Kubota M5040 Workshop Manual

Table of Contents

Quick Links

WORKSHOP MANUAL

TRACTOR

M5040,M6040,M7040

KiSC issued 06, 2008 A

Table of Contents

Chapters

Table of Contents

Troubleshooting

Need help?

Do you have a question about the M5040 and is the answer not in the manual?

Questions and answers

Steve Hart

February 3, 2025

How to remove fuel tank

1 comments:

Mr. Anderson

February 10, 2025

The provided context does not contain specific instructions on how to remove the fuel tank on a Kubota M5040. However, it mentions that accessing certain components may require dropping the fuel tank.

For proper removal, the general steps typically include:
1. Ensuring the tractor is on a level surface and turned off.
2. Draining the fuel from the tank to prevent spills.
3. Removing any floor coverings or panels obstructing access.
4. Disconnecting fuel lines and electrical connections.
5. Unbolting and carefully lowering the tank.

Refer to the Kubota M5040 service manual for detailed instructions.

This answer is automatically generated

Summary of Contents for Kubota M5040

Page 1 WORKSHOP MANUAL TRACTOR M5040,M6040,M7040 KiSC issued 06, 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 M5040, M6040 and M7040. 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 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS 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 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS 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 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 6: Safety Decals
M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
Page 7 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS KiSC issued 06, 2008 A...
Page 8 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS KiSC issued 06, 2008 A...
Page 9 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS KiSC issued 06, 2008 A...
Page 10 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS CABIN Model KiSC issued 06, 2008 A...
Page 11 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS KiSC issued 06, 2008 A...
Page 12 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS KiSC issued 06, 2008 A...
Page 13 M5040, M6040, M7040, WSM SAFETY INSTRUCTIONS KiSC issued 06, 2008 A...
Page 14: Specifications
M5040, M6040, M7040, WSM SPECIFICATIONS SPECIFICATIONS [ROPS Model] M5040 M6040 M7040 Model Model V3007-DI-E2 V3307-DI-E2 V3307-DI-E2-1 Type Direct injection, liquid cooled 4 cylinder diesel Number of cylinders Total displacement 3053 cm (186 cu.in.) 3331 cm (203 cu.in.) 94 × 110 mm (3.7 × 4.3 in.) 94 ×...
Page 15 M5040, M6040, M7040, WSM SPECIFICATIONS M5040 M6040 M7040 Model Hydraulic control system Position, draft (top link sensing) and mix control Pump capacity 41.6 L (11.0 U.S.gals., 9.2 Imp.gals.) / min. 3-point hitch SAE Category 1 and 2 1900 kg (4189 lbs) At lift points Max.
Page 16 M5040, M6040, M7040, WSM SPECIFICATIONS [CABIN Model] M5040 M6040 M7040 Model Model V3007-DI-E2 V3307-DI-E2 V3307-DI-E2-1 Type Direct injection, liquid cooled 4 cylinder diesel Number of cylinders Total displacement 3053 cm (186 cu.in.) 3331 cm (203 cu.in.) 94 × 110 mm (3.7 × 4.3 in.) 94 ×...
Page 17 M5040, M6040, M7040, WSM SPECIFICATIONS M5040 M6040 M7040 Model Hydraulic control system Position, draft (top link sensing) and mix control Pump capacity 41.6 L (11.0 U.S.gals., 9.2 Imp.gals.) / min. 3-point hitch SAE Category 1 and 2 1900 kg (4189 lbs) At lift points Max.
Page 18: Traveling Speeds
M5040, M6040, M7040, WSM TRAVELING SPEEDS TRAVELING SPEEDS (At rated engine rpm) Model M5040, M6040 M7040 Tire size (Rear) 14.9-28 16.9-28 16.9-30 Shuttle shift Range gear shift Main gear shift km/h (mph) lever lever lever 0.33 (0.20) 0.34 (0.21) 0.35 (0.22) 0.46 (0.29)
Page 19 M5040, M6040, M7040, WSM DIMENSIONS DIMENSIONS ROPS Model KiSC issued 06, 2008 A...
Page 20 M5040, M6040, M7040, WSM DIMENSIONS CABIN Model KiSC issued 06, 2008 A...
Page 21 GENERAL KiSC issued 06, 2008 A...
Page 22: Table Of Contents
GENERAL CONTENTS 1. TRACTOR IDENTIFICATION ................. G-1 [1] MODEL NAME AND SERIAL NUMBERS..........G-1 (1) ROPS Model ..................G-1 (2) CABIN Model ..................G-2 [2] CYLINDER NUMBER ................G-4 2. GENERAL PRECAUTIONS ................G-5 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-6 [1] WIRING......................
Page 23: Tractor Identification
G GENERAL 1. TRACTOR IDENTIFICATION [1] MODEL NAME AND SERIAL NUMBERS (1) ROPS Model 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 (2) Tractor Serial Number...
Page 24: Cabin Model
M5040, M6040, M7040, WSM G GENERAL (2) CABIN Model When contacting your local KUBOTA distributor, always specify engine serial number, tractor serial number and hourmeter reading. (1) Tractor Identification Plate (3) Tractor Serial Number (2) CABIN Identification Plate (4) Engine Serial Number...
Page 25: Engine Serial Number
M5040, M6040, M7040, WSM G GENERAL 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 26: Cylinder Number
M5040, M6040, M7040, WSM G GENERAL [2] CYLINDER NUMBER The cylinder numbers of KUBOTA diesel engine is designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2, No.3 and No.4 starting from the front cover side.
Page 27: 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 28: Handling Precautions For Electrical Parts And Wiring
M5040, M6040, M7040, WSM G GENERAL 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...
Page 29 M5040, M6040, M7040, WSM G GENERAL • 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 30: Battery
M5040, M6040, M7040, WSM G GENERAL [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 31: Handling Of Circuit Tester
M5040, M6040, M7040, WSM G GENERAL • 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 32: Lubricants, Fuel And Coolant
[4WD model] 4.8 Imp.qts. KUBOTA SUPER UDT fluid or Front axle gear SAE80, SAE90 gear oil 3.0 L case oil (one 3.2 U.S.qts. side) 2.6 Imp.qts. [4WD model] * KUBOTA original transmission hydraulic fluid. G-10 KiSC issued 06, 2008 A...
Page 33 • Transmission Oil : The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and complete lubrication of the transmission, it is important that a multi-grade transmission fluid be used in this system. We recommend the use of KUBOTA SUPER UDT fluid for optimum protection and performance.
Page 34: Tightening Torques
M5040, M6040, M7040, WSM G GENERAL 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 35: Hydraulic Fittings
M5040, M6040, M7040, WSM G GENERAL [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 36: Maintenance
M5040, M6040, M7040, WSM G GENERAL 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-21 50 Hr...
Page 37 M5040, M6040, M7040, WSM G GENERAL 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-31 400 Hr every Fuel filter...
Page 38 • The items listed above (@ marked) are registered as emisson related critical parts by KUBOTA in U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.
Page 39: Check And Maintenance
M5040, M6040, M7040, WSM G GENERAL 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 40: Check Points Of Initial 50 Hours
M5040, M6040, M7040, WSM G GENERAL [2] CHECK POINTS OF INITIAL 50 HOURS Adjusting Clutch Pedal (Synchro Shuttle Model) 1. Stop the engine and remove the key. 2. Slightly depress the clutch pedal and measure free travel at the top of pedal stroke.
Page 41 M5040, M6040, M7040, WSM G GENERAL Replacing Engine Oil Filter CAUTION • Be sure to stop the engine before changing oil filter cartridge. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Remove the oil filter (1).
Page 42 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 43: Check Points Of Every 50 Hours
M5040, M6040, M7040, WSM G GENERAL [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 44 M5040, M6040, M7040, WSM G GENERAL Checking Wheel Mounting Nuts Tightening Torque CAUTION • Never operate tractor with a loose rim, wheel, or axle. • Any time bolts and nuts are loosened, retighten to specified torque. • Check all bolts and nuts frequently and keep them tight.
Page 45: Check Points Of Every 100 Hours
M5040, M6040, M7040, WSM G GENERAL [4] CHECK POINTS OF EVERY 100 HOURS 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 46 M5040, M6040, M7040, WSM G GENERAL Cleaning Air Cleaner Element 1. Remove the air cleaner cover (4) and primary element (2). 2. Clean the primary element if: - When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm...
Page 47 M5040, M6040, M7040, WSM G GENERAL Adjusting Fan/Air Conditioner Belt Tension CAUTION • Be sure to stop the engine before checking belt tension. 1. Stop the engine and remove the key. 2. Apply moderate thumb pressure to belt between pulleys.
Page 48 M5040, M6040, M7040, WSM G GENERAL Adjusting Brake Pedal 1. To check and adjusting for brake pedal, refer to “[1] CHECKING AND ADJUSTING” at “5. BRAKES” section. W1025046 Adjusting Clutch Pedal (Synchro Shuttle Model) 1. To check and adjusting for clutch pedal, refer to “[2] CHECK POINTS OF INITIAL 50 HOURS”...
Page 49 M5040, M6040, M7040, WSM G GENERAL 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 50: Check Points Of Every 200 Hours
M5040, M6040, M7040, WSM G GENERAL [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 51: Adjusting Toe-In
M5040, M6040, M7040, WSM G GENERAL 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 52 M5040, M6040, M7040, WSM G GENERAL Cleaning Air Filter (CABIN Model) Fresh Air Filter 1. Remove the knob bolts (3) and pull out the fresh air filter (1). 2. Blow air from the opposite direction to the filter’s normal air flow.
Page 53: Check Points Of Every 300 Hours
M5040, M6040, M7040, WSM G GENERAL [6] CHECK POINTS OF EVERY 300 HOURS Replacing Hydraulic Oil Filter 1. Refer to “[2] CHECK POINTS OF INITIAL 50 HOURS” in this section. W1072600 Changing Engine Oil 1. Refer to “[2] CHECK POINTS OF INITIAL 50 HOURS” in this section.
Page 54: Check Points Of Every 600 Hours
M5040, M6040, M7040, WSM G GENERAL [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 55: Check Points Of Every 3000 Hours
M5040, M6040, M7040, WSM G GENERAL [11] CHECK POINTS OF EVERY 3000 HOURS Checking Injection Pump 1. Refer to “[1] CHECKING AND ADJUSTING” at “1. ENGINE” section. W1074724 [12] CHECK POINT OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1.
Page 56: Check Points Of Every 2 Years
M5040, M6040, M7040, WSM G GENERAL [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 57 M5040, M6040, M7040, WSM G GENERAL 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 58 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 59: Others
M5040, M6040, M7040, WSM G GENERAL [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 60 M5040, M6040, M7040, WSM G GENERAL Replacing Fuse (ROPS 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 61 M5040, M6040, M7040, WSM G GENERAL Replacing 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 62 M5040, M6040, M7040, WSM G GENERAL 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 63 M5040, M6040, M7040, WSM G GENERAL 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 64: Special Tools
M5040, M6040, M7040, WSM G GENERAL 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 65 M5040, M6040, M7040, WSM G GENERAL 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 66 M5040, M6040, M7040, WSM G GENERAL Small End Bushing Replacing Tool Application: Use to press out and to press fit the small end bushing. [Press out] 157 mm (6.181 in.) 14.0 mm (0.5512 in.) 120 mm (4.7244 in.) 27.4 mm dia. (1.0787 in. dia.) 30.95 mm dia.
Page 67 M5040, M6040, M7040, WSM G GENERAL Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. 225 mm (8.86 in.) 70 mm (2.76 in.) 45 mm (1.77 in.) 20 mm dia. (0.79 in dia.) 11.7 to 11.9 mm dia. (0.460 to 0.468 in. dia.) 6.5 to 6.6 mm dia.
Page 68 M5040, M6040, M7040, WSM G GENERAL Front Cover Oil Seal Replacing Tool Application: Use to press fit the front cover oil seal. 120 mm (4.7244 in.) 12 mm (0.4724 in.) 2.9 to 3.0 mm (0.1142 to 0.1181 in.) 10 mm (0.3937 in.) 80 mm (3.1496 in.)
Page 69 M5040, M6040, M7040, WSM G GENERAL Flywheel Housing Oil Seal Replacing Tool Application: Use to press fit the flywheel housing oil seal. 118 mm (4.6457 in.) 12 mm (0.4724 in.) 0.9 to 1.0 mm (0.0354 to 0.0394 in.) 10 mm (0.3937 in.) 80 mm (3.1496 in.)
Page 70 M5040, M6040, M7040, WSM G GENERAL Valve Bridge Shaft Replacing Tool Application: Use to press fit the valve bridge shaft. 9.5 mm dia. (0.3740 in. dia.) through hole 19 mm (0.7480 in.) 23.2 mm (0.9134 in.) 42.0 to 42.4 mm (1.6535 to 1.6693 in.) 12.5 mm dia.
Page 71 M5040, M6040, M7040, WSM G GENERAL Auxiliary Socket for Fixing Crankshaft Sleeve Application: Use to fix the crankshaft sleeve of the diesel engine. 1.5 mm (0.0591 in.) 33 mm (1.2992 in.) 0.523 rad (30 °) 115 mm (4.5276 in.) 34.925 to 34.950 mm dia. (1.3750 to 1.3760 in. dia.) 43 mm (1.6929 in.)
Page 72 M5040, M6040, M7040, WSM G GENERAL Engine Stand Application: Use to support engine. 107 mm (4.213 in.) 246 mm (9.685 in.) 21 mm (0.827 in.) 204 mm (8.032 in.) 102 mm (4.016 in.) 15 mm (0.591 in.) 59 mm (2.323 in.) 14 mm dia.
Page 73 M5040, M6040, M7040, WSM G GENERAL Flywheel Housing Guide Application: Use to install the flywheel housing to the crankcase. 70 mm (2.7559 in.) 8 mm (0.3150 in.) 22 mm (0.8661 in.) 30 mm (1.1811 in.) 87 mm dia. (3.4252 in. dia.) 82.036 to 82.071 mm dia.
Page 74 M5040, M6040, M7040, WSM G GENERAL Glow Plug Adapter Application: Use to check compression pressure through glow plug hole. 3 mm dia. (0.118 in. dia.) through hole 1.047 rad (60 °) 17 mm (0.669 in.) 1 mm (0.039 in.) 16 mm dia. (0.630 in. dia.) P0.5 17 mm (0.669 in.)
Page 75 M5040, M6040, M7040, WSM G GENERAL Injection Pump Gear Puller Application: Use for remove the injection pump gear from governor shaft. M35 x P1.5, 6 mm depth (0.2362 in. depth) 35 mm dia., 12 mm depth (1.3780 in. dia., 0.4724 in. depth) 30 mm dia., 27.5 mm depth...
Page 76 M5040, M6040, M7040, WSM G GENERAL Injection Pump Rack Fixing Tool Application: Use to fix the injection pump control rack. 1) Shaft 20 mm (0.787 in.) 6 mm (0.236 in.) 29.9 to 30.1 mm (1.177 to 1.185 in.) 2.0 to 3.0 mm (0.079 to 0.118 in.) M6 x P1.0...
Page 77 M5040, M6040, M7040, WSM G GENERAL Jig for Govenor Connecting Rod Application: Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly. 0.5 mm (0.0197 in.) 5 mm (0.1969 in.) 12.7 to 13.0 mm (0.5000 to 0.5118 in.) 4 mm (0.1575 in.)
Page 78 M5040, M6040, M7040, WSM G GENERAL Pin for Balancer Shaft Bearing Replacing Tool 7.2 to 7.4 mm (0.283 to 0.291 in.) 4.0 mm dia. (0.158 in. dia.) Ra = 0.8 a C0.1 Chamfer 0.1 mm (0.0039 in.) C0.5 Chamfer 0.5 mm (0.0197 in.)
Page 79 M5040, M6040, M7040, WSM G GENERAL Balancer Shaft 1 Bearing A Replacing Tool Application: Use to press fit the bearing. 18 mm (0.7087 in.) 23 mm (0.9055 in.) 130 mm (5.1181 in.) 0.349 rad (20 °) 1.2 mm (0.0472 in.) 24 mm (0.9449 in.)
