clutch Assembly Shuttle Clutch Assembly (F18/R18 Speed Transmission Model) (1) Seal Ring (2) Shuttle Shaft (3) Key (4) 28T Gear (5) Internal Circlip (6) Belleville Washer (Cupped Spring Washer) (7) Pressure Plate (8) Rubber...
Page 282 TRANSMISSION M8540, M9540, WSM Shuttle / Hi-Lo Dual Speed Clutch Assembly (F36/R36 Speed Transmission Model) (1) Seal Ring (2) Shuttle Shaft (3) Key (4) 28T Gear (5) Internal Circlip (6) Belleville Washer (Cupped Spring Washer) (7) Pressure Plate (8) Rubber...
Page 283 TRANSMISSION M8540, M9540, WSM Shuttle Shaft 1. Remove the bearing (4) and washer (3). 2. Remove the gear (2). 3. Tap out the shuttle shaft (1) with gear (5) to the forward. NOTE F18/R18 speed F36/R36 speed transmission model transmission model...
Page 284 TRANSMISSION M8540, M9540, WSM Shuttle Clutch Pack 1. Remove the internal circlip (1). 2. Remove the belleville washer (2), pressure plate (3), steel plate (5), (7) and clutch discs (6). (When reassembling) • Install the clutch discs (6) and steel plate (5), (7) mutually.
Page 285 TRANSMISSION M8540, M9540, WSM Piston 1. Press the washer (4) lightly by the hand made jig (refer to the “SPECIAL TOOLS” at GERERAL section), and remove the external circlip (3). 2. Remove the springs (7). 3. Draw out the piston (5) using a air pressure.
Page 286: Removing Dual Speed Clutch (F36/R36 Speed Transmission Model)
TRANSMISSION M8540, M9540, WSM (4) Removing Dual Speed Clutch (F36/R36 Speed Transmission Model) Dual Speed Clutch Assembly 1. Remove the holder (10). 2. Remove the oil seal (12) and external circlip (1). 3. Tap out the dual speed shaft (7) with clutch pack (5).
Page 287 TRANSMISSION M8540, M9540, WSM Dual Speed Clutch Pack 1. Remove the internal circlip (1). 2. Take out the pressure plate (2), clutch discs (4) and steel plates (3). (When reassembling) • Install the clutch discs (4) and steel plate (3) mutually.
Page 288 TRANSMISSION M8540, M9540, WSM Piston 1. Press the washer (4) lightly by the hand made jig (refer to the “SPECIAL TOOLS” at GERERAL section), and remove the external circlip (3). 2. Remove the springs (7). 3. Draw out the piston (5) using a air pressure.
Page 289: Shift Cover
TRANSMISSION M8540, M9540, WSM [8] SHIFT COVER Speed Change Lever 1. Set the main change shift lever (3) to the neutral position. 2. Set the range shift lever (2) to the H position (A). 3. Remove the shift cover (1) mounting screws.
Page 290 TRANSMISSION M8540, M9540, WSM Range Gear Shift Fork 1. Shift the 5-6th fork (4) to rearward (5th speed). 2. Remove the roll pin (1), fork rod (3) and range shift fork (2). 3. Remove the ball (detent) (5) and spring (6).
Page 291 TRANSMISSION M8540, M9540, WSM Main Shift Fork 1. Remove the roll pin (4), fork rod (5) and 3rd-4th fork (3). 2. Remove the roll pin (8), fork rod (10) and 5th-6th fork (9). 3. Remove the roll pin (6), fork rod (16) and 1st-2nd fork (7).
Page 292 TRANSMISSION M8540, M9540, WSM Main Shift Arm 1. Remove the stopper plate (14) and seal cap (13). 2. Remove the select lever (4) then remove the select arm (3). 3. Remove the seal cap (5). 4. Remove the internal circlip (8).
Page 293 TRANSMISSION M8540, M9540, WSM Creep Gear 1. Slide the shifter (2) and remove the external circlip (1). 2. Remove the internal circlip (9) and tap out the creep shaft 2 (4) with gears. 3. Remove the bearing (12) and (5).
Page 294 TRANSMISSION M8540, M9540, WSM Range Shift Arm 1. Remove the roll pin (2) and stopper plate (3). 2. Draw out the range shift arm (4). (When reassembling) • Be sure to assemble the range shift lever (1) as an original direction as shown in photo.
Page 295: Disassembling Clutch Housing Case
TRANSMISSION M8540, M9540, WSM [9] DISASSEMBLING CLUTCH HOUSING CASE (1) Removing 1st Shaft, 2nd Shaft and 3rd Shaft PTO Propeller Shaft and 30T Gear (27T Gear) 1. Tap out the PTO propeller shaft (2) rearward. 2. Remove the external circlip (4).
Page 296 TRANSMISSION M8540, M9540, WSM Bearing Holder and Speed Sensor 1. Remove the speed sensor (2). 2. Remove the external circlip and 33T DT gear (3). 3. Remove the bearing holder mounting screws, and take out the bearing holder (1). If the shaft comes out with bearing holder, tap in the shaft during take out the bearing holder (1).
Page 297: 1St Shaft Assembly
TRANSMISSION M8540, M9540, WSM (2) 1st Shaft Assembly 1st Shaft (1) Bearing (2) Thrust Collar (3) 26T Gear (4) Inner Race (5) Synchronizer Ring (6) Coupling (3-4 Speed) (7) Synchronizer Key (8) Shifter (9) 23T Gear (10) 32T Gear (11) Coupling (5-6 Speed)
Page 298: 2Nd Shaft
TRANSMISSION M8540, M9540, WSM 1st Shaft (Continued) 1. Remove the bearing (22) and external circlip (23). 2. Draw out the all synchronizer units and gears. (When reassembling) • Be sure to assemble the synchronizer unit, set the teeth (25) on the shifter (8) to the key (7) as shown in the figure.
Page 299: 3Rd Shaft
TRANSMISSION M8540, M9540, WSM (4) 3rd Shaft 3rd Shaft 1. Remove the bearing (1). 2. Remove the gears. (When reassembling) • Apply molybdenum disulfide (Three Bond 1901 or equivalent) to the inner races (3). (1) Bearing (7) Shifter (2) Thrust Collar...
Page 300: Disassembling Transmission Case
TRANSMISSION M8540, M9540, WSM [10] DISASSEMBLING TRANSMISSION CASE (1) Hydraulic Pump Holder Hydraulic Pump Holder 1. Tap out the 18T spiral bevel gear (4) with bearings. 2. Remove the shim (3) from pump holder (1). 3. Remove the bearing (5) using a puller.
Page 301: Pto Clutch Pack
TRANSMISSION M8540, M9540, WSM (2) Parking Brake Parking Brake Disc and Steel Plate 1. Remove the stopper screw (5) and upper pin (6). 2. Remove the disc (3) and (4). 3. Remove the 47T gear (1) with steel plates (2).
Page 302: Removing 4Wd Clutch
TRANSMISSION M8540, M9540, WSM (4) Removing 4WD Clutch 4WD Clutch 1. Remove the 4WD clutch (1). (When reassembling) • Replace the seal rings (2) with new one. • Apply grease to the seal rings (2) when assembling. (1) 4WD Clutch...
Page 303 TRANSMISSION M8540, M9540, WSM 4WD Piston 1. Press the pressure plate (4) to press down the 4WD piston (11), using jig (refer to “4. SPECIAL TOOLS” at “NG. GENERAL” section), and remove the internal circlip (3). 2. Remove the discs (5), steel plates (6), (7) and pressure plates (4).
Page 304: Removing Differential Gear And Bevel Pinion Shaft
TRANSMISSION M8540, M9540, WSM (6) Removing Differential Gear and Bevel Pinion Shaft Differential Lock Device 1. Remove the differential lock support (1) with piston (5). 2. Remove the pins (4). (When reassembling) • Apply transmission fluid to the O-ring (2).
Page 305: Differential Gear
TRANSMISSION M8540, M9540, WSM Spiral Bevel Pinion Shaft 1. Remove the stake of staking nut (1). 2. Set the staking nut locking wrench (2). 3. Set the spiral bevel pinion shaft turning wrench. 4. Turn the spiral bevel pinion shaft turning wrench to the counterclockwise, then remove it.
Page 306 TRANSMISSION M8540, M9540, WSM Differential Pinion Shaft and Differential Pinion Gear 1. Tap out the roll pin (1). 2. Draw out the differential pinion shaft 2 (5), and take out the differential pinion gear (3) and differential pinion washer (4).
Page 307: Differential Lock Piston
TRANSMISSION M8540, M9540, WSM (8) Differential Lock Piston Piston 1. Remove the piston (1) from the differential lock support (2). (When reassembling) • Apply transmission fluid to the O-rings (3). (1) Piston (3) O-ring (2) Differential Lock Support W1041076 KiSC issued 09, 2008 A...
Page 308: Pto Gear Case
TRANSMISSION M8540, M9540, WSM [11] PTO GEAR CASE (1) 540/540E Shift Type PTO Gear Case (1) PTO Gear Case Cover (2) Ball Bearing (3) PTO Drive Gear Shaft (4) Gear (5) Collar (6) Ball Bearing (7) Stake Nut (8) Washer...
Page 309: 540/1000 Interchangeable Type
TRANSMISSION M8540, M9540, WSM (2) 540/1000 Interchangeable Type (1) PTO Gear Case Cover (2) Ball Bearing (3) PTO Drive Gear Shaft (4) 18T Gear (5) Ball Bearing (6) Ball Bearing (7) Bearing (8) 49T Gear (9) Bearing (10) 43T Gear...
Page 310: Servicing
TRANSMISSION M8540, M9540, WSM 6. SERVICING [1] BEARING, SHIFT FORK AND SYNCHRONIZER Ball Bearing 1. Hold the inner race, push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 311: Traveling Clutch
TRANSMISSION M8540, M9540, WSM Flaw on Synchronizer Key and Spring 1. Check the projection in the center of the synchronizer key for wear. 2. Check the spring for fatigue or wear on the area where the spring contacts with the keys.
Page 312: Shuttle Clutch Pack
TRANSMISSION M8540, M9540, WSM [3] SHUTTLE CLUTCH PACK Clearance between Internal Circlip and Belleville Washer (Cupped Spring Washer) 1. Measure the clearance between internal circlip and belleville washer (cupped spring washer) with a feeler gauge while applying specified force. Specified force : 176 to 296 N (18 to 30 kgf, 39.6 to 66.1 lbf) 2.
Page 313: Dual Speed Clutch Pack (F36/R36 Speed Transmission Model)
TRANSMISSION M8540, M9540, WSM [4] DUAL SPEED CLUTCH PACK (F36/R36 SPEED TRANSMISSION MODEL) Clearance between Internal Circlip and Pressure Plate 1. Measure the clearance between internal circlip and pressure plate with a feeler gauge while applying specified force. Specified force : 176 to 296 N (18 to 30 kgf, 39.6 to 66.1 lbf) 2.
Page 314: Shaft And Gear
TRANSMISSION M8540, M9540, WSM [5] SHAFT AND GEAR Side Clearance of 1st Shaft 1. Measure the side clearance (L) between the two thrust collars (1). 2. If clearance (L) exceeds the factory specification, adjust the clearance using adjusting collar (2).
Page 315 TRANSMISSION M8540, M9540, WSM Flatness of Piston, Steel Plate and Pressure Plate 1. Place the part on a surface plate and check it unable to insert a feeler gauge (allowable limit size) underneath it (at lease four points). 2. If the gauge can be inserted, replace it.
Page 316: Hydraulic Pump Drive Gear
TRANSMISSION M8540, M9540, WSM [7] HYDRAULIC PUMP DRIVE GEAR Backlash between 18T Bevel Gear and 19T Bevel Gear 1. Hold the fuse (1) in place with grease. 2. Assemble the hydraulic pump holder to the transmission case. 3. Turn the input shaft using a damper disc or clutch disc.
Page 317: Differential Gear
TRANSMISSION M8540, M9540, WSM [8] DIFFERENTIAL GEAR IMPORTANT • When reassembling spiral bevel pinion shaft and differential assembly, be sure to adjust the following. • Turning torque of spiral bevel pinion shaft only. • Backlash and tooth contact between spiral bevel pinion shaft and spiral bevel gear.
Page 318 TRANSMISSION M8540, M9540, WSM Backlash and Tooth Contact between Spiral Bevel Gear and Spiral Bevel Pinion Shaft 1. Set the dial indictor (lever type) with its finger on the tooth surface. 2. Measure the backlash by fixing the spiral bevel pinion shaft (1) and moving the spiral bevel gear (3) by hand.
Page 319 TRANSMISSION M8540, M9540, WSM Backlash and Tooth Contact between Spiral Bevel Gear and Spiral Bevel Pinion Shaft (Continued) • Proper Contact More than 35 % red lead contact area on the gear tooth surface. The center of tooth contact at 1/3 of the entire width from the small end.
Page 320 TRANSMISSION M8540, M9540, WSM Clearance between Differential Case Bore (35T Bevel Gear Bore) and Differential Side Gear Boss 1. Measure the bore I.D. of the differential case and 35T bevel gear. 2. Measure the differential side gear boss O.D. and calculate the clearance.
Page 321 TRANSMISSION M8540, M9540, WSM Backlash between Differential Pinion and Differential Side Gear 1. Set a dial indicator (lever type) on the tooth of the differential pinion. 2. Hold the differential side gear and move the differential pinion to measure the backlash.
Page 322: Rear Axle
REAR AXLE KiSC issued 09, 2008 A...
Page 323 MECHANISM CONTENTS 1. FEATURES ....................4-M1 KiSC issued 09, 2008 A...
