wsm M6040 Workshop Manual

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WORKSHOP MANUAL

TRACTOR

M6040,M7040

KiSC issued 07, 2012 A

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Summary of Contents for wsm M6040

Page 1 WORKSHOP MANUAL TRACTOR M6040,M7040 KiSC issued 07, 2012 A...
Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the M6040 and M7040. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing".  Information This section primarily contains information below. • Safety First •...
Page 3 INFORMATION KiSC issued 07, 2012 A...
Page 4: Table Of Contents
INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-4 3. SPECIFICATIONS........................I-10 4. TRAVELING SPEEDS........................I-12 5. DIMENSIONS ..........................I-13 KiSC issued 07, 2012 A...
Page 5: Safety First
M6040, M7040, WSM INFORMATION 1. SAFETY FIRST 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 6 M6040, M7040, WSM INFORMATION OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
Page 7 M6040, M7040, WSM INFORMATION KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 8: Safety Decals
M6040, M7040, WSM INFORMATION 2. SAFETY DECALS The following safety decals (pictorial safety labels) are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
Page 9 M6040, M7040, WSM INFORMATION 9Y1210143INI0002US0 KiSC issued 07, 2012 A...
Page 10 M6040, M7040, WSM INFORMATION 9Y1210143INI0003US0 KiSC issued 07, 2012 A...
Page 11 M6040, M7040, WSM INFORMATION CABIN Model 9Y1210143INI0004US0 KiSC issued 07, 2012 A...
Page 12 M6040, M7040, WSM INFORMATION 9Y1210143INI0005US0 KiSC issued 07, 2012 A...
Page 13 M6040, M7040, WSM INFORMATION 9Y1210143INI0006US0 KiSC issued 07, 2012 A...
Page 14: Specifications
M6040, M7040, WSM INFORMATION 3. SPECIFICATIONS M6040 M7040 M7040DTH-SPA Model Model V3307-DI-TE3 Type Vertical, water-cooled, 4-cycle direct injection diesel engine Number of cylinders Total displacement 3331 cm (203 cu.in.) Bore and stroke 94 × 120 mm (3.7 × 4.7 in.)
Page 15 M6040, M7040, WSM INFORMATION M6040 M7040 M7040DTH-SPA Model Direction of Clockwise, viewed from tractor rear turning Live PTO (Independent) 6 spline: 540 min (rpm) / 2160 min (rpm) engine speed PTO speed 6 spline: 540E min (rpm) / 1825 min...
Page 16: Traveling Speeds
M6040, M7040, WSM INFORMATION 4. TRAVELING SPEEDS (At rated engine rpm) Model M6040 / M7040 M7040DTH-SPA Tire size (Rear) 420/85R30 (16.9R30) 420/70R28 Shuttle shift Range gear Main gear shift km/h (mph) km/h (mph) lever shift lever lever 0.43 (0.27) 0.40 (0.25) 0.61 (0.38)
Page 17: Dimensions
M6040, M7040, WSM INFORMATION 5. DIMENSIONS ROPS Model 9Y1210143INI0009US0 I-13 KiSC issued 07, 2012 A...
Page 18 M6040, M7040, WSM INFORMATION CABIN Model 9Y1210143INI0010US0 I-14 KiSC issued 07, 2012 A...
Page 19 GENERAL KiSC issued 07, 2012 A...
Page 20 GENERAL CONTENTS 1. TRACTOR IDENTIFICATION....................... G-1 [1] MODEL NAME AND SERIAL NUMBERS ................G-1 [2] ENGINE NUMBER ......................... G-2 [3] E3B ENGINE .......................... G-3 [4] CYLINDER NUMBER ......................G-3 2. GENERAL PRECAUTIONS......................G-4 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ........G-5 [1] WIRING ..........................
Page 21 (2) Rear Wheels ........................G-82 [3] WHEEL HUB ........................G-83 [4] TIRE LIQUID INJECTION..................... G-84 10. IMPLEMENT LIMITATIONS ....................... G-87 [1] IMPLEMENT CAPACITY ...................... G-88 [2] TRAILER LOAD CAPACITY ....................G-90 KiSC issued 07, 2012 A...
Page 22: Tractor Identification
M6040, M7040, WSM GENERAL 1. TRACTOR IDENTIFICATION [1] MODEL NAME AND SERIAL NUMBERS 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 23: Engine Number
M6040, M7040, WSM GENERAL [2] ENGINE NUMBER Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows. Year of manufacture...
Page 24: E3B Engine
M6040, M7040, WSM GENERAL [3] E3B ENGINE [Example: Engine Model Name V3307-DI-T-] The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission regulations depends on the engine output classification.
Page 25: General Precautions
M6040, M7040, WSM GENERAL 2. GENERAL PRECAUTIONS • When you disassemble, carefully put the parts in a clean area to make it easy to find the parts. You must install the screws, bolts and nuts in their initial position to prevent the reassembly errors.
Page 26: Handling Precautions For Electrical Parts And Wiring
M6040, M7040, WSM 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 wiring for damage and loosened connection every year.
Page 27 M6040, M7040, WSM GENERAL • Securely insert grommet. (1) Grommet (A) Correct (B) Incorrect WSM000001GEG0066US1 • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US1 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 28: Battery
M6040, M7040, WSM GENERAL [2] BATTERY • Take care not to confuse positive and negative terminal posts. • When removing battery cables, disconnect negative cable first. When installing battery cables, check for polarity and connect positive cable first. • Do not install any battery with capacity other than is specified (Ah).
Page 29: Handling Of Circuit Tester
M6040, M7040, WSM 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 WSM000001GEG0075US1 • Make certain that there is no female connector being too open.
Page 30: Color Of Wiring
M6040, M7040, WSM GENERAL [6] COLOR OF WIRING • Colors of wire are specified to the color codes. • This symbol of "/" shows color with stripe(s). (An example) Red stripe on white color: W/R Color of wiring Color code...
Page 31: Lubricants, Fuel And Coolant
M6040, M7040, WSM GENERAL 4. LUBRICANTS, FUEL AND COOLANT Capacity Place Lubricants, fuel and coolant ROPS CABIN 90 L 70 L 23.8 • No. 2-D diesel fuel Fuel tank 18.5 U.S.gals U.S.gals • No. 1-D diesel fuel if temperature 15.4 Imp.gals 19.8...
Page 32 M6040, M7040, WSM GENERAL Greasing Place No. of greasing point Capacity Type of grease Front axle gear case support Front axle support Top link Top link bracket Multipurpose NLGI-2 or Until grease overflows NLGI-1 (GC-LB) grease Lift rod Hydraulic lift cylinder...
Page 33 M6040, M7040, WSM GENERAL NOTE Engine Oil • Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above. • With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-sulfur fuel on on-road vehicle engines.
Page 34: Tightening Torques
M6040, M7040, WSM GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt...
Page 35: Hydraulic Fittings
M6040, M7040, WSM GENERAL [3] HYDRAULIC FITTINGS (1) Hydraulic Hose Fittings Tightening torque Hose size Thread side N·m kgf·m lbf·ft 13.8 to 15.6 1.40 to 1.60 10.2 to 11.5 22.6 to 27.4 2.30 to 2.80 16.7 to 20.2 45.2 to 52.9 4.60 to 5.40...
Page 36: Metric Screws, Bolts And Nuts
M6040, M7040, WSM GENERAL [4] METRIC SCREWS, BOLTS AND NUTS Grade Property class 8.8 Property class 10.9 Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft 24 to 27 2.4 to 2.8 18 to 20 30 to 34 3.0 to 3.5 22 to 25 48 to 55 4.9 to 5.7...
Page 37: Maintenance Check List
M6040, M7040, WSM GENERAL 6. MAINTENANCE CHECK LIST Indication on hour meter Refer- Impor- Item Interval ence tant 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 1 Engine start system Check G-22 ...
Page 38 M6040, M7040, WSM GENERAL Indication on hour meter Refer- Impor- Item Interval ence tant 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 24 Front axle pivot Adjust G-33  600 Hr every...
Page 39: Check And Maintenance
M6040, M7040, WSM 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. 9Y1210143GEG0007US0 [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
M6040, M7040, WSM GENERAL [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil CAUTION • Before changing oil, be sure to stop the engine. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. To drain the used oil, remove the drain plugs (2) at the bottom of the engine and drain the oil completely into the oil pan.
Page 41 M6040, M7040, WSM GENERAL Replacing Hydraulic Oil FIlter CAUTION • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Remove the drain plug (1) at the bottom of the transmission case and drain the oil completely into the oil pan.
Page 42 M6040, M7040, WSM GENERAL Changing Transmission Fluid CAUTION • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. To drain the used oil, remove the drain plug (1) at the bottom of the transmission case and drain the oil completely into the oil pan.
Page 43: Check Points Of Every 50 Hours
M6040, M7040, WSM 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: Check Points Of Every 100 Hours
M6040, M7040, WSM GENERAL [4] CHECK POINTS OF EVERY 100 HOURS Lubricating Grease Fittings 1. Apply a small amount of multipurpose grease to following points every 100 hours. 2. If you operated the machine in extremely wet and muddy condition, lubricate grease fittings more often.
Page 45 M6040, M7040, WSM 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 46 M6040, M7040, WSM 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. 3. If tension is incorrect, loosen the tension pulley nut (1) and lock nut (3).
Page 47 M6040, M7040, WSM GENERAL Checking Fuel Line 1. Check to see that all lines and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once. NOTE • If the fuel line is removed, be sure to properly bleed the fuel system.
Page 48 M6040, M7040, WSM GENERAL Directions for Storage CAUTION • When connecting the battery, do not reverse the polarities. Connection with reverse polarities will cause spark and troubles to the battery and electrical system in the tractor. • When disconnecting the cable from the battery, start with the negative terminal first.
Page 49: Check Points Of Every 200 Hours
M6040, M7040, WSM 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 50 M6040, M7040, WSM GENERAL Checking Power Steering Line 1. Check to see that all line and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once. (1) Power Steering Hose...
Page 51 M6040, M7040, WSM GENERAL Draining Fuel Tank Water 1. Loosen the drain plug (2) at the bottom of the fuel tank (1) to let sediments, impurities and water out of the tank. Finally tighten up the plug. IMPORTANT • If the fuel contains poor qualities with much water in it, drain the fuel tank at shorter intervals.
Page 52: Check Points Of Every 300 Hours
M6040, M7040, WSM 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 400 Hours
M6040, M7040, WSM GENERAL [7] CHECK POINTS OF EVERY 400 HOURS Replacing Fuel Filter 1. Remove the fuel filter (1). 2. Put a film of clean fuel on rubber seal of new filter. 3. Tighten the filter until it contacts the mounting surface. Tighten filter by hand an additional 1/2 turn only.
Page 54: Check Points Of Every 600 Hours
M6040, M7040, WSM GENERAL [8] CHECK POINTS OF EVERY 600 HOURS Replacing Engine Oil Filter 1. See page G-19. 9Y1210143GEG0038US0 Changing Transmission Fluid 1. See page G-21. 9Y1210143GEG0039US0 Changing Front Differential Case Oil 1. See page G-21. 9Y1210143GEG0040US0 Changing Front Axle Gear Case Oil 1.
Page 55: Check Point Of Every 1 Year
M6040, M7040, WSM GENERAL [12] CHECK POINT OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1. See page G-24. 9Y1210143GEG0047US0 Checking Air Conditioner Pipe and Hose (CABIN Model) 1. Check to see that all lines and hose clamps are tight and not damaged.
Page 56: Check Points Of Every 2 Years
M6040, M7040, WSM 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 M6040, M7040, WSM GENERAL Flush Cooling System and Changing Coolant  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 M6040, M7040, WSM GENERAL (Continued) 5. Adding the LLC a) Add only water if the mixture reduces in amount by evaporation. b) If there is a mixture leak, add the LLC of the same manufacture and type in the same mixture percentage.
Page 59 M6040, M7040, WSM GENERAL Replacing Power Steering Hose 1. Replace the hoses and clamps. (See page G-29.) 9Y1210143GEG0054US0 Replacing Fuel Hose 1. Replace the fuel hose and clamps. (See page G-26.) 9Y1210143GEG0055US0 Replacing Intake Air Line 1. Replace the hoses and clamps. (See page G-28.)
Page 60: Others
M6040, M7040, WSM 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 61 M6040, M7040, WSM 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 62 M6040, M7040, WSM 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 9Y1210143GEG0070US0 Checking Refrigerant (Gas) (CABIN Model) CAUTION • Liquid contact with eyes or skin may cause frostbite.
Page 63: Special Tools
M6040, M7040, WSM GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Diesel Engine Compression Tester (for Injection Nozzle) Code No. • 07909-30208 (Assembly) • 07909-30934 (A to F) • 07909-31211 (E and F) • 07909-31231 (H) • 07909-31251 (G) •...
Page 64 M6040, M7040, WSM GENERAL Injection Pump Pressure Tester Application • Use to check fuel tightness of injection pumps. NOTE • The following special tools are not provided, so make them referring to the figure. Pressure gauge full scale: More than 29.4 MPa (300 kgf/cm...
Page 65 M6040, M7040, WSM GENERAL Small End Bushing Replacing Tool Application • Use to press out and to press fit the small end bushing. NOTE • The following special tools are not provided, so make them referring to the figure. [Press out] 157 mm (6.181 in.)
Page 66 M6040, M7040, WSM GENERAL Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. NOTE • The following special tools are not provided, so make them referring to the figure. 225 mm (8.86 in.) 70 mm (2.76 in.)
Page 67 M6040, M7040, WSM GENERAL Front Cover Oil Seal Replacing Tool Application • Use to press fit the front cover oil seal. NOTE • The following special tools are not provided, so make them referring to the figure. 120 mm (4.7244 in.) 12 mm (0.4724 in.)
Page 68 M6040, M7040, WSM GENERAL Flywheel Housing Oil Seal Replacing Tool Application • Use to press fit the flywheel housing oil seal. NOTE • The following special tools are not provided, so make them referring to the figure. 118 mm (4.6457 in.) 12 mm (0.4724 in.)
Page 69 M6040, M7040, WSM GENERAL Valve Bridge Shaft Replacing Tool Application • Use to press fit the valve bridge shaft. NOTE • The following special tools are not provided, so make them referring to the figure. 9.5 mm dia. (0.3740 in. dia.) through hole 19 mm (0.7480 in.)
Page 70 M6040, M7040, WSM GENERAL Auxiliary Socket for Fixing Crankshaft Sleeve Application • Use to fix the crankshaft sleeve of the diesel engine. NOTE • The following special tools are not provided, so make them referring to the figure. 1.5 mm (0.0591 in.) 33 mm (1.2992 in.)
Page 71 M6040, M7040, WSM GENERAL Engine Stand Application • Use to support engine. NOTE • The following special tools are not provided, so make them referring to the figure. 107 mm (4.213 in.) 246 mm (9.685 in.) 21 mm (0.827 in.) 204 mm (8.032 in.)
Page 72 M6040, M7040, WSM GENERAL Flywheel Housing Guide Application • Use to install the flywheel housing to the crankcase. NOTE • The following special tools are not provided, so make them referring to the figure. 70 mm (2.7559 in.) 8 mm (0.3150 in.) 22 mm (0.8661 in.)
Page 73 M6040, M7040, WSM GENERAL Glow Plug Adapter Application • Use to check compression pressure through glow plug hole. NOTE • The following special tools are not provided, so make them referring to the figure. 3 mm dia. (0.118 in. dia.) through hole 1.047 rad (60 °)
Page 74 M6040, M7040, WSM GENERAL Injection Pump Gear Puller Application • Use for remove the injection pump gear from governor shaft. NOTE • The following special tools are not provided, so make them referring to the figure. M35 × P1.5, 6 mm depth (0.2362 in.