Page 80 M5040, M6040, M7040, WSM G GENERAL Balancer Shaft 1 Bearing C Replacing Tool Application: Use to press fit the bearing. 52.5 mm dia. (2.0669 in. dia.) 0.855 rad (49 °) 48.4 to 48.5 mm dia. (1.9055 to 1.9095 in.) 0.427 rad (24.5 °) 40 mm dia.
Page 81 M5040, M6040, M7040, WSM G GENERAL Balancer Shaft 1 Bearing D Replacing Tool Application: Use to press fit the bearing. 34.5 mm dia. (1.3583 in. dia.) 35 mm dia. (1.3780 in. dia.) 30.8 to 30.9 mm dia. (1.2126 to 1.2165 in. dia.) 23 mm (0.9055 in.)
Page 82 M5040, M6040, M7040, WSM G GENERAL Balancer Shaft 2 Bearing B Replacing Tool Application: Use to press fit the bearing. 18 mm (0.7087 in.) 0.523 rad (30 °) 125 mm (4.9213 in.) 35 mm dia. (1.3780 in. dia.) 1.2 mm (0.0472 in.) 9 mm (0.3543 in.)
Page 83 M5040, M6040, M7040, WSM G GENERAL Balancer Shaft 2 Bearing C Replacing Tool Application: Use to press fit the bearing. 52.5 mm dia. (2.0669 in. dia.) 9 mm (0.3543 in.) 48.3 to 48.4 mm dia. (1.9016 to 1.9055 in.) 84.5 to 85.5 mm (3.3268 to 3.3661 in.) 40 mm dia.
Page 84 M5040, M6040, M7040, WSM G GENERAL Balancer Shaft 2 Bearing D Replacing Tool Application: Use to press fit the bearing. 34.5 mm dia. (1.3583 in. dia.) 120 mm (4.7244 in.) 30.8 to 30.9 mm dia. (1.2126 to 1.2165 in.) 479 mm (18.8583 in.) 24 mm dia.
Page 85: Special Tools For Tractor
M5040, M6040, M7040, WSM G GENERAL [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 86 M5040, M6040, M7040, WSM G GENERAL 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 87 M5040, M6040, M7040, WSM G GENERAL 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.
Page 88 M5040, M6040, M7040, WSM G GENERAL 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 89 M5040, M6040, M7040, WSM G GENERAL Adaptor for Sliding Hammer Application : Use to removing the front axle bevel pinion shaft and hydraulic pump drive gear pin with sliding hammer. Front axle bevel pinion shaft Hydraulic pump drive gear pin M6 x P1.0...
Page 90 M5040, M6040, M7040, WSM G GENERAL Hydraulic Clutch Spring Compressor Application: Use exclusively for pushing the spring, to remove the external circlip for hydraulic shuttle clutch and PTO hydraulic clutch. PTO hydraulic clutch Hydraulic shuttle clutch 70 mm (2.76 in.) 70 mm (2.76 in.)
Page 91 M5040, M6040, M7040, WSM G GENERAL PTO Propeller Shaft Oil Seal Installer (Synchro Shuttle Model) Application : Use for installing the PTO propeller shaft oil seal. 200 mm (7.87 in.) 194 mm (7.64 in.) 24.4 to 24.6 mm dia. (0.961 to 0.969 in. dia.) 34.5 to 34.95 mm dia.
Page 92 M5040, M6040, M7040, WSM G GENERAL Bevel Gear Shaft Tool Application : Use for measuring and tightening the bevel gear shaft. Bevel gear for front axle Bevel gear for rear axle 12.75 to 12.90 mm square 12.75 to 12.90 mm square (0.50 to 0.51 in.
Page 93 M5040, M6040, M7040, WSM G GENERAL Draft Control Test Bar Application : Use for checking the lift range and floating range of hydraulic draft control. 1045 mm (41.14 in.) 1000 mm (29.37 in.) 20 mm dia. (0.79 in. dia.) 30 mm dia. (1.18 in. dia.) 100 mm (3.94 in.)
Page 94 M5040, M6040, M7040, WSM G GENERAL 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 95: Special Tools For Air Conditioner Unit
M5040, M6040, M7040, WSM G GENERAL [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 96 M5040, M6040, M7040, WSM G GENERAL 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 97: Tires
9. TIRES [1] TYPE OF TIRES IMPORTANT • Do not use tires other than those approved by KUBOTA. NOTE • When optional different-diameter tires are fitted on the machine, the travel speed display mode must be changed. Otherwise the travel speed will not get correctly displayed. Such mode switching is also needed when the original tires are back on the machine.
Page 98: Tread Adjustment
M5040, M6040, M7040, WSM G GENERAL [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 99: Front Wheels [4Wd Model]
M5040, M6040, M7040, WSM G GENERAL (2) Front Wheels [4WD Model] Front tread width can be adjusted as shown with the standard equipped tires. To change the tread width 1. Remove the wheel rim and disc mounting bolts. 2. Change the position of the rim and disc (right and left) to the desired position, and tighten the bolts.
Page 100: Rear Wheels
M5040, M6040, M7040, WSM G GENERAL (3) 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 101: Wheel Hub
M5040, M6040, M7040, WSM G GENERAL [3] WHEEL HUB Front wheel hub Rear wheel hub – Screw circle diameter 152.4 mm 203.2 mm 203.2 mm (6 in.) (8 in.) (8 in.) Number of screws M14 × P1.5 M16 × P1.5 M16 ×...
Page 102: Tire Liquid Injection
M5040, M6040, M7040, WSM G GENERAL [5] 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 103 M5040, M6040, M7040, WSM G GENERAL 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 104 M5040, M6040, M7040, WSM G GENERAL 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 105: 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 106 M5040, M6040, M7040, WSM G GENERAL M5040, M6040 M7040 Implement Remarks Max. Tank 3000 L (790 U.S.gals., 660 Imp.gals.) Capacity Slurry Tank Max. Load 4000 kg (8800 lbs) Capacity Max. Load 4500 kg 5000 kg 4500 kg 5000 kg Capacity...
Page 107 M5040, M6040, M7040, WSM G GENERAL M5040, M6040 M7040 Implement Remarks Numbers of Cultivating Tines Sub Soiler 300 mm 450 mm Cultivating Depth 400 mm (16 in.) (12 in.) (18 in.) 3050 mm 4270 mm Max. Width 3660 mm (144 in.) (120 in.)
Page 108 ENGINE KiSC issued 06, 2008 A...
Page 109 MECHANISM CONTENTS 1. FEATURE ...................... 1-M1 2. ENGINE BODY ..................... 1-M2 [1] CYLINDER BLOCK................. 1-M2 [2] COOLING JACKET................. 1-M3 [3] HALF-FLOATING HEAD COVER ............1-M3 [4] CYLINDER HEAD ................... 1-M4 [5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE .. 1-M5 [6] CENTER DIRECT INJECTION SYSTEM (E-CDIS)......
Page 110: Feature
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 111: Engine Body
M5040, M6040, M7040, WSM ENGINE 2. ENGINE BODY [1] CYLINDER BLOCK The 07 series DI engine employs ladder frame structure type crankcases - the crankcase 1 (1) with combustion part and the crankcase 2 (2) which supports the crankcase 1 (1).
Page 112: Cooling Jacket
M5040, M6040, M7040, WSM ENGINE [2] COOLING JACKET The 07 series DI engine employs coolant evenness distribution type cooling jacket inside crankcase 1. The coolant is evenly supplied to each cylinder through the main gallery in the jacket mold core.
Page 113: Cylinder Head
M5040, M6040, M7040, WSM ENGINE [4] 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...
Page 114: Screws Per Each Cylinder Assembling Structure
M5040, M6040, M7040, WSM ENGINE [5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE The 07 series DI engine employs 4 screws per each cylinder assembling structure. The cylinder head (2) and the crankcase 2 (5) are assembled from the top and bottom to the crankcase 1 (3) with each of 10 screws.
Page 115: Center Direct Injection System (E-Cdis)
M5040, M6040, M7040, WSM ENGINE [6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) The 07 series DI engine adopts the Center Direct Injection System (E-CDIS), in which the injection nozzle is positioned upright at the center of the cylinder. This system serves to inject fuel directly at the center of the cylinder.
Page 116: Gear Train Configuration
M5040, M6040, M7040, WSM ENGINE [7] GEAR TRAIN CONFIGURATION The 07 series DI engine employs gear train located at flywheel side. The following benefits are in the rear gear train configuration. 1. Flexibility of auxiliary parts arrangement. 2. Reduction of gear chattering noise from crankshaft of torsional and bending vibration.
Page 117: Lubricating System
M5040, M6040, M7040, WSM ENGINE 3. LUBRICATING SYSTEM [1] OIL COOLER The 07 series engine has a coolant-cooled oil cooler that not only cools hot oil, but also warms the cool engine oil shortly after start up. As shown in the figure, the oil flows inside the...
Page 118: Cooling System
M5040, M6040, M7040, WSM ENGINE 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 119: Bottom Bypass System
M5040, M6040, M7040, WSM ENGINE [2] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in the 07 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 120: Fuel System
ENGINE 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 121 M5040, M6040, M7040, WSM ENGINE At Idling Turn the speed control lever (2) clockwise to idle the engine. It tensions the governor spring (7) to pull the fork lever 2 (1). When the fork lever 2 is pulled, it moves the torque spring pin (3) and the fork lever 1 (5) in the direction of the arrow A to restrain the weight.
Page 122 M5040, M6040, M7040, WSM ENGINE 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 123: Stage Di Nozzle
M5040, M6040, M7040, WSM ENGINE [2] 2 STAGE DI NOZZLE Exhaust and noise regulations are becoming increasingly strict, particularly in regard to the reduction of NOx (nitrogen oxides) and particulates. The two-spring nozzle holder has been developed to reduce NOx (nitrogen oxides) and particulates from direct injection diesel engine exhaust.
Page 124: Injection Pump With F.s.p
M5040, M6040, M7040, WSM ENGINE 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 l : Needle Valve Pre-lift X1 : Cam Angle (°)
Page 125: Cpv Equipped Delivery Valve
M5040, M6040, M7040, WSM ENGINE [4] CPV EQUIPPED DELIVERY VALVE The Constant Pressure Valve (CPV) is a mechanism that maintains uniform residual pressure in the high pressure pipe. It stabilizes overall delivery quantity characteristics especially delivery quantity characteristics at low speeds.
Page 126 SERVICING CONTENTS 1. TROUBLESHOOTING ..................1-S1 2. SERVICING SPECIFICATIONS ..............1-S4 3. TIGHTENING TORQUES ................1-S11 4. CHECKING, DISASSEMBLING AND SERVICING........1-S13 [1] CHECKING AND ADJUSTING .............1-S13 (1) Engine Body..................1-S13 (2) Lubricating System ................1-S15 (3) Cooling System .................1-S16 (4) Fuel System ..................1-S19 [2] PREPARATION ..................1-S22 (1) Separating Front Axle and Front Frame as a Unit ......1-S22 (2) Separating Engine ................1-S25 [3] DISASSEMBLING AND ASSEMBLING..........1-S28...
Page 127: Troubleshooting
M5040, M6040, M7040, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel G-10 Start Air in the fuel system Vent air G-36 Water in the fuel system Change fuel and – repair or replace fuel...
Page 128 M5040, M6040, M7040, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-30 Not Smooth Air cleaner clogged Clean or replace G-23 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut...
Page 129 M5040, M6040, M7040, WSM ENGINE Reference Symptom Probable Cause Solution Page Fuel Mixed into Injection pump’s plunger worn Repair or replace 1-S20, 40, Lubricant Oil 41, 42 Deficient nozzle injection Repair or replace 1-S21, 28 nozzle Injection pump broken Replace...
Page 130: Servicing Specifications
M5040, M6040, M7040, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 3.92 MPa / 2.90 MPa / −1 −1 250 min (rpm) 250 min (rpm) 40.0 kgf/cm 29.6 kgf/cm −1 −1 250 min (rpm)
Page 131 M5040, M6040, M7040, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Spring (Intake and Exhaust) Setting Load / 63.547 N / 31.5 mm 45.864 N / Setting Length 6.48 kgf / 31.5 mm 31.5 mm 14.256 lbf / 1.2401 in.
Page 132 M5040, M6040, M7040, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Idle Gear Side Clearance 0.15 to 0.25 mm 0.9 mm 0.0059 to 0.0098 in. 0.0354 in. Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.050 to 0.091 mm 0.10 mm...
Page 133 M5040, M6040, M7040, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Balancer Shaft 1 Journal Oil Clearance 0.060 to 0.146 mm 0.2 mm 0.0024 to 0.0057 in. 0.0079 in. Balancer Shaft 1 Journal O.D. 48.934 to 48.950 mm –...
Page 134 M5040, M6040, M7040, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankshaft Side Clearance 0.15 to 0.35 mm 0.50 mm 0.0059 to 0.0138 in. 0.0197 in. Crankshaft Alignment – 0.02 mm 0.00079 in. Crank Pin to Crank Pin Bearing Oil Clearance 0.017 to 0.048 mm...
Page 135 M5040, M6040, M7040, WSM ENGINE COOLING SYSTEM Item Factory Specification Allowable Limit Fan/Air-conditioner Belt (ROPS Model) Tension 16 to 17 mm / 98 N – 0.63 to 0.66 in. / 98 N (10 kgf, 22 lbf) Fan/Air-conditioner Belt (CABIN Model)
Page 136 M5040, M6040, M7040, WSM ENGINE FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing V3007-DI-E2 0.035 to 0.070 rad – (M5040) (2.0 to 4.0 °) before T.D.C. V3307-DI-E2 0.044 to 0.078 rad (M6040) (2.5 to 4.5 °) before T.D.C. V3307-DI-E2-1 0.061 to 0.096 rad...
Page 137: Tightening Torques
M5040, M6040, M7040, WSM ENGINE 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 138 M5040, M6040, M7040, WSM ENGINE Item N·m kgf·m lbf·ft Balancer shaft set screw 23.5 to 27.5 2.4 to 2.8 17.3 to 20.3 *Connecting rod screw 68.6 to 73.5 7.0 to 7.5 50.6 to 54.2 *Crankcase 2 mounting screw 137.3 to 147.1 14.0 to 15.0...
Page 139: Checking, Disassembling And Servicing
M5040, M6040, M7040, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. After warming up the engine, shut it down and remove the air cleaner, the muffler, breather tube, glow lead and all glow plugs.
Page 140 M5040, M6040, M7040, WSM ENGINE Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the high pressure pipes, glow lead, glow plugs and the cylinder head cover. 2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (front cover side) comes to the compression top dead center.
Page 141: Lubricating System
M5040, M6040, M7040, WSM ENGINE (2) Lubricating System Engine Oil Pressure 1. Remove the oil switch and set a pressure tester (Code No. 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 142: Cooling System
M5040, M6040, M7040, WSM ENGINE (3) Cooling System Fan/Air-conditioner Belt Tension 1. Measure the deflection (L) at measurement point (a), depressing the belt halfway between the pulleys at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specifications, loosen the tension pulley nut (1) and lock nut (3).
Page 143 M5040, M6040, M7040, WSM ENGINE Belt Damage and Wear 1. Check the belt for damage. 2. If the belt is damaged, replace it. 3. Check if the belt is worn and sunk in the pulley groove. 4. If the belt is nearly worn out and deeply sunk in the pulley groove, replace it.
Page 144 M5040, M6040, M7040, WSM ENGINE CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water may gush out, scalding nearby people. Radiator Cap Air Leakage 1. Set a radiator tester on the radiator cap.
Page 145: Fuel System
M5040, M6040, M7040, WSM ENGINE (4) Fuel System Injection Timing 1. Make sure of matching the injection timing align mark (2) of the injection pump unit and the flywheel housing, as shown in the photo. 2. Remove the injection pipes.
Page 146 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 147 M5040, M6040, M7040, WSM ENGINE CAUTION • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the spray goes. • If the spray from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 148: Preparation