Page 324 REAR AXLE M8540, M9540, WSM 1. FEATURES (1) Rear Axle (4) 27T Planetary Gear (7) 35T Bevel Gear (9) Planetary Gear Pin (2) Rear Axle Case (5) 66T Internal Gear (8) Differential Bearing Support (10) Brake Shaft (12T Gear) (3) Planetary Gear Support (6) Differential Gear The rear axles are the final mechanism which transmit power from the transmission to the rear wheels.
Page 325: Servicing
SERVICING CONTENTS 1. TROUBLESHOOTING ..................4-S1 2. SERVICING SPECIFICATIONS ..............4-S2 3. TIGHTENING TORQUES ................4-S3 4. DISASSEMBLING AND ASSEMBLING ............4-S4 [1] SEPARATING REAR AXLE..............4-S4 (1) Removing Rear Axle (ROPS Model)...........4-S4 (2) Removing Rear Axle (CABIN Model) ..........4-S5 [2] DISASSEMBLING REAR AXLE..............4-S6 (1) Brake Section..................4-S6 (2) Rear Axle Case ...................4-S6 5.
Page 326: Troubleshooting
REAR AXLE M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive or Improper backlash between planetary gear and Replace 4-S9 Unusual Nose at All internal gear Time Bearing worn Replace 4-S9 Insufficient or improper type of transmission fluid...
Page 327: Servicing Specifications
REAR AXLE M8540, M9540, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Internal Gear to Planetary Gear Backlash 0.2 to 0.4 mm 0.5 mm 0.0078 to 0.0157 in. 0.020 in. Thrust Collar Thickness 1.55 to 1.65 mm 1.2 mm 0.0610 to 0.0650 in.
Page 328: Tightening Torques
REAR AXLE M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m...
Page 329: Disassembling And Assembling
REAR AXLE M8540, M9540, WSM 4. DISASSEMBLING AND ASSEMBLING [1] SEPARATING REAR AXLE (1) Removing Rear Axle (ROPS Model) Removing Rear Axle Assembly 1. Refer to the “5. DISASSEMBLING AND ASSEMBLING” at “3. TRANSMISSION” section. 2. Remove the cylinder support (1).
Page 330: Removing Rear Axle (Cabin Model)
REAR AXLE M8540, M9540, WSM (2) Removing Rear Axle (CABIN Model) Removing Rear Axle Assembly 1. Remove the cylinder support (2). 2. Support the cabin and remove the cabin mounting bolt (1). 3. Remove the rear axle case mounting screws and nuts.
Page 331: Disassembling Rear Axle
REAR AXLE M8540, M9540, WSM [2] DISASSEMBLING REAR AXLE (1) Brake Section Brake Shaft, Brake Disc, Steel Plate and Brake Plate 1. Remove the external circlip (1). 2. Draw out the brake shaft (5) with brake disc (8) and steel plates (7).
Page 332 REAR AXLE M8540, M9540, WSM Planetary Gear 1. Tap the roll pin (1) into the planetary gear shaft (3). 2. Draw out the planetary gear shaft (3), and remove the planetary gear (2). 3. Tap out the roll pin from the planetary gear shaft.
Page 333 REAR AXLE M8540, M9540, WSM Assembling Procedure for Rear Axle 1. Assemble the ball bearing (2) to the rear axle case. 2. Assemble the oil seal 1 (1), face the seal lip to outside. 3. Assemble the oil seal 2 (3) to the rear axle.
Page 334: Servicing
REAR AXLE M8540, M9540, WSM 5. SERVICING [1] BEARING Ball Bearing 1. Hold the inner race, push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 335 REAR AXLE M8540, M9540, WSM Clearance between Planetary Gear and Planetary Gear Shaft 1. Measure the planetary gear shaft O.D. (rubbing surface). 2. Measure the planetary gear I.D. (rubbing surface). 3. Measure the O.D. of the two needles installed diagonally in the needle bearing.
Page 336 BRAKES KiSC issued 09, 2008 A...
Page 337 MECHANISM CONTENTS 1. TRAVELLING BRAKE AND TRAILER BRAKE.......... 5-M1 [1] STRUCRURE................... 5-M1 [2] STRUCTURE FOR TRAVELING BRAKE..........5-M2 [3] STRUCTURE FOR TRAILER BRAKE ..........5-M3 [4] MASTER CYLINDER ASSEMBLY............5-M4 [5] HYDRAULIC TRAILER BRAKE VALVE ..........5-M5 (1) Structure .................... 5-M5 (2) Operation ...................
Page 338: Travelling Brake And Trailer Brake
BRAKES M8540, M9540, WSM 1. TRAVELLING BRAKE AND TRAILER BRAKE [1] STRUCRURE (1) Trailer Brake Valve (5) Delivery Pipe (To Outlet Block) (8) Brake Pedal (12) Return Pipe (Trailer Brake (2) Trailer Brake Coupler (6) Delivery Pipe (Hose) (9) Master Cylinder...
Page 339: Structure For Traveling Brake
BRAKES M8540, M9540, WSM [2] STRUCTURE FOR TRAVELING BRAKE (1) Brake Pedal (4) Bleeder (7) Brake Shaft (10) Master Cylinder (2) Return Pipe (5) Brake Piston (8) Brake Disc (3) Brake Pipe (6) Brake Plate (9) Power Steering Controller A : To Oil Cooler The traveling brake is a hydraulic wet disc type, which consists of the master cylinder (10), brake pipe (3), brake piston (5) and others.
Page 340: Structure For Trailer Brake
BRAKES M8540, M9540, WSM [3] STRUCTURE FOR TRAILER BRAKE (1) Outlet Block (4) Trailer Brake Coupler (7) Delivery Hose (9) Return Pipe (2) Delivery Pipe (Hose) (5) Trailer Brake Valve (from Hydraulic Pump) (10) Hydraulic Pump (for 3P Hydraulic System)
Page 341: Master Cylinder Assembly
BRAKES M8540, M9540, WSM [4] MASTER CYLINDER ASSEMBLY The master cylinder is one peace type which including oil tank (3), master cylinder (2) and equalizer (6). (The function for each parts, refer to “5. BRAKES” section in the workshop manual of tractor mechanism (Code No.
Page 342: Hydraulic Trailer Brake Valve
BRAKES M8540, M9540, WSM [5] HYDRAULIC TRAILER BRAKE VALVE (1) Structure Main Elements • Flow control valve (10) with throttle (9) and restrictor (11) : for controlling the delivery flow Qp and for regulating the fluid flow for the trailer brake.
Page 343: Operation
BRAKES M8540, M9540, WSM (2) Operation Tractor Brake Released The tractor service brake line X is pressureless. The brake line B is relieved to the reservoir through the control spool (2) and port R. The delivery flow Qp of the pump flows from port P past flow control valve (10), the flow Qp - Qx continues through port N to the tractor hydraulics.
Page 344 BRAKES M8540, M9540, WSM Partial Braking of Trailer Brake - Initiation Piston (7) of control head (6) is pressurized through control line X from the tractor service brake. Control spool (2) is thus shifted to the left and separates from the reservoir first brake line B and then bore (8).
Page 345 BRAKES M8540, M9540, WSM Partial Braking of Trailer Brake The trailer braking pressure Pb (acting on surface (1) of control spool (2)) is in equilibrium with the tractor braking pressure Px (acting on piston (7)). The brake line B remains separated from the reservoir and the oil in the trailer brake is thus enclosed.
Page 346 BRAKES M8540, M9540, WSM Maximum Braking of Trailer Brake - Braking Pressure Limited Flow control valve (10) and control spool (2) have the same spool positions (a and d) as in the case of partial braking. The fluid flows Qp and Qx pass as with partial braking.
Page 347: Parking Brake
BRAKES M8540, M9540, WSM 2. PARKING BRAKE • There are two systems for parking brake, one is the gear lock brake system and the other one is parking brake system. They are independent of the travelling brake system each other.
Page 348: Restriction Device (Gear Lock Brake Lever And Main Gear Shift Lever)
BRAKES M8540, M9540, WSM (2) Restriction Device (Gear Lock Brake Lever and Main Gear Shift Lever) When the gear lock brake is on, the main shift lever (1) cannot shift any speed range. When the main shift lever (1) is shifted, the operator cannot operate the gear lock brake lever (2).
Page 349: Parking Brake
BRAKES M8540, M9540, WSM [2] PARKING BRAKE Parking brakes are a wet disc brake, which is independent of the travelling brakes and provided on the bevel gear shaft (5). When the parking brake lever is pulled, the parking brake cam (3) is moved in the direction of arrow through the parking brake linkage.
Page 350 SERVICING CONTENTS 1. TROUBLESHOOTING ..................5-S1 2. SERVICING SPECIFICATIONS ..............5-S2 3. TIGHTENING TORQUES ................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING........5-S4 [1] CHECKING AND ADJUSTING ...............5-S4 (1) Traveling Brake ...................5-S4 (2) Trailer Brake Valve ................5-S7 (3) Gear Lock Brake .................5-S7 (4) Parking Brake ...................5-S11 [2] DISASSEMBLING AND ASSEMBLING..........5-S12 (1) Removing Master Cylinder (ROPS Model) ........5-S12 (2) Removing Master Cylinder (CABIN Model) ........5-S13...
Page 351: Troubleshooting
BRAKES M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Poor Braking Force Brake pedal free travel excessive Adjust 5-S4 Brake disc worn Replace 5-S18, 22 Brake piston warped Replace 5-S17, 22 Brake oil leakage from brake pipes, bleeder, Repair or replace –...
Page 352: Servicing Specifications
BRAKES M8540, M9540, WSM 2. SERVICING SPECIFICATIONS TRAVELING BRAKE Item Factory Specification Allowable Limit Brake Pedal R.H. Free Travel 5.0 to 10 mm – 0.20 to 0.39 in. Brake Pedal L.H. Free Travel Free travel of brake – pedal R.H. plus 5.0 to 10 mm...
Page 353: Tightening Torques
BRAKES M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m kgf·m...
Page 354: Checking, Disassembling And Servicing
BRAKES M8540, M9540, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING CAUTION • When checking, park the tractor on flat ground, and stop the engine. (1) Traveling Brake Adjusting Brake Pedal 1) Brake Pedal Free Travel 1. Set the parking brake.
Page 355 BRAKES M8540, M9540, WSM 2) Brake Pedal Stroke 1. Disengage the brake pedal lock (2). 2. Depress the brake pedal several time. 3. Step on either side brake pedal and measure the level difference (pedal stroke) between right and left pedals.
Page 356 BRAKES M8540, M9540, WSM Bleeding Brake System IMPORTANT • The shuttle lever and main change lever are shift in “NEUTRAL” position. • Set the parking brake lever to “ON” position. • Fill the transmission fluid to the equalizer and master cylinder when overhaul the master cylinder assembly.
Page 357: Trailer Brake Valve
BRAKES M8540, M9540, WSM (2) Trailer Brake Valve Checking Brake Pressure 1. Remove the trailer brake coupler, and set the trailer brake adaptor (3), joint (Code No. 07616-50401), cable (Code No. 07916-50331) and pressure gauge (1) (Code No. 07916-50321). 2. Interlock the left and right pedals.
Page 358 BRAKES M8540, M9540, WSM Adjusting Gear Lock Brake Lever (ROPS Model) 1. Check the clearance (L) between gear lock brake lever (1) and guide plate (3) when gear lock brake lever (1) pushed to outside. 2. If the clearance (L) is not within the factory specification, adjust with adjusting screw (2).
Page 359 BRAKES M8540, M9540, WSM Adjusting Restriction Lever 1. Check the restriction lever (2) when gear lock brake lever (1) at “OFF” position as follows. [ROPS Model] • The restriction lever (2) is positioned in vertically when gear lock brake lever (1) at “OFF” position.
Page 360 BRAKES M8540, M9540, WSM Parking Position 1. Unhook the spring (4). 2. Set the gear lock brake lever (1) to “PARKING” position (a). 3. Shake the tractor for forward and reverse to confirm the gear lock brake gears mesh with each other completely as shown in the figure (c).
Page 361: Parking Brake
BRAKES M8540, M9540, WSM (4) Parking Brake Adjusting Parking Brake 1. Check the length (L1) of upper parking brake rod (2). 2. Check the length (L2) of brake cam rod (3). 3. Check the height (L3) of stopper screw (4).
Page 362: Disassembling And Assembling
BRAKES M8540, M9540, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Removing Master Cylinder (ROPS Model) Master Cylinder Rod 1. Remove the panel cover refer to “[1] CLUTCH PEDAL” at “2. CLUTCH” section. 2. Remove the master cylinder rod pin (1) from brake pedal (2).
Page 363: Removing Master Cylinder (Cabin Model)
BRAKES M8540, M9540, WSM (2) Removing Master Cylinder (CABIN Model) Bonnet 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the connector (2) for head lights. 3. Disconnect the dampers (3). 4. Remove the bonnet (1).
Page 364 BRAKES M8540, M9540, WSM Panel Cover and Panel Under Cover 1. Remove the panel cover (1) and disconnect the connectors from hazard switch (2) and display mode switch (3). 2. Remove the air outlet (4) then remove the panel under cover R.H.
Page 365 BRAKES M8540, M9540, WSM Master Cylinder Rod 1. Remove the pedal shaft support (1) 2. Remove the master cylinder rod pins (2) from brake pedals (3). (1) Pedal Shaft Support (3) Brake Pedal (2) Pin W1023783 Brake Pipes and Master Cylinder Hoses 1.
Page 366: Master Cylinder
BRAKES M8540, M9540, WSM (3) Master Cylinder Master Cylinder 1. Drain the brake oil from the master cylinder assembly (4). 2. Remove the push rod (1) and boot (5) from the master cylinder. 3. Remove the internal circlip (2), and pull out the piston (6) and return spring (9).
Page 367: Brake Piston
BRAKES M8540, M9540, WSM Brake Pedal (CABIN Model) 1. Remove the pedal shaft support (1). 2. Remove the master cylinder rod pins (3). 3. Unhook the springs (2). 4. Draw out the brake pedals (4). (When reassembling) • Apply grease to the pedal shaft.