Page 75 M6040, M7040, WSM GENERAL Jig for Governor Connecting Rod Application • Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly. NOTE • The following special tools are not provided, so make them referring to the figure.
Page 76 M6040, M7040, WSM GENERAL Pin for Balancer Shaft Bearing Replacing Tool NOTE • The following special tools are not provided, so make them referring to the figure. 7.2 to 7.4 mm (0.283 to 0.291 in.) 4.0 mm dia. (0.158 in. dia.) Ra = 0.8 a...
Page 77 M6040, M7040, WSM GENERAL (Continued) 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.) 34 mm (1.3386 in.) 12 mm (0.4724 in.) 99 mm (3.8976 in.) 12 mm (0.4724 in.)
Page 78 M6040, M7040, WSM GENERAL Balancer Shaft 1 Bearing C Replacing Tool Application • Use to press fit the bearing. NOTE • The following special tools are not provided, so make them referring to the figure. 52.5 mm dia. (2.0669 in. dia.) 0.855 rad (49 °)
Page 79 M6040, M7040, WSM GENERAL Balancer Shaft 1 Bearing D Replacing Tool Application • Use to press fit the bearing. NOTE • The following special tools are not provided, so make them referring to the figure. 34.5 mm dia. (1.3583 in. dia.) 35 mm dia.
Page 80 M6040, M7040, WSM GENERAL Balancer Shaft 2 Bearing B Replacing Tool Application • Use to press fit the bearing. NOTE • The following special tools are not provided, so make them referring to the figure. 18 mm (0.7087 in.) 0.523 rad (30 °) 125 mm (4.9213 in.)
Page 81 M6040, M7040, WSM GENERAL Balancer Shaft 2 Bearing C Replacing Tool Application • Use to press fit the bearing. NOTE • The following special tools are not provided, so make them referring to the figure. 52.5 mm dia. (2.0669 in. dia.) 9 mm (0.3543 in.)
Page 82 M6040, M7040, WSM GENERAL Balancer Shaft 2 Bearing D Replacing Tool Application • Use to press fit the bearing. NOTE • The following special tools are not provided, so make them referring to the figure. 34.5 mm dia. (1.3583 in. dia.) 120 mm (4.7244 in.)
Page 83: Special Tools For Tractor
M6040, M7040, WSM GENERAL [2] SPECIAL TOOLS FOR TRACTOR Tie-rod End Lifter Code No. • 07909-39051 Application • Use for removing the tie-rod end with ease. WSM000001GEG0029US0 Steering Wheel Puller Code No. • 07916-51090 Application • Use for removing the steering wheel without damaging the steering shaft.
Page 84 M6040, M7040, WSM GENERAL Toe-in Gauge Code No. • 07909-31681 Application • This allows easy measurement of toe-in for all machine models. WSM000001GEG0034US0 Injector CH3 Code No. • 07916-52501 Application • Use to put calcium chloride solution into a rear wheel and to remove it.
Page 85 M6040, M7040, WSM GENERAL Power Steering Adaptor Code No. • 07916-54021 Application • Use for measuring the relief valve setting pressure for power steering. WSM000001GEG0038US0 Front Axle Rocking Restrictor NOTE • The following special tools are not provided, so make them referring to the figure.
Page 86 M6040, M7040, WSM GENERAL Sliding Hammer Application • Use to removing the bevel pinion shaft with adaptor for front axle. NOTE • The following special tools are not provided, so make them referring to the figure. 120 mm (4.72 in.) 14.5 mm dia.
Page 87 M6040, M7040, WSM GENERAL Adaptor for Sliding Hammer Application • Use to removing the front axle bevel pinion shaft and hydraulic pump drive gear pin with sliding hammer. NOTE • The following special tools are not provided, so make them referring to the figure.
Page 88 M6040, M7040, WSM GENERAL LSD Adaptor Application • Use for measuring the turning torque of LSD. NOTE • The following special tools are not provided, so make them referring to the figure. 24.65 to 24.80 mm dia. (0.970 to 0.976 in. dia.) 131.85 to 132.15 mm (5.19 to 5.20 in.)
Page 89 M6040, M7040, WSM GENERAL Hydraulic Clutch Spring Compressor Application • Use exclusively for pushing the spring, to remove the circlip for hydraulic clutch. NOTE • The following special tools are not provided, so make them referring to the figure. (1) Tool 4 (Plate) (5) Nut (M16 x P1.5 mm)
Page 90 M6040, M7040, WSM GENERAL (3) Tool 1 (Body) 140 mm dia. (5.51 in. dia.) Radius 50 mm (2.0 in.) Radius 3 mm (0.1 in.) 30 mm dia. (1.2 in. dia.) 2.09 rad (120 °) 17 mm dia. (0.67 in. dia.) 60 mm (2.4 in.)
Page 91 M6040, M7040, WSM GENERAL Valve Adaptor Application • Use for measuring the system pressure of shuttle valve, 4WD and PTO clutch valve. NOTE • The following special tools are not provided, so make them referring to the figure. 24 mm (0.94 in.) 27.7 mm (1.09 in.)
Page 92 M6040, M7040, WSM GENERAL Hydraulic Arm Shaft Bushing Press-Fitting Tool Application • Use for replacing the hydraulic arm shaft bushings in the hydraulic cylinder body. NOTE • The following special tools are not provided, so make them referring to the figure.
Page 93 M6040, M7040, WSM GENERAL Bevel Gear Shaft Tool Application • Use for measuring and tightening the bevel gear shaft. NOTE • The following special tools are not provided, so make them referring to the figure. Bevel gear for front axle Bevel gear for rear axle 12.75 to 12.90 mm square...
Page 94 M6040, M7040, WSM GENERAL Draft Control Test Bar Application • Use for checking the lift range and floating range of hydraulic draft control. NOTE • The following special tools are not provided, so make them referring to the figure. 1045 mm (41.14 in.) 1000 mm (29.37 in.)
Page 95 M6040, M7040, WSM 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. NOTE • The following special tools are not provided, so make them referring to the figure.
Page 96 M6040, M7040, WSM GENERAL Hydraulic Brake Adaptor Application • Use for testing the hydraulic brake oil linkage. NOTE • The following special tools are not provided, so make them referring to the figure. 18 mm (0.71 in.) 0.79 rad (45 °) 15 mm (0.59 in.)
Page 97: Special Tools For Air Conditioner Unit
M6040, M7040, WSM 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. 9Y1210143GEG0109US0 Air Conditioner Service Tool Code No. • DENSO 95048-00063 Application •...
Page 98 M6040, M7040, WSM GENERAL Stopper Magnet Clutch (For A/C Compressor) Application • Use to loosen and tighten the magnet clutch mounting nut. (Use radius M) NOTE • The following special tools are not provided, make them referring to the figure.
Page 99 M6040, M7040, WSM GENERAL Stopper Bolt (for A/C Compressor) Application • Use with the stopper magnet clutch. NOTE • The following special tools are not provided, make them referring to the figure. 12 mm (0.47 in.) 35 mm (1.38 in.) 7 mm (0.28 in.)
Page 100: Tires
M6040, M7040, WSM GENERAL 9. TIRES WARNING • Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure show in the operator's manual.
Page 101: Tread Adjustment
M6040, M7040, WSM 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. • Do not work under any hydraulically supported devices. They can settle, suddenly leak down, or be accidentally lowered.
Page 102 M6040, M7040, WSM GENERAL (Continued) [Except M7040DTH-SPA] Tread (a) 1435 mm 1545 mm 9.5R20 – – – 56.50 in. 60.83 in. 1584 mm 12.5/80-18 – – – – 62.36 in. 1441 mm 1495 mm 320/70R20 – – – 56.73 in.
Page 103: Rear Wheels
M6040, M7040, WSM GENERAL (2) Rear Wheels Rear tread width can be adjusted as shown with the standard equipped tires. To change the tread width 1. Remove the wheel rim and / or disc mounting bolts. 2. Change the position of the rim and disc (right and left) to the desired position, and tighten the bolts.
Page 104: Wheel Hub
M6040, M7040, WSM GENERAL [3] WHEEL HUB Front wheel hub Rear wheel hub Screw circle diameter 203.2 mm 203.2 mm (8 in.) (8 in.) Number of screws Screws M16 × P1.5 M16 × P1.5 152.4 mm 152.4 mm Hub pilot diameter (B) (6 in.)
Page 105: Tire Liquid Injection
M6040, M7040, WSM GENERAL [4] TIRE LIQUID INJECTION Auxiliary weights can be used to increase traction force for plowing in fields or clayey ground. Another way is to inject water or another liquid, such as a calcium chloride solution in the tires. Water must not be used in winter since it freezes at 0 °C (32 °F).
Page 106 M6040, M7040, WSM 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 107 M6040, M7040, WSM 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 108: Implement Limitations
M6040, M7040, WSM GENERAL 10. IMPLEMENT LIMITATIONS The KUBOTA Tractor has been thoroughly tested for proper performance with implements sold or approved by 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.
Page 109: Implement Capacity
M6040, M7040, WSM GENERAL [1] IMPLEMENT CAPACITY Implement Remarks M6040 M7040 Max. Tank Capacity 3000 L (790 U.S.gals, 660 Imp.gals) Slurry Tank Max. Load Capacity 4000 kg (8800 lbs) 5000 kg (11000 lbs) Max. Load Capacity Refer to "[2] TRAILER LOAD CAPACITY" on page G-90.
Page 110 M6040, M7040, WSM GENERAL Implement Remarks M6040 M7040 Max. Lifting 1150 kg (2535 lbs) Capacity *1, *2 Front Loader Max. Oil Pressure 19.6 MPa (200 kgf/cm , 2844 psi) Max. Cutting Width 1820 mm (72 in.) 2130 mm (84 in.) Box Blade Max.
Page 111: Trailer Load Capacity
M6040, M7040, WSM GENERAL [2] TRAILER LOAD CAPACITY Drawbar High-hitch Piton-fix Long Normal Automatic CUNA C CUNA D2 600 kg 520 kg 510 kg 530 kg 540 kg 1800 kg 1320 lbs 1150 lbs 1120 lbs 1170 lbs 1190 lbs...
Page 112 ENGINE KiSC issued 07, 2012 A...
Page 113 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-M3 [5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE........1-M4 [6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) .............
Page 114: Feature
M6040, M7040, WSM ENGINE 1. FEATURE The 07 series DI engine are the vertical type 4-cycle diesel engine featuring the advanced performances shown below.  New Concept • The Kubota 07 Series is a totally new concept in engine design developed with various requirements necessary for a wide range of industrial applications.
Page 115: Engine Body
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 116: Cooling Jacket
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. (1) Coolant Passage between...
Page 117: Screws Per Each Cylinder Assembling Structure
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 118: Center Direct Injection System (E-Cdis)
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 119: Gear Train Configuration
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 120: Lubricating System
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 121: Cooling System
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 122: Bottom Bypass System
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 123: Fuel System
M6040, M7040, WSM 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 124 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"...
Page 125: Stage Di Nozzle
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 126: Injection Pump With F.s.p
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 Full Needle Valve Lift Needle Valve Pre-lift X1: Cam Angle (°) Y1: Injection Rate (mm /°)
Page 127: Cpv Equipped Delivery Valve
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 128: Intake And Exhaust System
M6040, M7040, WSM ENGINE 6. INTAKE AND EXHAUST SYSTEM [1] TURBOCHARGER (1) Lock Nut (2) Thrust Bearing (3) Snap Ring (4) O-ring (5) Thrust Sleeve (6) Piston Ring (7) Turbine Wheel (8) Turbine Housing (9) Actuator (10) Compressor Wheel (11) Piston Ring...
Page 129: Exhaust Gas Recirculation (Egr) System
M6040, M7040, WSM ENGINE 7. EXHAUST GAS RECIRCULATION (EGR) SYSTEM [1] GENERAL In order to meet with the strict emission regulations, Kubota has adopted the EGR on the V3307-DI-T-E3. The nitrogen oxide (NOx) which is a hazardous component in exhaust gas is generated by oxidation of nitrogen in the air, due to rise of the combustion temperature in cylinders.
Page 130: Egr Cooler
M6040, M7040, WSM ENGINE (1) EGR Cooler The EGR (Exhaust Gas Recirculation) cooler (3) is used to lower combustion temperature and efficiently cool EGR gas, with the aim of reducing the NOx that is in the exhaust gas of diesel engine.
Page 131: Mechanical Egr Valve
M6040, M7040, WSM ENGINE (3) Mechanical EGR Valve Mechanical EGR valve (2) controls the flow of cooled EGR gas (c) to the intake manifold. If the boost pressure (b) is low, EGR valve (2) is closed, so cooled EGR gas (c) does not flow to the intake manifold (e).
Page 132 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S5 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 (5) Turbocharger .........................1-S22 (6) EGR System........................1-S23 [2] PREPARATION ........................1-S25 (1) Lubricant and Coolant ....................1-S25 (2) 4WD Propeller Shaft and Power Steering Hose............1-S25...
Page 133: Troubleshooting
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-39 Water in the fuel system Change fuel and – repair or replace fuel...
Page 134 M6040, M7040, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-32 Not Smooth Air cleaner clogged Clean or replace G-24 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut...
Page 135 M6040, M7040, WSM ENGINE Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust 1-S19 Engine's moving parts seem to be seizing Repair or replace – Injection pump malfunctioning Repair or replace 1-S20, 1-S49 Deficient nozzle injection Repair or replace...
Page 136 M6040, M7040, WSM ENGINE Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Replenish G-19 Oil strainer clogged Clean – Relief valve stuck with dirt Clean 1-S53 Relief valve spring weaken or broken Replace 1-S53 Excessive oil clearance of crankshaft bearing...
Page 137: Servicing Specifications
M6040, M7040, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 3.92 MPa / 2.90 MPa / 250 min (rpm) 250 min (rpm) 40.0 kgf/cm 29.6 kgf/cm 250 min (rpm) 250 min (rpm) 569 psi /...
Page 138 M6040, M7040, WSM ENGINE Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm 0.0006 to 0.0018 in. 0.0059 in. • Rocker Arm Shaft O.D. 14.973 to 14.984 mm – 0.5895 to 0.5899 in.
Page 139 M6040, M7040, WSM ENGINE Item Factory Specification Allowable Limit Cam Height Intake 37.50 mm 37.00 mm 1.4764 in. 1.4567 in. Exhaust 37.90 mm 37.40 mm 1.4921 in. 1.4724 in. Camshaft Oil Clearance 0.050 to 0.091 mm 0.15 mm 0.0020 to 0.0036 in.
Page 140 M6040, M7040, WSM ENGINE Item Factory Specification Allowable Limit Piston Ring Gap Top Ring 0.25 to 0.40 mm 1.25 mm 0.0098 to 0.0157 in. 0.0492 in. Second Ring 0.30 to 0.45 mm 1.25 mm 0.0118 to 0.0177 in. 0.0492 in.
Page 141 M6040, M7040, WSM ENGINE LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed – 50 kPa 0.5 kgf/cm 7.1 psi At Rated Speed 197 to 392 kPa 147.1 kPa 2.00 to 4.00 kgf/cm 1.50 kgf/cm 28.5 to 56.8 psi 21.3 psi...
Page 142 M6040, M7040, WSM ENGINE FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing V3307-DI-T-E3 0.00960 rad B.T.D.C. to – 0.0357 rad A.T.D.C. (0.550 ° B.T.D.C. to 2.05 ° A.T.D.C.) Pump Element Fuel Tightness – 18.63 MPa 190 kgf/cm 2702 psi...
Page 143: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft Glow lead mounting nut 0.98 to 1.7...
Page 144 M6040, M7040, WSM ENGINE Item N·m kgf·m lbf·ft Idle gear mounting screw (10T) 30 to 35 3.0 to 3.5 22 to 25 Balancer shaft set screw 24 to 27 2.4 to 2.8 18 to 20 *Connecting rod screw 69 to 73 7.0 to 7.5...
Page 145: Checking, Disassembling And Servicing
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 146 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 147: Lubricating System
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 148: Cooling System
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 149 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 150 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. 9Y1210143ENS0010US0 Radiator Cap Air Leakage 1. Set a radiator tester on the radiator cap.