M5040, M6040, M7040, WSM ENGINE [2] PREPARATION (1) Separating Front Axle and Front Frame as a Unit Draining Fuel and Transmission Fluid 1. Refer to "7. CHECK MAINTENANCE" and "4. LUBRICANTS, FUEL AND COOLANT" at "G. GENERAL" section. W1054682 Bonnet 1.
Page 149 M5040, M6040, M7040, WSM ENGINE Propeller Shaft (4WD Model) 1. Slide the propeller shaft cover (3) after removing the screw (8). 2. Tap out the roll pins (2) and then slide the coupling (1) to the rear. (When reassembling) • Apply grease to the splines of the propeller shaft (5) and pinion shaft.
Page 150 M5040, M6040, M7040, WSM ENGINE Air Cleaner Hose and Battery Cable 1. Disconnect the air cleaner hose (1). 2. Disconnect the battery cable (2) from the starter terminal B. (When reassembling) 9.8 to 11.8 N·m Starter’s B terminal Tightening torque 1.0 to 1.2 kgf·m...
Page 151: Separating Engine
M5040, M6040, M7040, WSM ENGINE Front Axle Support as a Unit 1. Make sure the clutch housing case and front frame are securely mounted on the disassembling stands. 2. Install the front axle rocking restrictor (1) (refer to “8. SPECIAL TOOL”...
Page 152 M5040, M6040, M7040, WSM ENGINE Steering Support Under Cover and Rear Bonnet 1. Remove the steering support under cover (1). 2. Loosen the rear bonnet mounting screws (4). 3. Remove the seal (6) and panel guide mounting screw (5). 4. Disconnect the wire harness and remove the panel guide (2) and rear bonnet (3).
Page 153 M5040, M6040, M7040, WSM ENGINE Separating Engine from Clutch Housing (ROPS Model) 1. Hoist the engine with a the hoist and chain. 2. Disconnect the brake rod (1) (R.H., L.H.). 3. Disconnect the clutch cable (2). 4. Remove the steering support mounting screws.
Page 154: Disassembling And Assembling
M5040, M6040, M7040, WSM ENGINE [3] DISASSEMBLING AND ASSEMBLING (1) External Components Air Cleaner, Muffler and Others 1. Remove the air cleaner, muffler, exhaust manifold, fan and fan belt. 2. Remove the fuel filter cartridge (1), fuel tubes (2), sedimenter (3), alternator (4) and starter (5).
Page 155 M5040, M6040, M7040, WSM ENGINE Nozzle Holder 1. Remove the over flow pipe (1). 2. Remove the nozzle holder clamps (2), nozzle holder assembly (3) and nozzle gaskets. (When reassembling) • Be sure to place the nozzle gaskets and the O-rings (4).
Page 156 M5040, M6040, M7040, WSM ENGINE Injection Nozzle Oil Seal (if necessary) 1. Remove the injection nozzle oil seal (2) from cylinder head cover (1). (When reassembling) • When installing the injection nozzle oil seal, use new one. (1) Cylinder Head Cover...
Page 157 M5040, M6040, M7040, WSM ENGINE 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 158: Thermostat
M5040, M6040, M7040, WSM ENGINE Valve 1. Remove the valve spring collets (2) after compressing the valve spring (3) with the valve spring retainer (1). (When reassembling) • Install the valve spring with its small-pitch end downward (at the cylinder head side).
Page 159: Injection Pump Unit
M5040, M6040, M7040, WSM ENGINE (4) Injection Pump Unit Injection Pump Unit (Removing the fuel injection pump unit) 1. Detach the window cover for the fuel injection pump unit (1) from the flywheel housing. 2. Place the piston of the 4th cylinder at the top dead center in the compression stroke.
Page 160 M5040, M6040, M7040, WSM ENGINE Injection Pump Unit (Continued) (Reassembling the fuel injection pump unit) 1. Place the piston of the 4th cylinder at the top dead center in the compression stroke. Fix the flywheel with the flywheel stopper. 2. Install the injection pump unit to the crankcase 1.
Page 161 M5040, M6040, M7040, WSM ENGINE Governor Housing Assembly 1. Remove the injection pump unit from the engine. (See the “Injection Pump Unit”.) 2. Remove the lubricating oil pipe (3). 3. Remove the stop solenoid (2). 4. Detach the sight cover (1) from the injection pump unit.
Page 162 M5040, M6040, M7040, WSM ENGINE Governor Fork Lever Assembly 1. Pull off the governor fork lever shaft (2) with the extra bolt (Dia : 4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (1). 2. Unhook the governor spring (3) at the governor fork lever (4) side.
Page 163 M5040, M6040, M7040, WSM ENGINE Governor Lever 1. Remove the spring pin (3). 2. Remove the speed control lever (2) and the return spring (1). 3. Remove the governor lever assembly (4) from the governor housing. 4. Remove the start spring (6).
Page 164 M5040, M6040, M7040, WSM ENGINE 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 (4). 4. Remove the fuel camshaft lock screws.
Page 165 M5040, M6040, M7040, WSM ENGINE Fuel Camshaft and Governor Weight (Continued) 1. Pull out the injection pump gear using gear puller. (Refer to “8. SPECIAL TOOLS” at “G. GENERAL” section.) 2. Loosen the fuel camshaft stopper mounting screws (2) and remove the fuel camshaft stopper (3).
Page 166 M5040, M6040, M7040, WSM ENGINE Replacing Injection Pump Assembly (If necessary) • The injection pump can be replaced with the crankshaft in whatever position. 1. Disconnect all injection pipes (2). 2. Disconnect the fuel hose (3) and fuel overflow pipe (1).
Page 167 M5040, M6040, M7040, WSM ENGINE Installing Procedure of Injection Pump Assembly 1. Install the fuel injection pump assembly (2) in its unit (1), and tighten the mounting screws and nuts. 2. Hook the governor connecting rod (4) to the rack pin of the injection pump assembly (5).
Page 168 M5040, M6040, M7040, WSM ENGINE Installing Procedure of Injection Pump Assembly (Continued) 1. Move the stop lever (1) and visually check to see if the fuel injection pump control rack comes smoothly back to the start position by the counter force of the start spring.
Page 169: Water Pump And Oil Cooler
M5040, M6040, M7040, WSM ENGINE (5) Water Pump and Oil Cooler Water Pump (if necessary) 1. Remove the water pump (1). (When reassembling) • When mounting the water pump, use the new water pump gasket. (1) Water Pump W1187742 Oil Cooler 1.
Page 170: Flywheel And Timing Gears
M5040, M6040, M7040, WSM ENGINE Relief Valve 1. Remove the relief valve retaining screw (5). 2. Remove the relief valve (2), the spring (3) and the packing (4). 68.6 to 78.4 N·m Relief valve retaining Tightening torque 7.0 to 8.0 kgf·m screw 50.6 to 57.9 lbf·ft...
Page 171 M5040, M6040, M7040, WSM ENGINE Flywheel Housing 1. Remove the outside flywheel housing mounting screws (2). 2. Set the flywheel housing guide screws (1). 3. Remove the inside flywheel housing mounting screws (3). 4. Remove the flywheel housing. (When reassembling) •...
Page 172 M5040, M6040, M7040, WSM ENGINE Camshaft and Idle Gear 1. Rotate the cylinder head side of the engine crankcase to the lower side. 2. Remove three set screws of the camshaft holder (7) and draw out the camshaft. 3. Remove the idle gear mounting screws (8) and draw out the idle gear.
Page 173: Piston And Connecting Rod
M5040, M6040, M7040, WSM ENGINE (8) 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 screws (3), and remove the oil strainer (4).
Page 174 M5040, M6040, M7040, WSM ENGINE 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 175 M5040, M6040, M7040, WSM ENGINE 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 (4) from the piston (3). (When reassembling) • Be sure to fix the crankpin bearing and the connecting rod are same I.D.
Page 176: Crankshaft And Crankcase
M5040, M6040, M7040, WSM ENGINE (9) Crankshaft and Crankcase Crankshaft and Crankcase 1. Remove the crankcase 2 mounting screw and crankcase 2 flange screw in the order of Z to A. 2. Remove the crankcase 2 (1) from the crankcase 1 (2).
Page 177 M5040, M6040, M7040, WSM ENGINE Crankshaft and Crankcase (Continued) (When reassembling) • Make sure the crankcase 1 (3) and 2 (1) are clean. • Reassemble the thrust bearing (2), with the oil groove facing outside, into both flywheel housing edge journal side of the crankcase 1 (3) and 2 (1).
Page 178: Servicing
M5040, M6040, M7040, WSM ENGINE [4] SERVICING (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head (remove the cylinder head gasket completely). 2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7...
Page 179 M5040, M6040, M7040, WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with the detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
Page 180 M5040, M6040, M7040, WSM ENGINE 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 181 M5040, M6040, M7040, WSM ENGINE 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 182 M5040, M6040, M7040, WSM ENGINE Valve Spring Setting Load 1. Place the valve spring on a tester and compress it to the same length it is actually compressed in the engine. 2. Read the compression load on the gauge. 3. If the measurement is less than the allowable limit, replace it.
Page 183 M5040, M6040, M7040, WSM ENGINE Replacing Bridge Arm Shaft 1. Remove the used bridge arm shaft. 2. Clean the bridge arm shaft mounting hole. 3. Using bridge arm shaft replacing tool (3), press in the new shaft (2). (Refer to “8. SPECIAL TOOLS” at “G. GENERAL” section.) (1) Bridge Arm A : 31.1 to 31.7 mm (1.22 to 1.25 in.)
Page 184: Timing Gears
M5040, M6040, M7040, WSM ENGINE (2) Timing Gears 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 185 M5040, M6040, M7040, WSM ENGINE Oil Clearance between Idle Gear Shaft and Idle Gear 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 186 M5040, M6040, M7040, WSM ENGINE Cam Height 1. Measure the height of the cam at its highest point with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. Intake 37.50 mm valve 1.4764 in.
Page 187 M5040, M6040, M7040, WSM ENGINE Balancer Shaft Side Clearance 1. Set a dial indicator with tip on the balancer shaft. 2. Measure the side clearance by moving the balancer shaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the balancer shaft.
Page 188 M5040, M6040, M7040, WSM ENGINE 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 bearing.
Page 189 M5040, M6040, M7040, WSM ENGINE Replacing Balancer Shaft Bearing 1. Remove the used balancer shaft bearings (1), (2), (3) and (4). 2. Set the new bearing to the balancer shaft bearing replacing tools. (Refer to “8. SPECIAL TOOLS” at “G. GENERAL” section.) Confirm that the cut off position of the bearing (C) matched with the pin of the replacing tool.
Page 190: Piston And Connecting Rod
M5040, M6040, M7040, WSM ENGINE (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
Page 191 M5040, M6040, M7040, WSM ENGINE Replacing Small End Bushing (When removing) 1. Press out the used bushing using a small end bushing replacing tool. (Refer to “8. SPECIAL TOOLS” at “G. GENERAL” section.) (When installing) 1. Clean a new small end bushing and bore, and apply engine oil to them.
Page 192 M5040, M6040, M7040, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the liner (the least worn part). 2. Measure the ring gap with a feeler gauge. 3. If the gap exceeds the allowable limit, replace the piston ring.
Page 193: Crankshaft
M5040, M6040, M7040, WSM ENGINE (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
Page 194 M5040, M6040, M7040, WSM ENGINE 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 195 M5040, M6040, M7040, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1. Clean the crankshaft journal (2) 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 196 M5040, M6040, M7040, WSM ENGINE Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve. 2. Set the sleeve guide (2) to the crankshaft gear (4). 3. Heat a new sleeve (3) to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown in figure.
Page 197: Cylinder
M5040, M6040, M7040, WSM ENGINE (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 198 M5040, M6040, M7040, WSM ENGINE 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 199 CLUTCH KiSC issued 06, 2008 A...
Page 200 MECHANISM CONTENTS 1. TRAVELING CLUTCH .................. 2-M1 [1] STRUCTURE ................... 2-M1 [2] OIL FLOW ....................2-M2 2. PTO CLUTCH ....................2-M3 [1] STRUCTURE ................... 2-M3 [2] OIL FLOW ....................2-M5 [3] PTO CLUTCH VALVE................2-M5 KiSC issued 06, 2008 A...
Page 201: Traveling Clutch
M5040, M6040, M7040, WSM CLUTCH 1. TRAVELING CLUTCH [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 (3) Damper Disc (5) Forward Side Clutch The damper disc (3) helps ease the shock load when engaging the shuttle clutch.
Page 202: Oil Flow
M5040, M6040, M7040, WSM CLUTCH [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 Contoller (C) Oil Cooler (D) PTO Clutch When the shuttle lever (4) shifts to the forward or reverse, the oil flows to the forward or reverse clutch (2), (3) respectively.
Page 203: Pto Clutch
M5040, M6040, M7040, WSM CLUTCH 2. PTO CLUTCH [1] STRUCTURE The PTO shift lever (1) and the PTO clutch valve (3) are connected by the PTO shift cable (2) as shown in the photo. When the PTO shift lever (1) is moved to the B side, the PTO clutch valve (3) is set at “Engaged”...
Page 204 M5040, M6040, M7040, WSM CLUTCH As shown in the figure above, the PTO propeller shaft 1 is splined to the spline hub and is always rotating while the engine is running. The PTO clutch pack has three clutch discs (6), three drive plates (7), a belleville washer (cupped spring washer) (9) and one pressure plate (5).
Page 205: Oil Flow
M5040, M6040, M7040, WSM CLUTCH [2] OIL FLOW When the PTO lever (3) is at the disengaged position, the oil flows is stopped by the PTO clutch valve (1). When the PTO lever (3) is at the engaged position, the oil flows through the PTO clutch valve (1) to the PTO clutch pack (2) to engage it.
Page 206 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 2. SERVICING SPECIFICATIONS ..............2-S4 3. TIGHTENING TORQUES ................2-S6 4. CHECKING AND ADJUSTING ..............2-S7 [1] TRAVELING CLUTCH ................2-S7 [2] PTO CLUTCH ..................2-S8 5. DISASSEMBLING AND ASSEMBLING ............2-S10 [1] PREPARATION ..................2-S10 (1) Separating Engine from Clutch Housing (ROPS Model) ....2-S10 (2) Separating Engine from Clutch Housing (CABIN Model)....2-S14 (3) Separating Clutch Housing from Transmission Case .......2-S19 (4) Removing PTO Clutch Valve ............2-S22...
Page 207: Troubleshooting
M5040, M6040, M7040, WSM CLUTCH 1. TROUBLESHOOTING TRAVELING CLUTCH (HYDRAULIC SHUTTLE MODEL) Reference Symptom Probable Cause Solution Page Shuttle Clutch Slip Operating pressure is low Adjust 2-S9, 3-S13 Shuttle clutch valve malfunctioning Replace 3-S26 Clutch disc or steel plate excessively worn...
Page 208 M5040, M6040, M7040, WSM CLUTCH TRAVELING CLUTCH (SYNCHRO SHUTTLE MODEL) Reference Symptom Probable Cause Solution Page Clutch Drags Clutch pedal free travel excessive Adjust 2-S7 Dust on clutch disc generated from clutch disc Remove rust 2-S23 facing Release fork broken...
Page 209 M5040, M6040, M7040, WSM CLUTCH PTO CLUTCH Reference Symptom Probable Cause Solution Page PTO Clutch Slip Operating pressure is low Adjust 2-S9 PTO clutch valve malfunctioning Repair or replace 2-S22 Clutch disc or drive plate excessively worn Replace 2-S25, 28...
Page 210: Servicing Specifications