Page 368: Brake Disc And Plate
BRAKES M8540, M9540, WSM (6) Brake Disc and Plate Brake Shaft, Brake Disc, Steel Plate and Brake Plate 1. Remove the external circlip (1). 2. Draw out the brake shaft (5) with brake disc (8) and steel plates (7). 3. Remove the external circlip (6).
Page 369: Gear Lock Brake Gear
BRAKES M8540, M9540, WSM (7) Gear Lock Brake Gear • Separating transmission case and clutch housing case, refer to “5. DISASSEMBLING AND ASSEMBLING” at “3. TRANSMISSION” section. Bearing Holder and Speed Sensor 1. Remove the speed sensor (4). 2. Remove the external circlip (3) and 33T gear (2).
Page 370 BRAKES M8540, M9540, WSM Gear Lock Gear 1. Remove the external circlip (3) and draw out the gear lock cam shaft (1). 2. Remove the roll pin (4) and remove the gear lock gear pin (7) and gear lock gear (6).
Page 371: Parking Brake
BRAKES M8540, M9540, WSM (8) Parking Brake Parking Brake Disc and Steel Plate 1. Remove the stopper screw (5) and upper pin (6). 2. Remove the disc (3) and (4). 3. Remove the 47T gear (1) with steel plates (2).
Page 372: Servicing
BRAKES M8540, M9540, WSM [3] SERVICING (1) Brake Pedal Brake Pedal Bushing 1. Measure the brake pedal bushing I.D. with inside micrometer. 2. Measure the pedal shaft O.D. with outside micrometer and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace it.
Page 373: Parking Brake
BRAKES M8540, M9540, WSM (3) Parking Brake Parking Brake Pad and Steel Plate Wear 1. Measure the brake pad thickness with a vernier caliper. 2. Measure the steel plate thickness with a vernier caliper. 3. If the thickness is less than the allowable limit, replace it.
Page 374: Front Axle
FRONT AXLE KiSC issued 09, 2008 A...
Page 375 MECHANISM CONTENTS 1. STRUCTURE ....................6-M1 [1] FRONT AXLE..................6-M1 [2] LIMITED SLIP DIFFERENTIAL (LSD) ..........6-M2 KiSC issued 09, 2008 A...
Page 376 FRONT AXLE M8540, M9540, WSM 1. STRUCTURE The front axle supports the front of tractor and facilitates steering. The four-wheel drive axle has powered front wheels. NOTE • Refer to “6. FRONT AXLE” section in the workshop manual of tractor mechanism (Code No. 9Y021-18200).
Page 377 FRONT AXLE M8540, M9540, WSM [2] LIMITED SLIP DIFFERENTIAL (LSD) (1) Differential Case (2) Side Gear (3) Side Gear (LSD) (4) Friction Disc (5) Case Cover (6) Belleville Washer (Cupped Spring Washer) (7) Steel Plate (8) Adjustment Shim (LSD) (9) Adjustment Shim...
Page 378 SERVICING CONTENTS 1. TROUBLESHOOTING ..................6-S1 2. SERVICING SPECIFICATIONS ..............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 Front Axle ..............6-S8 (3) Removing Differential Gear and Bevel Pinion Shaft ......6-S11 (4) Disassembling Differential Gear (LSD) ..........6-S12 [3] SERVICING ....................6-S14 (1) 4WD Model ..................6-S14...
Page 379: Troubleshooting
FRONT AXLE M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Tire pressure uneven Adjust G-72 Wander to Right or Improper toe-in adjustment (improper alignment) Adjust 6-S5 Left Front axle bracket (front, rear) bushing Replace 6-S11, 19...
Page 380: Servicing Specifications
FRONT AXLE M8540, M9540, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Toe-in 2.0 to 8.0 mm – 0.078 to 0.315 in. Front Wheel Steering Angle 0.925 to 0.960 rad – 53 to 55 ° Axial Sway Less than 5.0 mm –...
Page 381 FRONT AXLE M8540, M9540, WSM Item Factory Specification Allowable Limit Front Wheel Case Support Bushing Alloy Thickness 0.57 mm – 0.0224 in. Bearing Retainer O.D. 59.97 to 60.00 mm – 2.36102 to 2.36220 in. Front Wheel Case Bushing Alloy Thickness 0.57 mm...
Page 382: Tightening Torques
FRONT AXLE M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m...
Page 383: Checking, Disassembling And Servicing
FRONT AXLE M8540, M9540, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Adjusting Toe-in 1. Park tractor on a flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lower the implement, lock the park brake and stop the engine.
Page 384 FRONT AXLE M8540, M9540, WSM Adjusting Front Axle Pivot 1. Jack up the tractor body, then loosen the front axle rocking force adjusting lock nut (2). 2. Screw in the adjusting screw (1) until seated, then tighten the adjusting screw (1) with an additional 1/6 turn.
Page 385: Disassembling And Assembling
FRONT AXLE M8540, M9540, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Separating Front Axle Draining Front Axle Gear Case (Right and Left) and Front Differential Case Oil 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL”...
Page 386: Disassembling Front Axle
FRONT AXLE M8540, M9540, WSM Front Axle 1. Place a disassembling stand under the front axle case and support it with a jack. 2. Disconnect the breather hose (1). 3. Remove the bracket (front) (3) mounting screws and nuts. 4. Remove the bracket (rear) (2) mounting screws and nuts.
Page 387 FRONT AXLE M8540, M9540, WSM Bevel Gear Case 1. Remove the internal circlip (3) and shim (2) then draw out the 17T bevel gear (1) with bearing. 2. Remove the front wheel case support (8). 3. Draw out the 18T bevel gear (9) and bevel gear shaft (5).
Page 388 FRONT AXLE M8540, M9540, WSM Bevel Gear 1. Remove the bevel gear and bearing with a puller. W1016676 Planetary Gear 1. Remove the external circlip (1). 2. Remove the planetary gear support assembly. 3. Tap the roll pin (6) into the planetary gear shaft (5).
Page 389: Removing Differential Gear And Bevel Pinion Shaft
FRONT AXLE M8540, M9540, WSM Front Axle Oil Seal 1. Remove the internal circlip (1) and tap out the bearing (2). 2. Draw out the oil seal (3), (4). (When reassembling) • Install the oil seal outward to the front wheel case cover so that its lip faces the outward.
Page 390: Disassembling Differential Gear (Lsd)
FRONT AXLE M8540, M9540, WSM (4) Disassembling Differential Gear (LSD) Spiral Bevel Gear 1. Remove the external circlip (6) and the 23T spiral bevel gear (5) with bearing (4). 2. Remove the bearing (1). 3. Remove the differential case cover mounting screws and remove the differential case cover.
Page 391 FRONT AXLE M8540, M9540, WSM LSD Disc and Steel Plate 1. Draw out the LSD side gear (4), LSD shim (5), steel plates (3), LSD discs (6) and belleville washers (cupped spring washer) (2). (When reassembling) • Apply transmission fluid to the LSD discs.
Page 392: Servicing
FRONT AXLE M8540, M9540, WSM [3] SERVICING (1) 4WD Model Ball Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 393 FRONT AXLE M8540, M9540, WSM Backlash and Tooth Contact between Bevel Pinion Shaft and Bevel Gear 1. Set a dial indicator (lever type) with its finger on the tooth surface. 2. Measure the backlash by fixing the bevel pinion shaft (2) and moving the bevel gear (1) by hand.
Page 394 FRONT AXLE M8540, M9540, WSM Clearance between Differential Case and Differential Side Gear 1. Measure the differential side gear boss O.D.. 2. Measure the differential case bore I.D. and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace it.
Page 395 FRONT AXLE M8540, M9540, WSM Backlash between Differential Pinion and LSD Side Gear 1. Assemble the pinion gear (1), (6) and pinion shaft (2) without differential side gear (13). 2. Assemble the LSD side gear (4) without belleville washers (cupped spring washer) (11), steel plates (9), LSD discs (12) and LSD shim (8).
Page 396 FRONT AXLE M8540, M9540, WSM Slip Torque of LSD Disc 1. Set the differential assembly on the vice securely. 2. Check the LSD slip torque using a jig as shown in the photo. 3. If the LSD slip torque is not within the factory specification, adjust with LSD shim (1).
Page 397 FRONT AXLE M8540, M9540, WSM Front Bracket and Rear Bracket Bushing 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy portion (L), replace it.
Page 398 FRONT AXLE M8540, M9540, WSM Bevel Gear Case and Front Wheel Case Bushing 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy portion (L), replace it.
Page 399 FRONT AXLE M8540, M9540, WSM Backlash of Bevel Gear in Front Wheel Case 1. Set a dial indicator (lever type) on the shaft (Kingpin). 2. Move the shaft (Kingpin) by hand and measure the circumferential play of the shaft. 3. Calculate the backlash from the ratio of the shaft diameter to the gear diameter.
Page 400 FRONT AXLE M8540, M9540, WSM Thrust Collar Thickness 1. Measure the thickness of the thrust collar. 2. If the measurement is less than the allowable limit, replace it. 0.75 to 0.85 mm Factory spec. 0.02953 to 0.03346 in. Thrust collar thickness 0.5 mm...
Page 401 STEERING KiSC issued 09, 2008 A...
Page 402 MECHANISM CONTENTS 1. STEERING MECHANISM ................7-M1 2. STEERING CYLINDER................. 7-M2 KiSC issued 09, 2008 A...
Page 403 STEERING M8540, M9540, WSM 1. STEERING MECHANISM (1) Hydraulic Pump (3) Steering Cylinder (5) Power Steering Pipe a : To Oil Cooler and Brake (2) Steering Controller (4) Power Steering Hose (6) Magnet Filter Master Cylinder b : To 3-point Hydraulic System All models are provided with a full hydrostatic power steering.
Page 404: Steering Cylinder
STEERING M8540, M9540, WSM 2. STEERING CYLINDER (1) Rod (2) Scraper Seal (3) Oil Seal (4) O-ring (5) Slipper Seal (6) Piston (7) Guide (8) Bushing (9) O-ring (10) Backup Ring (11) Piston Seal (12) Circlip W1012783 The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.
Page 405 SERVICING CONTENTS 1. TROUBLESHOOTING ..................7-S1 2. SERVICING SPECIFICATIONS ..............7-S2 3. TIGHTENING TORQUES ................7-S3 4. CHECKING, DISASSEMBLING AND SERVICING........7-S4 [1] CHECKING AND ADJUSTING ...............7-S4 (1) Steering Controller ................7-S4 (2) Hydraulic Pump...................7-S4 [2] REMOVING STEERING CONTROLLER..........7-S5 (1) ROPS Model ..................7-S5 (2) CABIN Model ..................7-S8 [3] REMOVING STEERING CYLINDER ............7-S10 [4] DISASSEMBLING AND ASSEMBLING..........7-S12 (1) Steering Controller ................7-S12...
Page 406: Troubleshooting
STEERING M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Tractor Cannot Be Drive shaft in the power steering controller Reassemble 7-S7, 9 Steered improper assembled Pipe broken Replace – Hard Steering Oil improper Change with specified oil...
Page 407: Servicing Specifications
STEERING M8540, M9540, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Relief Valve Setting Pressure At Idling Engine Above 12.3 MPa – Speed 125 kgf/cm 1777.9 psi At Maximum Below 18.1 MPa – Engine Speed 185 kgf/cm 2631.3 psi Steering Cylinder I.D.
Page 408: Tightening Torques
STEERING M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m kgf·m...
Page 409: Checking, Disassembling And Servicing
STEERING M8540, M9540, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Steering Controller Relief Valve Setting Pressure 1. Disconnect the delivery hose 1 (or 2) from steering cylinder and set a pressure gauge (3) (Code No. 07916-50321) between them using power steering adaptor (1) (Code No.
Page 410: Removing Steering Controller
STEERING M8540, M9540, WSM [2] REMOVING STEERING CONTROLLER (1) ROPS Model Bonnet 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the connectors (2) for head lights. 3. Disconnect the dampers (3). 4. Remove the bonnet (1).
Page 411 STEERING M8540, M9540, WSM Steering Support Under Cover 1. Remove the steering support under cover (1). (1) Steering Support Under Cover W1014598 Shuttle Cable and Oil Pipes 1. Disconnect the shuttle cable (3). 2. Disconnect the power steering delivery hose 1 (4) and 2 (5) from power steering controller.
Page 412 STEERING M8540, M9540, WSM Pipes for Master Cylinder 1. Disconnect the master cylinder delivery pipe (2) and master cylinder return pipe (1). 2. Disconnect the brake pipe L.H. (4) and R.H. (3) from master cylinder. 3. Remove the brake pipe clamp (5).
Page 413: Cabin Model
STEERING M8540, M9540, WSM (2) CABIN Model Bonnet 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the connector (2) for head lights. 3. Disconnect the dampers (3). 4. Remove the bonnet (1). (When reassembling) • The connector (2) should be placed within the space of controller pipe (6), power steering controller (4) and stay (5).
Page 414 STEERING M8540, M9540, WSM Oil Pipes and Hoses 1. Remove the fuse box (slow blow) (1). 2. Disconnect the power steering delivery hose 1 (6) and 2 (7) from power steering controller (8). 3. Disconnect the controller pipe (4) and oil cooler pipe (3).
Page 415: Removing Steering Cylinder
STEERING M8540, M9540, WSM [3] REMOVING STEERING CYLINDER Tie-rod 1. Remove the both cylinder cover (1). 2. Disconnect the both power steering delivery hoses (2) from cylinder. 3. Remove the both hose joints (3) from steering cylinder. 4. Pull out the cotter pin and remove the tie-rod end slotted nuts (4).