Page 151: Fuel System
M6040, M7040, WSM ENGINE (4) Fuel System Injection Timing 1. Make sure of matching the injection timing align mark (1) of the injection pump unit and the flywheel housing, as shown in the illustration. 2. Remove the injection pipes. 3. Remove the stop solenoid.
Page 152 M6040, M7040, WSM ENGINE Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
Page 153 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 154: Turbocharger
M6040, M7040, WSM ENGINE (5) Turbocharger Turbine Side 1. Check the exhaust port (2) and inlet port (4) side of turbine housing (3) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (1) / (5) with new one.
Page 155: Egr System
M6040, M7040, WSM ENGINE (6) EGR System Function of EGR System 1. Check the coolant temperature and monitor the coolant temperature while checking 1) and 2). 2. If the coolant temperature is already 55 °C (131 °F), cool down the engine.
Page 156 M6040, M7040, WSM ENGINE 2) If the coolant temperature is over 70 °C (158 °F), the surface temperature of EGR pipe must be over 150 °C (302 °F). 9Y1210143ENS0026US0 1-S24 KiSC issued 07, 2012 A...
Page 157: Preparation
M6040, M7040, WSM ENGINE [2] PREPARATION (1) Lubricant and Coolant Draining Coolant and Engine Oil 1. See page G-10 and G-19. 9Y1210143ENS0027US0 (2) 4WD Propeller Shaft and Power Steering Hose Propeller Shaft 1. Slide the propeller shaft cover (3) after removing the screw (8).
Page 158: Separating Engine (Rops Model)
M6040, M7040, WSM ENGINE Front Axle Rocking Restrictor 1. Install the front axle rocking restrictor (1) (see page G-64) to the front axle bracket. (1) Front Axle Rocking Restrictor 9Y1210143ENS0030US0 [3] SEPARATING ENGINE (ROPS MODEL) (1) Separating Front Axle and Front Frame as a Unit Bonnet 1.
Page 159 M6040, M7040, WSM ENGINE Radiator Hose, Muffler, Power Steering Hose, Oil Cooler Pipe and Battery Cable 1. Remove the muffler (3). 2. Disconnect the radiator hoses (2) and (6). 3. Remove the power steering hose clamps (5) and cover (4).
Page 160: Separating Engine
M6040, M7040, WSM ENGINE (2) Separating Engine Accelerator Wire, Fuel Hose and Wire Harness 1. Disconnect the accelerator wire (6) and fuel hose (4). 2. Disconnect the wire harness from water temperature sensor (7), engine speed sensor (5) and glow plug (3).
Page 161 M6040, M7040, WSM ENGINE Brake Pipe 1. Remove the intake hose (3) and pipe (1). 2. Remove the brake pipe (2). (1) Intake Pipe (3) Intake Hose (2) Brake Pipe 9Y1210143ENS0040US0 Separating Engine from Clutch Housing 1. Hoist the engine with a the hoist and chain.
Page 162: Separating Engine (Cabin Model)
M6040, M7040, WSM ENGINE [4] SEPARATING ENGINE (CABIN MODEL) (1) Separating Front Axle and Front Frame as a Unit Preparation 1 1. Open the bonnet (1) and disconnect the battery (2) negative terminal and 6P connector (5) for head light.
Page 163 M6040, M7040, WSM ENGINE Preparation 2 1. Remove the muffler pipe (1) and bonnet support (2). 2. Remove the air cleaner hose (3) from the turbocharger. 3. Remove the power steering hoses (4). 4. Remove the U-joint (6). 5. Remove the oil cooler pipe (5) and (7).
Page 164 M6040, M7040, WSM ENGINE Condenser and Compressor 1. Remove the air conditioner belt (3). 2. Remove the compressor (4) and condenser (5) without removing the air conditioner hoses. 3. Disconnect the heater hoses (1). 4. Remove the radiator hoses (2) from the engine.
Page 165: Separating Engine
M6040, M7040, WSM ENGINE (2) Separating Engine Preparation 1 1. Remove the harness (2) for the ground. 2. Remove the muffler (1). 3. Remove the harness from alternator (4) engine oil pressure switch (6), stop solenoid (5), water temperature sensor, starter motor (7) and engine speed sensor (8).
Page 166: Disassembling And Assembling
M6040, M7040, WSM ENGINE [5] DISASSEMBLING AND ASSEMBLING (1) External Components Air Cleaner, Muffler and Others 1. Remove the fan (6), fan belt (7), cover (5), fuel filter cartridge (4), fuel tubes (2), alternator (8) and starter (1). (When reassembling) •...
Page 167 M6040, M7040, WSM ENGINE Turbocharger Assembly and Exhaust Manifold 1. Remove the cover (1) and exhaust manifold mounting screws (3). 2. Take off the turbocharger assembly (4) with exhaust manifold (2). 3. Remove the oil pipe 1 (6) and oil pipe 2 (9). (If necessary) 4.
Page 168: Exhaust Gas Recirculation (Egr)
M6040, M7040, WSM ENGINE (2) Exhaust Gas Recirculation (EGR) EGR System Assembly 1. Disconnect the EGR valve coolat hoses (2) and the boost pressure hose 1 (3). 2. Disconnect boost the pressure hose 2 (4). (If necessary) 3. Remove the EGR system assembly (5).
Page 169: Cylinder Head And Valves
M6040, M7040, WSM ENGINE EGR Valve and Reed Valve (If necessary) 1. Remove the EGR valve (1) from the EGR valve flange (5). 2. Remove the reed valve (3) from the EGR valve (1). (When reassembling) • Replace the gaskets (2) / (4) / (6) with new ones.
Page 170 M6040, M7040, WSM ENGINE Nozzle Holder 1. Remove the overflow 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 171 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 172 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 173: Thermostat
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 174 M6040, M7040, WSM ENGINE (5) Injection Pump Unit Injection Pump Unit (Removing the fuel injection pump unit) 1. Detach the window cover (1) for the fuel injection pump unit from the flywheel housing. 2. Place the piston of the 4th cylinder at the top dead center in the compression stroke.
Page 175 M6040, M7040, WSM ENGINE Injection Pump Unit (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 176 M6040, M7040, WSM ENGINE Governor Housing Assembly 1. Remove the injection pump unit from the engine. (See page 1-S42.) 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 177 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 178 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 179 M6040, M7040, WSM ENGINE Fuel Camshaft and Governor Weight 1. Separate the governor housing assembly from the injection pump unit. (See page 1-S42.) 2. Remove the governor sleeve (1). 3. Remove the injection pump assembly (4). 4. Remove the fuel camshaft lock screws.
Page 180 M6040, M7040, WSM ENGINE (Continued) 1. Pull out the injection pump gear using gear puller (1). (See page G-53.) 2. Loosen the fuel camshaft stopper mounting screws (2) and remove the fuel camshaft stopper (3). 3. Pull out the fuel camshaft (8) and bearings (9) together.
Page 181 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 182 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 (2).
Page 183 M6040, M7040, WSM ENGINE (Continued) 1. Move the stop lever (1) and visually check to see if the fuel injection pump control rack comes smoothly back to the start position by the counter force of the start spring. 2. If the control rack fails to move back smoothly, remove the start spring and the lock nut, take the above steps from 2 of the former page again.
Page 184: Water Pump And Oil Cooler
M6040, M7040, WSM ENGINE (6) 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 9Y1210143ENS0072US0 Oil Cooler 1.
Page 185: Flywheel And Timing Gears
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). 69 to 78 N·m Tightening torque Relief valve retaining screw 7.0 to 8.0 kgf·m 51 to 57 lbf·ft...
Page 186 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) • Apply engine oil to the flywheel housing oil seal (5).
Page 187 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 188: Piston And Connecting Rod
M6040, M7040, WSM ENGINE (9) 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 189 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 190 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 191: Crankshaft And Crankcase
M6040, M7040, WSM ENGINE (10) 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 192 M6040, M7040, WSM ENGINE (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 193: Servicing
M6040, M7040, WSM ENGINE [6] 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 mm long fuse wires to 3 to 4 spots on the piston top with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
Page 194 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 195 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 196 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 197 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 198 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). (See page G-48.) (1) Bridge Arm 31.1 to 31.7 mm (1.22 to 1.25 in.)
Page 199: Timing Gears
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 200 M6040, M7040, WSM ENGINE Replacing Idle Gear Bushing (When removing) 1. Using an idle gear bushing replacing tool, press out the used bushing. (See page G-44.) (When installing) 1. Clean a new idle gear bushing and idle gear bore, and apply engine oil to them.
Page 201 M6040, M7040, WSM ENGINE Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with an inside micrometer. 3. If the clearance exceeds the allowable limit, replace the camshaft.
Page 202 M6040, M7040, WSM ENGINE Balancer Shaft Alignment 1. Support the balancer shaft with V blocks on the surface plate and set a dial indicator with its tip on the intermediate journal at high angle. 2. Rotate the balancer shaft on the V block and get the misalignment (half of the measurement value).
Page 203 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. (See page G-55 to G-61.) Confirm that the cut off position of the bearing (C) matched with the pin of the replacing tool.
Page 204: Piston And Connecting Rod
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 205 M6040, M7040, WSM ENGINE Replacing Small End Bushing (When removing) 1. Press out the used bushing using a small end bushing replacing tool. (See page G-44.) (When installing) 1. Clean a new small end bushing and bore, and apply engine oil to them.
Page 206 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 207: Crankshaft
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 208 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 209 M6040, M7040, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1. Clean the crankshaft journal (3) 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 210: Cylinder
M6040, M7040, WSM ENGINE Replacing Flywheel Housing Oil Seal 1. Remove the used oil seal. 2. Clean the new flywheel housing oil seal (2) and apply engine oil to it. 3. Install the new oil seal (2) to the specific position using replacing tool (1).
Page 211: Oil Pump
M6040, M7040, WSM ENGINE Correcting Cylinder (Oversize) 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. 94.500 to 94.522 mm Cylinder I.D. (2) Factory specification 3.7205 to 3.7213 in. 94.65 mm...
Page 212 CLUTCH KiSC issued 07, 2012 A...
Page 213 MECHANISM CONTENTS 1. PTO CLUTCH..........................2-M1 [1] STRUCTURE ........................2-M1 [2] PTO SOLENOID VALVE, RELIEF VALVE AND OIL FLOW ..........2-M2 KiSC issued 07, 2012 A...
Page 214: Pto Clutch
M6040, M7040, WSM CLUTCH 1. PTO CLUTCH [1] STRUCTURE As shown in the figure above, the PTO propeller shaft 1 (3) is splined to the input shaft (2) and is always rotating while the engine is running. The PTO clutch pack (4) has three clutch discs (8), three drive plates (9), a belleville washer (cupped spring washer) (11) and one pressure plate (7).
Page 215 M6040, M7040, WSM CLUTCH [2] PTO SOLENOID VALVE, RELIEF VALVE AND OIL FLOW When the PTO switch is at the OFF position, the oil flows is stopped by the PTO solenoid valve (3). When the PTO switch is at ON position, the solenoid...
Page 216 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 2. SERVICING SPECIFICATIONS ....................2-S2 3. TIGHTENING TORQUES......................2-S3 4. CHECKING AND ADJUSTING....................2-S4 [1] TRAVELING CLUTCH......................2-S4 (1) ROPS Model........................2-S4 (2) CABIN Model........................2-S4 [2] PTO CLUTCH........................2-S5 5. DISASSEMBLING AND ASSEMBLING ..................2-S6 [1] REMOVING PTO CLUTCH PACK AND HOLDER..............2-S6 (1) Separating Transmission Case ..................2-S6 (2) PTO Clutch Pack and Holder ..................2-S6 [2] SOLENOID VALVE (PTO).....................2-S7 (1) Removing Solenoid Valve Assembly................2-S7...
Page 217: Troubleshooting
M6040, M7040, WSM CLUTCH 1. TROUBLESHOOTING PTO CLUTCH Reference Symptom Probable Cause Solution Page PTO Clutch Slip Operating pressure is low Adjust 2-S5 PTO solenoid valve malfunctioning Repair or replace 2-S7, 2-S11 Clutch disc or drive plate excessively worn Replace...
Page 218: Servicing Specifications
M6040, M7040, WSM CLUTCH 2. SERVICING SPECIFICATIONS TRAVELING CLUTCH Item Factory Specification Allowable Limit Clutch Pedal (ROPS Model) Free Travel 15 to 25 mm – 0.59 to 0.98 in. Total Stroke 145 to 155 mm – 5.71 to 6.10 in.
Page 219: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft PTO clutch holder mounting screw 23.5 to 27.4...
Page 220: Checking And Adjusting
M6040, M7040, WSM CLUTCH 4. CHECKING AND ADJUSTING [1] TRAVELING CLUTCH (1) ROPS Model Clutch Pedal Free Travel (Hydraulic Shuttle Model) 1. Measure the clutch pedal free travel "L". 2. If adjustment is needed, change with clutch wire cable (3) lock nut (2) so that the free travel becomes 15.0 to 25.0 mm (0.59 to...
Page 221 M6040, M7040, WSM CLUTCH [2] PTO CLUTCH PTO Clutch Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the main shift lever and shuttle lever in Neutral position.
Page 222 M6040, M7040, WSM CLUTCH 5. DISASSEMBLING AND ASSEMBLING [1] REMOVING PTO CLUTCH PACK AND HOLDER (1) Separating Transmission Case Separating Transmission Case 1. Refer to "(3) Separating Transmission Case" on page 3-S28. 2. Refer to "[2] DISASSEMBLING AND ASSEMBLING" on page 10-S33.
Page 223 M6040, M7040, WSM CLUTCH [2] SOLENOID VALVE (PTO) (1) Removing Solenoid Valve Assembly Solenoid Valve Assembly 1. Refer to "(4) Solenoid Valve Assembly" on page 3-S16. (1) Solenoid Valve Assembly 9Y1210143CLS0009US0 2-S7 KiSC issued 07, 2012 A...
Page 224 M6040, M7040, WSM CLUTCH [3] 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) and the hub (2).
Page 225 M6040, M7040, WSM CLUTCH Clutch Case 1. Remove the external circlip (7). 2. Remove the clutch holder (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 226 M6040, M7040, WSM CLUTCH 6. SERVICING [1] PTO CLUTCH PACK PTO Clutch Disc Wear 1. Measure the thickness of PTO clutch disc with vernier calipers. 2. If the thickness is less than the allowable limit, replace it. 2.5 to 2.7 mm Factory specification 0.098 to 0.106 in.
Page 227 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 specification 0.096 to 0.098 in.
Page 228 TRANSMISSION KiSC issued 07, 2012 A...
Page 229 MECHANISM CONTENTS 1. STRUCTURE..........................3-M1 [1] F15/R15 SPEED TRANSMISSION MODEL ................ 3-M1 [2] LIVE PTO-GROUND PTO MODEL (ITA MODEL) ............... 3-M2 2. POWER TRAIN FOR TRAVELING GEAR ................. 3-M3 [1] SHUTTLE SHIFT SECTION ....................3-M3 (1) Structure ......................... 3-M3 (2) Oil Flow........................... 3-M4 (3) Hydraulic Clutch Pack ....................
Page 230: Structure
M6040, M7040, WSM TRANSMISSION 1. STRUCTURE [1] F15/R15 SPEED TRANSMISSION MODEL (1) Damper (3) Main Gear Shift Section (5) PTO Gear Case (6) Front Wheel Drive Section (7) Creep Gear (Cassette Type (8) Range Gear Shift Section (2) Hydraulic Shuttle Clutch...
Page 231: Live Pto-Ground Pto Model (Ita Model)
M6040, M7040, WSM TRANSMISSION [2] LIVE PTO-GROUND PTO MODEL (ITA MODEL) (1) Damper (3) Main Gear Shift Section (5) Live PTO-Ground PTO Section (7) Front Wheel Drive Section (8) Creep Gear (Cassette Type (9) Range Gear Shift Section (2) Hydraulic Shuttle Clutch...