M5040, M6040, M7040, WSM CLUTCH 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 –...
Page 211 M5040, M6040, M7040, WSM CLUTCH PTO CLUTCH Item Factory Specification Allowable Limit PTO Clutch Valve Relief Valve 2.16 to 2.26 MPa – Condition Setting Pressure 22 to 23 kgf/cm • Engine Speed Maximum 312.91 to 327.14 psi • Oil temperature 45 to 55 °C...
Page 212: Tightening Torques
M5040, M6040, M7040, WSM CLUTCH 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 213: Checking And Adjusting
M5040, M6040, M7040, WSM CLUTCH 4. CHECKING AND ADJUSTING [1] TRAVELING CLUTCH 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) lock nut (2) so that the free travel becomes 15.0 to 20.0 mm (0.59 to 0.79 in.).
Page 214: Pto Clutch
M5040, M6040, M7040, WSM CLUTCH [2] PTO CLUTCH PTO Clutch Lever Stroke 1. Be sure to contact the stopper pin (1) and PTO valve lever (2) when shifting the PTO clutch lever (5) to ON position. 2. If not making contact between the PTO valve lever (2) with stopper pin (1), adjust the PTO wire (4) retaining position with nuts (3).
Page 215 M5040, M6040, M7040, WSM CLUTCH Relief Valve Setting 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. • Set the parking brake lever in parking position.
Page 216 M5040, M6040, M7040, WSM CLUTCH 5. DISASSEMBLING AND ASSEMBLING [1] PREPARATION (1) Separating Engine from Clutch Housing (ROPS Model) Draining Fuel and Transmission Fluid 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL” section.
Page 217 M5040, M6040, M7040, WSM CLUTCH Propeller Shaft (4WD Model) 1. Slide the propeller shaft cover (3) after removing the screw (8). 2. Tap out the roll pins (2) and then slide the coupling (1) to the rear. (When reassembling) • Apply grease to the splines of the propeller shaft (5) and pinion shaft.
Page 218 M5040, M6040, M7040, WSM CLUTCH Accelerator Wire, Fuel Hose and Wire Harness 1. Disconnect the accelerator wire (4) and fuel hose (2). 2. Disconnect the wire harness from water temperature sensor (3), engine speed sensor (5) and glow plug (1).
Page 219 M5040, M6040, M7040, WSM CLUTCH Oil Cooler Pipe 1. Remove the oil cooler pipes (1) and (2). 2. Disconnect the power steering hoses (3). (When reassembling) 49.0 to 68.6 N·m Oil cooler pipe retaining 5.0 to 7.0 kgf·m 36.2 to 50.6 lbf·ft Tightening torque 22.6 to 27.5 N·m...
Page 220 M5040, M6040, M7040, WSM CLUTCH (2) Separating Engine from Clutch Housing (CABIN Model) Draining Fuel and Transmission Fluid 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL” section. W1095369 Bonnet 1. Open the bonnet (1) and disconnect the negative battery terminal.
Page 221 M5040, M6040, M7040, WSM CLUTCH Propeller Shaft (4WD Model) 1. Slide the propeller shaft cover (3) after removing the screw (8). 2. Tap out the roll pins (2) and then slide the coupling (1) to the rear. (When reassembling) • Apply grease to the splines of the propeller shaft (5) and pinion shaft.
Page 222 M5040, M6040, M7040, WSM CLUTCH Condenser and Compressor 1. Remove the air conditioner belt (2). 2. Remove the compressor (3) and condenser (4) without removing the air conditioner hoses. 3. Disconnect the heater hoses (1). (When reassembling) • Take care not to damage the air condenser fin.
Page 223 M5040, M6040, M7040, WSM CLUTCH Power Steering Pipe and Oil Cooler Pipe 1. Disconnect the power steering pipe (1). 2. Disconnect the oil cooler pipe (2). 3. Remove the steering joint shaft (3). 4. Disconnect the heater hoses (4). 5. Disconnect the breather hose (5) and grounding wire (6).
Page 224 M5040, M6040, M7040, WSM CLUTCH Separating Engine from Clutch Housing 1. Check the engine and clutch housing case are securely mounted on the disassembling stands. 2. Install the front axle rocking restrictor (1) (refer to “8. SPECIAL TOOLS” at “G. GENERAL” section) to the front axle bracket.
Page 225 M5040, M6040, M7040, WSM CLUTCH (3) Separating Clutch Housing from Transmission Case Removing Cabin from Body (CABIN Model) 1. Refer to “10. CABIN” section. W1044097 Removing ROPS Upper 1. Loosen the ROPS under frame (4) mounting screws. (Do not remove screws.) 2.
Page 226 M5040, M6040, M7040, WSM CLUTCH Hydraulic Control Rod, Shift Change Rod and Wire 1. Disconnect the position control rod (6) and draft control rod (5). 2. Remove the differential lock rod (4). 3. Disconnect the auxiliary hydraulic control wire (7) from auxiliary hydraulic control valve.
Page 227 M5040, M6040, M7040, WSM CLUTCH Separating Transmission Case 1. Make sure the clutch housing case and transmission case are securely mounted on the disassembling stands. 2. Remove the transmission case mounting screws and nuts. 3. Separate the transmission case from the clutch housing.
Page 228 M5040, M6040, M7040, WSM CLUTCH (4) Removing PTO Clutch Valve Draining Fuel 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL” section. W1046689 Rear Wheel (L.H.) and Fender (L.H.) 1. Place the disassembling stand under the transmission case.
Page 229 M5040, M6040, M7040, WSM CLUTCH [2] DAMPER DISC (HYDRAULIC SHUTTLE MODEL) Removing 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 230 M5040, M6040, M7040, WSM CLUTCH [4] PTO CLUTCH VALVE Disassembling PTO Clutch Valve (1) External Circlip (2) Lever (3) Oil Seal (4) External Circlip (5) Washer (6) Relief Sleeve (7) Relief Poppet (8) Push Pin (9) Spring Seat (10) Relief Body...
Page 231 M5040, M6040, M7040, WSM CLUTCH [5] 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 232 M5040, M6040, M7040, WSM CLUTCH 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 233 M5040, M6040, M7040, WSM CLUTCH 6. SERVICING [1] TRAVELING CLUTCH (HYDRAULIC SHUTTLE MODEL) Backlash between Damper Disc Boss and Shaft 1. Mount the damper disc to the input shaft. 2. Hold the shaft so that it does not turn. 3. Rotate disc lightly and measure the displacement around the disc edge.
Page 234 M5040, M6040, M7040, WSM CLUTCH Checking Pressure Plate Assembly and Flywheel 1. Wash the disassembling parts except clutch disc with a suitable cleaning solvent to remove dirt and grease before making inspection and adjustment. 2. Inspect the friction surface of pressure plate and flywheel for scoring or roughness.
Page 235 M5040, M6040, M7040, WSM CLUTCH Flatness of PTO Piston and PTO Steel Plate 1. Place the part on a surface plate. 2. Try to insert a feeler gauge (allowable limit size) underneath it at least four points. 3. If the gauge can be inserted, replace it.
Page 236 M5040, M6040, M7040, WSM CLUTCH 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 237 TRANSMISSION KiSC issued 06, 2008 A...
Page 238 MECHANISM CONTENTS 1. STRUCTURE ....................3-M1 [1] HYDRAULIC SHUTTLE MODEL ............3-M1 [2] SYNCHRO SHUTTLE MODEL .............. 3-M2 2. SHUTTLE SHIFT ..................3-M3 [1] HYDRAULIC SHUTTLE ................3-M3 [2] SYNCHRO SHUTTLE (DISC TYPE) ............ 3-M4 [3] HYDRAULIC SHUTTLE VALVE (HYDRAULIC SHUTTLE MODEL) .. 3-M7 (1) Structure ....................
Page 239: Structure
M5040, M6040, M7040, WSM TRANSMISSION 1. STRUCTURE [1] HYDRAULIC SHUTTLE MODEL F8/R8 Speed Transmission 3TMACAP3P001A (1) Damper (2) Hydraulic Shuttle Clutch (3) Main Gear Shift (4) Front Wheel Drive Shift (5) Range Gear Shift (6) PTO Clutch (7) PTO Gear Case...
Page 240: Synchro Shuttle Model
M5040, M6040, M7040, WSM TRANSMISSION [2] SYNCHRO SHUTTLE MODEL F8/R8 Speed Transmission 3TMACAP3P002A (1) Traveling Clutch (2) Shuttle Gear Shift (3) Main Gear Shift (4) Front Wheel Drive Shift (5) Range Gear Shift (6) PTO Clutch (7) PTO Gear Case...
Page 241: Shuttle Shift
M5040, M6040, M7040, WSM TRANSMISSION 2. SHUTTLE SHIFT [1] HYDRAULIC SHUTTLE The shuttle shift section allows the operators to change forward and reverse with a shuttle lever. It is using hydraulic clutch shifting. It also operaates as a reduction when shifting from forward to reverse.
Page 242: Synchro Shuttle (Disc Type)
M5040, M6040, M7040, WSM TRANSMISSION [2] SYNCHRO SHUTTLE (DISC TYPE) The shuttle shift section allows the operators to change forward and reverse with a shuttle lever. It uses a wet disc synchromesh type gear shift. (1) Input Shaft (5) Coupling...
Page 243 M5040, M6040, M7040, WSM TRANSMISSION First Stage An effort to place the shuttle lever to change the direction causes the shifter (5) and synchronizer keys (4) to move slightly. Then, the end surface of the synchronizer key (4) presses the holder 2 (3) against the plates (9) and discs (8).
Page 244 M5040, M6040, M7040, WSM TRANSMISSION Final Stage When the shifter (5) speed becomes the same as the holder 1 (2) and holder 2 (3) speed, the force of the holder 2 (3) in its rotating direction is not applied to the shifter (5) and the holder 2 (3) rotation is no longer transmitted to the shifter (5).
Page 245: Hydraulic Shuttle Valve (Hydraulic Shuttle Model)
M5040, M6040, M7040, WSM TRANSMISSION [3] HYDRAULIC SHUTTLE VALVE (HYDRAULIC SHUTTLE MODEL) (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...
Page 246: Operation
M5040, M6040, M7040, WSM TRANSMISSION (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...
Page 247 M5040, M6040, M7040, WSM TRANSMISSION 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 248 M5040, M6040, M7040, WSM TRANSMISSION 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 249 M5040, M6040, M7040, WSM TRANSMISSION 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 250 M5040, M6040, M7040, WSM TRANSMISSION 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...
Page 251: Lubrication For Transmission
M5040, M6040, M7040, WSM TRANSMISSION 3. LUBRICATION FOR TRANSMISSION [1] HYDRAULIC SHUTTLE MODEL Hydraulic shuttle section, main shift change synchromesh gears, hydraulic pump drive / driven gear, PTO hydraulic pack and PTO brake are forcedly lubricated. The lubrication oil from the PTO valve to PTO clutch holder and lubricate the each section through PTO propeller shaft and 1st shaft.
Page 252 M5040, M6040, M7040, WSM TRANSMISSION [2] SYNCHRO SHUTTLE MODEL Synchro shuttle section, main shift change synchromesh gears, hydraulic pump drive / driven gear, PTO hydraulic pack and PTO brake are forcedly lubricated. The lubrication oil from the PTO valve to PTO clutch holder and lubricate the each section through PTO propeller shaft and 1st shaft.
Page 253 SERVICING CONTENTS 1. TROUBLESHOOTING ..................3-S1 2. SERVICING SPECIFICATIONS ..............3-S2 3. TIGHTENING TORQUES ................3-S4 4. CHECKING AND ADJUSTING ..............3-S5 [1] SHUTTLE LEVER ..................3-S5 (1) Hydraulic Shuttle Model ..............3-S5 (2) Synchro Shuttle Model................3-S7 (3) Engine Start Condition ................3-S9 [2] MAIN GEAR SHIFTING ................3-S10 [3] SHUTTLE VALVE ..................3-S13 5.
Page 254 M5040, M6040, M7040, WSM TRANSMISSION 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive Transmission fluid insufficient Replenish G-10 Transmission Noise Improper backlash between bevel pinion shaft Adjust 3-S52 and bevel gear Improper backlash between differential pinion Adjust 3-S55 and side gear...
Page 255 M5040, M6040, M7040, WSM TRANSMISSION 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Gear on 1st Shaft (3rd-4th) Side Clearance Less than 0.2 mm – [Hydraulic Shuttle Model] 0.0078 in. Gear on 1st Shaft (1st-2nd) Side Clearance Less than 0.2 mm –...
Page 256 M5040, M6040, M7040, WSM TRANSMISSION Item Factory Specification Allowable Limit Differential Pinion Shaft to Differential Clearance 0.08 to 0.122 mm 0.25 mm Pinion 0.004 to 0.0048 in. 0.010 in. Differential Pinion Shaft O.D. 20.06 to 20.081 mm – 0.7898 to 0.79059 in.
Page 257 M5040, M6040, M7040, WSM TRANSMISSION 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 258: Hydraulic Shuttle Model
M5040, M6040, M7040, WSM TRANSMISSION 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 259 M5040, M6040, M7040, WSM TRANSMISSION 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 260: Synchro Shuttle Model
M5040, M6040, M7040, WSM TRANSMISSION (2) Synchro 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 261 M5040, M6040, M7040, WSM TRANSMISSION Adjusting Shuttle Shift Neutral Position and Lever Guide Neutral Position 1. The synchro shuttle shift rod is provided with F, N and R ball detents. (Lift the shuttle lever (1) and slowly move it to the F and R directions until you feel the lever clicking at the ball detents.)
Page 262: Engine Start Condition
M5040, M6040, M7040, WSM TRANSMISSION (3) 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 263: Main Gear Shifting
M5040, M6040, M7040, WSM TRANSMISSION [2] MAIN GEAR SHIFTING 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 264 M5040, M6040, M7040, WSM TRANSMISSION 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 265 M5040, M6040, M7040, WSM TRANSMISSION Checking Function of Range Shift (CABIN Model Only) 1. Check the function of the range gear shift. - Hi and Lo position. 2. If shift feels abnormal, check the length of range gear shift rod 1 (3) and 2 (1).
Page 266: Shuttle Valve
M5040, M6040, M7040, WSM TRANSMISSION [3] SHUTTLE VALVE Checking of Shuttle Valve System Pressure 1. Prepare a can for fuel, place in the fuel and fuel return hose into a can. 2. Remove the plugs of F, R, M and install the adaptor (refer to “8.
Page 267: Disassembling And Assembling
M5040, M6040, M7040, WSM TRANSMISSION 5. DISASSEMBLING AND ASSEMBLING [1] PREPARATION (1) Separating Engine and Clutch Housing Case (ROPS Model) Draining Transmission Fluid and Fuel 1. Refer to “7. CHECK MAINTENANCE” and “4. LUBRICANTS, FUEL AND COOLANT” at “G. GENERAL”...
Page 268 M5040, M6040, M7040, WSM TRANSMISSION Propeller Shaft (4WD Model) 1. Slide the propeller shaft cover (3) after removing the screw (8). 2. Tap out the roll pins (2) and then slide the coupling (1) to the rear. (When reassembling) • Apply grease to the splines of the propeller shaft (5) and pinion shaft.
Page 269 M5040, M6040, M7040, WSM TRANSMISSION Accelerator Wire, Fuel Hose and Wire Harness 1. Disconnect the accelerator wire (4) and fuel hose (2). 2. Disconnect the wire harness from water temperature sensor (3), engine speed sensor (5) and glow plug (1).
Page 270 M5040, M6040, M7040, WSM TRANSMISSION Oil Cooler Pipe 1. Remove the oil cooler pipes (1) and (2). 2. Disconnect the power steering hoses (3). (When reassembling) 49.0 to 68.6 N·m Oil cooler pipe retaining 5.0 to 7.0 kgf·m 36.2 to 50.6 lbf·ft Tightening torque 22.6 to 27.5 N·m...
Page 271: Separating Engine From Clutch Housing (Cabin Model)
M5040, M6040, M7040, WSM TRANSMISSION (2) Separating Engine from Clutch Housing (CABIN Model) Draining Fuel and Transmission Fluid 1. Refer to "7. CHECK MAINTENANCE" and "4. LUBRICANTS, FUEL AND COOLANT" at "G. GENERAL" section. W1013567 Bonnet 1. Open the bonnet (1) and disconnect the negative battery terminal.
Page 272 M5040, M6040, M7040, WSM TRANSMISSION Propeller Shaft (4WD Model) 1. Slide the propeller shaft cover (3) after removing the screw (8). 2. Tap out the roll pins (2) and then slide the coupling (1) to the rear. (When reassembling) • Apply grease to the splines of the propeller shaft (5) and pinion shaft.