Page 416 STEERING M8540, M9540, WSM Steering Cylinder 1. Remove the both tie-rod joint (1). 2. Remove the internal circlip (3) and set screw (2). 3. Draw out the steering cylinder to the right. (When reassembling) • Apply liquid lock (Three Bond 1372 or equivalent) to the tie-rod joint.
Page 417: Disassembling And Assembling
STEERING M8540, M9540, WSM [4] DISASSEMBLING AND ASSEMBLING (1) Steering Controller Removing Gerotor 1. Secure the housing (3) in a vise and remove seven gerotor mounting screws and gerotor assembly (1). 2. Remove the distributor plate (11) and driven shaft (2).
Page 418 STEERING M8540, M9540, WSM Grand Seal, Needle Bearing, Sleeve and Spool 1. Remove the retaining ring (1) with a screw driver. 2. Hold the control valve unit vertically and spool and sleeve align the cross pin parallels to flat side of housing (flow priority valve mounting side), the cross pin is visible through open end of spool.
Page 419: Disassembling Steering Cylinder
STEERING M8540, M9540, WSM (2) Disassembling Steering Cylinder Steering Cylinder (4WD Model) 1. Draw out the cylinder head (4). 2. Draw out the cylinder rod (1). (When reassembling) • Apply transmission fluid to the O-ring (3), rod seal (5) and inside of cylinder tube (9).
Page 420 HYDRAULIC SYSTEM KiSC issued 09, 2008 A...
Page 421 MECHANISM CONTENTS 1. STRUCTURE ....................8-M1 [1] ROPS MODEL ..................8-M1 [2] CABIN MODEL ..................8-M2 2. HYDRAULIC CIRCUIT .................. 8-M4 [1] TOTAL HYDRAULIC CIRCUIT .............. 8-M4 (1) F18/R18 Speed Transmission Model..........8-M4 (2) F36/R36 Speed Transmission Model..........8-M5 [2] OIL COOLER RELIEF VALVE (ROPS MODEL)......... 8-M6 3.
Page 422: Structure
M8540, M9540, WSM HYDRAULIC SYSTEM 1. STRUCTURE [1] ROPS MODEL (15) (14) (14) (13) (12) (11) (10) (15) (16) (17) 3TMACBH8P001A (1) Relief Valve (3) Cylinder Safety Valve (6) Brake Master Cylinder (8) Oil Cooler (11) Solenoid Valve Assembly (13) Auxiliary Control Valves...
Page 423: Cabin Model
M8540, M9540, WSM HYDRAULIC SYSTEM [2] CABIN MODEL (17) (16) (12) (11) (10) (17) (16) (15) (14) (13) (12) (18) (19) (11) (10) 3TMACBH8P002A (1) Relief Valve (3) Cylinder Safety Valve (6) Oil Cooler Check Valve (9) Hi-Lo Dual Speed Valve...
Page 424 HYDRAULIC SYSTEM M8540, M9540, WSM The hydraulic system of the M8540 and M9540 tractor is composed of a 3-point hitch, remote hydraulic control for implements, power steering, PTO clutch, shuttle clutch, 4WD, rear differential lock, Hi-Lo dual speed (F36/R36 speed transmission model) and hydraulic brakes shown above.
Page 425: Hydraulic Circuit
HYDRAULIC SYSTEM M8540, M9540, WSM 2. HYDRAULIC CIRCUIT [1] TOTAL HYDRAULIC CIRCUIT (1) F18/R18 Speed Transmission Model (1) Oil Tank (Transmission Case) (12) Control Valve (for 3-point) (22) Relief Valve (31) Oil Cooler Relief Valve (2) Hydraulic Oil Filter Cartridge...
Page 426: Pto Clutch Pack
HYDRAULIC SYSTEM M8540, M9540, WSM (2) F36/R36 Speed Transmission Model (1) Oil Tank (Transmission Case) (12) Control Valve (for 3-point) (22) Relief Valve (31) Clutch Pack (Hi) (2) Hydraulic Oil Filter Cartridge (13) Steering Cylinder (for Lubricating Line) (32) Clutch Pack (Lo)
Page 427: Oil Cooler Relief Valve (Rops Model)
HYDRAULIC SYSTEM M8540, M9540, WSM [2] OIL COOLER RELIEF VALVE (ROPS MODEL) The oil cooler relief valve is located on the right hand side of the engine. This valve uses a direct acting relief valve, which is suitable for low volume and less frequent operations.
Page 428: Three Point Hitch Hydraulic System
HYDRAULIC SYSTEM M8540, M9540, WSM 3. THREE POINT HITCH HYDRAULIC SYSTEM [1] HYDRAULIC CIRCUIT (1) Auxiliary Control Valve (S/D) (2) Auxiliary Control Valve (SCD) (3) Control Valve (4) Lowering Speed Adjusting Valve (5) Cylinder Safety Valve (6) Hydraulic Cylinder (Exterior)
Page 429: Hydraulic Block
HYDRAULIC SYSTEM M8540, M9540, WSM [2] HYDRAULIC BLOCK (1) Relief Valve (5) Hydraulic Arm Shaft (10) Control Valve (a) From Hydraulic Pump (2) Cylinder Safety Valve (6) Torsion Bar (11) Position Feedback Rod (b) To or From Hydraulic (3) Draft Control Linkage...
Page 430: Linkage Mechanism
HYDRAULIC SYSTEM M8540, M9540, WSM [3] LINKAGE MECHANISM (1) Position Control Position control is a linkage mechanism to raise or lower the implement attached to the tractor in proportion to the movement of the position control lever. The implement can be positioned at any height by moving the position control lever. Fine position adjustment is also easy.
Page 431 HYDRAULIC SYSTEM M8540, M9540, WSM Down (1) Position Control Lever (5) Position Lever Shaft 2 (9) Position Feedback Lever A : LIFT (2) Position Lever Shaft 1 (6) Spool (10) Position Feedback Rod B : DOWN (3) Position Link 1...
Page 432: Draft Control
HYDRAULIC SYSTEM M8540, M9540, WSM (2) Draft Control Draft control is a system which maintains a constant traction load, and is suited for the work which needs heavy traction load such as plowing. The implement is automatically raised when its traction load is increased, and lowers when the traction load is decreased.
Page 433 HYDRAULIC SYSTEM M8540, M9540, WSM Draft Control Operation (1) Draft Control Lever (5) Draft Link Shaft (9) Draft Feedback Lever (13) Torsion Bar (2) Draft Lever Shaft (6) Spool Drive Lever (Draft) (10) Draft Feedback Rod (14) Top Link Holder...
Page 434 HYDRAULIC SYSTEM M8540, M9540, WSM Draft Control Operation (Continued) (6) Spool Drive Lever (Draft) (8) Draft Feedback Link Shaft (10) Draft Feedback Rod A : LIFT (7) Spool (9) Draft Feedback Lever (14) Top Link Holder B : DOWN C : Neutral Position 2.
Page 435: Mixed Control
HYDRAULIC SYSTEM M8540, M9540, WSM (3) Mixed Control Mixed control is a system combining position control with draft control. When traction load increases, the draft control functions to raise the lift arms (implement). When traction load reduces, the lift arms (implement) lower to...
Page 436: Hydraulic Cylinder
HYDRAULIC SYSTEM M8540, M9540, WSM [4] HYDRAULIC CYLINDER The external type hydraulic cylinders are used for 3- point linkage system. This hydraulic cylinder is single acting type, and it is installed directly between hydraulic lift arms. The main components of the hydraulic cylinder are shown in the figure.
Page 437 SERVICING CONTENTS 1. TROUBLESHOOTING ..................8-S1 2. SERVICING SPECIFICATIONS ..............8-S2 3. TIGHTENING TORQUES ................8-S5 4. CHECKING AND ADJUSTING ..............8-S6 [1] HYDRAULIC PUMP .................8-S6 [2] RELIEF AND SAFETY VALVE ..............8-S8 [3] POSITION AND DRAFT CONTROL LINKAGE ........8-S10 (1) Control Rod..................8-S10 (2) Position Control.................8-S11 (3) Draft Control..................8-S13 (4) Control Lever Operating Force ............8-S16 [4] AUXILIARY CONTROL VALVE LINKAGE...........8-S17...
Page 438: Troubleshooting
HYDRAULIC SYSTEM M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not Control linkage improperly assembled or Repair or replace 8-S24 Raise (Not Noise) damaged Control valve malfunctioning (unload valve, Repair or replace 8-S28 spool, check valve, poppet valve)
Page 439: Servicing Specifications
HYDRAULIC SYSTEM M8540, M9540, WSM 2. SERVICING SPECIFICATIONS HYDRAULIC PUMP Item Factory Specification Allowable Limit Hydraulic Pump for Power Steering Delivery Above 18.0 L/min. Condition 21.3 L/min. 4.76 U.S.gals/min. • Engine speed : 5.63 U.S.gals/min. 3.96 Imp.gals/min. Approx. 2600 min (rpm) 4.69 Imp.gals/min.
Page 440 HYDRAULIC SYSTEM M8540, M9540, WSM POSITION AND DRAFT CONTROL LINKAGE Item Factory Specification Allowable Limit Position Control Rod (ROPS) Length Approx. 155 mm – 6.10 in. Draft Control Rod (ROPS) Length Approx. 144 mm – 5.67 in. Position Control Rod (CABIN) Length Approx.
Page 441 HYDRAULIC SYSTEM M8540, M9540, WSM OIL COOLER RELIEF VALVE (ROPS MODEL) Item Factory Specification Allowable Limit Oil cooler relief valve Operating 4.4 to 4.9 MPa – Pressure 45.0 to 50.0 kgf/cm 640 to 711 psi W1013874 OIL COOLER CHECK VALVE (CABIN MODEL)
Page 442: Tightening Torques
HYDRAULIC SYSTEM M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m...
Page 443: Checking And Adjusting
4. CHECKING AND ADJUSTING [1] HYDRAULIC PUMP Hydraulic Flow Test IMPORTANT • When using flowmeter other than KUBOTA specified flowmeter, be sure to use the instructions with the flowmeter. • Do not close the flowmeter loading valve completely, before testing, because it has no relief valve.
Page 444 HYDRAULIC SYSTEM M8540, M9540, WSM Hydraulic Flow Test (Continued) [Power Steering Pump Delivery] Condition • Engine speed : Approx. 2600 min (rpm) • Rated pressure : 18.1 MPa 185 kgf/cm 2631 psi • Oil temperature : 50 to 60 °C 122 to 140 °F...
Page 445: Relief And Safety Valve
HYDRAULIC SYSTEM M8540, M9540, WSM [2] RELIEF AND SAFETY VALVE Relief Valve Setting Pressure Test Using Pressure Tester (Coupler) 1. Set the relief valve set pressure adaptor G (Code No. 07916- 52751) to the half male of the quick coupler and then set a pressure gauge (Code No.
Page 446 HYDRAULIC SYSTEM M8540, M9540, WSM Safety Valve Setting Pressure Test Using Injection Nozzle Tester 1. Remove the safety valve assembly (1). 2. Attach the safety valve to an injection nozzle tester with a safety valve setting adaptor (refer to “8. SPECIAL TOOLS” at “G.
Page 447: Position And Draft Control Linkage
HYDRAULIC SYSTEM M8540, M9540, WSM [3] POSITION AND DRAFT CONTROL LINKAGE (1) Control Rod Adjusting Position Control Rod and Draft Control Rod 1. Be sure to adjust the position control rod (1) length (L1) and draft control rod (3) length (L2).
Page 448: Position Control
HYDRAULIC SYSTEM M8540, M9540, WSM (2) Position Control Adjusting Position Control 1. Attach a weight of approx. 490 N (50 kgf, 110 lbf) to the end of the lower links. 2. Set the position control lever (2) and draft control lever (1) to the lowest position.
Page 449 HYDRAULIC SYSTEM M8540, M9540, WSM Adjusting Uppermost Position of Lift Arm 1. Move the position and draft control levers all the way down. 2. Start the engine and set the speed at maximum speed. 3. Operate the position control lever to the uppermost position.
Page 450: Draft Control
HYDRAULIC SYSTEM M8540, M9540, WSM (3) Draft Control Adjusting Draft Control 1. Attach a weight of approx. 490 N (50 kgf, 110 lbf) to the end of the lower links. 2. Start the engine and set the speed at 1000 min (rpm).
Page 451 HYDRAULIC SYSTEM M8540, M9540, WSM Draft Lever Free Range 1. Attach the weight (3) of approx. 490 N (50 kgf, 110 lbf) to the end of the lower links. 2. Attach the test bar (1) (refer to “8. SPECIAL TOOLS” at “G.
Page 452 HYDRAULIC SYSTEM M8540, M9540, WSM Draft Floating Range Check 1. Attach the weight (3) of approx. 490 N (50 kgf, 110 lbf) to the end of the lower links. 2. Attach the test bar (1) to the top link bracket (2).
Page 453: Control Lever Operating Force
HYDRAULIC SYSTEM M8540, M9540, WSM (4) Control Lever Operating Force Position and Draft Control Lever Operating Force 1. Check the position and draft control lever operating force. 2. If measurement is not within the factory specification, adjust the with tightening nuts (3).
Page 454: Auxiliary Control Valve Linkage
HYDRAULIC SYSTEM M8540, M9540, WSM [4] AUXILIARY CONTROL VALVE LINKAGE (1) ROPS Model Preparation 1. Remove the hand accelerator lever grip (1). 2. Remove the shift lever cover 2 (3) and 1 (2). (1) Hand Accelerator Lever Grip (3) Shift Lever Cover 2...
Page 455: Cabin Model
HYDRAULIC SYSTEM M8540, M9540, WSM (2) CABIN Model Preparation 1. Remove the inner cover R.H. 2 (1). (1) Inner Cover R.H. 2 W1019238 Adjusting Wire of Auxiliary Control Valve (Lever Side) 1. Screw in the wire (4) to the rod end (1) fully.