Page 232: Power Train For Traveling Gear
M6040, M7040, WSM TRANSMISSION 2. POWER TRAIN FOR TRAVELING GEAR [1] SHUTTLE SHIFT SECTION (1) Structure (1) Return Spring (4) Belleville Washer (6) Reverse Side Clutch (8) Hydraulic Shuttle Valve (2) Clutch Pedal (Cupped Spring Washer) (7) Clutch Spool (9) Clutch Cable...
Page 233: Oil Flow
M6040, M7040, WSM TRANSMISSION (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 234: Hydraulic Clutch Pack
M6040, M7040, WSM TRANSMISSION (3) Hydraulic Clutch Pack The shuttle shift section allows the operators to change forward and reverse with a shuttle lever. It is using hydraulic clutch shifting. When the shuttle lever is move to the F or R position, clutch is engaged to the front or rear by the hydraulic.
Page 235: Hydraulic Shuttle Valve
M6040, M7040, WSM TRANSMISSION [2] HYDRAULIC SHUTTLE VALVE (1) Structure (1) Shuttle Shift Spool (7) Line Filter (e) Clutch Pedal Released Pressure Check Port (Forward, Reverse) (8) Accumulate Valve Position (Forward) (2) Inching Valve Spool To Clutch Body (Forward) (3) Line Filter...
Page 236: Operation
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 Check Port (Modulation)
Page 237 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 238 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 239 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 240 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 (7) Shuttle Lever...
Page 241: Main Gear Shift Section
M6040, M7040, WSM TRANSMISSION [3] MAIN GEAR SHIFT SECTION (1) 1st Shaft (6) 28T Gear (11) Coupling (15) 33T Gear (2) 19T Gear (7) Coupling (12) Shifter (16) 37T Gear (3) Shifter (8) Shifter (13) 2nd Shaft (17) 41T Gear...
Page 242: Hi-Lo-Creep Shift Section
M6040, M7040, WSM TRANSMISSION [4] HI-LO-CREEP SHIFT SECTION Hi-Lo-Creep Shift (1) 41T Gear (2) 2nd Shaft (16T Gear) (3) 3rd Shaft (4) 27T Gear (5) Shifter (6) Coupling (7) 42T-21T Gear (8) 47T Gear (9) 14T Gear Shaft (Creep) Hi Range...
Page 243: Shift Fork Rod And Fork
M6040, M7040, WSM TRANSMISSION [5] SHIFT FORK ROD AND FORK (1) 1st-2nd Shift Fork Rod (6) 5th Shift Fork (11) Main Shift Lever (A) Engage to 1st-2nd Shift (2) 1st-2nd Shift Fork (7) 5th Shift Fork Rod (12) Select Lever...
Page 244: Lubrication For Transmission
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 lubricates to PTO clutch holder and the each sections through PTO propeller shaft and 1st shaft.
Page 245: Power Train For Pto System
M6040, M7040, WSM TRANSMISSION 4. POWER TRAIN FOR PTO SYSTEM [1] PTO GEAR SECTION (1) PTO Propeller Shaft 1 (5) 13T-13T Gear Shaft (8) Hub 540 PTO (2) PTO Clutch (6) PTO Shaft (9) Shifter 540E PTO (3) PTO Propeller Shaft 2...
Page 246: Ground Pto And Live Pto Section (Ita Model)
M6040, M7040, WSM TRANSMISSION [2] GROUND PTO AND LIVE PTO SECTION (ITA MODEL) (1) PTO Clutch Pack (4) Propeller Shaft 3 (7) 33T G-PTO Gear Live PTO (2) Propeller Shaft 2 (5) Coupling (8) 60T Coupling Gear Neutral (3) 26T G-PTO Gear...
Page 247: Power Train For 4Wd
M6040, M7040, WSM TRANSMISSION 5. POWER TRAIN FOR 4WD [1] 4WD HYDRAULIC CLUTCH SECTION (1) DT Propeller Shaft (2) 35T Gear (3) Neutral Cover (4) 4WD Piston (5) Spring (6) Clutch Body (7) 4WD Shaft (8) 32T Gear The 4WD clutch is controlled by the solenoid valve and the hydraulic flow.
Page 248: 4Wd Oil Flow
M6040, M7040, WSM TRANSMISSION [2] 4WD OIL FLOW Oil pressure-fed from the power steering hydraulic pump is flowed to the 4WD solenoid valve (1) through the steering controller and oil cooler. The system hydraulic pressure-fed to disengaged position for 4WD clutch (4) when 4WD switch at 2WD position.
Page 249 SERVICING CONTENTS 1. TROUBLESHOOTING.........................3-S1 2. SERVICING SPECIFICATIONS ....................3-S3 3. TIGHTENING TORQUES......................3-S5 4. CHECKING AND ADJUSTING....................3-S6 [1] SHUTTLE LEVER .........................3-S6 (1) Engine Start Condition.....................3-S8 [2] GEAR SHIFTING LINKAGE ....................3-S9 (1) Main Gear Shift........................3-S9 (2) Range Gear Shift......................3-S11 [3] SHUTTLE VALVE........................3-S12 [4] 2WD-4WD CLUTCH ......................3-S13 5.
Page 250 [12]PTO GEAR CASE .......................3-S49 [13]GROUND PTO AND LIVE PTO...................3-S50 6. SERVICING ..........................3-S52 [1] BEARING, SHIFT FORK AND SYNCHRONIZER ...............3-S52 [2] TRAVELING CLUTCH ......................3-S53 [3] SHUTTLE CLUTCH PACK ....................3-S54 [4] SHAFT AND GEAR ......................3-S54 [5] 4WD CLUTCH PACK ......................3-S55 [6] DIFFERENTIAL GEAR ......................3-S56 (1) Spiral Bevel Pinion Shaft ....................3-S56 (2) Backlash and Tooth Contact (Except ITA Model)............3-S57 (3) Backlash and Tooth Contact (ITA Model)..............3-S59...
Page 251: Troubleshooting
M6040, M7040, WSM TRANSMISSION 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Shuttle Clutch Slip Operating pressure is low Adjust 3-S12, 3-S13 Shuttle clutch valve malfunctioning Replace 3-S16 Clutch disc or steel plate excessively worn Replace 3-S31, 3-S54 Deformation of piston or steel plate Replace –...
Page 252 M6040, M7040, WSM TRANSMISSION 4WD CLUTCH Reference Symptom Probable Cause Solution Page 4WD Clutch Slip Operating pressure is low Adjust 3-S13 4WD solenoid valve malfunctioning Repair or replace 3-S16 Clutch disc or drive plate excessively worn Replace 3-S42, 3-S43 Deformation of piston or return plate...
Page 253: Servicing Specifications
M6040, M7040, WSM TRANSMISSION 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit [ROPS Model] • Main Shift Rod 1 Length 262 mm – 10.32 in. • Main Shift Rod 2 Length 359 mm – 14.13 in. [CABIN Model] • Main Shift Rod 1...
Page 254 M6040, M7040, WSM TRANSMISSION Item Factory Specification Allowable Limit Differential Case Bore to Differential Side Clearance 0.080 to 0.181 mm 0.35 mm Gear Boss 0.004 to 0.00712 in. 0.014 in. • Differential Case Bore I.D. 40.53 to 40.592 mm –...
Page 255: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft...
Page 256: Checking And Adjusting
M6040, M7040, WSM TRANSMISSION 4. CHECKING AND ADJUSTING [1] SHUTTLE LEVER 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 257 M6040, M7040, WSM TRANSMISSION (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". 8. Shift the free play "D" toward the rear direction and slowly lower the shuttle lever (1) as shown in the figure.
Page 258: Engine Start Condition
M6040, M7040, WSM TRANSMISSION (1) 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 259: Gear Shifting Linkage
M6040, M7040, WSM TRANSMISSION [2] GEAR SHIFTING LINKAGE (1) Main Gear Shift Checking Function of Main Gear Shift (ROPS Model) 1. Check the function of the main gear shift. • Neutral position to 1st gear position. • Neutral position to 2nd gear position.
Page 260 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 261: Range Gear Shift
M6040, M7040, WSM TRANSMISSION (2) Range Gear Shift Checking Function of Range Shift (CABIN Model Only) 1. Check the function of the range gear shift. • Hi and Lo position. 2. If shift feels abnormal, check the length of range gear shift rod 1 (3) and 2 (1).
Page 262: Shuttle Valve
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 (see page G-70), threaded joint, cable, and pressure gauge (Code No.:...
Page 263: 2Wd-4Wd Clutch
M6040, M7040, WSM TRANSMISSION [4] 2WD-4WD CLUTCH Clutch Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the main shift lever and shuttle lever in Neutral position.
Page 264: Disassembling And Assembling
M6040, M7040, WSM TRANSMISSION 5. DISASSEMBLING AND ASSEMBLING [1] HYDRAULIC SHUTTLE VALVE AND SOLENOID VALVE ASSEMBLY (1) Removing Fuel Tank (ROPS Model) Draining Transmission Fluid and Fuel 1. See page G-10 and G-21. 9Y1210143TRS0011US0 Rear Wheel (L.H.) and Fender (L.H.) 1.
Page 265 M6040, M7040, WSM TRANSMISSION Rear Wheel and Fuel Tank 1. Place the disassembling stand under the transmission case. 2. Remove the left rear wheel. 3. Place the disassembling stand under the rear axle case. 4. Remove the fuel sensor 2P connector (1).
Page 266: Hydraulic Shuttle Valve
M6040, M7040, WSM TRANSMISSION (3) Hydraulic Shuttle Valve Shuttle Valve Assembly 1. Disconnect the shuttle cable (1). 2. Disconnect the clutch cable (2) and spring (3). 3. Remove the shuttle valve pipe (6). 4. Remove the external circlip (5) and plate (4).
Page 267: Preparation For Separating Each Block
M6040, M7040, WSM TRANSMISSION [2] PREPARATION FOR SEPARATING EACH BLOCK (1) Lubricant and Coolant Draining Transmission Fluid and Fuel 1. See page G-10 and G-21. 9Y1210143TRS0011US0 (2) 4WD Propeller Shaft and Power Steering Hose Propeller Shaft 1. Slide the propeller shaft cover (3) after removing the screw (8).
Page 268: Front Axle Rocking Restrictor
M6040, M7040, WSM TRANSMISSION (3) Front Axle Rocking Restrictor Front Axle Rocking Rectrictor 1. Install the front axle rocking restrictor (1) (see page G-64) to the front axle bracket on both side. (1) Front Axle Rocking Restrictor 9Y1210143TRS0023US0 (4) Bonnet (ROPS Model) Bonnet 1.
Page 269: Bonnet And Muffler Pipe (Cabin Model)
M6040, M7040, WSM TRANSMISSION (5) Bonnet and Muffler Pipe (CABIN Model) Preparation 1 1. Open the bonnet (1) and disconnect the battery (2) negative terminal and 6P connector (5) for head light. 2. Remove the bonnet dampers (4) and bonnet (1).
Page 270: Rops Model
M6040, M7040, WSM TRANSMISSION [3] SEPARATING ENGINE AND CLUTCH HOUSING CASE (1) ROPS Model 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 271 M6040, M7040, WSM TRANSMISSION Air Intake Hose 1. Remove the air intake hose (1). (1) Air Intake Hose 9Y1210143TRS0031US0 Oil Cooler Pipe 1. Remove the oil cooler pipes (1) and (2). 2. Disconnect the power steering hoses (3). 3. Remove the steering support mounting screw (4) for front side.
Page 272: Cabin Model
M6040, M7040, WSM TRANSMISSION (2) CABIN Model 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) • Be sure to assemble the heater hoses to the original position.
Page 273 M6040, M7040, WSM TRANSMISSION Power Steering Pipe and Oil Cooler Pipe 1. Remove the pipe clamp (2), oil cooler pipe 2 (4) and power steering pipe (1). 2. Disconnect the brake hoses (3). 3. Remove the steering joint shaft (5).
Page 274: Separating Clutch Housing Case From Transmission Case
M6040, M7040, WSM TRANSMISSION [4] SEPARATING CLUTCH HOUSING CASE FROM TRANSMISSION CASE (1) Preparation for CABIN Model Removing Cabin from Body 1. Refer to "[2] DISASSEMBLING AND ASSEMBLING" on page 10-S33. 9Y1210143TRS0038US0 Hydraulic Pipe 1. Remove the 3-point hitch delivery pipe 2 (1).
Page 275 M6040, M7040, WSM TRANSMISSION Lift Rod, Lower Link and Fender (R.H., L.H.) 1. Place the disassembling stand under the transmission case. 2. Remove the lift rod (3) and lower link (4). 3. Remove the both rear wheel (2). 4. Place the stand under the both rear axle after remove the rear wheel (2).
Page 276 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 main shift change rod (1) and H-L change shift rod (3).
Page 277 M6040, M7040, WSM TRANSMISSION ROPS Under and Step 1. Remove the screws for parking brake support (1). 2. Remove the both ROPS under frame (2). 3. Remove the step (3). (When reassembling) 259.9 to 304.0 N·m ROPS under frame Tightening torque 26.5 to 31.0 kgf·m...
Page 278: Separating Transmission Case
M6040, M7040, WSM TRANSMISSION (3) Separating Transmission Case Separating Clutch Housing Case from 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.
Page 279: Damper Disc
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 280: Hydraulic Shuttle Clutch
M6040, M7040, WSM TRANSMISSION [7] 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 × Pitch 1.25 mm screws into holes (a) and guide screws (2).
Page 281 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 M6040, M7040, WSM TRANSMISSION Piston 1. Press the washer (4) lightly by the hand made jig (see page G-68), and remove the external circlip (3). 2. Remove the springs (7). 3. Draw out the piston (5) using a air pressure.
Page 283: Shift Cover
M6040, M7040, WSM TRANSMISSION [8] SHIFT COVER Speed Change Lever 1. Set the main change shift lever (3) to the neutral position. 2. Set the range shift lever (2) to the H position. 3. Remove the shift cover (1) mounting screws.
Page 284 M6040, M7040, WSM TRANSMISSION Main Shift Fork 1. Remove the roll pin (12), fork rod (10) and 1st-2nd fork (11). 2. Remove the roll pin (13) and (8), fork rod (9) and 3rd-4th fork (7). 3. Remove the roll pin (6), fork rod (4) and 5th fork (5).
Page 285 M6040, M7040, WSM TRANSMISSION Main Shift Arm 1. Remove the stopper plate (14) and seal cap (13). 2. Remove the select lever (4) then remove the select arm (3). 3. Remove the seal cap (5). 4. Remove the internal circlip (8).
Page 286: Clutch Housing
M6040, M7040, WSM TRANSMISSION [9] CLUTCH HOUSING (1) Creep Gear Assembly Creep Gear 1. Remove the creep gear cover (2) as a unit. 2. Remove the internal circlip (1). 3. Tap out the creep gear shift (4) and remove the creep gear (3).
Page 287 M6040, M7040, WSM TRANSMISSION PTO Shaft and Bearing Holder 1. Pull out the PTO shaft (1) with 33T gear (3). 2. Remove the bearing holder mounting screws. 3. Screw in a M12 × 1.25 mm screw (5) into threaded hole (a) to remove the bearing holder (2).
Page 288: 1St Shaft
M6040, M7040, WSM TRANSMISSION (3) 1st Shaft 1st Shaft Assembly 1. Remove the bearing (1). 2. Draw out the 1st-2nd, 3rd-4th synchronizer unit and gears. 3. Remove the bearing (26) and external circlip (25). 4. Draw out the 5th synchronizer unit and gears.
Page 289 M6040, M7040, WSM TRANSMISSION (Continued) (1) Bearing (18) 32T Gear (2) Thrust Collar (19) Thrust Collar (3) Inner Race (20) 1st Shaft (4) Needle Bearing (21) Inner Race (5) 19T Gear (22) 37T Gear (5-speed) (6) Collar (23) Coupling (5-speed)
Page 290: 2Nd Shaft
M6040, M7040, WSM TRANSMISSION (4) 2nd Shaft 2nd Shaft Assembly 1. Remove the bearing (1) and (9). 2. Remove the gears. (1) Bearing (6) External Circlip (2) 46T Gear (7) 29T Gear (3) 41T Gear (8) 2nd Shaft (4) 41T Gear...
Page 291: Pto Clutch Pack And Holder
M6040, M7040, WSM TRANSMISSION [10] TRANSMISSION CASE (1) Removing Solenoid Valve Assembly Solenoid Valve Assembly 1. Remove the hydraulic pipe (2) and (3). 2. Remove the solenoid valve assembly (1). 3. Remove the hydraulic pipes (4). (When reassembling) • Apply transmission fluid to the O-rings.
Page 292: Removing 4Wd Clutch
M6040, M7040, WSM TRANSMISSION (3) Removing 4WD Clutch 4WD Clutch 1. Remove the 4WD clutch (1). (When reassembling) • Replace the seal rings (2) with new one. • Apply grease to the seal rings (2) when assembling. (1) 4WD Clutch...
Page 293: Disassembling 4Wd Clutch Pack
M6040, M7040, WSM TRANSMISSION (4) Disassembling 4WD Clutch Pack 4WD Hydraulic Pack 1. Remove the bearing (1) and thrust collar (2). 2. Remove the 32T gear (3). 3. Remove the external circlip (4). 4. Tap out the 4WD shaft (9).
Page 294 M6040, M7040, WSM TRANSMISSION 4WD Piston 1. Press the pressure plate (4) to press down the 4WD piston (11), using jig (see page G-68), and remove the internal circlip (3). 2. Remove the discs (5), steel plates (6), (7) and pressure plates (4).
Page 295: Removing Differential Gear And Bevel Pinion Shaft
M6040, M7040, WSM TRANSMISSION (5) Removing Differential Gear and Bevel Pinion Shaft Brake Cam Plate 1. Remove the return spring (1). 2. Remove the brake cam plate (2). (When reassembling) • Apply grease to the brake ball seats. (Do not apply excessively.) •...