Page 273 M5040, M6040, M7040, WSM TRANSMISSION Condenser and Compressor 1. Remove the air conditioner belt (2). 2. Remove the compressor (3) and condenser (4) without removing the air conditioner hoses. 3. Disconnect the heater hoses (1). (When reassembling) • Take care not to damage the air condenser fin.
Page 274 M5040, M6040, M7040, WSM TRANSMISSION Power Steering Pipe and Oil Cooler Pipe 1. Disconnect the power steering pipe (1). 2. Disconnect the oil cooler pipe (2). 3. Remove the steering joint shaft (3). 4. Disconnect the heater hoses (4). 5. Disconnect the breather hose (5) and grounding wire (6).
Page 275 M5040, M6040, M7040, WSM TRANSMISSION Separating Engine from Clutch Housing 1. Check the engine and clutch housing case are securely mounted on the disassembling stands. 2. Install the front axle rocking restrictor (1) (refer to “8. SPECIAL TOOLS” at “G. GENERAL” section) to the front axle bracket.
Page 276: Separating Clutch Housing From Transmission Case
M5040, M6040, M7040, WSM TRANSMISSION (3) Separating Clutch Housing from Transmission Case Removing Cabin from Body (CABIN Model) 1. Refer to “10. CABIN” section. W1014893 Removing ROPS Upper 1. Loosen the ROPS under frame (4) mounting screws. (Do not remove screws.) 2.
Page 277 M5040, M6040, M7040, WSM TRANSMISSION Hydraulic Control Rod, Shift Change Rod and Wire 1. Disconnect the position control rod (6) and draft control rod (5). 2. Remove the differential lock rod (4). 3. Disconnect the auxiliary hydraulic control wire (7) from auxiliary hydraulic control valve.
Page 278: Removing Shuttle Valve Assembly
M5040, M6040, M7040, WSM TRANSMISSION Hydraulic Pipe 1. Remove the 3-point hitch delivery pipe 2 (3). 2. Remove the 3-point hitch delivery pipe 1 (2) with outlet block (1). (When reassembling) 107.9 to 117.7 N·m 3-point hitch delivery pipe Tightening torque 11.0 to 12.0 kgf·m...
Page 279 M5040, M6040, M7040, WSM TRANSMISSION Shuttle Valve Assembly 1. Disconnect the shuttle cable (1). 2. Disconnect the clutch cable (2) and spring (3). 3. Remove the DT rod (4). 4. Remove the shuttle valve pipe (7). 5. Remove the external circlips (6) and plate (5).
Page 280: Hydraulic Shuttle Clutch
M5040, M6040, M7040, WSM TRANSMISSION [2] HYDRAULIC SHUTTLE CLUTCH Shuttle Case Assembly 1. Remove the shuttle case mounting screws and nuts. 2. Remove the shuttle case assembly (1) by using M10 x Pitch 1.25 mm screws into holes (a) and guide screws (2).
Page 281 M5040, M6040, M7040, WSM TRANSMISSION Disassembling Shuttle Clutch Assembly 1. Remove the ball bearing (1) and collar (2). 2. Remove the 29T gear (4). 3. Remove the oil seal (9) and external circlip (10). 4. Tap out the input shaft (8) with shuttle clutch (6).
Page 282 M5040, M6040, M7040, WSM TRANSMISSION Piston 1. Press the washer (4) lightly by the hand press, using the hand made jig (refer to the figure left), and remove the external circlip (3). 2. Remove the springs (7). 3. Draw out the piston (5) using a air pressure.
Page 283: Synchro Shuttle Gear
M5040, M6040, M7040, WSM TRANSMISSION [3] SYNCHRO SHUTTLE GEAR Release Holder and Clutch Release Lever 1. Remove the release holder and clutch release lever (refer to “5. DISASSEMBLING AND ASSEMBLING” at “2. CLUTCH” section). W1015185 Neutral Switch and Shuttle Shift Lever 1.
Page 284 M5040, M6040, M7040, WSM TRANSMISSION Shuttle Gear Case with Shuttle Gears 1. Remove the shuttle gear case mounting screws and nuts. 2. Remove the shuttle gear case with shuttle gears as a unit by using M10 x Pitch 1.25 mm screws into threaded hole (a) and guide screws (2).
Page 285 M5040, M6040, M7040, WSM TRANSMISSION Shuttle Gear Case 1. Unscrew the detent screw (1) and remove the spring (2) and ball (3). 2. Tap out the input shaft (6) and remove the input shaft assembly with shift fork (4) and rod (5).
Page 286 M5040, M6040, M7040, WSM TRANSMISSION Input Shaft and Shuttle Shaft 1. Remove the bearing (1) and external circlip (2) from input shaft (15). 2. Draw out the 27T gear (4) to forward. 3. Remove the external circlip (12) and draw out the coupling (14).
Page 287 M5040, M6040, M7040, WSM TRANSMISSION Assembling Procedure for Disc Type Synchromesh 1. Install the holder 1 (1) to gear (2). 2. Install the disc (3) and steel plates (4) alternately. 3. Install the holder 2 (5). NOTE • Apply enough transmission fluid to the clutch disc.
Page 288: Clutch Housing
M5040, M6040, M7040, WSM TRANSMISSION [4] CLUTCH HOUSING Shift Change Cover 1. Set the main change shift lever (3) and range shift lever (2) to the neutral position. 2. Remove the shift change cover (1) mounting screws. 3. Screw in a M12 x 1.25 mm screw into threaded hole (a) to remove the shift cover (1).
Page 289 M5040, M6040, M7040, WSM TRANSMISSION 37T Gear and 35T Gear 1. Remove the external circlip (1) and 37T gear (2). 2. Remove the external circlip (4) and 35T gear (3). (When reassembling) • Check the clearance (L) between external circlip (1) and adjusting collar (5).
Page 290 M5040, M6040, M7040, WSM TRANSMISSION PTO Shaft and Bearing Holder 1. Draw out the PTO shaft (1) with 33T gear (3). 2. Remove the bearing holder mounting screws. 3. Screw in a M12 x 1.25 mm screw (4) into threaded hole (a) to remove the bearing holder (2).
Page 291 M5040, M6040, M7040, WSM TRANSMISSION 1st Shaft Assembly 1. Remove the bearing (1) and external circlip (2). 2. Draw out the 1st-2nd synchronizer unit and gears. 3. Remove the bearing (25). 4. Draw out the 3rd-4th synchronizer unit and gears.
Page 292 M5040, M6040, M7040, WSM TRANSMISSION (1) Bearing (23) Inner Race (2) External Circlip (24) Collar (3) Collar (25) Bearing (4) 37T Gear (26) 1st Shaft (5) Coupling (1-2 Speed) (27) Without Teeth (6) Shifter (28) Teeth (7) Synchronizer Key (29) Coupling (1-2 Speed) for Hydraulic...
Page 293 M5040, M6040, M7040, WSM TRANSMISSION DT Gear and Shaft 1. Tap out the roll pin (3) and remove the DT shift lever (4). 2. Remove the DT shift arm (6) retaining plate (2). 3. Pull the DT shift arm (6) to outside.
Page 294: Removing Pto Clutch Valve
M5040, M6040, M7040, WSM TRANSMISSION [5] TRANSMISSION CASE Removing PTO Clutch Valve 1. Remove the PTO clutch valve (1). (When reassembling) • Apply transmission fluid to O-ring and hydraulic pipes (2). • Remove the two hydraulic pipes from the PTO clutch holder.
Page 295 M5040, M6040, M7040, WSM TRANSMISSION Removing Rear Axle Case 1. Remove the rear axle case mounting screws and nuts. 2. Remove the rear axle case assembly (1). (When reassembling) • Apply liquid gaskets (Three Bond 1206C or equivalent) to joint face.
Page 296: Differential Gear
M5040, M6040, M7040, WSM TRANSMISSION Differential Gear Assembly 1. Remove the differential support (2), noting the number of shims (1). 2. Take out the differential gear assembly (3) from transmission case. (When reassembling) • Be sure to adjust the turning torque of spiral bevel pinion shaft (refer to “6.
Page 297 M5040, M6040, M7040, WSM TRANSMISSION 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 298: Pto Gear Case
M5040, M6040, M7040, WSM TRANSMISSION [7] PTO GEAR CASE Disassembling PTO Gear Case (1) Staking Nut (2) PTO Shaft (3) Oil Seal W1021401 1. Remove the stake of staking nut and remove the staking nut (1). 2. Tap out the PTO shaft (2) to the rear side.
Page 299: Servicing
M5040, M6040, M7040, WSM TRANSMISSION 6. SERVICING [1] BEARING, SHIFT FORK AND SYNCHRONIZER 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 300: Shuttle Clutch Pack (Hydraulic Shuttle Model)
M5040, M6040, M7040, WSM TRANSMISSION [2] SHUTTLE CLUTCH PACK (HYDRAULIC SHUTTLE MODEL) 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.
Page 301: Shuttle Clutch Pack (Synchro Shuttle Model)
M5040, M6040, M7040, WSM TRANSMISSION [3] SHUTTLE CLUTCH PACK (SYNCHRO SHUTTLE MODEL) Clearance between Shift Fork and Shifter Groove 1. Measure the width of shift fork. 2. Measure the shifter groove width, and calculate the clearance. 3. If the clearance exceeds the allowable limit, replace them.
Page 302 M5040, M6040, M7040, WSM TRANSMISSION Clearance between Holder 2 and Coupling 1. Measure the clearance (L) between holder 2 and coupling with a feeler gauge. 2. If the clearance (L) exceeds the factory specification, adjust the clearance using different thickness of steel plate.
Page 303: Shift And Gear
M5040, M6040, M7040, WSM TRANSMISSION [4] SHIFT AND GEAR Side Clearance of 1st-2nd Gear and 3rd-4th Gear on 1st Shaft (Hydraulic Shuttle Model) 1. Measure the side clearance (L1) between external circlip (4) and adjusting collar (1). 2. If clearance (L1) exceeds the factory specification, adjust the clearance using adjusting collar (1).
Page 304: Differential Gear
M5040, M6040, M7040, WSM TRANSMISSION [5] DIFFERENTIAL GEAR IMPORTANT • When reassembling spiral bevel pinion shaft and differential assembly, be sure to adjust the following. • Turning torque of spiral bevel pinion shaft only. • Backlash and tooth contact between spiral bevel pinion shaft and spiral bevel gear.
Page 305 M5040, M6040, M7040, WSM TRANSMISSION 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 306 M5040, M6040, M7040, WSM TRANSMISSION 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 307 M5040, M6040, M7040, WSM TRANSMISSION Clearance between Differential Case Bore (39T Bevel Gear Bore) and Differential Side Gear Boss 1. Measure the bore I.D. of the differential case and 39T bevel gear. 2. Measure the differential side gear boss O.D. and calculate the clearance.
Page 308 M5040, M6040, M7040, WSM TRANSMISSION 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 309: Rear Axle
REAR AXLE KiSC issued 06, 2008 A...
Page 310 MECHANISM CONTENTS 1. STRUCTURE ....................4-M1 KiSC issued 06, 2008 A...
Page 311 M5040, M6040, M7040, WSM REAR AXLE 1. STRUCTURE (1) Rear Axle (5) Differential Case (9) 39T Bevel Gear (13) 27T Planetary Gear (2) Rear Axle Case (6) Differential Side Gear (10) Differential Gear (14) 66T Internal Gear (3) Planetary Gear Support...
Page 312 SERVICING CONTENTS 1. TROUBLESHOOTING ..................4-S1 2. SERVICING SPECIFICATIONS ..............4-S2 3. TIGHTENING TORQUES ................4-S3 4. DISASSEMBLING AND SERVICING............4-S4 [1] PREPARATION ..................4-S4 (1) Separating Rear Axle Case from Transmission Case ......4-S4 [2] DISASSEMBLING AND ASSEMBLING..........4-S5 (1) Rear Axle Case ...................4-S5 [3] SERVICING ....................4-S7 KiSC issued 06, 2008 A...
Page 313: Troubleshooting
M5040, M6040, M7040, WSM REAR AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive or Improper backlash between planetary gear and Replace 4-S5, 7 Unusual Nose at All internal gear Time Bearing worn Replace 4-S5, 7 Insufficient or improper type of transmission fluid...
Page 314: Servicing Specifications
M5040, M6040, M7040, WSM REAR AXLE 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 315: Tightening Torques
M5040, M6040, M7040, WSM REAR AXLE 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 316: Disassembling And Servicing
M5040, M6040, M7040, WSM REAR AXLE 4. DISASSEMBLING AND SERVICING [1] PREPARATION (1) Separating Rear Axle Case from Transmission Case Draining Fuel and Transmission Fluid 1. Refer to "7. CHECK MAINTENANCE" and "4. LUBRICANTS, FUEL AND COOLANT" at "G. GENERAL"...
Page 317: Disassembling And Assembling
M5040, M6040, M7040, WSM REAR AXLE Hydraulic Cylinder 1. Disconnect the cylinder hose (4) and return hose (5). 2. Remove the pin 1 (1), pin 2 (3) and hydraulic cylinder (2). (When reassembling) 34.3 to 48.1 N·m Tightening torque Cylinder hose retaining nut 3.5 to 4.9 kgf·m...
Page 318 M5040, M6040, M7040, WSM REAR AXLE 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 319 M5040, M6040, M7040, WSM REAR AXLE [3] SERVICING 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 320 M5040, M6040, M7040, WSM REAR AXLE 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 321 BRAKES KiSC issued 06, 2008 A...
Page 322 MECHANISM CONTENTS 1. STRUCTURE ....................5-M1 KiSC issued 06, 2008 A...
Page 323 M5040, M6040, M7040, WSM BRAKES 1. STRUCTURE (1) Brake Shaft (4) Plate (6) Spring (8) Brake Cam (2) Brake Plate (5) Cam Plate (7) Ball (9) Brake Cam Lever (3) Brake Disc These tractors are used hanging type brake pedals to have wider space of the platform.
Page 324: Servicing
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) Brake Pedal ..................5-S4 [2] DISASSEMBLING AND ASSEMBLING..........5-S4 (1) Separating Rear Axle Case from Transmission Case ......5-S4 (2) Removing Brake Disc and Plate ............5-S6 [3] SERVICING ....................5-S7 KiSC issued 06, 2008 A...
Page 325: Troubleshooting
M5040, M6040, M7040, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Uneven Braking Brake pedal free travel unevenly adjusted Adjust 5-S4 Force Brake disc worn Replace 5-S6, 7 Cam plate warped Replace 5-S6, 7 Brake Drags Brake pedal free travel too small...
Page 326: Servicing Specifications
M5040, M6040, M7040, WSM BRAKES 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Brake Pedal Free Travel 40 to 45 mm – 1.6 to 1.8 in. Cam Plate Flatness – 0.3 mm 0.012 in. Cam Plate and Ball Height 25.45 to 25.55 mm 25.00 mm...
Page 327: Tightening Torques
M5040, M6040, M7040, WSM BRAKES 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 328: Checking, Disassembling And Servicing
M5040, M6040, M7040, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Brake Pedal Brake Pedal Free Travel CAUTION • Stop the engine and remove the key, then choke the wheel before checking brake pedal. 1. Release the parking brake.
Page 329 M5040, M6040, M7040, WSM BRAKES Lift Rod, Lower Link, Rear Wheel (L.H.) and Fender (L.H.) 1. Place the disassembling stand under the transmission case. 2. Remove the lift rod (3) and lower link (4). 3. Remove the rear wheel (2) (L.H.).
Page 330: Removing Brake Disc And Plate
M5040, M6040, M7040, WSM BRAKES (2) Removing Brake Disc and Plate Brake Shaft, Brake Disc and Brake Plate 1. Draw out the brake shaft (5) with brake disc (1) and steel plate (3). 2. Remove the external circlip (4). 3. Remove the brake plate (2), collars (7) and pins (8).
Page 331: Servicing
M5040, M6040, M7040, WSM BRAKES [3] SERVICING Cam Plate Flatness 1. Place the cam plate on the surface plate. 2. Measure the flatness of cam plate with a feeler gauge at four points on a diagonal line. 3. If the measurement exceeds the allowable limit, replace it.
Page 332: Front Axle
FRONT AXLE KiSC issued 06, 2008 A...
Page 333 MECHANISM CONTENTS 1. STRUCTURE ....................6-M1 [1] 2 WHEEL DRIVE ................... 6-M1 [2] 4 WHEEL DRIVE ................... 6-M2 [3] LIMITED SLIP DIFFERENTIAL (LSD) [M7040] ........6-M3 KiSC issued 06, 2008 A...
Page 334 M5040, M6040, M7040, WSM FRONT AXLE 1. STRUCTURE The front axle supports the front of tractor and facilitates steering. There are two kinds of front axles. The two-wheel drive axle has free-running front wheels and four-wheel drive axle has powered front wheels.