Page 456: Oil Cooler Relief Valve
HYDRAULIC SYSTEM M8540, M9540, WSM [5] OIL COOLER RELIEF VALVE Operating Pressure of Oil Cooler Relief Valve (ROPS Model) 1. Attach the oil cooler relief valve to a injection nozzle tester with a relief valve adaptor (refer to “8. SPECIAL TOOLS”...
Page 457: Disassembling And Assembling
HYDRAULIC SYSTEM M8540, M9540, WSM 5. DISASSEMBLING AND ASSEMBLING [1] HYDRAULIC PUMP Removing Hydraulic Pump Assembly 1. Place the disassembling stand under the transmission case and right rear axle. 2. Remove the right rear wheel. 3. Unscrew the delivery pipes for power steering (2) and delivery pipe for three point linkage (1) retaining screws from hydraulic pump (3).
Page 458: 3-Point Hitch Hydraulic Block Assembly
HYDRAULIC SYSTEM M8540, M9540, WSM [2] 3-POINT HITCH HYDRAULIC BLOCK ASSEMBLY (1) Removing Top Cover (3-Point Hitch Hydraulic Block) (ROPS Model) Preparation 1 1. Remove the lower links (2) and lift rods (1). 2. Disconnect the connector (3) for trailer coupler then remove the top link holder (8) with trailer coupler.
Page 459 HYDRAULIC SYSTEM M8540, M9540, WSM Preparation 2 1. Remove the trailer brake outlet pipe (1) with a holder (2). (1) Trailer Brake Outlet Pipe (3) Trailer Brake Valve (2) Holder W1017715 Removing Top Cover (3-Point Hitch Hydraulic Block) 1. Remove the top cover mounting screws and nuts.
Page 460: Removing Top Cover (3-Point Hydraulic Block) (Cabin Model)
HYDRAULIC SYSTEM M8540, M9540, WSM (2) Removing Top Cover (3-Point Hydraulic Block) (CABIN Model) Preparation 1. Park the tractor on a flat place. 2. Remove the lower links (4), lift rods (3) and top link (1). 3. Remove the trailer coupler stay (2).
Page 461: Hydraulic Linkage
HYDRAULIC SYSTEM M8540, M9540, WSM Removing Top Cover (3-Point Hitch Hydraulic Block) 1. Remove the both cabin mounting bolt (1) and lift up the cabin rear side approx. 38.0 to 50.0 mm (1.5 to 2.0 in.) then support the cabin.
Page 462 HYDRAULIC SYSTEM M8540, M9540, WSM Linkage Bracket 1. Remove the bracket (1). (When reassembling) • Be sure to assemble the position lever 2 (5) and 3 (4) as shown in figure. • Be sure to assemble the draft link cam 2 (2) and draft lever 3 (3) as shown in figure.
Page 463 HYDRAULIC SYSTEM M8540, M9540, WSM Position Feedback Rod and Draft Feedback Rod 1. Tap out the roll pin (4), remove the position feedback rod (1) with position feedback lever (3) and washer (7). 2. Remove the draft feedback rod (2) with draft feedback lever (5) and key (8).
Page 464 HYDRAULIC SYSTEM M8540, M9540, WSM Position and Draft Control Shaft and Position and Draft Feedback Shaft 1. Remove the position and draft feedback rod (6) and (5). 2. Remove the external circlip (1) then draw out the position and draft control shaft (4) and (2).
Page 465: Control Valve
HYDRAULIC SYSTEM M8540, M9540, WSM [4] CONTROL VALVE Removing Control Valve 1. Remove the E-shaped stopper (2). 2. Remove the control valve mounting screws. 3. Remove the control valve (1). NOTE • Do not loosen adjusting section at the end of the spool unless necessary.
Page 466 HYDRAULIC SYSTEM M8540, M9540, WSM Plug and Unload Valve 1. Secure the control valve with a vise. 2. Remove the seat plug 1 (1) for unload poppet 1 (3). 3. Draw out the spring (2) for unload poppet 1 (3).
Page 467: Hydraulic Cylinder
HYDRAULIC SYSTEM M8540, M9540, WSM [5] HYDRAULIC CYLINDER Removing Hydraulic Cylinder 1. Remove the lift rod pin (1). 2. Disconnect the hydraulic hose (2) from hydraulic cylinder. 3. Remove the hydraulic cylinder cover (3). 4. Remove the cylinder pin (upper) (4).
Page 468: Relief Valve
HYDRAULIC SYSTEM M8540, M9540, WSM Installing Piston Seal 1. Place the slide jig (2) on the piston (3). 2. Install the piston seal (1) to the piston using the slide jig. (Refer to “SPECIAL TOOLS” section) 3. Compress the piston seal to the correct size by installing the piston into the correcting jig (5).
Page 469: Safety Valve
HYDRAULIC SYSTEM M8540, M9540, WSM [7] SAFETY VALVE Safety Valve 1. Remove the safety valve assembly (1). 2. Secure the safety valve assembly in a vise. 3. Loosen the lock nut (3), and remove the adjust screw (2). 4. Draw out the spring (4), seat (5) and ball (6).
Page 470: Lift Arm And Lift Arm Shaft
HYDRAULIC SYSTEM M8540, M9540, WSM [9] LIFT ARM AND LIFT ARM SHAFT Lift Arm and Lift Arm Shaft 1. Remove the external circlip (6). 2. Remove the lift arm R.H. (2). 3. Draw out the lift arm shaft (3) and lift arm L.H. (1) as a unit.
Page 471: Servicing
HYDRAULIC SYSTEM M8540, M9540, WSM 6. SERVICING [1] LIFT ARM AND TOP LINK BRACKET Lift Arm Support Bushing 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy portion (A), replace it.
Page 472 HYDRAULIC SYSTEM M8540, M9540, WSM Torsion Bar and Top Link Bracket 1. Visually inspect the DX bushings for signs of wear or damage. (The DX bushing tends to show concentrated wear.) 2. If the DX bushing is worn beyond the alloy portion (A), replace it.
Page 473 ELECTRICAL SYSTEM KiSC issued 09, 2008 A...
Page 474 MECHANISM CONTENTS 1. WIRING DIAGRAM ..................9-M1 [1] ROPS MODEL ..................9-M1 (1) Main Harness..................9-M1 [2] CABIN MODEL ..................9-M2 (1) Main Harness..................9-M2 (2) Cabin Harness ................... 9-M3 (3) Engine Harness ................. 9-M4 2. ELECTRICAL CIRCUIT DETAILED CHART..........9-M5 [1] ROPS MODEL ..................
Page 475: Wiring Diagram
M8540, M9540, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] ROPS MODEL (1) Main Harness DT/Bi-Speed Engine Relay Main Key Meter Panel Engine Coolant Front DT Switch Traveling Switch Display Mode Fuel Temperature Steering Rear Diff. Speed Rotation Select Switch Air Cleaner...
Page 476: Cabin Model
M8540, M9540, WSM ELECTRICAL SYSTEM [2] CABIN MODEL (1) Main Harness J/C A J/C B Temperature Main Key Meter Panel Control Mode Select FRS/REC Select Thermo Amplifier Dual Pressure Blower Switch ServoMotor ServoMotor ServoMotor Unit Switch Resistor Dual Shift Dual Shift...
Page 477: Cabin Harness
M8540, M9540, WSM ELECTRICAL SYSTEM (2) Cabin Harness TO MAIN HARNESS 2 TO MAIN HARNESS 1 <WIRE HARNESS CABIN> 0.85 LG/W +B+1 0.85 L Rear Wiper Motor 0.85 LG/B (-) S 0.85 B Servomotor Output 2 (Hot Output) 0.50 Y Servomotor Output 1 (Cool Output) 0.50 Y/B...
Page 478: Engine Harness
M8540, M9540, WSM ELECTRICAL SYSTEM (3) Engine Harness <WIRE HARNESS ENGINE> TO MAIN HARNESS 1 TO MAIN HARNESS 2 TO MAIN HARNESS 3 <WIRE HARNESS BODY> 10 11 12 13 14 15 16 DS Valve Solenoid 0.50 Y/L 0.50 Y/L 0.50 B...
Page 479: Electrical Circuit Detailed Chart
M8540, M9540, WSM ELECTRICAL SYSTEM 2. ELECTRICAL CIRCUIT DETAILED CHART [1] ROPS MODEL (1) Starting System, Charging System and Power Supply 3R/B 3R/W (g) (h) (l) (m) (10) GLOW START (21) 0.5R/W 0.5W/G (27) (15) (20) (a)-33 (24) (27) (11)
Page 480: Lighting System
M8540, M9540, WSM ELECTRICAL SYSTEM (2) Lighting System 0.85G 0.85R/Y 0.85LG/R 0.5BR (f)-15 0.5OR FREE LOCK FREE PUSH 0.5BR 0.85OR 0.85OR (10) (12) (13) 0.5L/G (11) (f)-14 0.85B 0.5G/B 0.5G/B 0.5G/W (f)-16 (f)-21 0.5R/B 0.5R/B 0.85R/B (f)-12 0.85G/W 0.85R/B 0.85G/B 0.85R/B...
Page 481: 4Wd System
M8540, M9540, WSM ELECTRICAL SYSTEM (3) 4WD System (D/+1) +B +1 IL FREE LOCK (+B) (IL) 0.5R (C)-30 0.85V 0.5R 0.5W/G (C)-28 0.5G/W 0.5G/W (C)-26 0.5G/OR (C)-2 3TMACBH9P026A (1) 4WD Switch (12 V, 3 W) (3) Diode (4WD Brake) (5) DT Valve (Solenoid) (7) Diode (Bi-speed, DIFF, LOCK) (9) DIFF.
Page 482: Instrument Panel Board (Meter Panel)
M8540, M9540, WSM ELECTRICAL SYSTEM (4) Instrument Panel Board (Meter Panel) 0.5R/G (c) (d) (8) (9) (10) (11) (12) (13) (20) (14) (15) (16) (17) (18) (19) (29) (21) (22) (25) (26) (23) (24) (30) (27) (28) 0.5B/W (31) (32)
Page 483: Cabin Model
M8540, M9540, WSM ELECTRICAL SYSTEM [2] CABIN MODEL (1) Starting System and Charging System 5R/B 3R/W 3R/W 3W/R 3W/R 3R/L 3R/L 3R/Y 3R/Y 3R/L 3R/B 2R/B (d) (e) (h) (i) 5R/B 5W/R (14) (11) 0.5R/W 0.5R/W (26) (m) (n) 0.5W/G...
Page 484: Lighting System
M8540, M9540, WSM ELECTRICAL SYSTEM (2) Lighting System 0.85G 0.85R/Y 0.85R/B 0.5R/B 0.85BR 0.5BR (13) 14V1.4W 0.85OR FREE FREE PUSH LOCK (11) 0.5R/B 0.85L/W 0.85BR 0.85OR (12) DOOR 0.5L/G (14) 0.5B/P (10) 0.85B 0.5G/B 0.5G/W 0.5R/B 0.85R/B 0.85R/B 0.85G/W 0.85Y 0.5Y...
Page 485: 4Wd (T/M Control) System
M8540, M9540, WSM ELECTRICAL SYSTEM (3) 4WD (T/M Control) System FREE LOCK (10) 0.5GY 0.5GY (d)-31 (d)-31 0.85V 0.5W/G (d)-29 0.5Y/L (12) (11) 3TMACBH9P028A (1) 4WD Switch (14 V, 1.12 W) (4) DT Valve (Solenoid) (7) Diff. Lock Valve (Solenoid)
Page 486: Instrument Panel Board (Meter Panel)
M8540, M9540, WSM ELECTRICAL SYSTEM (4) Instrument Panel Board (Meter Panel) 0.5R/G 0.5R/B 0.85R/B (9) (10) (11) (12) (13) (14) (21) (15) (16) (17) (18) (19) (20) (24) (23) (31) (22) 10 11 12 13 15 16 17 18 19 20 0.5R/G...
Page 487: Working Light And Radio
M8540, M9540, WSM ELECTRICAL SYSTEM (5) Working Light and Radio 0.5L/Y (16) 0.85W/B (10) (14) (13) (15) (11) (12) (17) 3TMACBF9P042A (1) Working Light Relay (5) Front Side Working Light Relay (8) Front Side Working Lamp L.H. (10) Rear Working Light Switch (12) Rear Working Lamp R.H.
Page 488: Air Conditioner
M8540, M9540, WSM ELECTRICAL SYSTEM (6) Air Conditioner 0.5Y/B (15) (18) (14) 0.5W (19) (10) (20) (22) (11) Full (12) Front Cool 0.5B/Y 0.5L 0.5Y/L (21) (13) (16) (17) 3TMACAN9P071A (1) Servomotor Temperature Control (5) Mode Select Switch (9) Thermo Amplifier...
Page 489: Wiper System
M8540, M9540, WSM ELECTRICAL SYSTEM (7) Wiper System 0.85L WASH WASH 0.85L/Y WV WM WASH 0.85Lg/W WASH 0.85Lg/B 0.85L/R 0.85L 0.85L/W 3TMACAN9P072C (1) Front Wiper Motor (2) Front Wiper Motor Relay (3) Front Wiper Switch (4) Front Wiper Relay/Timer (5) Washer Motor...
Page 490: Wiring Color
ELECTRICAL SYSTEM M8540, M9540, WSM [3] WIRING COLOR B ... Black Br/B ..Brown / Black Or/W ..Orange / White G ..Green Br/Y ..Brown / Yellow P/W .... Pink / White L ... Blue Br/R ..Brown / Red P/L ....
Page 491: Starting System
ELECTRICAL SYSTEM M8540, M9540, WSM 3. STARTING SYSTEM [1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT (1) ROPS Model (1) Battery (2) Starter Motor (3) Starter Relay (4) Alternator (5) Heater Relay (6) Intake Air Heater (7) Neutral Safety Switch (Shuttle) (8) Main Switch...