Page 296 M6040, M7040, WSM TRANSMISSION Differential Gear Assembly 1. Remove the differential bearing support (1), noting the number of shims (2). 2. Take out the differential gear assembly (4) from transmission case. (When reassembling) • Be sure to fix the O-rings (3).
Page 297: Differential Gear
M6040, M7040, WSM TRANSMISSION Spiral Bevel Pinion Shaft 1. Remove the stake of staking nut (1). 2. Set the staking nut locking wrench (2). 3. Set the spiral bevel pinion shaft turning wrench. 4. Turn the spiral bevel pinion shaft turning wrench to the clockwise, then remove it.
Page 298 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 299: Pto Gear Case
M6040, M7040, WSM TRANSMISSION [12] PTO GEAR CASE Disassembling PTO Gear Case (1) PTO Gear Case Cover Screw (2) PTO Gear Case Cover (3) Internal Circlip (4) Ball Bearing (5) PTO Gear Shaft (6) Ball Bearing (7) PTO Gear Case...
Page 300: Ground Pto And Live Pto
M6040, M7040, WSM TRANSMISSION [13] GROUND PTO AND LIVE PTO Top Cover Assembly and PTO Gear Case Assembly 1. Remove the top cover mounting screws and nuts. 2. Remove the top cover assembly (1). 3. Remove the PTO gear case (2) and PTO drive shaft as a unit.
Page 301 M6040, M7040, WSM TRANSMISSION Differential Pipe and Coupling 1. Remove the coupling (2). 2. Remove the differential lock fork (1). (When reassembling) • When assemble the coupling (2), toward the ID paint mark (a) to the rearward. (1) Differential Lock Fork...
Page 302: Servicing
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 303: Traveling Clutch
M6040, M7040, WSM TRANSMISSION Flaw on Synchronizer Key and Spring 1. Check the projection in the center of the synchronizer key for wear. 2. Check the spring for fatigue or wear on the area where the spring contacts with the keys.
Page 304: Shuttle Clutch Pack
M6040, M7040, WSM TRANSMISSION [3] SHUTTLE CLUTCH PACK Clearance between Internal Circlip and Belleville Washer (Cupped Spring Washer) 1. Measure the clearance between internal circlip and belleville washer (cupped spring washer) with a feeler gauge while applying specified force. Specified force: 176 to 296 N (18 to 30 kgf, 39.6 to 66.1 lbf) 2.
Page 305: 4Wd Clutch Pack
M6040, M7040, WSM TRANSMISSION [5] 4WD CLUTCH PACK Clutch Disc Wear 1. Measure the thickness of clutch disc with vernier calipers. 2. If the thickness is less than the allowable limit, replace it. 2.1 to 2.3 mm Factory specification 0.083 to 0.090 in.
Page 306: Differential Gear
M6040, M7040, WSM TRANSMISSION [6] DIFFERENTIAL GEAR (1) Spiral Bevel Pinion Shaft 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 307: Backlash And Tooth Contact (Except Ita Model)
M6040, M7040, WSM TRANSMISSION (2) Backlash and Tooth Contact (Except ITA Model) 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 308 M6040, M7040, WSM TRANSMISSION (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. • Shallow or Heel Contact Replace the adjusting collar (2) with thicker one to move the spiral bevel pinion shaft backward.
Page 309: Backlash And Tooth Contact (Ita Model)
M6040, M7040, WSM TRANSMISSION (3) Backlash and Tooth Contact (ITA Model) 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 310 M6040, M7040, WSM TRANSMISSION (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. • Shallow or Heel Contact Change the combination of adjusting collar 1 (6) and 2 (7) with thicker one to move the spiral bevel pinion shaft backward.
Page 311: Differential Case Differential Pinion Gear And Differential Side Gear
M6040, M7040, WSM TRANSMISSION (4) Differential Case Differential Pinion Gear and Differential Side Gear 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.
Page 312: Differntial Lock Shifter
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 313: Rear Axle
REAR AXLE KiSC issued 07, 2012 A...
Page 314 MECHANISM CONTENTS 1. STRUCTURE..........................4-M1 KiSC issued 07, 2012 A...
Page 315 M6040, M7040, WSM REAR AXLE 1. STRUCTURE (1) Rear Axle (4) Differential Gear (7) Planetary Gear Pin (10) Differential Bearing Support (2) Rear Axle Case (5) 39T Bevel Gear (8) 27T Planetary Gear (11) Differential Lock Shift Fork (3) Planetary Gear Support...
Page 316: Servicing
SERVICING CONTENTS 1. TROUBLESHOOTING.........................4-S1 2. SERVICING SPECIFICATIONS ....................4-S2 3. TIGHTENING TORQUES......................4-S3 4. DISASSEMBLING AND ASSEMBLING ..................4-S4 [1] SEPARATING REAR AXLE ....................4-S4 (1) ROPS Model........................4-S4 (2) CABIN Model........................4-S5 [2] DISASSEMBLING REAR AXLE ....................4-S6 (1) Brake Section ........................4-S6 (2) Rear Axle Case .......................4-S6 [3] SERVICING ...........................4-S8 KiSC issued 07, 2012 A...
Page 317: Troubleshooting
M6040, M7040, WSM REAR AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Excessive or Unusual Improper backlash between planetary gear and Replace 4-S6, 4-S8 Nose at All Time internal gear Bearing worn Replace 4-S8, 4-S8 Insufficient or improper type of transmission fluid...
Page 318: Servicing Specifications
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 319: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft...
Page 320: Disassembling And Assembling
M6040, M7040, WSM REAR AXLE 4. DISASSEMBLING AND ASSEMBLING [1] SEPARATING REAR AXLE (1) ROPS Model Rear Axle Case 1. Refer to "5. DISASSEMBLING AND ASSEMBLING" on page 3-S14. 2. Disconnect the cylinder hose (4) and return hose (5). 3. Remove the pin 2 (3) and cylinder support (6).
Page 321: Cabin Model
M6040, M7040, WSM REAR AXLE (2) CABIN Model Rear Axle Case 1. Remove the cylinder support (2). 2. Support the cabin and remove the cabin mounting bolt (1). 3. Disconnect the hydraulic brake hoses. 4. Remove the rear axle case mounting screws and nuts.
Page 322: Disassembling Rear Axle
M6040, M7040, WSM REAR AXLE [2] DISASSEMBLING REAR AXLE (1) Brake Section Brake Shaft, Brake Disc, Steel Plate and Brake Plate 1. Draw out the brake shaft (1) with brake discs (6) and steel plates (10). 2. Remove the external circlip (3) and collar (4).
Page 323 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 324: Servicing
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 325 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 326 BRAKES KiSC issued 07, 2012 A...
Page 327 MECHANISM CONTENTS 1. TRAVELING BRAKE ........................5-M1 [1] STRUCTURE ........................5-M1 [2] MASTER CYLINDER ASSEMBLY ..................5-M2 2. PARKING BRAKE ........................5-M3 [1] STRUCTURE ........................5-M3 KiSC issued 07, 2012 A...
Page 328: Traveling Brake
M6040, M7040, WSM BRAKES 1. TRAVELING BRAKE [1] STRUCTURE (1) Brake Pedal (4) Bleeder (7) Return Hose (10) Master Cylinder (2) Brake Piston (5) Brake Disc (8) Brake Pipe (3) Brake Shaft (6) Steel Plate (9) Power Steering Controller To Oil Cooler •...
Page 329: Master Cylinder Assembly
M6040, M7040, WSM BRAKES [2] MASTER CYLINDER ASSEMBLY The master cylinder is one peace type which including oil tank (3), master cylinder (2) and equalizer (7). (The function for each parts, refer to "5. BRAKES" section in the workshop manual of tractor mechanism (Code No.
Page 330: Parking Brake
M6040, M7040, WSM BRAKES 2. PARKING BRAKE [1] STRUCTURE (1) Brake Plate (5) Brake Piston (8) Brake Cam (11) Brake Cam Lever (2) Brake Disc (6) Brake Shaft (9) Parking Hand Brake (12) Parking Cable L.H. (3) Steel Plate (7) Ball (10) Parking Cable Lever (13) Parking Cable R.H.
Page 331 SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICING SPECIFICATIONS ....................5-S2 3. TIGHTENING TORQUES......................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............5-S4 [1] CHECKING AND ADJUSTING....................5-S4 (1) Traveling Brake .......................5-S4 (2) Parking Brake ........................5-S7 [2] DISASSEMBLING AND ASSEMBLING ................5-S8 (1) Removing Master Cylinder (ROPS Model)..............5-S8 (2) Removing Master Cylinder (CABIN Model) ..............5-S9 (3) Master Cylinder ......................5-S12 (4) Brake Piston ........................5-S12...
Page 332: Troubleshooting
M6040, M7040, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Poor Braking Force Brake pedal free travel excessive Adjust 5-S4 Brake disc worn Replace 5-S14, 5-S16 Brake piston warped Replace 5-S13, 5-S16 Brake oil leakage from brake pipes, bleeder, Repair or replace –...
Page 333: Servicing Specifications
M6040, M7040, WSM BRAKES 2. SERVICING SPECIFICATIONS TRAVELING BRAKE Item Factory Specification Allowable Limit Brake Pedal Free Travel 7 to 14 mm – 0.28 to 0.55 in. Stroke 100 mm – 3.9 in. Equalizer Working Level Level Difference Over –...
Page 334: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft Brake rod turnbuckle lock nut 29.4 to 34.3...
Page 335: Checking, Disassembling And Servicing
M6040, M7040, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING CAUTION • When checking, park the tractor on flat ground, and stop the engine. 9Y1210143BRS0004US0 (1) Traveling Brake Adjusting Brake Pedal 1) Brake Pedal Free Travel 1. Set the parking brake.
Page 336 M6040, M7040, WSM BRAKES 2) Brake Pedal Stroke 1. Disengage the brake pedal lock (2). 2. Depress the brake pedal several time. 3. Step on either side brake pedal and measure the level difference (pedal stroke) between right and left pedals.
Page 337 M6040, M7040, WSM BRAKES Bleeding Brake System IMPORTANT • The shuttle lever and main change lever are shift in "NEUTRAL" position. • Set the parking brake lever to "ON" position. • Fill the transmission fluid to the equalizer and master cylinder when overhaul the master cylinder assembly.
Page 338: Parking Brake
M6040, M7040, WSM BRAKES (2) Parking Brake Adjusting Parking Brake Lever CAUTION • Stop the engine and chock the wheels before checking parking brake. 1. Raise the parking brake lever (2) to the parking position while counting the ratchet sound made by the parking brake lever (2).
Page 339: Disassembling And Assembling
M6040, M7040, WSM BRAKES [2] DISASSEMBLING AND ASSEMBLING (1) Removing Master Cylinder (ROPS Model) Master Cylinder Rod 1. Remove the rear bonnet. 2. Remove the master cylinder rod pin (1) from brake pedal (2). (1) Pin (2) Brake Pedal 9Y1210143BRS0011US0 Brake Pipes and Master Cylinder Pipes 1.
Page 340: Removing Master Cylinder (Cabin Model)
M6040, M7040, WSM BRAKES Master Cylinder 1. Remove the master cylinder (1) with master cylinder bracket (2), (3) and stay (4). 2. Remove the master cylinder assembly (1). (When reassembling) • After mounting the master cylinder assembly, be sure to bleed air.
Page 341 M6040, M7040, WSM BRAKES Panel Cover and Panel Under Cover 1. Remove the panel cover (1) and disconnect the connectors from hazard switch (2) and display mode switch (3). 2. Remove the air outlet (4) then remove the panel under cover R.H.
Page 342 M6040, M7040, WSM BRAKES Master Cylinder Rod 1. Remove the pedal shaft support (1). 2. Remove the master cylinder rod pins (2) from brake pedals (3). (1) Pedal Shaft Support (3) Brake Pedal (2) Pin 9Y1210143BRS0016US0 Brake Pipes and Master Cylinder Hoses 1.
Page 343: Master Cylinder
M6040, M7040, WSM BRAKES (3) Master Cylinder Master Cylinder 1. Drain the brake oil from the master cylinder assembly (4). 2. Remove the push rod (1) and boot (5) from the master cylinder. 3. Remove the internal circlip (2), and pull out the piston (6) and return spring (9).
Page 344 M6040, M7040, WSM BRAKES Cam Plate 1. Remove the spring (1). 2. Remove the cam plate (2) and ball (3). (When reassembling) • Be sure to assemble the spring (1). • Be sure to assemble the cam plate to the original position, refer to the I.D.
Page 345: Differential Support And Cam Plate Support
M6040, M7040, WSM BRAKES (5) Differential Support and Cam Plate Support Differential Support R.H. and Cam Plate Support L.H. 1. Remove the differential support R.H. (3). 2. Remove the cam plate support L.H. (2). (When reassembling) • Assemble the mark (1) toward the top side.
Page 346: Servicing
M6040, M7040, WSM BRAKES Brake Cam and Brake Cam Lever 1. Remove the external circlip (1). 2. Remove the brake cam (2) and brake cam lever (3). (When reassembling) • Apply grease to the O-ring (4) and take care not to damage the O-ring.
Page 347 M6040, M7040, WSM BRAKES Height of Cam Plate and Ball 1. Measure the dimensions of the cam plate with the ball installed. 2. If the measurement is less than the allowable limit, replace the cam plate and balls. 3. Inspect the ball holes of cam plate for uneven wear. If the uneven wear is found, replace it.
Page 348: Front Axle
FRONT AXLE KiSC issued 07, 2012 A...
Page 349 MECHANISM CONTENTS 1. STRUCTURE..........................6-M1 [1] 4 WHEEL DRIVE ........................6-M1 [2] LIMITED SLIP DIFFERENTIAL (LSD).................. 6-M2 KiSC issued 07, 2012 A...
Page 350 M6040, M7040, WSM FRONT AXLE 1. STRUCTURE The front axle supports the front of tractor and facilitates steering. NOTE • Refer to "6. FRONT AXLE" section in the workshop manual of tractor mechanism (Code No. 9Y021-18200). 9Y1210143FAM0001US0 [1] 4 WHEEL DRIVE...
Page 351 M6040, M7040, WSM FRONT AXLE [2] LIMITED SLIP DIFFERENTIAL (LSD) (1) Differential Case (2) Side Gear (3) Side Gear (LSD) (4) Friction Disc (5) Case Cover (6) Belleville Washer (Cupped Spring Washer) (7) Steel Plate (8) Adjustment Shim (LSD) (9) Adjustment Shim...
Page 352 SERVICING CONTENTS 1. TROUBLESHOOTING.........................6-S1 2. SERVICING SPECIFICATIONS ....................6-S2 3. TIGHTENING TORQUES......................6-S4 4. CHECKING, DISASSEMBLING AND SERVICING ..............6-S5 [1] CHECKING AND ADJUSTING....................6-S5 [2] PREPARATION ........................6-S6 (1) Separating Front Axle......................6-S6 [3] DISASSEMBLING AND ASSEMBLING ................6-S8 (1) Disassembling Front Axle....................6-S8 (2) Removing Differential Gear and Bevel Pinion Shaft............6-S11 (3) Disassembling Differential Gear ..................6-S12 [4] SERVICING .........................6-S14 KiSC issued 07, 2012 A...
Page 353: Troubleshooting
M6040, M7040, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Tire pressure uneven Adjust G-79 Wander to Right or Improper toe-in adjustment (improper alignment) Adjust 6-S5 Left Clearance between front axle case boss and Replace...
Page 354: Servicing Specifications
M6040, M7040, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Toe-in 2.0 to 8.0 mm – 0.078 to 0.315 in. Front Wheel Steering Angle [except M7040-SPA] – 0.93 to 0.95 rad 53 to 55 ° [M7040-SPA] –...
Page 355 M6040, M7040, WSM FRONT AXLE Item Factory Specification Allowable Limit Front Bracket to Rear Bracket Bushing Alloy Thickness 0.57 mm – 0.0224 in. • Rear Differential Case Boss O.D. 89.965 to 90.000 mm – 3.5420 to 3.5433 in. • Front Differential Case Boss O.D.
Page 356: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft...
Page 357: Checking, Disassembling And Servicing
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 358: Preparation
M6040, M7040, WSM FRONT AXLE Adjusting between Bevel Gear Case and Stopper 1. Inflate the tires to the specified pressure. 2. Steer the wheels to the extreme right until the knuckle arm (1) contacts with the bevel gear case (2).
Page 359 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 360: Disassembling And Assembling
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. 4. Remove the bracket (rear) (2) mounting screws and nuts.
Page 361 M6040, M7040, WSM FRONT AXLE Separating of Front Differential Case from Bevel Gear Case 1. Remove the bevel gear case (2) and the front wheel case (3) as a unit from the front differential case (1). (When reassembling) • Apply grease to the O-ring.