Page 335 M5040, M6040, M7040, WSM FRONT AXLE [2] 4 WHEEL DRIVE (1) Front Axle Case Support (5) Front Axle (9) Differential Yoke Shaft (12) Propeller Shaft (2) 18T Bevel Gear (6) 10T Bevel GEar (10) Differential Gear Assembly (13) 9T Bevel Pinion Shaft...
Page 336 M5040, M6040, M7040, WSM FRONT AXLE [3] LIMITED SLIP DIFFERENTIAL (LSD) [M7040] (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)
Page 337 SERVICING CONTENTS 1. TROUBLESHOOTING ..................6-S1 2. SERVICING SPECIFICATIONS ..............6-S2 3. TIGHTENING TORQUES ................6-S5 4. CHECKING, DISASSEMBLING AND SERVICING........6-S6 [1] CHECKING AND ADJUSTING ...............6-S6 [2] PREPARATION ..................6-S8 (1) Separating Front Axle [2WD Model] ...........6-S8 (2) Separating Front Axle [4WD Model] ...........6-S8 [3] DISASSEMBLING AND ASSEMBLING..........6-S10 (1) Disassembling Front Axle [2WD Model] ...........6-S10 (2) Disassembling Front Axle [4WD Model] ...........6-S12...
Page 338: Troubleshooting
M5040, M6040, M7040, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Tire pressure uneven Adjust G-78 Wander to Right or Improper toe-in adjustment (improper alignment) Adjust 6-S6 Left Clearance between front axle case boss and...
Page 339: Servicing Specifications
M5040, M6040, M7040, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS [2WD] Item Factory Specification Allowable Limit Toe-in 1.0 to 5.0 mm – 0.04 to 0.20 in. Front Wheel Steering Angle 0.925 to 0.960 rad – 53 to 55 ° Axial Sway Less than 5.0 mm...
Page 340 M5040, M6040, M7040, WSM FRONT AXLE [4WD] 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 341 M5040, M6040, M7040, WSM FRONT AXLE 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 342: Tightening Torques
M5040, M6040, M7040, WSM FRONT AXLE 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.)
Page 343: Checking, Disassembling And Servicing
M5040, M6040, M7040, WSM FRONT AXLE 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 344 M5040, M6040, M7040, WSM FRONT AXLE Adjusting Front Axle Pivot 1. Jack up the tractor body, then loosen the front axle rocking force adjusting lock nut (2). 2. Measure the adjusting screw tightening torque. 3. If tightening torque is not within the factory specifications, adjust the front axle rocking force adjusting screw (1).
Page 345: Preparation
M5040, M6040, M7040, WSM FRONT AXLE [2] PREPARATION (1) Separating Front Axle [2WD Model] Front Wheel and Power Steering Hoses 1. Check the front axle and engine are securely mounted on the disassembly stand. 2. Loosen the front wheel mounting nuts.
Page 346 M5040, M6040, M7040, WSM FRONT AXLE Propeller Shaft 1. Slide the propeller shaft cover (3) after removing the screw (8). 2. Tap out the roll pins (2) and then slide the coupling (1) to the rear. (When reassembling) • Apply grease to the splines of the propeller shaft (5) and pinion shaft.
Page 347: Disassembling And Assembling
M5040, M6040, M7040, WSM FRONT AXLE 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.
Page 348 M5040, M6040, M7040, WSM FRONT AXLE Tie-rod 1. Pull out the cotter pin and loosen the tie-rod end nut. 2. Disconnect the tie-rod (1) with a tie-rod end lifter (2) (Code No. 07909-39051). 3. Remove the tie-rod end nut and tie-rod end.
Page 349: Disassembling Front Axle [4Wd Model]
M5040, M6040, M7040, WSM FRONT AXLE (2) Disassembling Front Axle [4WD Model] Tie-rod 1. Pull out the cotter pin and remove the tie-rod end slotted nuts. 2. Remove the tie-rod with a tie-rod end lifter (Code No. 07909- 39051). (When reassembling) •...
Page 350 M5040, M6040, M7040, WSM FRONT AXLE Front Wheel Case Cover 1. Remove the front wheel case cover (1) from the front wheel case (4). (When reassembling) • Apply transmission fluid to the O-ring. • Install the shim (3) to its original position.
Page 351 M5040, M6040, M7040, WSM FRONT AXLE Front Axle 1. Take out the collar (5). 2. Tap out the axle (1). (When reassembling) • Install the oil seal (8) of front wheel case cover (2), noting its direction as shown in the figure below.
Page 352: Removing Differential Gear And Bevel Pinion Shaft
M5040, M6040, M7040, WSM FRONT AXLE (3) Removing Differential Gear and Bevel Pinion Shaft Bevel Pinion Shaft 1. Remove the front bracket (2) and rear bracket (1). 2. Remove the oil seal (3), internal circlip (4). 3. Pull out the bevel pinion shaft (6) using a slide hammer (8).
Page 353: Disassembling Differential Gear
M5040, M6040, M7040, WSM FRONT AXLE (4) Disassembling Differential Gear Spiral Bevel Gear 1. Remove the external circlip (6) and the 21T 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 354 M5040, M6040, M7040, WSM FRONT AXLE 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 355: Servicing
M5040, M6040, M7040, WSM FRONT AXLE [4] SERVICING (1) 2WD Model Clearance between Front Axle Middle Boss and Bracket Bushing 1. Measure the front axle middle boss O.D. at several points where it contacts with the bushings. 2. Measure the front axle bracket (front) bushing I.D. and bracket (rear) bushing I.D.
Page 356: 4Wd Model
M5040, M6040, M7040, WSM FRONT AXLE (2) 4WD Model 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 357 M5040, M6040, M7040, WSM FRONT AXLE 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 358 M5040, M6040, M7040, WSM FRONT AXLE Backlash between Differential Pinion and Differential Side Gear 1. Put the fuse (2) on the pinion gear (1). 2. Turn the pinion gear (1) to mash the fuse. 3. Measure the thickness of fuse.
Page 359 M5040, M6040, M7040, WSM FRONT AXLE 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 360 M5040, M6040, M7040, WSM FRONT AXLE Turning Torque of Spiral Bevel Pinion Shaft (Pinion Shaft Only) 1. Install the spiral bevel pinion shaft assembly only to the front axle case. 2. Measure the turning torque of spiral bevel pinion shaft.
Page 361 M5040, M6040, M7040, WSM FRONT AXLE Slip Torque of LSD Disc 1. Set the differential assembly in 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 362 M5040, M6040, M7040, WSM FRONT AXLE 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 363 M5040, M6040, M7040, WSM FRONT AXLE 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 364 M5040, M6040, M7040, WSM FRONT AXLE 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.
Page 365 STEERING KiSC issued 06, 2008 A...
Page 366 MECHANISM CONTENTS 1. STEERING MECHANISM ................7-M1 2. STEERING CYLINDER................. 7-M2 KiSC issued 06, 2008 A...
Page 367 M5040, M6040, M7040, WSM STEERING 1. STEERING MECHANISM (1) Hydraulic Pump (3) Steering Cylinder (5) Power Steering Pipe a : To Oil Cooler and PTO Valve (2) Steering Controller (4) Power Steering Hose (6) Magnet Filter b : To 3-point Hydraulic System All models are provided with a full hydrostatic power steering.
Page 368: Steering Cylinder
M5040, M6040, M7040, WSM STEERING 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 [A] 2WD Model...
Page 369 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-S5 [2] PREPARATION ..................7-S6 (1) Removing Power Steering Hydraulic Pump ........7-S6 (2) Removing Power Steering Controller (ROPS Model) ......7-S7 (3) Removing Steering Controller (CABIN Model)........7-S8 (4) Removing Power Steering Cylinder (2WD Model) ......7-S9...
Page 370: Troubleshooting
M5040, M6040, M7040, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Tractor Cannot Be Drive shaft in the power steering controller Reassemble 7-S14 Steered improper assembled Pipe broken Replace – Hard Steering Oil improper Change with G-10 specified oil...
Page 371: Servicing Specifications
M5040, M6040, M7040, WSM STEERING 2. SERVICING SPECIFICATIONS POWER STEERING PUMP Item Factory Specification Allowable Limit Hydraulic Pump Delivery Above 18.0 L/min. Condition 21.4 L/min. 4.76 U.S.gals./min. • Engine Speed Above 3.96 Imp.gals./min. −1 2600 min (rpm) 5.65 U.S.gals./min. • Rated Pressure Above 18.1 MPa...
Page 372: Tightening Torques
M5040, M6040, M7040, WSM STEERING 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 373: Checking, Disassembling And Servicing
M5040, M6040, M7040, WSM STEERING 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Steering Controller Relief Valve Setting Pressure 1. Disconnect one of the delivery hose 1 from steering cylinder and set a pressure gauge (3) (Code No. 07916-50321) between them using power steering adaptor (1) (Code No.
Page 374: Hydraulic Pump
STEERING (2) 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 375: Removing Power Steering Hydraulic Pump
M5040, M6040, M7040, WSM STEERING 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 376: Removing Power Steering Controller (Rops Model)
M5040, M6040, M7040, WSM STEERING (2) Removing Power Steering Controller (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 (4). 4. Remove the bonnet (1) and side cover (3) (R.H) (L.H.).
Page 377: Removing Steering Controller (Cabin Model)
M5040, M6040, M7040, WSM STEERING Steering Controller 1. Disconnect the shuttle cable (7). 2. Disconnect the power steering delivery hose 1 (1) and hose 2 (2) from power steering controller. 3. Disconnect the oil cooler pipes (2), (3). 4. Remove the steering controller mounting screws (5) and steering controller (6).
Page 378: Removing Power Steering Cylinder (2Wd Model)
M5040, M6040, M7040, WSM STEERING Steering Controller 1. Disconnect the power steering pipe (2) and oil cooler pipe (1). 2. Disconnect the power steering delivery hoses (3), (4). 3. Remove the steering joint shaft mounting screw (5). 4. Remove the steering controller mounting screws and steering controller (6).
Page 379 M5040, M6040, M7040, WSM STEERING Steering Cylinder 1. Remove the cylinder cover. 2. Disconnect the power steering delivery hoses (3). 3. Remove the cylinder clamps (1). 4. Take out the steering cylinder (2). (When reassembling) • If the hose joint (4) was removed, apply teflon tape and fix the direction as shown in the figure.
Page 380: Removing Steering Cylinder (4Wd Model)
M5040, M6040, M7040, WSM STEERING (5) Removing Steering Cylinder (4WD Model) Tie-rod 1. Remove the both cylinder covers (1). 2. Disconnect the both power steering delivery hoses (2) from cylinder. 3. Remove the both hose joints (3) from steering cylinder.
Page 381 M5040, M6040, M7040, WSM STEERING Steering Cylinder 1. Remove the both tie-rod joints (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 382: Disassembling And Assembling
M5040, M6040, M7040, WSM STEERING [3] DISASSEMBLING AND ASSEMBLING (1) Hydraulic Pump Hydraulic Pump 1. Put the parting marks (1), (3), (5), (7) on the flange (6), housing (4), housing (8) and housing cover (2). 2. Unscrew the housing cover mounting screw and separate the flange (6) and housing cover (2) from the housing (4).
Page 383: Steering Controller
M5040, M6040, M7040, WSM STEERING (2) 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). 3. Remove the rotor (9), O-ring (5) between the distributor plate and stator (6).
Page 384 M5040, M6040, M7040, WSM STEERING 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 385: Disassembling Steering Cylinder
M5040, M6040, M7040, WSM STEERING (3) Disassembling Steering Cylinder Steering Cylinder (2WD Model) 1. Carefully clamp the cylinder in a vise. 2. Remove the cylinder guide assembly (1) and draw out the piston rod (4). (When reassembling) • Apply transmission fluid to the oil seal and O-ring.
Page 386: Servicing
M5040, M6040, M7040, WSM STEERING [4] SERVICING Steering Cylinder I.D. 1. Measure the steering cylinder I.D. with a cylinder gauge. 2. If the cylinder I.D. exceeds the allowable limit, replace the cylinder barrel. 50.000 to 50.062 mm Factory spec. 1.9686 to 1.9709 in.
Page 387: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 06, 2008 A...
Page 388 MECHANISM CONTENTS 1. STRUCTURE ....................8-M1 2. HYDRAULIC CIRCUIT .................. 8-M2 [1] TOTAL HYDRAULIC CIRCUIT .............. 8-M2 (1) Hydraulic Shuttle Model ..............8-M2 (2) Synchro Shuttle Model............... 8-M3 3. THREE POINT HITCH HYDRAULIC SYSTEM.......... 8-M4 [1] THREE POINT HITCH HYDRAULIC CIRCUIT........8-M4 [2] HYDRAULIC BLOCK ................
Page 389: Structure
(6) 3-point Hitch Delivery Pipe 1 Valve The hydraulic system of the M5040, M6040 and M7040 tractor is composed of a 3-point hitch, remote hydraulic control for implements, power steering, PTO clutch and shuttle clutch. This system has the following functions.
Page 390: Pto Clutch Pack
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 2. HYDRAULIC CIRCUIT [1] TOTAL HYDRAULIC CIRCUIT (1) Hydraulic Shuttle Model (1) Auxiliary Control Valve (7) Oil Cooler (14) Relief Valve for 3-point Hitch (19) Hydraulic Pump (for 3-point (2) Control Valve (for 3-point...
Page 391: Pto Clutch Pack
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM (2) Synchro Shuttle Model (1) Auxiliary Control Valve (7) Oil Cooler (12) Oil Cooler Check Valve (17) Hydraulic Oil Filter Cartridge (2) Control Valve (for 3-point (8) PTO Clutch Pack (13) Exterior Hydraulic Cylinder...
Page 392: Three Point Hitch Hydraulic System
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 3. THREE POINT HITCH HYDRAULIC SYSTEM [1] THREE POINT HITCH HYDRAULIC CIRCUIT (1) Auxiliary Control Valve (2) Control Valve (3) Cylinder Safety Valve (4) Lowering Speed Adjusting Valve (5) Hydraulic Cylinder (Exterior) (6) Relief Valve...
Page 393: Hydraulic Block
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [2] HYDRAULIC BLOCK (1) Relief Valve (5) Lift 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 394: Linkage Mechanism
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [3] LINKAGE MECHANISM (1) Position Lever Shaft 1 (2) Position Link 1 (3) Position Link 2 (4) Position Lever Shaft 2 (5) Draft Link (6) Draft Link Shaft (7) Spool Drive Lever (Draft) (8) Spool Drive Lever (Position)
Page 395: Position Control
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM (1) Position Control (1) Position Lever Shaft 1 (5) Control Valve (9) Lift Arm A : Lift (2) Position Link 1 (6) Spool (10) Position Feedback Rod B : Down (3) Position Link 2...
Page 396: Draft Control
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM (2) Draft Control (1) Draft Link (6) Draft Feedback Lever (10) Draft Lever (14) Top Link Holder (2) Draft Link Shaft (7) Control Valve (11) Lift Arm (3) Spool Drive Lever (Draft) (8) Draft Control Valve...
Page 397: Hydraulic Cylinder
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [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 398 SERVICING CONTENTS 1. TROUBLESHOOTING ..................8-S1 2. SERVICING SPECIFICATIONS ..............8-S2 3. TIGHTENING TORQUES ................8-S4 4. CHECKING AND ADJUSTING ..............8-S5 [1] HYDRAULIC PUMP (FOR THREE POINT HITCH)......8-S5 [2] RELIEF AND SAFETY VALVE ..............8-S6 [3] POSITION AND DRAFT CONTROL LINKAGE ........8-S8 5. DISASSEMBLING AND ASSEMBLING ............8-S13 [1] HYDRAULIC PUMP ................8-S13 [2] THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY....8-S14 (1) Removing 3-point Hitch Hydraulic Block (ROPS Model) ....8-S14...