Page 492: Cabin Model
ELECTRICAL SYSTEM M8540, M9540, WSM (2) CABIN Model (1) Battery (2) Starter Motor (3) Starter Relay (4) Alternator (5) Heater Relay (6) Intake Air Heater (7) Neutral Safety Switch (Shuttle) (8) Main Switch (9) PTO Safety Relay (10) PTO Switch...
Page 493: Components
ELECTRICAL SYSTEM M8540, M9540, WSM [2] COMPONENTS (1) Air Heater The PTC intake air heater is introduced in order to further improve the starting performance in cold regions. The intake air heater is mounted on the air inlet manifold, while the conventional glow plug on the cylinder head.
Page 494: Instrument Panel
ELECTRICAL SYSTEM M8540, M9540, WSM 4. INSTRUMENT PANEL [1] INDICATION ITEMS OF METER PANEL (1) Hazard / Turn Signal Indicator (2) High Beam Indicator (3) Trailer Indicator (4) PTO Clutch Indicator (5) Liquid Crystal Display (6) Electrical Charge Indicator (7) Engine Oil Pressure...
Page 495: Easy Checker (Tm)
ELECTRICAL SYSTEM M8540, M9540, WSM [2] EASY CHECKER (TM) If the warning lamps in the Easy Checker (TM) come on during operation, immediately stop the engine, and find the cause as shown below. Never operate the tractor while Easy Checker (TM) lamp is on.
Page 496: Lcd Monitor Indication
ELECTRICAL SYSTEM M8540, M9540, WSM [3] LCD MONITOR INDICATION (1) LCD Monitor (3) PTO/Hour Meter Select Switch (5) PTO Indication [A] ROPS Model (2) Traveling Speed Select Switch (4) Hour Meter Indication [B] CABIN Model The LCD monitor gives three different modes : “display mode”, “setting mode” and “checking mode”.
Page 497: Setting Mode
ELECTRICAL SYSTEM M8540, M9540, WSM Switching “km/h” and “mph” Indication Press the traveling speed select switch (1) to change the “km/h” and “mph” indication. (1) PTO/Hour Meter Select A : mph (Traveling Speed) Switch B : km/h (Traveling Speed) (2) LCD Monitor...
Page 498: Checking Mode
ELECTRICAL SYSTEM M8540, M9540, WSM (3) Checking Mode The checking mode checking for sensors, battery voltage and engine revolution. The CPU (5) process the input dates from sensors resistance, taco pulse and voltage to indicate with the LCD monitor (7).
Page 499: Lighting System
ELECTRICAL SYSTEM M8540, M9540, WSM 5. LIGHTING SYSTEM [1] COMPONENTS (1) Flasher Unit Flasher Unit The function of flasher unit is as follows. 1. The flasher unit blinks the turn signal light (3), (4) and hazard indicator light (2) when the hazard switch (13) is turned on.
Page 500: Trailer Socket
ELECTRICAL SYSTEM M8540, M9540, WSM 6. TRAILER SOCKET The trailer socket is provided to take out the electrical power from tractor to trailer or implement. The function of each terminal is shown below. Color of wire harness Terminal Function ROPS Model CABIN Model Turn signal light (L.H.)
Page 501 SERVICING CONTENTS 1. TROUBLESHOOTING ..................9-S1 2. SERVICING SPECIFICATIONS ..............9-S6 3. TIGHTENING TORQUES ................9-S7 4. CHECKING AND ADJUSTING ..............9-S8 [1] BATTERY, FUSE, GROUNDING AND CONNECTOR......9-S8 (1) Battery....................9-S8 (2) Checking Fuse ..................9-S10 (3) Checking Grounding Wires ...............9-S12 (4) Connector ..................9-S12 [2] MAIN SWITCH ..................9-S13 (1) Main Switch (ROPS Model) ..............9-S13 (2) Main Switch (CABIN Model) .............9-S14 [3] AIR HEATER..................9-S16...
Page 502 ELECTRICAL SYSTEM M8540, M9540, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Recharge or replace 9-S9 Equipments Do Not Battery positive cable disconnected or Repair or replace 9-S8 Operate improperly connected Battery negative cable disconnected or...
Page 503 ELECTRICAL SYSTEM M8540, M9540, WSM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown Replace 9-S10, 11 Light Bulb blown Replace G-40 Wiring harness disconnected or improperly Repair or replace – connected Illumination Light Fuse blown...
Page 504 ELECTRICAL SYSTEM M8540, M9540, WSM EASY CHECKER Reference Symptom Probable Cause Solution Page Engine Oil Pressure Engine oil pressure too low Repair 1-S16 Lamp Lights Up Engine oil insufficient Replenish When Engine is Engine oil pressure switch defective Replace 9-S26...
Page 505 ELECTRICAL SYSTEM M8540, M9540, WSM EASY CHECKER (Continued) Reference Symptom Probable Cause Solution Page Coolant Temperature Fuse blown Replace – Indicator Does Not Coolant temperature sensor is defective Replace 9-S26 Light When Water Wiring harness disconnected or improperly Repair or replace –...
Page 506 ELECTRICAL SYSTEM M8540, M9540, WSM Reference Symptom Probable Cause Solution Page Front Wheel Does 4WD switch or wiring harness is defective Replace 9-S31 Not Drive When 4WD 4WD relay defective Replace 9-S41 Switch is Turned ON 4WD solenoid valve defective...
Page 507: Servicing Specifications
ELECTRICAL SYSTEM M8540, M9540, WSM 2. SERVICING SPECIFICATIONS STARTER MOTOR Item Factory Specification Allowable Limit Commutator O.D. 32.0 mm 31.4 mm 1.26 in. 1.24 in. Mica Undercut 0.50 to 0.80 mm 0.2 mm 0.020 to 0.031 in. 0.0079 in. Brush Length 18.0 mm...
Page 508: Tightening Torques
ELECTRICAL SYSTEM M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G.GENERAL” section) Item N·m kgf·m...
Page 509: Checking And Adjusting
ELECTRICAL SYSTEM M8540, M9540, WSM 4. CHECKING AND ADJUSTING CAUTION • To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. • Never remove the battery cap while the engine is running.
Page 510: Battery
ELECTRICAL SYSTEM M8540, M9540, WSM Battery Condition Indicator 1. Check the battery condition by reading the indicator (2). State of indicator display Specific gravity of electrolyte and quality of Green electrolyte are both in good condition. Black Needs charging battery...
Page 511: Checking Fuse
ELECTRICAL SYSTEM M8540, M9540, WSM Directions for Storage 1. When shutting down the tractor for long periods of time, remove the battery from the tractor, store the battery in a well ventilated placed where it is not exposed to direct sunlight.
Page 512 ELECTRICAL SYSTEM M8540, M9540, WSM Fuse (CABIN Model) 1. When inspect the circuit line, check the related fuses. 2. If any of the fuse is blown, replace with a new one of the same capacity. IMPORTANT • If a fuse is blown, check the cause and be sure to replace it with a new one of the same capacity.
Page 513: Checking Grounding Wires
ELECTRICAL SYSTEM M8540, M9540, WSM (3) Checking Grounding Wires Grounding Wire 1. Check the whether the grounding wire (1) is connected securely to the tractor chassis. 2. If the grounding wire is broken or disconnected, replace it. (1) Grounding Wire...
Page 514: Main Switch
ELECTRICAL SYSTEM M8540, M9540, WSM [2] MAIN SWITCH (1) Main Switch (ROPS Model) Main Switch 1. Remove the panel cover (1), refer to “[1] CLUTCH PEDAL” at “2. CLUTCH” section. 2. Disconnect the meter panel and the main switch connectors after turning the main switch off.
Page 515: Main Switch (Cabin Model)
ELECTRICAL SYSTEM M8540, M9540, WSM Main Switch at START Position 1. Turn and hold the main switch at the START position. 2. Measure the resistances with an ohmmeter across the terminal B and the terminal ST and across terminal B and the terminal M.
Page 516 ELECTRICAL SYSTEM M8540, M9540, WSM Main Switch at ON Position 1. Turn the main switch to ON position. 2. Measure the resistance with an ohmmeter across the terminal 3 and the terminal 6. 3. If 0 ohm is not indicated, the 3 – 6 contacts of the main switch are faulty.
Page 517: Air Heater
ELECTRICAL SYSTEM M8540, M9540, WSM [3] AIR HEATER Intake Air Heater 1. Disconnect the lead. 2. Measure the resistance between + terminal (1) and intake air heater body (2). 3. If the resistance is infinity, the intake air heater is faulty.
Page 518: Engine Stop Solenoid
ELECTRICAL SYSTEM M8540, M9540, WSM Magnet Switch Test 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter terminal B (4). 3. Remove the starter from the engine. 4. Disconnect the connecting lead (3) from the starter terminal C (2).
Page 519: Alternator
ELECTRICAL SYSTEM M8540, M9540, WSM [6] ALTERNATOR Preparation 1. Disconnect the 2P connector (3) from alternator after turning the main switch OFF. 2. Perform the following checkings. (1) Terminal B (3) 2P Connector (2) Alternator W1030485 Connector Voltage 1. Turn off the main switch. Measure the voltage between the terminal B (1) and the chassis.
Page 520: Meter Panel
ELECTRICAL SYSTEM M8540, M9540, WSM [7] METER PANEL (1) Setting Mode (Select the PTO Display Mode Switching, Tractor Model Select and Entering Travel Speed Coefficient) CAUTION • To perform the meter panel, the operator must be seated on the tractor.
Page 521 ELECTRICAL SYSTEM M8540, M9540, WSM PTO Speed Display Mode Switching (Setting Mode) 1. While pressing the PTO/Hour meter select switch (1), turn the key switch to “ON” position. The current numerical code starts flashing. 2. Each time the PTO/Hour meter select switch (1) is pressed, the code changes in the order of [1] →...
Page 522 ELECTRICAL SYSTEM M8540, M9540, WSM Entering Traveling Speed Coefficient [Example : Entering 179.0 inch] 1. While pressing the traveling speed select switch (2), turn the key switch to “ON” position. The setting of the current tire’s circumference is displayed in inches (a) or millimeters (b). The highest-digit numeral starts flashing.
Page 523 ELECTRICAL SYSTEM M8540, M9540, WSM Model Select (Setting Mode) 1. While pressing the PTO/Hour meter select switch (1) and traveling speed select switch (2), turn the key switch to “ON” position. The current numerical code starts flashing. 2. Each time the traveling speed select switch (2) is pressed, the code changes in order of [1] →...
Page 524: Checking Mode
ELECTRICAL SYSTEM M8540, M9540, WSM (2) Checking Mode Checking Mode 1. Turn the key switch to “ON” position. 2. Press the PTO/Hour meter select switch (1) and traveling speed select switch (2) more than 2 seconds. 3. Each time the PTO/Hour meter select switch (1) is pressed, the code number changes in order of [1] →...
Page 525: Checking Meter Panel, Pto/Hour Meter Select Switch And Traveling Speed Select Switch
ELECTRICAL SYSTEM M8540, M9540, WSM (3) Checking Meter Panel, PTO/Hour Meter Select Switch and Traveling Speed Select Switch CAUTION • For checking of electric circuit, use the circuit tester. • As for the checking of sensors and switches, do the following order; check the battery, fuse and grounding line first, check by the test function of meter panel next, and check the connectors of panel or related electronic switch or sensor.
Page 526 ELECTRICAL SYSTEM M8540, M9540, WSM Terminal Color of Terminal Name Measuring across T40 (Ground) Condition wiring Main switch at ON and PTO/Hour LG/B PTO/Hour meter select switch Battery voltage meter select switch ON Main switch at ON and traveling Traveling speed select switch...
Page 527: Switch And Sensor
ELECTRICAL SYSTEM M8540, M9540, WSM PTO/Hour Meter Select Switch and Traveling Speed Select Switch 1. Check the resistance between terminal a and terminal c while pushing the PTO/Hour meter select switch (1). 2. It is OK if 0 ohm is indicated.
Page 528 ELECTRICAL SYSTEM M8540, M9540, WSM PTO Switch 1) Connector Voltage 1. Remove the PTO switch connector (3). 2. Turn the main switch ON position. 3. Measure the voltage across terminal 2 (a) and chassis. 4. If the voltage differs from battery voltage, the wiring harness, fuse, or main switch is faulty.
Page 529 ELECTRICAL SYSTEM M8540, M9540, WSM Shuttle Neutral Switch 1) Shuttle Neutral Switch Continuity 1. Check the continuity with an ohmmeter across the switch terminals. 2. If it does not conduct or any value is indicated when the switch is pushed, the switch is faulty.
Page 530 ELECTRICAL SYSTEM M8540, M9540, WSM Brake Switch 1) Wiring Harness 1. Disconnect the leads from the brake switch (1). 2. Connect the wiring harness lead terminals to each other and turn the main switch ON. 3. If the stop lights do not light, the fuse, wiring harness or bulb is faulty.
Page 531 ELECTRICAL SYSTEM M8540, M9540, WSM Checking Fuel Level Sensor 1. Remove the fuel level sensor from the fuel tank. 2. Measure the resistance with an ohmmeter across the terminal a and terminal b. 3. If the measurement is not indicated, the sensor is faulty.
Page 532 ELECTRICAL SYSTEM M8540, M9540, WSM Engine Rotation Sensor and Traveling Speed Sensor 1. Check the engine speed meter and traveling speed display. 2. It is OK if engine speed is displayed in the meter panel. 3. It is OK if traveling speed is displayed in the LCD monitor.
Page 533 ELECTRICAL SYSTEM M8540, M9540, WSM 4WD Switch (CABIN Model) 1) Connector Voltage 1. Turn the main switch to ON position. 2. Measure the voltage with a voltmeter across the terminal b and chassis. 3. If the voltage differ from the battery voltage, the wiring harness or fuse is faulty.