Page 362 M6040, M7040, WSM FRONT AXLE Front Wheel Case 1. Remove the cap (10) which is installed in the bottom of front wheel case. 2. Remove the internal circlip (9) and take out the adjusting shims (8). 3. Tap the bevel gear to downward, and take out the 10T bevel gear (6) with bearing.
Page 363: Removing Differential Gear And Bevel Pinion Shaft
M6040, M7040, WSM FRONT AXLE (2) 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 the bevel pinion shaft (6) using a slide hammer (8).
Page 364: Disassembling Differential Gear
M6040, M7040, WSM FRONT AXLE (3) 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 365 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 366: Servicing
M6040, M7040, WSM FRONT AXLE [4] SERVICING Backlash and Tooth Contact between Bevel Pinion Shaft and Bevel Gear 1. Set a dial indicator (lever type) with its finger on the tooth surface. 2. Measure the backlash by fixing the bevel pinion shaft (2) and moving the bevel gear (1) by hand.
Page 367 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 368 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 369 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. 3. If the turning torque is not within the factory specifications, adjust with the lock nut (1).
Page 370 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 371 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 372 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 Front wheel case 0.57 mm...
Page 373 M6040, M7040, WSM FRONT AXLE Clearance between Front Axle and Front Gear Case 1. Assemble the front axle (1) and 51T gear (4) and related parts with standard thickness of shims (5) and (6) or original shims (5) and (6).
Page 374 M6040, M7040, WSM FRONT AXLE Backlash between 10T Bevel Gear and 51T Bevel Gear 1. Stick a strip of plastigauge to three spots on the 51T bevel gear (6) with grease. 2. Assemble the front axle cover (2) and front gear case (3).
Page 375 STEERING KiSC issued 07, 2012 A...
Page 376 MECHANISM CONTENTS 1. STEERING MECHANISM ......................7-M1 2. STEERING CYLINDER ......................7-M2 KiSC issued 07, 2012 A...
Page 377 M6040, M7040, WSM STEERING 1. STEERING MECHANISM (1) Hydraulic Pump (3) Steering Cylinder (5) Power Steering Pipe To Oil Cooler and Brake (2) Steering Controller (4) Power Steering Hose (6) Magnet Filter Master Cylinder To 3-point Hydraulic System All models are provided with a full hydrostatic power steering. Generally power steerings are divided into 4 types: booster type, integral type, semi-integral type and full hydrostatic type.
Page 378: Steering Cylinder
M6040, M7040, WSM STEERING 2. STEERING CYLINDER (1) Rod (2) Scraper Seal (3) Backup Ring (4) Oil Seal (5) O-ring (6) Piston Seal (7) Piston (8) Guide (9) Bushing (10) Circlip The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.
Page 379 SERVICING CONTENTS 1. TROUBLESHOOTING.........................7-S1 2. SERVICING SPECIFICATIONS ....................7-S2 3. TIGHTENING TORQUES......................7-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............7-S4 [1] CHECKING AND ADJUSTING....................7-S4 (1) Steering Controller......................7-S4 (2) Hydraulic Pump .......................7-S4 [2] REMOVING POWER STEERING CONTROLLER ...............7-S5 (1) ROPS Model........................7-S5 (2) CABIN Model........................7-S6 [3] REMOVING STEERING CYLINDER ..................7-S8 [4] DISASSEMBLING AND ASSEMBLING ................7-S10 (1) Steering Controller......................7-S10...
Page 380: Troubleshooting
M6040, M7040, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Tractor Cannot Be Drive shaft in the power steering controller Reassemble – Steered improper assembled Pipe broken Replace 7-S10 Hard Steering Oil improper Change with G-10 specified oil...
Page 381: Servicing Specifications
M6040, M7040, WSM STEERING 2. SERVICING SPECIFICATIONS POWER STEERING CONTROLLER Item Factory Specification Allowable Limit Relief Valve Setting Pressure At Idling Engine Above – Speed 12.3 MPa 125 kgf/cm 1777.9 psi At Maximum Below – Engine Speed 18.1 MPa 185 kgf/cm 2631.3 psi...
Page 382: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft Power steering delivery hose retaining nut 22.6 to 27.5...
Page 383: Checking, Disassembling And Servicing
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...
Page 384: Removing Power Steering Controller
M6040, M7040, WSM STEERING [2] REMOVING POWER STEERING CONTROLLER (1) ROPS Model Bonnet 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the connector (3) for head lights. 3. Disconnect the damper (4). 4. Remove the bonnet (1) and side cover (2) for both side.
Page 385: Cabin Model
M6040, M7040, WSM STEERING Steering Controller 1. Disconnect the shuttle cable (7). 2. Disconnect the power steering delivery hose 1 (1) and hose 2 (3) from power steering controller. 3. Disconnect the oil cooler pipes (2) and (4). 4. Remove the steering controller mounting screws (5) and steering controller (6).
Page 386 M6040, M7040, WSM STEERING Steering Controller 1. Remove the pipe clamp (2), brake hose (4), power steering pipe (3) and oil cooler pipe (1). 2. Disconnect the power steering delivery hoses (6) and (7). 3. Remove the steering joint shaft mounting screw (5).
Page 387: Removing Steering Cylinder
M6040, M7040, WSM STEERING [3] REMOVING STEERING CYLINDER 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. 4. Pull out the cotter pin and remove the tie-rod end slotted nuts (4).
Page 388 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 389: Disassembling And Assembling
M6040, M7040, WSM STEERING [4] DISASSEMBLING AND ASSEMBLING (1) Steering Controller Removing Gerotor 1. Secure the housing (3) in a vise and remove seven gerotor mounting screws and gerotor assembly (1). 2. Remove the distributor plate (11) and driven shaft (2).
Page 390 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 391: Disassembling Steering Cylinder
M6040, M7040, WSM STEERING (2) Disassembling Steering Cylinder Steering Cylinder 1. Draw out the cylinder head (4). 2. Draw out the cylinder rod (1). (When reassembling) • Apply transmission fluid to the O-ring (3), rod seal (5) and inside of cylinder tube (9).
Page 392: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 07, 2012 A...
Page 393 MECHANISM CONTENTS 1. STRUCTURE..........................8-M1 [1] ROPS MODEL........................8-M1 [2] CABIN MODEL ........................8-M2 2. HYDRAULIC CIRCUIT ....................... 8-M4 [1] TOTAL HYDRAULIC CIRCUIT..................... 8-M4 (1) Except ITA model ......................8-M4 (2) ITA Model ........................8-M5 3. THREE POINT HITCH HYDRAULIC SYSTEM ................8-M6 [1] HYDRAULIC CIRCUIT ......................
Page 394: Structure
M6040, M7040, WSM HYDRAULIC SYSTEM 1. STRUCTURE [1] ROPS MODEL (1) Relief Valve (3-Point Lifting Linkage) (4) Solenoid Valve Assembly (PTO, 4WD) (7) Brake Master Cylinder (10) Hydraulic Outlet (13) Auxiliary Control Valves (16) Oil Filter (2) Cylinder Safety Valve...
Page 395: Cabin Model
M6040, M7040, WSM HYDRAULIC SYSTEM [2] CABIN MODEL (1) Relief Valve (3-Point Lifting Linkage) (4) Solenoid Valve Assembly (PTO, 4WD) (7) Power Steering Controller (10) Hydraulic Outlet (13) Auxiliary Control Valves (16) Oil Filter (2) Cylinder Safety Valve (5) Shuttle Valve...
Page 396 M6040, M7040, WSM HYDRAULIC SYSTEM The hydraulic system of the M6040 and M7040 tractor is composed of a 3-point hitch, remote hydraulic control for implements, power steering, PTO clutch, shuttle clutch, 4WD and hydraulic brakes as shown figure. This system has the following functions.
Page 397: Hydraulic Circuit
M6040, M7040, WSM HYDRAULIC SYSTEM 2. HYDRAULIC CIRCUIT [1] TOTAL HYDRAULIC CIRCUIT (1) Except ITA model (1) Oil Tank (Transmission Case) (11) Power Steering Controller (20) Solenoid Valve (4WD) (27) Shuttle Clutch Pack (2) Hydraulic Oil Filter Cartridge (12) Steering Cylinder...
Page 398: Pto Clutch Pack
M6040, M7040, WSM HYDRAULIC SYSTEM (2) ITA Model (1) Oil Tank (Transmission Case) (11) Power Steering Controller (20) Solenoid Valve (4WD) (27) Shuttle Clutch Pack (2) Hydraulic Oil Filter Cartridge (12) Steering Cylinder (21) Solenoid Valve (PTO) (28) Relief Valve for 3-point...
Page 399: Three Point Hitch Hydraulic System
M6040, M7040, WSM HYDRAULIC SYSTEM 3. THREE POINT HITCH HYDRAULIC SYSTEM [1] HYDRAULIC CIRCUIT (1) Auxiliary Control Valve (2) Flow Priority Valve (3) Control Valve (4) Lowering Speed Adjusting Valve (5) Cylinder Safety Valve (6) Hydraulic Cylinder (Exterior) (7) Relief Valve...
Page 400: Flow Priority Valve
M6040, M7040, WSM HYDRAULIC SYSTEM [2] FLOW PRIORITY VALVE (1) Spring (2) Spool (3) Groove (4) Orifice Pressure Port Neutral Port Tank Port 1. This priority valve controls for 40 L/min (11 U.S.gals/min, 8.8 Imp.gals/min) to flow to the 3P control valve from the hydraulic pump.
Page 401: Hydraulic Block
M6040, M7040, WSM HYDRAULIC SYSTEM [3] HYDRAULIC BLOCK (1) Relief Valve (5) Lift Arm Shaft (10) Control Valve (a) To Implement Cylinder (2) Cylinder Safety Valve (6) Torsion Bar (11) Position Feedback Rod (b) To or From Hydraulic (3) Draft Control Linkage...
Page 402: Linkage Mechanism
M6040, M7040, WSM HYDRAULIC SYSTEM [4] 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 403: Position Control
M6040, M7040, WSM HYDRAULIC SYSTEM (1) Position Control (1) Position Lever Shaft 1 (5) Control Valve (9) Lift Arm Lift (2) Position Link 1 (6) Spool (10) Position Feedback Rod Down (3) Position Link 2 (7) Spool Drive Lever (Position)
Page 404: Draft Control
M6040, M7040, WSM HYDRAULIC SYSTEM (2) Draft Control (1) Draft Link (6) Draft Feedback Lever (11) Lift Arm Lift (2) Draft Link Shaft (7) Control Valve (12) Torsion Bar Down (3) Spool Drive Lever (Draft) (8) Draft Control Valve (13) Draft Feedback Rod...
Page 405: Hydraulic Cylinder
M6040, M7040, WSM HYDRAULIC SYSTEM [5] 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 406 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 ......................8-S5 [2] RELIEF AND SAFETY VALVE ....................8-S7 [3] POSITION AND DRAFT CONTROL LINKAGE..............8-S9 (1) Control Rod ........................8-S9 (2) Position Control ......................8-S10 (3) Draft Control ........................8-S12 (4) Control Lever Operating Force ..................8-S15 [4] AUXILIARY CONTROL VALVE LINKAGE ................8-S16 (1) ROPS Model........................8-S16...
Page 407 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-S9 Raise (Not Noise) damaged Control valve malfunctioning (unload valve, Repair or replace 8-S26 spool, check valve, poppet valve)
Page 408: Servicing Specifications
M6040, M7040, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS HYDRAULIC PUMP Item Factory Specification Allowable Limit Hydraulic Pump for Power Steering Delivery Above 18.0 L/min Condition 21.3 L/min 4.76 U.S.gals/min • Engine speed 5.63 U.S.gals/min 3.96 Imp.gals/min Approx. 2600 min (rpm) 4.69 Imp.gals/min...
Page 409 M6040, M7040, WSM HYDRAULIC SYSTEM POSITION AND DRAFT CONTROL LINKAGE Item Factory Specification Allowable Limit Position Control Rod (ROPS) Length Approx. – 159 mm 6.26 in. Draft Control Rod (ROPS) Length Approx. – 146 mm 5.75 in. Position Control Rod (CABIN) Length Approx.
Page 410: Tightening Torques
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" on page G-13.) Item N·m kgf·m lbf·ft...
Page 411: Checking And Adjusting
M6040, M7040, WSM HYDRAULIC SYSTEM 4. CHECKING AND ADJUSTING [1] HYDRAULIC PUMP Hydraulic Flow Test IMPORTANT • When using flowmeter other than KUBOTA specified flowmeter, be sure to use the instructions with the flowmeter. • Do not close the flowmeter loading valve completely, before testing, because it has no relief valve.
Page 412 M6040, M7040, WSM HYDRAULIC SYSTEM (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) Above Hydraulic pump delivery 21.8 L/min...
Page 413: Relief And Safety Valve
M6040, M7040, WSM HYDRAULIC SYSTEM [2] RELIEF AND SAFETY VALVE Relief Valve Setting Pressure Test Using Pressure Tester (Coupler) 1. Install the relief valve set pressure adaptor G (Code No. 07916-52751) to the male half of the quick coupler and then install a pressure gauge (Code No.
Page 414 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 (see page G-74).
Page 415: Position And Draft Control Linkage
M6040, M7040, WSM HYDRAULIC SYSTEM [3] POSITION AND DRAFT CONTROL LINKAGE (1) Control Rod Adjusting Position Control Rod and Draft Control Rod 1. Be sure to adjust the position control rod (1) length "L1" and draft control rod (3) length "L2".
Page 416: Position Control
M6040, M7040, WSM HYDRAULIC SYSTEM (2) Position Control Adjusting Position Control 1. Attach a weight of approx. 490 N (50 kgf, 110 lbf) to the end of the lower links. 2. Set the position control lever (2) and draft control lever (1) to the lowest position.
Page 417 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 418: Draft Control
M6040, M7040, WSM HYDRAULIC SYSTEM (3) Draft Control Adjusting Draft Control 1. Attach a weight of approx. 490 N (50 kgf, 110 lbf) to the end of the lower links. 2. Start the engine and set the engine speed at 1000 min (rpm).
Page 419 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) (see page G-73) to the top link bracket (3).
Page 420 M6040, M7040, WSM HYDRAULIC SYSTEM Draft Control 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 421: Control Lever Operating Force
M6040, M7040, WSM HYDRAULIC SYSTEM (4) Control Lever Operating Force Position and Draft Control Lever Operating Force 1. Check the position and draft control lever operating force. 2. If measurement is not within the factory specification, adjust the with tightening nuts (3).
Page 422: Auxiliary Control Valve Linkage
M6040, M7040, WSM HYDRAULIC SYSTEM [4] AUXILIARY CONTROL VALVE LINKAGE (1) ROPS Model Preparation 1. Remove the hand accelerator lever grip (1). 2. Remove the shift lever cover 2 (3) and 1 (2). (1) Hand Accelerator Lever Grip (3) Shift Lever Cover 2...
Page 423: Cabin Model
M6040, M7040, WSM HYDRAULIC SYSTEM (2) CABIN Model Preparation 1. Remove the inner cover R.H. 2 (1). (1) Inner Cover R.H. 2 9Y1210143HYS0016US0 Adjusting Wire of Auxiliary Control Valve (Lever Side) 1. Screw in the wire (4) to the rod end (1) fully.
Page 424: Disassembling And Assembling
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 425: 3-Point Hitch Hydraulic Block Assembly
M6040, M7040, WSM HYDRAULIC SYSTEM [2] 3-POINT HITCH HYDRAULIC BLOCK ASSEMBLY (1) Removing 3-point Hitch Hydraulic Block (ROPS Model) Preparation 1. Remove the seat and seat support. 2. Disconnect the auxiliary control valve wire (1). 3. Disconnect the cylinder hoses (4), (6).
Page 426 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 e-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 427: Removing 3-Point Hitch Hydraulic Block (Cabin Model)
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 428: Hydraulic Linkage
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 429 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 430 M6040, M7040, WSM HYDRAULIC SYSTEM Draft Lever 3 and Position Lever 3 1. Tap out the roll pin (3). 2. Remove the position lever 3 (2), washer (1), draft lever 3 (5) and key (4). (1) Washer (4) Key (2) Position Lever 3...
Page 431 M6040, M7040, WSM HYDRAULIC SYSTEM Control Valve and Spool Lever 1. Remove the control valve mounting screws. 2. Remove the E-shaped stopper (3). 3. Take out the control valve (1) and spool lever (2). (When reassembling) • Be sure to fix the O-rings to the control valve and apply grease to them.