Page 399: Troubleshooting
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not Control linkage improperly assembled or Repair or replace 8-S17 Raise (Not Noise) damaged Control valve malfunctioning (unload valve, Repair or replace 8-S20 spool, check valve, poppet valve)
Page 400: Servicing Specifications
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS HYDRAULIC PUMP Item Factory Specification Allowable Limit Hydraulic Pump for Three Point Linkage Delivery Above 32.2 L/min. Condition 38.3 L/min. 8.51 U.S.gals/min. • Engine speed : 10.12 U.S.gals/min. 7.08 Imp.gals/min. Approx. 2600 min (rpm) 8.42 Imp.gals/min.
Page 401 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM CONTROL VALVE Item Factory Specification Allowable Limit Spool Joint Length 24.5 to 25.0 mm – 0.9646 to 0.9842 in. W1013874 LIFT ARM AND TOP LINK BRACKET Bushing Press-fit Location 11.0 mm – 0.433 in.
Page 402: Tightening Torques
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 403: Checking And Adjusting
4. CHECKING AND ADJUSTING [1] HYDRAULIC PUMP (FOR THREE POINT HITCH) Hydraulic Flow Test IMPORTANT • When using flowmeter other than KUBOTA specified flowmeter, be sure to use the instructions with the flowmeter. • Do not close the flowmeter loading valve completely, before testing, because it has no relief valve.
Page 404: Relief And Safety Valve
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM Hydraulic Flow Test (Continued) Condition • Engine speed : Approx. 2600 min (rpm) • Rated pressure : 18.6 MPa 190 kgf/cm 2703 psi • Oil temperature : 50 to 60 °C 122 to 140 °F Above 39.1 L/min.
Page 405 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 406: Position And Draft Control Linkage
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [3] POSITION AND DRAFT CONTROL LINKAGE 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). IMPORTANT •...
Page 407 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 408 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 engine speed at maximum speed. 3. Operate the position control lever to the uppermost position.
Page 409 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM Draft Lever Free Range 1. Attach the weight (2) 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 410 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM Draft Floating Range Check 1. Attach the weight (2) 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 (3).
Page 411: Disassembling And Assembling
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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. Remove the differential lock rod (7).
Page 412: Three Point Hitch Hydraulic Block Assembly
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [2] THREE POINT HITCH HYDRAULIC BLOCK ASSEMBLY (1) Removing 3-point Hitch Hydraulic Block (ROPS Model) Preparation 1. Remove the seat (1) and seat support (2). 2. Disconnect the auxiliary control valve wire (3). 3. Disconnect the cylinder hoses (6), (8).
Page 413 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM Removing 3-point Hitch Hydraulic Block Assembly 1. Remove the 3-point hitch hydraulic block mounting screws and nuts. 2. Remove the 3-point hitch hydraulic block assembly with nylon lift strap and hoist. (When reassembling) • Apply liquid gasket (Three Bond 1206C or equivalent) to joint face of transmission case and cylinder block.
Page 414: Removing 3-Point Hitch Hydraulic Block (Cabin Model)
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM (2) Removing 3-point Hitch Hydraulic Block (CABIN Model) Preparation 1. Park the tractor on a flat place. 2. Place the disassembling stand under the transmission case and rear axle. 3. Remove the rear wheel (R.H.).
Page 415: Hydraulic Linkage
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM Removing 3-Point Hitch Hydraulic Block 1. Remove the rear cabin mounting bolts (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. 2. Remove the 3-point hitch hydraulic block mounting screws and nuts.
Page 416 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 417 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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). 2. Remove the draft feedback rod (2) with draft feedback lever (5).
Page 418: Control Valve
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [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 disassemble the spool joint 1 (3) from the spool (4) unless necessary.
Page 419 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM Disassembling Control Valve 1. Secure the control valve with a vise. 2. Remove the seat plug 1 (1) then take out the spring (2) and poppet (3). 3. Remove the spring plate (6) and spring (7).
Page 420: Hydraulic Cylinder
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [5] HYDRAULIC CYLINDER Removing Hydraulic Cylinder 1. Remove the lift rod pin (2). 2. Disconnect the hydraulic hose (3) from hydraulic cylinder (5). 3. Remove the cylinder cover (7). 4. Disconnect the return hose (6).
Page 421 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 422: Relief Valve
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [6] RELIEF VALVE Disassembling Relief Valve 1. Remove the relief valve assembly (1). 2. Secure the relief valve assembly (1) in a vise. 3. Loosen the lock nut (10). 4. Remove the adjuster (9), and remove the spring (8) and then pilot valve (7).
Page 423: Lift Arm And Lift Arm Shaft
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM [8] LIFT ARM AND LIFT ARM SHAFT Disassembling 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 424: Servicing
M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 425 M5040, M6040, M7040, WSM HYDRAULIC SYSTEM 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 426 ELECTRICAL SYSTEM KiSC issued 06, 2008 A...
Page 427 MECHANISM CONTENTS 1. WIRING DIAGRAM ..................9-M1 [1] MAIN HARNESS (ROPS MODEL) ............9-M1 [2] MAIN HARNESS (CABIN MODEL)............9-M2 [3] CABIN HARNESS (CABIN MODEL)............. 9-M3 [4] ENGINE HARNESS (CABIN MODEL)..........9-M4 2. ELECTRICAL CIRCUIT RETAILED CHART..........9-M5 [1] INSTRUMENT PANEL BOARD (METER PANEL) ......9-M5 [2] ROPS MODEL ..................
Page 428: Wiring Diagram
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] MAIN HARNESS (ROPS MODEL) Main Key Switch Engine Traveling Engine Engine Oil Coolant Display Mode GLOW Meter Panel Seat Speed Rotation Fuel Pressure Switch Temperature Select Switch Buzzer Switch START...
Page 429: Main Harness (Cabin Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [2] MAIN HARNESS (CABIN MODEL) Main Key Switch Blower Motor (-) (+) Engine Harness Cabin Harness Blower Motor Resistor Blower Harness Meter Panel 10 11 12 14 15 17 18 19 20 Option 21 22...
Page 430: Cabin Harness (Cabin Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [3] CABIN HARNESS (CABIN MODEL) Main Harness 0.85 G/B Front Flasher Lamp L.H. 0.85 B 0.5 Y/B 0.5 G/W 0.5 B/Y 0.5 B 0.5 W/B 0.5 B 0.85 G/B 0.5 L/Or Rear Hazard Lamp L.H. Upper 0.5 G/B...
Page 431: Engine Harness (Cabin Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [4] ENGINE HARNESS (CABIN MODEL) Main Harness Light Harness 0.85 B 0.5 B 0.5 B 0.85 B Front Side Working Light L.H. 0.85 W/R 0.85 W/R 0.85 W/R 0.85 W/R 0.85 Br 0.85 Br 0.85 Or...
Page 432: Electrical Circuit Retailed Chart
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 2. ELECTRICAL CIRCUIT RETAILED CHART [1] INSTRUMENT PANEL BOARD (METER PANEL) 0.5R/G 0.5R/G (20) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (21) (22) 0.5R/G (25) (26) (27) (23) (24) (28) (29) 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0.5B/W...
Page 433: Rops Model
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [2] ROPS MODEL (1) Starting System, Charging System and Working Light 3R/B 3R/W 3R/W (10) 5W/R GLOW START (16) 0.5R/W 0.5W/G (22) (17) (15) (23) (11) FREE LOCK 0.85Y/R 0.85R 0.85P/W (18) 0.85B/Y (20)
Page 434: Lighting System
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (2) Lighting System 0.85Lg/B 0.85G 0.85Lg/B 0.5Br 0.5Or FREE B2 R L B1 T 1 LOCK 0.5B/R 0.5Br 0.85Or 0.85Or 0.85B 0.5G/B 0.5R/B 0.85R/B 0.5G/W 0.5G/W 0.85G/B 0.85G/B 0.85R/B 0.85G/W 0.85G/W (10) (13) (14) 1.25Y...
Page 435: Cabin Model
M5040, M6040, M7040 WSM ELECTRICAL SYSTEM [3] CABIN MODEL (1) Starting System and Charging System 3R/B 3R/B 3R/W 3R/W 3W/R 3W/R 3R/L 3R/L 3R/Y 3R/Y 3R/L 3R/B 2R/B 5R/B 5A 10A (14) 5W/R AM ACC M GL ST (11) 0.5R/W 0.5R/W...
Page 436: Lighting System
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (2) Lighting System 0.85G 0.5Br 0.5Br 0.5R/B 0.85Or FREE LOCK 0.5R/B 0.85Br 0.85Or DOOR 0.5B/P 0.85B (10) 0.5G/B 0.5R/B 0.5G/W 0.85G/B 0.85G/B 0.85R/B 0.85R/B 0.85G/W 0.85G/W 0.5G/W 0.85G/B 0.85R/B 0.85G/B 0.85G/W 0.85G/W 0.5L/W 0.5L/W...
Page 437: Working Light, Radio And Defogger
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (3) Working Light, Radio and Defogger If equipped 0.5L/Y (20) (14) (17) 0.5Or 0.5Y/R (12) (16) (18) (21) (19) FREE FULL (13) (11) (22) (23) (24) (10) (15) 3TMACAN9P070A (1) Working Light Relay (5) Front Working Lamp R.H.
Page 438: Air Conditioner
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (4) 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 439: Wiper System
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (5) Wiper System Option 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 3TMACAN9P072A (1) Front Wiper Motor (2) Front Wiper Motor Relay (3) Front Wiper Switch (4) Front Wiper Relay/Timer...
Page 440: Wiring Color
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [4] WIRING COLOR B ... Black Br/B ..Brown / Black Or/W ..Orange / White G ..Green Br/Y ..Brown / Yellow R/B .... Red / Black L ... Blue Br/R ..Brown / Red R/G ....
Page 441: Starting System
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 3. STARTING SYSTEM [1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT (1) ROPS Model (1) Battery (2) Starter Motor (3) Starter Relay (4) Alternator (5) Glow Relay (6) Glow Plug (7) Neutral Safety Switch (Shuttle) (8) Main Switch...
Page 442: Cabin Model
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (2) CABIN Model (1) Battery (2) Starter Motor (3) Starter Relay (4) Alternator (5) Glow Relay (6) Glow Plug (7) Neutral Safety Switch (Shuttle) (8) Main Switch (9) PTO Safety Relay (10) PTO Switch...
Page 443: Instrument Panel
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 4. INSTRUMENT PANEL [1] INDICATION ITEMS OF METER PANEL (1) Hazard/Turn Signal Indicator (2) PTO Clutch Indicator (3) Liquid Crystal Display (4) Electrical Charge Indicator (5) Engine Oil Pressure Indicator (6) Tachometer (7) 4WD Indicator...
Page 444: Easy Checker (Tm)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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 445: Lcd Monitor Indication
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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 446: Setting Mode
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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)
Page 447: Checking Mode
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (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 448: Opc (Operator Presence Control)
(B) Alternator W1014680 M5040, M6040 and M7040 tractors equip operator presence control (OPC) system which automatically whistling when operator stands from the seat while engaging PTO clutch. This system is controlled by the seat switch (3), CPU (2), PTO switch (4) and buzzer (5).
Page 449: Lighting System
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 6. LIGHTING SYSTEM [1] COMPONENTS (1) Flasher Unit Flasher Unit Flusher unit controls the blinking frequency as a only one side of lamp blinking of turn signal and both right and left side lamps blinking of hazard signal.
Page 450: Trailer Socket
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 7. 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...
Page 451 SERVICING CONTENTS 1. TROUBLESHOOTING ..................9-S1 2. SERVICING SPECIFICATIONS ..............9-S5 3. TIGHTENING TORQUES ................9-S6 4. CHECKING AND ADJUSTING ..............9-S7 [1] BATTERY, FUSE, GROUNDING AND CONNECTOR......9-S7 (1) Battery....................9-S7 (2) Checking Fuse ..................9-S9 (3) Checking Grounding Wires ...............9-S11 (4) Connector ..................9-S11 [2] MAIN SWITCH ..................9-S12 (1) Main Switch (ROPS Model) ..............9-S12 (2) Main Switch (CABIN Model) .............9-S13 [3] GLOW PLUG ..................9-S15...
Page 452: Troubleshooting
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Recharge or replace 9-S8 Equipments Do Not Battery positive cable disconnected or Repair or replace 9-S7 Operate improperly connected Battery negative cable disconnected or...
Page 453 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown Replace G-37, 38 Light Bulb blown Replace G-39 Wiring harness disconnected or improperly Repair or replace 9-S29, 30 connected Illumination Light...
Page 454 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM EASY CHECKER Reference Symptom Probable Cause Solution Page Engine Oil Pressure Engine oil pressure too low Repair 1-S15 Lamp Lights Up Engine oil insufficient Replenish G-10 When Engine is Engine oil pressure switch defective...
Page 455 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM ENGINE KEY SWITCH SHUT-OFF SYSTEM Reference Symptom Probable Cause Solution Page Engine Does Not Fuse blown Replace G-37, 38 Stop When Main Key stop relay defective Replace 9-S36 Switch Is Turned Engine stop relay defective...
Page 456: Servicing Specifications
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS STARTER MOTOR Item Factory Specification Allowable Limit Commutator O.D. 32.0 mm 31.4 mm 1.2598 in. 1.2362 in. Mica Undercut 0.50 to 0.80 mm 0.2 mm 0.0197 to 0.0315 in. 0.0079 in.
Page 457: Tightening Torques
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 458: Checking And Adjusting
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 459: Battery
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 460 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 461 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 462: Checking Grounding Wires
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (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 463: Main Switch
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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 464: Main Switch (Cabin Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 465 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 466: Glow Plug
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [3] GLOW PLUG Glow Plug 1. Disconnect the leads from the glow plugs. 2. Measure the resistance with an ohmmeter across the glow plug terminal and chassis. 3. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.
Page 467: Engine Stop Solenoid