Page 534 ELECTRICAL SYSTEM M8540, M9540, WSM Air Cleaner Sensor 1) Wiring Harness 1. Disconnect the leads from the air cleaner sensor (1) after turning the main switch OFF. 2. Turn the main switch ON and connect a jumper lead between the leads.
Page 535: Lighting Switches And Flasher Unit
ELECTRICAL SYSTEM M8540, M9540, WSM [8] LIGHTING SWITCHES AND FLASHER UNIT (1) Combination Switch (ROPS Model) Checking Connector Voltage 1. Disconnect the combination switch connector. 2. Measure the voltage with voltmeter across the connector terminal B1 and chassis, across the terminal B2 and chassis, across the terminal B3 and chassis.
Page 536: Lever Combination Switch And Horn Switch (Cabin Model)
ELECTRICAL SYSTEM M8540, M9540, WSM (2) Lever Combination Switch and Horn Switch (CABIN Model) Checking Connector Voltage 1. Disconnect the lever combination switch connector (1). 2. measure the voltage with voltmeter across the connector terminal B1 and chassis, across the terminal B2 and chassis.
Page 537: Hazard Switch
ELECTRICAL SYSTEM M8540, M9540, WSM Checking Horn Switch Continuity (CABIN Model) 1. Measure the resistance with ohmmeter across the terminal a and terminal c, and across the terminal d and terminal e. 2. If the measurement is not following below, the hazard switch or the bulb are faulty.
Page 538: Flasher Unit
ELECTRICAL SYSTEM M8540, M9540, WSM Checking Hazard Switch Continuity 1. Measure the resistance with ohmmeter across the terminal a and terminal c, and across the terminal d and terminal e. 2. If the measurement is not following below, the hazard switch or the bulb are faulty.
Page 539: Front Work Light Switch (Rops Model)
ELECTRICAL SYSTEM M8540, M9540, WSM (5) Front Work Light Switch (ROPS Model) Checking Connector Voltage 1. Turn the main switch to ON position. 2. Measure the voltage with a voltmeter across the terminal a and chassis. 3. If the voltage differ from the battery voltage, the wiring harness or fuse is faulty.
Page 540: Front/Rear Work Light And Beacon Light Switch (Cabin Model)
ELECTRICAL SYSTEM M8540, M9540, WSM (6) Front/Rear Work Light and Beacon Light Switch (CABIN Model) Checking Connector Voltage 1. Turn the main switch to ON position. 2. Measure the voltage with a voltmeter across the terminal b and chassis. 3. If the voltage differ from the battery voltage, the wiring harness or fuse is faulty.
Page 541: Starter Relay And Heater Relay
ELECTRICAL SYSTEM M8540, M9540, WSM [9] RELAYS (1) Starter Relay and Heater Relay Checking Connector Voltage 1. Measure the voltage with a voltmeter across the battery terminal and chassis as table below. 2. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.
Page 542 ELECTRICAL SYSTEM M8540, M9540, WSM (2) Relays (ROPS Model) Checking Connector Voltage 1. Measure the voltage with a voltmeter across the battery terminal and chassis as table below. 2. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.
Page 543: Relays (Cabin Model)
ELECTRICAL SYSTEM M8540, M9540, WSM (3) Relays (CABIN Model) Checking Connector Voltage 1. Measure the voltage with a voltmeter across the battery terminal and chassis as table below. 2. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.
Page 544: Solenoid Valve
ELECTRICAL SYSTEM M8540, M9540, WSM [10] SOLENOID VALVE (1) PTO, 4WD and Rear Differential Lock Solenoid Valves 1) Connector Voltage 1. Remove the connector (1). 2. Turn on the main switch, PTO switch, 4WD switch or rear differential lock switch at ON position.
Page 545: Hi-Lo Dual Speed (F36/R36 Speed Transmission Model)
ELECTRICAL SYSTEM M8540, M9540, WSM (2) Hi-Lo Dual Speed (F36/R36 Speed Transmission Model) Solenoid Valves 1) Connector Voltage 1. Remove the connector (1). 2. Turn on the dual speed switch at Lo position. 3. Measure the voltage across the each terminal and chassis.
Page 546: Disassembling And Assembling
ELECTRICAL SYSTEM M8540, M9540, WSM 5. DISASSEMBLING AND ASSEMBLING [1] STARTER MOTOR Disassembling Motor 1. Disconnect the solenoid switch (3). 2. Remove the 2 through screws (9) and the 2 brush holder lock screws. Take out the rear end frame (13) and the brush holder (12).
Page 547 ELECTRICAL SYSTEM M8540, M9540, WSM Pulley 1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut using a M24 box wrench. 58.3 to 78.9 N·m Tightening torque Pulley nut 5.95 to 8.05 kgf·m 43.0 to 58.2 lbf·ft...
Page 548 ELECTRICAL SYSTEM M8540, M9540, WSM Reassembling the Brush 1. Fit the brush with its sliding face in the clockwise direction when viewed from front. IMPORTANT • Be sure to keep the 2 brushes deep in the brush holder. Otherwise the rotor and the rear section can not be fitted into position.
Page 549: Fuse (Slow Blow 100 A) For Cabin Model
ELECTRICAL SYSTEM M8540, M9540, WSM [3] FUSE (SLOW BLOW 100 A) FOR CABIN MODEL Fuse [Replacing procedure for 100 A] 1. Remove the battery negative cable. 2. Remove the top cover (1) and protect tape (3). 3. Draw out the fuse stay (5) from the fuse box (2).
Page 550: Servicing
ELECTRICAL SYSTEM M8540, M9540, WSM 6. SERVICING [1] STARTER Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
Page 551 ELECTRICAL SYSTEM M8540, M9540, WSM Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
Page 552: Alternator
ELECTRICAL SYSTEM M8540, M9540, WSM Field Coil 1. Check the continuity across the lead (1) and brush (2) with an ohmmeter. 2. If it does not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.
Page 553 ELECTRICAL SYSTEM M8540, M9540, WSM Slip Ring 1. Check the slip ring for score. 2. If scored, correct with an emery paper or on a lathe. 3. Measure the O.D. of slip ring with vernier calipers. 4. If the measurement is less than the allowable limit, replace it.
Page 554 CABIN KiSC issued 09, 2008 A...
Page 555 MECHANISM CONTENTS 1. AIR CONDITIONING SYSTEM ..............10-M1 [1] STRUCTURE ..................10-M1 [2] COMPRESSOR ..................10-M2 [3] AIR CONDITIONER UNIT..............10-M3 [4] SYSTEM CONTROL................10-M4 [5] AIR FLOW..................... 10-M5 [6] AIR CONTROL VENT ................10-M5 [7] ELECTRICAL SYSTEM ................ 10-M6 (1) Electrical Circuit ................
Page 556: Air Conditioning System
CABIN M8540, M9540, WSM 1. AIR CONDITIONING SYSTEM [1] STRUCTURE (1) Control Panel (2) Outer Roof (3) Fresh Air Filter (4) Inner Air Filter (5) Inner Air Duct (6) Fresh Air Duct (7) Air Conditioner Unit (8) Front Duct (9) Dashboard Blow Port...
Page 557: Compressor
CABIN M8540, M9540, WSM [2] COMPRESSOR The vane type compressor installed on this cabin is composed of a cylinder (1) with an oval cross section and a rotor (2) with five vanes (3). The vane type compressor is provided with two suction ports and two discharge ports respectively.
Page 558: Air Conditioner Unit
CABIN M8540, M9540, WSM [3] AIR CONDITIONER UNIT The air conditioner unit (3) consists of evaporator (2), expansion valve (4), heater core (1), blower (5). etc.. (1) Heater Core (4) Expansion Valve (2) Evaporator (5) Blower (3) Air Conditioner Unit...
Page 559: System Control
CABIN M8540, M9540, WSM [4] SYSTEM CONTROL (1) Fresh Air Inlet Port (9) Blower (16) Temperature Control Dial (d) Air is blown the dashboard (2) Heater (10) D1 : Air Intake Door and defroster air outlets (3) Dashboard (11) Recirculated Air Inlet Port...
Page 560: Air Flow
CABIN M8540, M9540, WSM [5] AIR FLOW Flow Air in the cabin and fresh air introduced into the cabin flow as shown below. Adjust the 7 air ports to obtain the desired condition. IMPORTANT • Do not pour water directly into the fresh air port while washing the vehicle.
Page 561: Electrical System
CABIN M8540, M9540, WSM [7] ELECTRICAL SYSTEM (1) Electrical Circuit (1) Battery (6) Pressure Switch (10) Blower High Relay (14) A/C Control Panel (2) Slow Blow Fuse (7) Compressor Relay (11) Blower Resistor (15) A/C Switch (3) Main Switch (8) Blower Relay...
Page 562: Blower Relay And Compressor Relay
CABIN M8540, M9540, WSM (2) Blower Relay and Compressor Relay Remove the seat, the seat under cover and the relays on the right side of the air conditioner unit : blower relay (5), blower high relay (7) and compressor relay (4).
Page 563: Blower Switch
CABIN M8540, M9540, WSM (3) Blower Switch When Blower Switch is in Low, Medium 1, Medium 2 or High Position (1) Battery (4) Blower Relay (7) Blower Resistor (a) Resistor M2 (2) Slow Blow Fuse (5) Blower Motor (8) Blower Switch...
Page 564 SERVICING CONTENTS 1. TROUBLESHOOTING ..................10-S1 2. SERVICING SPECIFICATIONS ..............10-S5 3. TIGHTENING TORQUES ................10-S6 4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE ......10-S7 [1] HANDLING OF SERVICE TOOLS............10-S8 (1) Manifold Gauge Set ................10-S8 (2) Refrigerant Charging Hose .............10-S10 (3) Vacuum Pump Adaptor..............10-S11 (4) Electric Gas Leak Tester..............10-S11 (5) Can Tap Valve ................10-S12 (6) T-joint ....................10-S12 (7) R134a Refrigerant Recover and Recycling Machine ......10-S12...
Page 565 CABIN M8540, M9540, WSM 1. TROUBLESHOOTING COMPRESSOR Reference Symptom Probable Cause Solution Page Noisy Bearing of compressor worn or damaged Replace 10-S43 (Compressor ON) Valves in compressor damaged Replace 10-S43 Belt slipping Adjust or replace G-31 Compressor bracket mounting screws loosen Tighten –...
Page 566 CABIN M8540, M9540, WSM AIR CONDITIONING SYSTEM (Continued) Reference Symptom Probable Cause Solution Page Insufficient Cooling Belt slipping Adjust or replace G-31 (Compressor Does Magnetic clutch defective Repair or replace 10-S22 Not Rotate Properly) Compressor defective Replace 10-S43 Insufficient Cooling...
Page 567 CABIN M8540, M9540, WSM AIR CONDITIONING SYSTEM (Continued) Reference Symptom Probable Cause Solution Page Insufficient Cooling Refrigerant too short Check with manifold 10-S21 (Hi-pressure Level is gauge Too Low) Compressor discharge valve damaged Replace 10-S43 Compressor gasket damaged Replace 10-S43...
Page 568 CABIN M8540, M9540, WSM WINDSHIELD WIPER Reference Symptom Probable Cause Solution Page Windshield Wiper Fuse blown (Short-circuit, burnt component Correct cause and – Does Not Operate inside motor or other part for operation) replace Wiper motor defective (Broken armature, worn...
Page 569: Servicing Specifications
CABIN M8540, M9540, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit A/C Compressor Magnetic Clutch Air Gap 0.30 to 0.65 mm – 0.0118 to 0.0255 in. 3.0 to 4.0 Ω Magnetic Clutch Stator Coil Resistance – Refrigerating Cycle Pressure 0.15 to 0.20 MPa...
Page 570 CABIN M8540, M9540, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts : Refer to “5. TIGHTENING TORQUES” at “G. GENERAL” section.) Item N·m kgf·m...
Page 571: Precautions At Repairing Refrigerant Cycle
CABIN M8540, M9540, WSM 4. PRECAUTIONS AT REPAIRING REFRIGERANT CYCLE When checking or repairing the air conditioning system, the following precautions and rules must be observed. And it is of first importance that no other personnel than a well-trained serviceman should be allow to handle the refrigerant.
Page 572: Handling Of Service Tools
CABIN M8540, M9540, WSM (Reference) Replacing Parts Replenish Quantity Brand Name 40 cc Condenser 0.042 U.S.qts. 0.035 Imp.qts. 40 cc Evaporator 0.042 U.S.qts. 0.035 Imp.qts. ND-OIL 8 10 cc <PAG* oil> Receiver 0.011 U.S.qts. 0.009 Imp.qts. 10 cc Hose 0.011 U.S.qts.
Page 573 CABIN M8540, M9540, WSM When LO Valve is Closed and HI Valve is Opened Two circuits are established. Port (C) → LO pressure gauge (1) → Port (B) → Port (D) (Schrader valve must be opened) Port (A) → HI pressure gauge (2) NOTE •...
Page 574: Refrigerant Charging Hose
CABIN M8540, M9540, WSM (2) Refrigerant Charging Hose The charging hoses are classified into three colors. Each charging hose must be handled as follows : • The air conditioner manufacture recommends that the blue hose (6) is used for the LO pressure side (suction side), the green hose (5) for refrigeration side (center connecting port) and the red hose (3) for HI pressure side (discharged side).
Page 575: Vacuum Pump Adaptor
CABIN M8540, M9540, WSM (3) Vacuum Pump Adaptor Objective of the Vacuum Pump Adaptor 1. After vacuum has been created in the air conditioning cycle, when the vacuum pump is stopped, since there is vacuum in hoses within the gauge manifold, the vacuum pump oil flows back into the charging hose.