Page 432: Control Valve
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 433 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 434: Hydraulic Cylinder
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 435: Relief Valve
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. (See page G-73.) 3. Compress the piston seal to the correct size by installing the piston into the correcting jig (5).
Page 436: Safety Valve
M6040, M7040, WSM HYDRAULIC SYSTEM [7] SAFETY VALVE Disassembling Safety Valve 1. Remove the safety valve assembly (1). 2. Secure the safety valve assembly in a vise. 3. Loosen the lock nut (3), and remove the adjust screw (2). 4. Draw out the spring (4), seat (5) and ball (6).
Page 437: Lowering Speed Adjusting Valve
M6040, M7040, WSM HYDRAULIC SYSTEM [9] LOWERING SPEED ADJUSTING VALVE Disassembling Lowering Speed Adjusting Valve 1. Remove the plate (1). 2. Remove out the roll pin (2) using a vice grip pliers. 3. Remove the lowering speed adjusting valve assembly (3).
Page 438: Servicing
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 (When installing) •...
Page 439 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 (When installing) •...
Page 440 ELECTRICAL SYSTEM KiSC issued 07, 2012 A...
Page 441 MECHANISM CONTENTS 1. WIRING DIAGRAM........................9-M1 [1] ROPS MODEL........................9-M1 (1) Main Harness ......................... 9-M1 [2] CABIN MODEL ........................9-M2 (1) Main Harness (Except ITA Model).................. 9-M2 (2) Main Harness (ITA Model)....................9-M3 (3) Cabin Harness........................ 9-M4 (4) Engine Harness ......................9-M5 2.
Page 442: Wiring Diagram
M6040, M7040, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM [1] ROPS MODEL (1) Main Harness 9-M1 KiSC issued 07, 2012 A...
Page 443: Cabin Model
M6040, M7040, WSM ELECTRICAL SYSTEM [2] CABIN MODEL (1) Main Harness (Except ITA Model) 9-M2 KiSC issued 07, 2012 A...
Page 444: Main Harness (Ita Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (2) Main Harness (ITA Model) 9-M3 KiSC issued 07, 2012 A...
Page 445: Cabin Harness
M6040, M7040, WSM ELECTRICAL SYSTEM (3) Cabin Harness 9-M4 KiSC issued 07, 2012 A...
Page 446: Engine Harness
M6040, M7040, WSM ELECTRICAL SYSTEM (4) Engine Harness 9-M5 KiSC issued 07, 2012 A...
Page 447: Electrical Circuit Detailed Chart
M6040, M7040, WSM ELECTRICAL SYSTEM 2. ELECTRICAL CIRCUIT DETAILED CHART [1] ROPS MODEL (1) Starting System, Charging System and Power Supply (1) Slow Blow Fuse Box (9) Starter Motor (17) PTO Valve (Solenoid) (25) Working Lamp Front Side L.H. (12 V, 21 W)
Page 448: Lighting System
M6040, M7040, WSM ELECTRICAL SYSTEM (2) Lighting System (1) Hazard Switch (14 V, 1.4 W) (7) Head Light HI Relay (13) Head Light R.H. (H4 12 V, 55/60 W) (18) Tail/Stop Lamp (5/21 W) (A) Key/Light (c) Fuse (Horn) (2) Combination Light Switch (8) Brake Switch R.H.
Page 449: 4Wd System
M6040, M7040, WSM ELECTRICAL SYSTEM (3) 4WD System (1) 4WD Switch (12 V, 3 W) (3) Diode (4WD Brake) (5) Diode (PTO/DT) (A) Key/IG (a) Fuse (T/M Control) (c) To Meter Panel (2) Brake Switch L.H. (4) DT Valve (Solenoid) (b) To Brake Switch R.H.
Page 450: Instrument Panel Board (Meter Panel)
M6040, M7040, WSM ELECTRICAL SYSTEM (4) Instrument Panel Board (Meter Panel) (1) Display Mode Swlect Switch (9) Charge Indicator (17) Trailer Indicator (25) Engine Coolant Temperature Sensor (A) Light / Defogger (e) To Light Switch (High Beam) (2) PTO/Hour (10) PTO Indicator...
Page 451: Cabin Model
M6040, M7040, WSM ELECTRICAL SYSTEM [2] CABIN MODEL (1) Starting System and Charging System (Except ITA Model) (1) Slow Blow Fuse Box 2, 3 (10) Battery (19) PTO Switch (A) Head Light (c) Fuse (Radio) (m) To Rear Diff. Lock Switch...
Page 452: Starting System And Charging System (Ita Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (2) Starting System and Charging System (ITA Model) (1) Slow Blow Fuse Box 2, 3 (10) Battery (19) PTO Switch (A) Head Light (d) Fuse (Air Conditioner (Control)) (n) To Dual Speed Switch (2) Blower...
Page 453: Lighting System
M6040, M7040, WSM ELECTRICAL SYSTEM (3) Lighting System (1) Hazard Switch (14 V, 1.4 W) (8) Dome Light (Room) (12 V, 5 W) (15) Licence Light (12 V / 10 W) (22) Rear Combination Lamp R.H. (12 V, 5/21 W) (a) Fuse (Flasher, Hazard) (g) To Meter Panel (12: Turn R.H.)
Page 454: 4Wd System
M6040, M7040, WSM ELECTRICAL SYSTEM (4) 4WD System (1) 4WD Switch (14 V, 1.12 W) (3) Diode (4WD Brake) (5) Diode (PTO/DT) (A) Key/IG (a) Fuse (T/M Control, Alternator, PTO, Engine) (d) To Meter Panel (2) Brake Switch L.H. (4) DT Valve (Solenoid...
Page 455: Instrument Panel Board (Meter Panel) (Except Ita Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (5) Instrument Panel Board (Meter Panel) (Except ITA Model) (1) Display Mode Select Switch (10) Charge Indicator (19) 4WD Indicator (28) Engine Coolant Temperature Sensor (a) To Main Key (Start) (h) To Flasher Unit (Trailer)
Page 456: Instrument Panel Board (Meter Panel) (Ita Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (6) Instrument Panel Board (Meter Panel) (ITA Model) (1) Display Mode Select Switch (10) Charge Indicator (19) 4WD Indicator (27) Fuel Sensor (A) Light / Defogger (g) To Flasher Unit (Output R) (2) PTO/Hour (11) PTO Indicator...
Page 457: Working Light And Radio
M6040, M7040, WSM ELECTRICAL SYSTEM (7) Working Light and Radio (1) Working Light Relay (6) Front Working Lamp L.H. (12 V, 55 W) (10) Rear Working Light Switch (14 V, 1.12 W) (14) Antenna (A) Light/DEF (a) Fuse (Work Light Front) (2) Beacon Switch (14 V, 1.12 W)
Page 458: Air Conditioner
M6040, M7040, WSM ELECTRICAL SYSTEM (8) Air Conditioner (1) Servomotor Temperature Control (6) Servomotor FRS/REC (11) A/C Indicator (16) Surge Cut Diode (A) Blower Motor (a) To Light Switch (2) Illumination Lamp (14 V, 1.96 W) (7) F/R Indicator (12) A/C Switch...
Page 459: Wiper System
M6040, M7040, WSM ELECTRICAL SYSTEM (9) Wiper System (1) Front Wiper Motor (3) Front Wiper Switchy (5) Washer Motor (6) Rear Wiper Switch (7) Rear Wiper Motor (A) Key ACC (2) Front Wiper Motor Relay (4) Front Wiper Relay/Timer (a) Fuse (Wiper)
Page 460: Starting System
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 461: Cabin Model
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 (11) Key Stop Relay...
Page 462: Instrument Panel
M6040, M7040, WSM ELECTRICAL SYSTEM 4. INSTRUMENT PANEL [1] INDICATION ITEMS OF METER PANEL (1) Hazard / Turn Signal Indicator (2) High Beam Indicator (3) Trailer Indicator (4) PTO Clutch Indicator (5) Liquid Crystal Display (6) Electrical Charge Indicator (7) Engine Oil Pressure Indicator...
Page 463: Easy Checker
M6040, M7040, WSM ELECTRICAL SYSTEM [2] EASY CHECKER™ If the warning lamps in the Easy Checker™ come on during operation, immediately stop the engine, and find the cause as shown below. Never operate the tractor while Easy Checker™ lamp is on.
Page 464: Lcd Monitor Indication
M6040, M7040, WSM ELECTRICAL SYSTEM [3] LCD MONITOR INDICATION (1) LCD Monitor (3) PTO/Hour Meter Select (5) PTO Indication [A] ROPS Model (2) Traveling Speed Select Switch [B] CABIN Model Switch (4) Hour Meter Indication The LCD monitor gives three different modes: "display mode", "setting mode" and "checking mode".
Page 465: Setting Mode
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) Traveling Speed Select mph (Traveling Speed) Switch km/h (Traveling Speed) (2) LCD Monitor 9Y1210143ELM0026US0 When Operate PTO Clutch Control Switch (At hour meter mode) •...
Page 466: Checking Mode
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 467: Lighting System
M6040, M7040, WSM ELECTRICAL SYSTEM 5. LIGHTING SYSTEM [1] COMPONENTS (1) Flasher Unit Flasher Unit The function of flasher unit is as follows. 1. The flasher unit blinks the turn signal light (3), (4) and hazard indicator light (2) when the hazard switch (13) is turned on.
Page 468 M6040, M7040, WSM ELECTRICAL SYSTEM 6. TRAILER SOCKET The trailer socket is provided to take out the electrical power from tractor to trailer or implement. Terminal Function Color of wire harness Turn signal light (L.H.) Green / White – –...
Page 469 SERVICING CONTENTS 1. TROUBLESHOOTING.........................9-S1 2. SERVICING SPECIFICATIONS ....................9-S7 3. TIGHTENING TORQUES......................9-S8 4. CHECKING AND ADJUSTING....................9-S9 [1] BATTERY, FUSE, GROUNDING AND CONNECTOR ............9-S9 (1) Battery ..........................9-S9 (2) Checking Fuse.......................9-S11 (3) Checking Grounding Wires....................9-S13 (4) Connector ........................9-S14 [2] MAIN SWITCH ........................9-S14 (1) Main Switch (ROPS Model)...................9-S14 (2) Main Switch (CABIN Model) ..................9-S15 [3] GLOW PLUG ........................9-S16 [4] STARTER MOTOR ......................9-S17...
Page 470 M6040, M7040, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Recharge or replace 9-S10 Equipments Do Not Battery positive cable disconnected or improperly Repair or replace 9-S9 Operate connected Battery negative cable disconnected or...
Page 471 M6040, M7040, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown Replace 9-S11 Light Bulb blown Replace G-40 Lighting switch defective Replace 9-S36 Illumination Light Fuse blown Replace 9-S11 Does Not Light...
Page 472 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 Replace...
Page 473 M6040, M7040, WSM ELECTRICAL SYSTEM Reference Symptom Probable Cause Solution Page Air Cleaner Clogged Air cleaner clogged Clean or replace G-24 Lamp Lights Up Air cleaner sensor defective Repair or replace 9-S35 Short circuit between air cleaner sensor lead and...
Page 474 M6040, M7040, WSM ELECTRICAL SYSTEM ENGINE KEY SWITCH SHUT-OFF SYSTEM Reference Symptom Probable Cause Solution Page Engine Does Not Fuse blown Replace 9-S11 Stop When Main Key stop relay defective Replace 9-S43 Switch Is Turned OFF Engine stop relay defective...
Page 475 M6040, M7040, WSM ELECTRICAL SYSTEM LCD MONITOR Reference Symptom Probable Cause Solution Page Nothing is Displayed Battery discharged or defective (Battery voltage Recharge or replace 9-S10 in LCD is below 10 V) Slow blow fuse blown Replace 9-S11 Meter panel connector disconnect...
Page 476: Flasher Unit
M6040, M7040, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS STARTER MOTOR Item Factory Specification Allowable Limit Commutator O.D. 32.0 mm 31.4 mm 1.26 in. 1.24 in. Mica Undercut 0.50 to 0.80 mm 0.2 mm 0.020 to 0.031 in. 0.0079 in. Brush Length 18.0 mm...
Page 477 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" on page G-13) Item N·m kgf·m lbf·ft...
Page 478: Checking And Adjusting
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 479 M6040, M7040, WSM ELECTRICAL SYSTEM Recharging CAUTION • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
Page 480: Checking Fuse
M6040, M7040, WSM ELECTRICAL SYSTEM (2) Checking Fuse 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 481 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 482: Checking Grounding Wires
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 483: Connector
M6040, M7040, WSM ELECTRICAL SYSTEM (4) Connector Checking Connector 1. When inspect the circuit line, check the related connectors. 2. Disconnect the connectors and check their terminals for contamination and deformation. 3. Check to see that cable does not broken or terminals are not shelled off.
Page 484: Main Switch (Cabin Model)
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 485: Glow Plug
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 486: Starter Motor
M6040, M7040, WSM ELECTRICAL SYSTEM [4] STARTER MOTOR Starter Motor Terminal B Voltage 1. Measure the voltage with a voltmeter across the terminal B and chassis. 2. If the voltage differs from the battery voltage, the battery's positive cable or the battery negative cable is faulty.
Page 487: Engine Stop Solenoid
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. 4. Disconnect the connecting lead (3) from the starter terminal C (2).
Page 488: Alternator
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 9Y1210143ELS0030US0 Connector Voltage 1. Turn off the main switch. Measure the voltage between the terminal B (1) and the chassis.
Page 489: Meter Panel
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 490 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 491 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 492 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 493 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 494: Checking Meter Panel, Pto/Hour Meter Select Switch And Traveling Speed Select Switch
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 495 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 496 M6040, M7040, WSM ELECTRICAL SYSTEM Terminal Color of Terminal Name Measuring across T40 (Ground) Condition wiring Engine tachometer sensor Battery voltage Main switch at ON Main switch (ON position) Battery voltage Main switch at ON Main voltage (battery) Battery voltage...
Page 497: Switch And Sensor
M6040, M7040, WSM ELECTRICAL SYSTEM (4) Switch and Sensor Checking Engine Oil Pressure Switch 1. Measure the resistance with an ohmmeter across the switch terminal and the chassis. 2. If 0 ohm is not indicated in the normal state, the switch is faulty.
Page 498 M6040, M7040, WSM ELECTRICAL SYSTEM PTO Switch 1) Connector Voltage 1. Remove the PTO switch connector (3). 2. Turn the main switch ON position. 3. Measure the voltage across terminal 2 (a) and chassis. 4. If the voltage differs from battery voltage, the wiring harness, fuse, or main switch is faulty.
Page 499 M6040, M7040, WSM ELECTRICAL SYSTEM Shuttle Neutral Switch 1) Shuttle Neutral Switch Continuity 1. Check the continuity with an ohmmeter across the switch terminals. 2. If it does not conduct or any value is indicated when the switch is pushed, the switch is faulty.
Page 500 M6040, M7040, WSM ELECTRICAL SYSTEM Brake Switch 1) Wiring Harness 1. Disconnect the leads from the brake switch (1). 2. Connect the wiring harness lead terminals to each other and turn the main switch ON. 3. If the stop lights do not light, the fuse, wiring harness or bulb is faulty.
Page 501 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 502 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 503 M6040, M7040, WSM ELECTRICAL SYSTEM 2) 4WD Switch 1. Check the continuity through switch with an ohmmeter. 2. If continuity specified below are not indicated, the switch is faulty. (1) 4WD Switch (4) Terminal W/L for Illumination (2) 4WD Switch Connector...
Page 504 M6040, M7040, WSM ELECTRICAL SYSTEM Air Cleaner Sensor 1) Wiring Harness 1. Disconnect the leads from the air cleaner sensor (1) after turning the main switch OFF. 2. Turn the main switch ON and connect a jumper lead between the leads.
Page 505: Lighting Switches And Flasher Unit
M6040, M7040, WSM ELECTRICAL SYSTEM Ground PTO Switch (ITA Model) 1) Ground PTO Switch Continuity 1. Check the continuity with an ohmmeter across the switch connector (2). 2. If it does not conduct or any value is indicated when the switch is pushed, the switch is faulty.
Page 506: Lever Combination Switch And Horn Switch (Cabin Model)
M6040, M7040, WSM ELECTRICAL SYSTEM Checking Light Switch and Turn Signal Switch 1. Test the continuity through the switch with an ohmmeter. (1) Turn Signal Switch (a) Right Turn (2) Combination Switch (b) OFF (3) Horn Switch (c) Left Turn...
Page 507 M6040, M7040, WSM ELECTRICAL SYSTEM Checking Light Switch and Turn Signal Switch 1. Test the continuity through the switch with an ohmmeter. 2. If the continuity specified below is not indicated, the switch is faulty. (1) Lever Combination Switch (a) Right Turn...