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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.
Page 468: Alternator
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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 469: Meter Panel
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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 470 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 471 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 472 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 473: Checking Mode
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (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 474: Checking Meter Panel, Pto/Hour Meter Select Switch And Traveling Speed Select Switch
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (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 475 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM Connector (40P) of Wire Harness Side Terminal Color of Terminal Name Measuring across T40 (Ground) Condition wiring Heater relay Battery voltage Main switch at ON Br/R Engine stop relay Battery voltage Main switch at ON...
Page 476: Switch And Sensor
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 477 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM PTO Switch 1) Wiring Harness 1. Disconnect the leads from the PTO switch (1). 2. Connect the wiring harness lead terminals to each other and turn the main switch to “ON” position. 3. If the indicator do not light, the fuse, wiring harness or bulb is faulty.
Page 478 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 479 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM Engine Rotation Sensor and Travel Speed Sensor 1. Check the engine speed meter and travel 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 480: Lighting Switches And Flasher Unit
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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.
Page 481: Lever Combination Switch (Cabin Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (2) Lever Combination 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 482: Hazard Switch
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (3) Hazard Switch Checking Connector Voltage 1. Connect the battery negative code, then measure the voltage with a voltmeter across the terminal a and chassis. 2. If the voltage differ from the battery voltage, the wiring harness is faulty.
Page 483: Flasher Unit
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (4) Flasher Unit Connector Voltage 1. Disconnect the flusher unit connector. 2. Measure the voltage with voltmeter across the wiring harness connector's terminal 5 and chassis. 3. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.
Page 484: Front Work Light Switch (Rops Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM Functional Check 1. Turn on the turn signal switch (2) or hazard switch (3). 2. Count the number of blinking. 3. If the factory specification is not indicated, replace the flusher unit. Times of blinking light Factory spec.
Page 485: Front And Rear Work Light Switch (Cabin Model)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (6) Front and Rear Work 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 486: Starter Relay And Glow Relay
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [9] RELAYS (1) Starter Relay and Glow 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 487: Relays (Pto Safety, Key Stop, Work Light, Auxiliary Power, A/C Compressor And A/C)
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM (2) Relays (PTO Safety, Key Stop, Work Light, Auxiliary Power, A/C Compressor and A/C) 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 488: Opc (Operator Presence Control) System
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM Functional Check NOTE • The relays described here are used same ones so that these are interchangeable. 1. Apply battery voltage across the terminals a and c, and check for continuity across the terminals d and e.
Page 489 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM Buzzer 1. Remove the buzzer (1). 2. Connect the jumper lead across the battery positive terminal and terminal 1 of connector. 3. Connect the jumper lead across the battery negative terminal and terminal 2 of connector.
Page 490: Disassembling And Assembling
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 491 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 492 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 493: Fuse (Slow Blow 100 A) For Cabin Model
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM [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 494: Servicing
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 495 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 496: Alternator
M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 497 M5040, M6040, M7040, WSM ELECTRICAL SYSTEM 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 498 CABIN KiSC issued 06, 2008 A...
Page 499 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 500: Air Conditioning System
M5040, M6040, M7040, WSM CABIN 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...
Page 501 M5040, M6040, M7040, WSM CABIN [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 502: Air Conditioner Unit
M5040, M6040, M7040, WSM CABIN [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 503: System Control
M5040, M6040, M7040, WSM CABIN [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 504: Air Flow
M5040, M6040, M7040, WSM CABIN [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 505: Electrical System
M5040, M6040, M7040, WSM CABIN [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...
Page 506: Blower Relay And Compressor Relay
M5040, M6040, M7040, WSM CABIN (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 507: Blower Switch
M5040, M6040, M7040, WSM CABIN (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 508 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 509: Troubleshooting
M5040, M6040, M7040, WSM CABIN 1. TROUBLESHOOTING COMPRESSOR Reference Symptom Probable Cause Solution Page Noisy Bearing of compressor worn or damaged Replace 10-S39, 40 (Compressor ON) Valves in compressor damaged Replace 10-S39, 40 Belt slipping Adjust or replace G-24 Compressor bracket mounting screws loosen Tighten –...
Page 510 M5040, M6040, M7040, WSM CABIN AIR CONDITIONING SYSTEM (Continued) Reference Symptom Probable Cause Solution Page Insufficient Cooling Belt slipping Adjust or replace G-24 (Compressor Does Magnetic clutch defective Repair or replace 10-S22 Not Rotate Properly) Compressor defective Replace 10-S38 Insufficient Cooling...
Page 511 M5040, M6040, M7040, WSM CABIN 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-S39, 40 Compressor gasket damaged...
Page 512 M5040, M6040, M7040, WSM CABIN 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 513: Servicing Specifications
M5040, M6040, M7040, WSM CABIN 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 514: Tightening Torques
M5040, M6040, M7040, WSM CABIN 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 515: Precautions At Repairing Refrigerant Cycle
M5040, M6040, M7040, WSM CABIN 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 516: Handling Of Service Tools
M5040, M6040, M7040, WSM CABIN (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 <PAG* oil> 10 cc Receiver 0.011 U.S.qts. 0.009 Imp.qts. 10 cc Hose 0.011 U.S.qts.
Page 517 M5040, M6040, M7040, WSM CABIN 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 518: Refrigerant Charging Hose
M5040, M6040, M7040, WSM CABIN (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 519: Vacuum Pump Adaptor
M5040, M6040, M7040, WSM CABIN (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 520: Can Tap Valve
M5040, M6040, M7040, WSM CABIN (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 521: Checking And Charging Refrigerant Cycle
M5040, M6040, M7040, WSM CABIN 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 522 M5040, M6040, M7040, WSM CABIN 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 523 M5040, M6040, M7040, WSM CABIN 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 524 M5040, M6040, M7040, WSM CABIN 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 525: Discharging, Evacuating And Charging
M5040, M6040, M7040, WSM CABIN 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 526: Evacuating The System
M5040, M6040, M7040, WSM CABIN (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 527: Charging The Refrigerant
M5040, M6040, M7040, WSM CABIN (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 528 M5040, M6040, M7040, WSM CABIN 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 529: Checking Charge Refrigerant Amount
M5040, M6040, M7040, WSM CABIN (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 530: Checking, Disassembling And Servicing
M5040, M6040, M7040, WSM CABIN 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 531: Wiper Relay
M5040, M6040, M7040, WSM CABIN (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 532: Control Panel (Blower Switch, A/C Switch, Mode Control Dial, Temperature Control Dial And Recirculation/Fresh Air Selection Switch)
M5040, M6040, M7040, WSM CABIN (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 533 M5040, M6040, M7040, WSM CABIN 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 534 M5040, M6040, M7040, WSM CABIN 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 535: Blower Resistor
M5040, M6040, M7040, WSM CABIN (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 536: Temperature Motor
M5040, M6040, M7040, WSM CABIN (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 537: Recirculation/Fresh Air Motor
M5040, M6040, M7040, WSM CABIN (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.
Page 538: Pressure Switch
M5040, M6040, M7040, WSM CABIN (10) Pressure Switch Pressure Switch 1) HI Pressure Side 1. Connect the manifold gauge (5) to compressor as following procedure. Close the HI and LO pressure valves (3), (4) of manifold gauge tightly, and connect the charging hoses (2), (1) (red and blue) to the respective compressor service valves.
Page 539: Front Wiper Switch
M5040, M6040, M7040, WSM CABIN (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 540: Rear Wiper Switch (If Equipped)
M5040, M6040, M7040, WSM CABIN (13) Rear Wiper Switch (If Equipped) Connector Voltage 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 541: Disassembling And Assembling
M5040, M6040, M7040, WSM CABIN [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 542 M5040, M6040, M7040, WSM CABIN Preparation 2 Without discharging the refrigerant from system 1. Remove the air conditioner belt (2). 2. Remove the compressor (3) and condenser (4) without removing the air conditioner hoses. 3. Disconnect the heater hoses (1).
Page 543 M5040, M6040, M7040, WSM CABIN Preparation 4 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 544 M5040, M6040, M7040, WSM CABIN Preparation 5 1. Disconnect the clutch cable (1). 2. Disconnect the shuttle cable (2). 3. Remove the brake rod (3) (R.H., L.H.). 4. Remove the 4WD shift rod (4). (When reassembling) • Be sure to adjust the clutch cable for the clutch pedal free travel.
Page 545 M5040, M6040, M7040, WSM CABIN Preparation 6 1. Place the disassembling stand under the transmission case and drawbar bracket. 2. Remove the rear wheels (R.H., L.H.). 3. Remove the fuel tank (1). 4. Disconnect the shuttle cable (2) and clutch cable (3).
Page 546 M5040, M6040, M7040, WSM CABIN Preparation 7 1. Disconnect the position control rod (1) and draft control rod (2). 2. Disconnect the select cable (4). 3. Remove the differential lock rod (3). 4. Disconnect the range gear shift rod (5).
Page 547: Removing Compressor Assembly
M5040, M6040, M7040, WSM CABIN (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 548 M5040, M6040, M7040, WSM CABIN 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 549: Removing Air Conditioner Unit
M5040, M6040, M7040, WSM CABIN (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 550 M5040, M6040, M7040, WSM CABIN Air Conditioner Ducts and Covers 1. Remove the duct 1 (1). 2. Remove the DT shift lever grip (2). 3. Remove the inner cover (L.H.) (3). 4. Remove the duct 2 (4). 5. Remove the seat under cover 1 (5).
Page 551: Removing Air Conditioner Pipes
M5040, M6040, M7040, WSM CABIN Air Conditioning Unit 1. Disconnect the heater hoses (1). 2. Remove the pressure pipes joint mounting screw and pressure pipes joint. 3. Disconnect the high pressure pipe 2 (3) and low pressure pipe (2). 4. Take off the unit.
Page 552 M5040, M6040, M7040, WSM CABIN High Pressure Pipe 1, 2 and Low Pressure Pipe 1. Disconnect the low pressure pipe (3) and high pressure pipe 1 (1) from the compressor (2), then cap the open fittings immediately to keep moisture out of the system.
Page 553: Removing Heater Hoses
M5040, M6040, M7040, WSM CABIN (5) Removing Heater Hoses Draining Coolant 1. Refer to “[2] DISASSEMBLING AND ASSEMBLING” in this section. W1034298 Side Cover (R.H.) and Heater Hoses 1. Remove the side cover (R.H.) (1). 2. Disconnect the heater hoses (2) and (3) from the engine.
Page 554 M5040, M6040, M7040, WSM CABIN 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 555: 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 556 M5040, M6040, M7040, WSM CABIN 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 557: Wiper Motor
M5040, M6040, M7040, WSM CABIN (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 558: Servicing
M5040, M6040, M7040, WSM CABIN 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 559 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 Printed in Japan 2008. 05, S, EI, EI, e Code No.9Y011-13746 KUBOTA Corporation 2006.

This manual is also suitable for:

M7040 M6040

Kubota M5040 Workshop Manual

General

1 Tractor Identification

2 General Precautions

3 Handling Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Maintenance

7 Check and Maintenance

8 Special Tools

9 Tires

10 Implement Limitations

Mechanism

1 Feature

2 Engine Body

3 Lubricating System

4 Cooling System

5 Fuel System

Servicing

Mechanism

1 Traveling Clutch

2 Pto Clutch

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

Mechanism

1 Structure

2 Shuttle Shift

3 Lubrication for Transmission

Servicing

Servicing

Servicing

Servicing

Servicing

Mechanism

1 Structure

2 Hydraulic Circuit

3 Three Point Hitch Hydraulic System

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

5 Disassembling and Assembling

6 Servicing

Mechanism

1 Wiring Diagram

2 Electrical Circuit Retailed Chart

3 Starting System

4 Instrument Panel

5 Opc (Operator Presence Control)

6 Lighting System

7 Trailer Socket

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

5 Disassembling and Assembling

6 Servicing

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

Related Manuals for Kubota M5040

Summary of Contents for Kubota M5040