Page 576: Can Tap Valve
CABIN M8540, M9540, WSM (5) Can Tap Valve The can tap valve that is used to charge the refrigerant into the air conditioning system, should be used as follows : 1. Before putting the can tap valve on the refrigerant container, turn the handle (1) counterclockwise till the valve needle is fully retracted.
Page 577: Checking And Charging Refrigerant Cycle
CABIN M8540, M9540, WSM 5. CHECKING AND CHARGING REFRIGERANT CYCLE [1] CHECKING WITH MANIFOLD GAUGE IMPORTANT • The gauge indications described in the following testing are those taken under the same condition, so it should be noted that the gauge readings will differs somewhat with the ambient conditions.
Page 578 CABIN M8540, M9540, WSM Insufficient Refrigerant 1. Symptoms seen in refrigerating cycle - Both LO and HI pressure side (1), (2) pressures too low. LO pressure side (1) : 0.05 to 0.10 MPa (0.5 to 1.0 kgf/cm , 7.1 to 14.2 psi) HI pressure side (2) : 0.69 to 0.98 MPa...
Page 579 CABIN M8540, M9540, WSM Air Entered in the Cycle 1. Symptoms seen in refrigerating cycle - Both LO and HI pressure side (1), (2) pressures too high. LO pressure side (1) : 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm , 28.4 to 49.8 psi)
Page 580 CABIN M8540, M9540, WSM Refrigerant Fails to Circulate 1. Symptoms seen in refrigerating cycle - LO pressure side (1) pressure is vacuum and, HI pressure side (2) is low pressure. LO pressure side (1) : Vacuum HI pressure side (2) : 0.49 to 0.59 MPa (5 to 6 kgf/cm , 71.2 to 85.3 psi)
Page 581: Discharging, Evacuating And Charging
CABIN M8540, M9540, WSM Faulty Compression of Compressor 1. Symptoms seen in refrigerating cycle - LO pressure side (1) : 0.39 to 0.59 MPa (4 to 6 kgf/cm , 56.9 to 85.3 psi) - HI pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm , 99.6 to 142.2 psi)
Page 582: Evacuating The System
CABIN M8540, M9540, WSM (2) Evacuating the System Evacuating the System 1. Discharge refrigerant from the system by R134a refrigerant recovery and recycling machine. (Refer to “(1) Discharging the Refrigerant” in this section.) 2. Connect the charging hose (red) (4) to the HI pressure side charging valve and connect the charging hose (blue) (5) to the LO pressure side charging valve.
Page 583: Charging The Refrigerant
CABIN M8540, M9540, WSM (3) Charging the Refrigerant Charging an Empty System (Liquid) This procedure is for charging an empty system through the HI pressure side with the refrigerant in the liquid state. CAUTION • Never run the engine when charging the system through the HI pressure side.
Page 584 CABIN M8540, M9540, WSM Charging an Empty or Partially Charged System (Vapor) This procedure is to charge the system through the LO pressure side with refrigerant in the vapor state. When the refrigerant container is placed right side up, refrigerant will enter the system as a vapor.
Page 585: Checking Charge Refrigerant Amount
CABIN M8540, M9540, WSM (4) Checking Charge Refrigerant Amount After charging the refrigerant, check for amount of charging refrigerant as follows. NOTE • The pressure on the following checking is the gauge indications at ambient temperature 30 °C (86 °F), so it should be noted that the pressure will differ some what with the ambient temperature.
Page 586: Checking, Disassembling And Servicing
CABIN M8540, M9540, WSM 6. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Compressor Operation of Magnetic Clutch 1. Turn off the A/C switch after starting the engine. 2. Check whether abrasion or abnormal noise is heard when only the magnetic clutch pulley is running.
Page 587: Wiper Relay
CABIN M8540, M9540, WSM (3) Wiper Relay Connector Voltage 1. Disconnect the 6P connector (2) from wiper relay (1). 2. Turn the main switch to “ON” position. 3. Measure the voltage with a voltmeter across the connector terminal c and chassis.
Page 588: Control Panel (Blower Switch, A/C Switch, Mode Control Dial, Temperature Control Dial And Recirculation/Fresh Air Selection Switch)
CABIN M8540, M9540, WSM (4) Control Panel (Blower Switch, A/C Switch, Mode Control Dial, Temperature Control Dial and Recirculation/Fresh Air Selection Switch) Blower Switch Connector Voltage 1. Disconnect the 6P connector (2) from blower switch. 2. Turn the main switch to “ON” position.
Page 589 CABIN M8540, M9540, WSM Connector Voltage 1. Disconnect the 16P connector (2) from control panel switch. 2. Turn the main switch to “ON” position. 3. Measure the voltage with a voltmeter across the terminal o and terminal n. 4. If the voltage differs from the battery voltage, the wiring harness, A/C relay or fuse is faulty.
Page 590 CABIN M8540, M9540, WSM Temperature Control Dial Checking 1. Turn the temperature control dial counterclockwise till it stops (at “COOL” position). 2. Measure the voltage with a voltmeter across the terminal b and terminal d. Make the following measurement with the terminals connected.
Page 591: Blower Resistor
CABIN M8540, M9540, WSM (5) Blower Resistor Blower Resistor Check 1. Disconnect the 4P connector (2) from blower resistor (1). 2. Measure each resistance from terminal Hi. 3. If the factory specifications are not indicated, replace blower resistor. Terminal Hi –...
Page 592: Temperature Motor
CABIN M8540, M9540, WSM (7) Temperature Motor Temperature Motor Checking 1. Confirm whether the temperature control dial (2) is defective. (Refer to “(4) Control Panel” in this section.) 2. Turn the main switch to “ON” position. 3. Turn the blower switch (3) at 1 position.
Page 593: Recirculation/Fresh Air Motor
CABIN M8540, M9540, WSM (9) Recirculation/Fresh Air Motor Recirculation/Fresh Air Motor Checking 1. Confirm whether the recirculation/fresh air selection switch (2) is defective. (Refer to “(4) Control Panel” in this section.) 2. Turn the main switch to “ON” position. 3. Turn the blower switch at 1 position.
Page 594: Pressure Switch
CABIN M8540, M9540, WSM (10) Pressure Switch Pressure Switch 1) HI Pressure Side 1. Connect the manifold gauge (3) to compressor as following procedure. Close the HI and LO pressure valves (4), (5) of manifold gauge tightly, and connect the charging hoses (2), (1) (red and blue) to the respective compressor service valves.
Page 595: Front Wiper Switch
CABIN M8540, M9540, WSM (11) Front Wiper Switch Connector Voltage 1. Disconnect the 6P connector from front wiper switch (1). 2. Turn the main switch to “ON” position. 3. Measure the voltage with a voltmeter across the connector terminal e of wiring harness side and chassis.
Page 596: Rear Wiper Switch
CABIN M8540, M9540, WSM (13) Rear Wiper Switch Connector Voltage (If equipped) 1. Disconnect the 5P connector from rear wiper switch (1). 2. Turn the main switch to “ON” position. 3. Measure the voltage with a voltmeter across the connector terminal b of the wiring harness side and chassis.
Page 597: Disassembling And Assembling
CABIN M8540, M9540, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Separating Cabin from Tractor Draining Coolant CAUTION • Never remove the radiator cap until coolant temperature is well below its boiling point. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely.
Page 598 CABIN M8540, M9540, WSM Preparation 1 1. Open the bonnet (2) and disconnect the battery (3) negative terminal and 6P connector (5) for head light. 2. Remove the bonnet dampers (6) and bonnet (2). 3. Remove the both side covers (4).
Page 599 CABIN M8540, M9540, WSM Preparation 2 1. Remove the both side cover guides (3). 2. Remove the both side panels (1). 3. Remove the air cleaner hose (2). (1) Side Panel (3) Side Cover Guide (2) Air Cleaner Hose W1025955...
Page 600 CABIN M8540, M9540, WSM Preparation 3 Without discharging the refrigerant from system 1. Detach the air conditioner hoses from the hose retainer (1) and slide out the condenser (2). 2. Remove the hose clamps (3). 3. Remove the slow blow fuse boxes (4) and relays (6).
Page 601 CABIN M8540, M9540, WSM Preparation 3 (Continued) 1. Remove the compressor (1) with hoses and compressor bracket. (When reassembling) • Take care not damage the air condenser fin. • After reassembling the compressor, be sure to adjust the air conditioner belt tension.
Page 602 CABIN M8540, M9540, WSM Preparation 4 1. Remove the hose clamps (3). 2. Disconnect the heater hoses (2). 3. Disconnect the accelerator wire (1). 4. Disconnect the master cylinder hose (7) and master cylinder return hose (8). 5. Remove the bonnet support (4).
Page 603 CABIN M8540, M9540, WSM Preparation 5 1. Remove the fuel filling port (1). 2. Remove the floor mat 1 (3) and mat 2 (4). 3. Remove the floor cover (5). 4. Disconnect the connectors (6) and pull out them from cabin.
Page 604 CABIN M8540, M9540, WSM Preparation 6 1. Disconnect the clutch cable (1). 2. Remove the shuttle select rod mounting nut (2) from shuttle select rod (4) then disconnect the shuttle select rod (4). 3. Disconnect the shuttle cable (3). (When reassembling) •...
Page 605 CABIN M8540, M9540, WSM Preparation 7 1. Place the disassembling stand under the transmission case and drawbar bracket. 2. Remove the rear wheels (R.H., L.H.). 3. Disconnect the lowering speed rod (1). 4. Disconnect the auxiliary control wires (2). 5. Disconnect the breather hose (3).
Page 606 CABIN M8540, M9540, WSM Preparation 8 1. Disconnect the position control rod (2) and draft control rod (1). 2. Disconnect the select cable (6). 3. Disconnect the range gear shift rod (5). 4. Disconnect the main gear shift rod (4).
Page 607: Removing Compressor Assembly
CABIN M8540, M9540, WSM (2) Removing Compressor Assembly Compressor Assembly 1. Discharge the refrigerant from the system. (Refer to “(1) Discharging the Refrigerant” in this section.) 2. Disconnect the low pressure pipe (suction) (1) and high pressure pipe 1 (discharge) (2) from the compressor, then cap the open fitting immediately to keep moisture out of the system.
Page 608 CABIN M8540, M9540, WSM Hub Plate 1. Three stopper bolts (1) are set in stopper magnet clutch (2) at the position corresponding to the shape of compressor. (Refer to “8. SPECIAL TOOLS” at “G. GENERAL” section.) 2. The stopper magnet clutch (2) is hung on hub plate (3) and it is fixed that the compressor rotates.
Page 609: Removing Air Conditioner Unit
CABIN M8540, M9540, WSM (3) Removing Air Conditioner Unit Draining Coolant 1. Refer to “[2] DISASSEMBLING AND ASSEMBLING” in this section. W1031565 Discharging Refrigerant Gas 1. Refer to “(1) Discharging the Refrigerant” in this section. W1031483 Seat, Floor Mats and Floor Cover 1.
Page 610 CABIN M8540, M9540, WSM Air Conditioner Ducts and Covers 1. Remove the duct 1 (1). 2. Remove the parking brake lever (2). 3. Remove the inner cover (L.H.) (3). 4. Remove the duct 2 (4). 5. Remove the seat under cover 1 (5).
Page 611 CABIN M8540, M9540, WSM Wiring Harness 1. Disconnect the 2P connector (1) for pressure switch. 2. Disconnect the 2P connector (2) for blower motor. 3. Disconnect the 4P connector (7) for blower resistor. 4. Disconnect the 5P connector (6) for recirculation/fresh air selection motor.
Page 612: Removing Air Conditioner Pipes
CABIN M8540, M9540, WSM (4) Removing Air Conditioner Pipes Discharging Refrigerant Gas 1. Refer to “(1) Discharging the Refrigerant” in this section. W1033151 Cover and Guide 1. Remove the both side panel guides (3). 2. Remove the both side panels (2).
Page 613: Removing Heater Hoses
CABIN M8540, M9540, WSM High Pressure Pipe 2 and Low Pressure Pipe 1. Remove the rubber (1) and pressure pipes joint mounting screw. 2. Remove the pressure pipes joint. 3. Disconnect the high pressure pipe 2 (3) and low pressure pipe (2), then cap the open fitting immediately to keep moisture out of the system.
Page 614 CABIN M8540, M9540, WSM Inner Cover (R.H.) 1. Remove the hand accelerator lever grip (10). 2. Remove the range gear shift lever grip (1). 3. Remove the main shift lever grip (2). 4. Remove the auxiliary control lever grip (4).
Page 615: Cab Windshield
• Sika Tack-Ultrafast and cleaner No. 1 are made by Sika Corporation. • These materials can not be provided by Kubota Corporation. • Therefore, please find the local made equivalent materials in your country and use them when you need.
Page 616 CABIN M8540, M9540, WSM Before Replacing Windshields (3) 1. Check that the glasses are not damaged and cracked. 2. Turn over the glass and clean this surface of the glass by Sika- cleaner No. 1. 3. The cleaning area of the rear surface is indicated “a” in the figure left.
Page 617: Wiper Motor
CABIN M8540, M9540, WSM (7) Wiper Motor Front Wiper Motor 1. Remove the panel cover (1). 2. Disconnect the 5P connector (2) from hazard switch. 3. Disconnect the 3P connector (4) from display switch. 4. Remove the meter panel (5) mounting screw (3).
Page 618: Servicing
CABIN M8540, M9540, WSM Rear Wiper Motor (If equipped) 1. Remove the wiper motor cover (7). 2. Disconnect the 4P connector from rear wiper motor. 3. Remove the wiper arm mounting nut (4) and wiper arm (5). 4. Remove the wiper link cap (1) and nut (2).
Page 619 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp KUBOTA Corporation Printed in Japan 2008. 09, S, EI, EI, e...

This manual is also suitable for:

M9540

Save PDF