Page 508: Hazard Switch
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 each terminal c/e and chassis. 2. If the voltage differ from the battery voltage, the wiring harness is faulty.
Page 509: Flasher Unit
M6040, M7040, WSM ELECTRICAL SYSTEM (4) Flasher Unit Flasher Unit 1. Disconnect the connector from the flasher unit. 2. Turn the main switch at ON position. 3. Measure the voltage between the terminal 12, 13 and chassis. 4. If the voltage differ from the battery voltage, the wiring harness is faulty.
Page 510: Front Work Light Switch (Rops Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (5) Front Work Light Switch (ROPS Model) Checking Connector Voltage 1. Turn the main switch to ON position. 2. Measure the voltage with a voltmeter across the terminal a and chassis. 3. If the voltage differ from the battery voltage, the wiring harness or fuse is faulty.
Page 511: Front/Rear Work Light And Beacon Light Switch (Cabin Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (6) Front/Rear Work Light and Beacon Light Switch (CABIN Model) Checking Connector Voltage 1. Turn the main switch to ON position. 2. Measure the voltage with a voltmeter across the terminal b and chassis. 3. If the voltage differ from the battery voltage, the wiring harness or fuse is faulty.
Page 512: Starter Relay And Glow Relay
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 513 M6040, M7040, WSM ELECTRICAL SYSTEM (2) Relays (ROPS Model) Checking Connector Voltage 1. Measure the voltage with a voltmeter across the battery terminal and chassis as table below. 2. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.
Page 514 M6040, M7040, WSM ELECTRICAL SYSTEM Functional Check 1. Apply battery voltage across the terminals a and c, and check for continuity across the terminals d and e. 2. If continuity is not established across terminals d and e, replace (1) Battery...
Page 515: Relays (Cabin Model)
M6040, M7040, WSM ELECTRICAL SYSTEM (3) Relays (CABIN Model) Checking Connector Voltage 1. Measure the voltage with a voltmeter across the battery terminal and chassis as table below. 2. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.
Page 516: Solenoid Valve
M6040, M7040, WSM ELECTRICAL SYSTEM Functional Check 1. Apply battery voltage across the terminals a and c, and check for continuity across the terminals d and e. 2. If continuity is not established across terminals d and e, replace (1) Battery...
Page 517: Disassembling And Assembling
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 518 M6040, M7040, WSM ELECTRICAL SYSTEM Rotor 1. Remove the 4 screws and detach the bearing retainer. 2. Temporarily install the nut on the pulley screw, and detach the rotor. 9Y1210143ELS0080US0 Brush 1. When the rotor is detached, the 2 brushes are found to stretch out of the shaft hole.
Page 519: Fuse (Slow Blow 100 A) For Cabin Model
M6040, M7040, WSM ELECTRICAL SYSTEM Bearing at Slip Ring Side 1. Lightly secure the rotor (1) with a vise to prevent damage, and remove the bearing (2) with a puller (3). (1) Rotor (3) Puller (2) Bearing 9Y1210143ELS0083US0 [3] FUSE (SLOW BLOW 100 A) FOR CABIN MODEL...
Page 520: Servicing
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 521 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 522: Alternator
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 523 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 524 CABIN KiSC issued 07, 2012 A...
Page 525 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 526: Air Conditioning System
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 (9) Dashboard Blow Port...
Page 527: Compressor
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 528: Air Conditioner Unit
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 529: System Control
M6040, M7040, WSM CABIN [4] SYSTEM CONTROL (1) Fresh Air Inlet Port (10) D1: Air Intake Door (A) Control Pane (e) Air is blown from only the (2) Heater (11) Recirculated Air Inlet Port (B) Block Diagram of Air Flow...
Page 530: Air Flow
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 531: Electrical System
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 (8) Blower Relay...
Page 532: Blower Relay And Compressor Relay
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 533: Blower Switch
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 534 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-S9 (1) Manifold Gauge Set.......................10-S9 (2) Refrigerant Charging Hose..................10-S10 (3) Vacuum Pump Adaptor ....................10-S11 (4) Electric Gas Leak Tester .....................10-S11 (5) Can Tap Valve......................10-S11 (6) T-joint...........................10-S12 (7) R134a Refrigerant Recover and Recycling Machine...........10-S12...
Page 535 M6040, M7040, WSM CABIN 1. TROUBLESHOOTING COMPRESSOR Reference Symptom Probable Cause Solution Page Noisy Bearing of compressor worn or damaged Replace 10-S42 (Compressor ON) Valves in compressor damaged Replace 10-S42 Belt slipping Adjust or replace 10-S42 Compressor bracket mounting screws loosen Tighten –...
Page 536 M6040, M7040, WSM CABIN Reference Symptom Probable Cause Solution Page Insufficient Cooling Belt slipping Adjust or replace 10-S42 (Compressor Does Magnetic clutch defective Repair or replace 10-S22 Not Rotate Properly) Compressor defective Replace 10-S42 Insufficient Cooling Thermostat defective Replace –...
Page 537 M6040, M7040, WSM CABIN Reference Symptom Probable Cause Solution Page Insufficient Cooling Refrigerant overcharged Check with manifold 10-S21 (Low-pressure Level gauge is Too High) Heat-sensitive tube in poor contact Check and repair – Expansion valve too open Replace – Insufficient Cooling...
Page 538 M6040, M7040, WSM CABIN WINDSHIELD WIPER Reference Symptom Probable Cause Solution Page Windshield Wiper Fuse blown (Short-circuit, burnt component Correct cause and 9-S11 Does Not Operate inside motor or other part for operation) replace Wiper motor defective (Broken armature, worn...
Page 539: Servicing Specifications
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. Magnetic Clutch Stator Coil Resistance 3.0 to 4.0 Ω – Refrigerating Cycle Pressure 0.15 to 0.20 MPa...
Page 540 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" on page G-13.) Item N·m kgf·m lbf·ft Power steering joint shaft mounting screw 23.6 to 27.4...
Page 541: Precautions At Repairing Refrigerant Cycle
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 542 M6040, M7040, WSM CABIN (Continued) (Refrigerant) R134a Kinds of refrigerant Factory specification 0.85 to 0.95 kg (Charge amount) 1.87 to 2.09 lbs (Compressor Oil) Quantity (Total) Brand Name 100 to 120 cc ND-OIL 8 0.106 to 0.127 U.S.qts <PAG* oil>...
Page 543: Manifold Gauge Set
M6040, M7040, WSM CABIN [1] HANDLING OF SERVICE TOOLS (1) Manifold Gauge Set The hand valves on the manifold gauge set are used to open and close the valve. The hand valve inscribed LO is for the low pressure side valve (5) and HI is for the high pressure side valve (3).
Page 544: Refrigerant Charging Hose
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 545: Vacuum Pump Adaptor
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 (2) is stopped, since there is vacuum in hoses within the gauge manifold, the vacuum pump oil flows back into the charging hose.
Page 546: T-Joint
M6040, M7040, WSM CABIN (6) T-joint T-joint (2) is used to increase efficiency of gas charging using two refrigerant containers (4) at a time. 1. Install two refrigerant container service valves to T-joint (2) sides and connect the charging hose (1) to it.
Page 547: Checking And Charging Refrigerant Cycle
M6040, M7040, WSM CABIN 5. CHECKING AND CHARGING REFRIGERANT CYCLE [1] CHECKING WITH MANIFOLD GAUGE NOTE • 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 548 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 (7 to 10 kgf/cm...
Page 549 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) HI pressure side (2) 1.96 to 2.45 MPa (20 to 25 kgf/cm...
Page 550 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 551: Discharging, Evacuating And Charging
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 552: Evacuating The System
M6040, M7040, WSM CABIN (2) Evacuating the System 9Y1210143CAS0028US0 Evacuating the System 1. Discharge refrigerant from the system by R134a refrigerant recovery and recycling machine. (See page 10-S17.) 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 553: Charging The Refrigerant
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 554 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 555: Checking Charge Refrigerant Amount
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 556: Checking, Disassembling And Servicing
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 engine. 2. Check whether abrasion or abnormal noise is heard when only the magnetic clutch pulley is running.
Page 557: Wiper Relay
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 558: Control Panel (Blower Switch, A/C Switch, Mode Control Dial, Temperature Control Dial And Recirculation/Fresh Air Selection Switch)
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 559 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 560 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 561: Blower Resistor
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 562: Temperature Motor
M6040, M7040, WSM CABIN (7) Temperature Motor Temperature Motor Checking 1. Confirm whether the temperature control dial (2) is defective. (See page 10-S24.) 2. Turn the main switch to "ON" position. 3. Turn the blower switch (3) at 1 position.
Page 563: Recirculation/Fresh Air Motor
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. (See page 10-S24.) 2. Turn the main switch to "ON" position. 3. Turn the blower switch at 1 position.
Page 564: Pressure Switch
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 565: Front Wiper Switch
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 566: Rear Wiper Switch (If Equipped)
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 567: Disassembling And Assembling
M6040, M7040, WSM CABIN [2] DISASSEMBLING AND ASSEMBLING (1) Separating Cabin from Tractor Drain 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 568 M6040, M7040, WSM CABIN Preparation 1 1. Open the bonnet (2) and disconnect the battery (3) negative terminal and 6P connector (5) for head light. 2. Remove the bonnet dampers (6) and bonnet (2). 3. Remove the both side covers (4).
Page 569 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 570 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 571 M6040, M7040, WSM CABIN Preparation 5 1. Disconnect the clutch cable (1). 2. Remove the shuttle select rod mounting nut (2) from shuttle select rod (4) then disconnect the shuttle select rod (4). 3. Disconnect the shuttle cable (3). (When reassembling) •...
Page 572 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 step (2). 4. Remove the breather hose (3) and fuel tank (1).
Page 573 M6040, M7040, WSM CABIN Preparation 7 1. Disconnect the auxiliary control wires (2). 2. Disconnect the lowering speed adjusting rod (1). 3. Disconnect the ground cable (3). 4. Remove the external control rod (4). (1) Lowering Speed Adjusting Rod (3) Ground Cable...
Page 574 M6040, M7040, WSM CABIN Preparation 8 1. Disconnect the position control rod (2) and draft control rod (1). 2. Disconnect the select cable (4). 3. Remove the differential lock rod (3). 4. Disconnect the range gear shift rod (5). 5. Disconnect the main gear shift rod (6).
Page 575 M6040, M7040, WSM CABIN Dismounting Cabin 1. Remove the cabin mounting all screws and nut (1). 2. Set the cabin dismounting tool (2) to the cabin. 3. Dismounting the cabin from tractor body. (When reassembling) 124 to 147 N·m Cabin mounting screw and Tightening torque 12.6 to 15.0 kgf·m...
Page 576: Removing And Disassembling Compressor Assembly
M6040, M7040, WSM CABIN (2) Removing and Disassembling Compressor Assembly Compressor Assembly 1. Discharge the refrigerant from the system. (See page 10-S17.) 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 577 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. (See page G-77.) 2. The stopper magnet clutch (2) is hung on hub plate (3) and it is fixed that the compressor rotates.
Page 578: Removing Air Conditioner Unit
M6040, M7040, WSM CABIN (3) Removing Air Conditioner Unit Draining Coolant 1. See page 10-S33. 9Y1210143CAS0073US0 Discharging Refrigerant Gas 1. See page 10-S17. 9Y1210143CAS0074US0 Seat, Floor Mats and Floor Cover 1. Disconnect the battery negative cable from battery. 2. Remove the seat (1).
Page 579 M6040, M7040, WSM CABIN Air Conditioner Ducts and Covers 1. Remove the duct 1 (1). 2. Remove the parking brake lever (2). 3. Remove the inner cover (L.H.) (3). 4. Remove the duct 2 (4). 5. Remove the seat under cover 1 (5).
Page 580 M6040, M7040, WSM CABIN Wiring Harness 1. Disconnect the 2P connector (1) for pressure switch. 2. Disconnect the 2P connector (2) for blower motor. 3. Disconnect the 4P connector (8) for blower resistor. 4. Disconnect the 5P connector (7) for recirculation/fresh air selection motor.
Page 581: Removing Air Conditioner Pipes
M6040, M7040, WSM CABIN (4) Removing Air Conditioner Pipes Discharging Refrigerant Gas 1. See page 10-S17. 9Y1210143CAS0074US0 Cover and Guide 1. Remove the both side panel guides (3). 2. Remove the both side panels (2). 3. Remove the both side covers (1).
Page 582: Removing Heater Hoses
M6040, M7040, WSM CABIN High Pressure Pipe 2 and Low Pressure Pipe 1. Remove the rubber (1) and pressure pipes joint mounting screw. 2. Remove the pressure pipes joint. 3. Disconnect the high pressure pipe 2 (3) and low pressure pipe (2), then cap the open fitting immediately to keep moisture out of the system.
Page 583 M6040, M7040, WSM CABIN Seat, Mats and Floor Cover 1. See page 10-S44. 9Y1210143CAS0082US0 Air Conditioner Ducts and Covers 1. See page 10-S45. 9Y1210143CAS0083US0 Inner Cover (R.H.) 1. Remove the hand accelerator lever grip (9). 2. Remove the range gear shift lever grip (1).
Page 584: Cab Windshield
M6040, M7040, WSM CABIN (6) Cab Windshield Preparation 1. Prepare the followings. • Cutter knife: 1 piece • Scraper: 1 piece • Gun for coating: 1 piece • Sika Tack-Ultrafast or equivalent • Sika-cleaner No. 1 • Gummed tape NOTE •...
Page 585 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 586: Wiper Motor
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 587: Servicing
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 (3). 4. Remove the wiper link cap (1) and nut (2).
Page 588 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 2012. 07, S, EI, EI, engusa Code No.9Y111-01434 2008.

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M7040

wsm M6040 Workshop Manual

Information

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 Check List

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

6 Intake and Exhaust System

7 Exhaust Gas Recirculation (Egr) System

Servicing

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

Mechanism

1 Structure

2 Power Train for Traveling Gear

3 Lubrication for Transmission

4 Power Train for Pto System

5 Power Train for 4Wd

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

5 Disassembling and Assembling

6 Servicing

Servicing

Mechanism

1 Traveling Brake

2 Parking Brake

Servicing

Servicing

Servicing

Mechanism

1 Structure

2 Hydraulic Circuit

3 Three Point Hitch Hydraulic System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for wsm M6040