Page 1 WORKSHOP MANUAL TRACTOR M8560,M9960 KiSC issued 08, 2012 A...
Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the M8560 and M9960. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing". � Information This section primarily contains information below. • Safety First •...
Page 3 INFORMATION KiSC issued 08, 2012 A...
Page 4: Table Of Contents
INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-5 3. SPECIFICATIONS........................I-18 4. TRAVELING SPEEDS........................I-20 5. DIMENSIONS ..........................I-28 KiSC issued 08, 2012 A...
Page 5: Safety First
INFORMATION M8560, M9960, WSM 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 INFORMATION M8560, M9960, WSM 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 INFORMATION M8560, M9960, WSM AVOID HOT EXHAUST • Servicing machine or attachments with engine running can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components. • Exhaust parts and streams become very hot during operation.
Page 8 INFORMATION M8560, M9960, WSM DISCARD FLUIDS CORRECTLY • Do not discard fluids on the ground, down the drain, into a stream, pond, or lake. Obey related environmental protection regulations when you discard oil, fuel, coolant, electrolyte and other dangerous waste.
Page 9: Safety Decals
INFORMATION M8560, M9960, WSM 2. SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
Page 10 INFORMATION M8560, M9960, WSM 9Y1210686INI0002US0 KiSC issued 08, 2012 A...
Page 11 INFORMATION M8560, M9960, WSM 9Y1210686INI0003US0 KiSC issued 08, 2012 A...
Page 12 INFORMATION M8560, M9960, WSM 9Y1210686INI0004US0 KiSC issued 08, 2012 A...
Page 13 INFORMATION M8560, M9960, WSM ROPS (Low Profile) Model 9Y1210686INI0010US0 KiSC issued 08, 2012 A...
Page 14 INFORMATION M8560, M9960, WSM 9Y1210686INI0011US0 I-10 KiSC issued 08, 2012 A...
Page 15 INFORMATION M8560, M9960, WSM 9Y1210686INI0012US0 I-11 KiSC issued 08, 2012 A...
Page 16 INFORMATION M8560, M9960, WSM 9Y1210686INI0013US0 I-12 KiSC issued 08, 2012 A...
Page 17 INFORMATION M8560, M9960, WSM CABIN Model 9Y1210686INI0005US0 I-13 KiSC issued 08, 2012 A...
Page 18 INFORMATION M8560, M9960, WSM 9Y1210686INI0006US0 I-14 KiSC issued 08, 2012 A...
Page 19 INFORMATION M8560, M9960, WSM 9Y1210686INI0007US0 I-15 KiSC issued 08, 2012 A...
Page 20 INFORMATION M8560, M9960, WSM 9Y1210686INI0008US0 I-16 KiSC issued 08, 2012 A...
Page 21 INFORMATION M8560, M9960, WSM 9Y1210686INI0009US0 CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
Page 22: Specifications
INFORMATION M8560, M9960, WSM 3. SPECIFICATIONS M8560 M9960 Model Model V3800-CR-TE4 V3800-CR-TIE4 4 cylinder in-line, Common Rail System, 4 cylinder in-line, Common Rail System, Type direct injection direct injection with inter cooler Number of cylinders Total displacement 3769 cm (230 cu.in.) Bore and stroke 100 ×...
Page 23 INFORMATION M8560, M9960, WSM M8560 M9960 Model Hydraulic control system Position, draft (top link sensing) and mix control ROPS 60.0 L/min.(15.9 U.S.gals/min, 13.2 Imp.gals/min) Pump capacity CABIN 64.3 L/min.(17.0 U.S.gals/min, 14.1 Imp.gals/min) Three point hitch Category 2 3200 kg (7055 lbs),...
Page 24: Traveling Speeds
INFORMATION M8560, M9960, WSM 4. TRAVELING SPEEDS ROPS Model (without Low Profile Model) (At rated engine rpm) M8560 / M9960 Model F8/R8 Model F12/R12 Model Tire size (Rear) 18.4-30 Shuttle shift Range gear Main gear shift km/h km/h lever shift lever lever 0.35...
Page 25 INFORMATION M8560, M9960, WSM (At rated engine rpm) M8560 / M9960 Model F8/R8 Model F12/R12 Model Tire size (Rear) 18.4-30 Shuttle shift Range gear Main gear shift km/h km/h lever shift lever lever 0.35 0.22 0.36 0.22 0.53 0.33 0.49 0.31...
Page 26 INFORMATION M8560, M9960, WSM ROPS Model (with Low Profile Model) (At rated engine rpm) M9960 Model F12/R12 Model Tire size (Rear) 16.9-24 Shuttle shift Range gear Main gear shift km/h lever shift lever lever 0.31 0.19 0.42 0.26 0.54 0.34...
Page 27 INFORMATION M8560, M9960, WSM (At rated engine rpm) M9960 Model F12/R12 Model Tire size (Rear) 16.9-24 Shuttle shift Range gear Main gear shift km/h lever shift lever lever 0.30 0.19 0.42 0.26 0.54 0.34 CREEP (option) 0.69 0.43 0.86 0.54 1.23...
Page 28 INFORMATION M8560, M9960, WSM CABIN Model (without Dual Speed Type) (At rated engine rpm) M8560 / M9960 Model F8/R8 Model F12/R12 Model Tire size (Rear) 18.4-30 Shuttle shift Range gear Main gear shift km/h km/h lever shift lever lever 0.38 0.24...
Page 29 INFORMATION M8560, M9960, WSM (At rated engine rpm) M8560 / M9960 Model F8/R8 Model F12/R12 Model Tire size (Rear) 18.4-30 Shuttle shift Range gear Main gear shift km/h km/h lever shift lever lever 0.38 0.24 0.39 0.24 0.58 0.36 0.53 0.33...
Page 30 INFORMATION M8560, M9960, WSM CABIN Model (with Dual Speed Model) (At rated engine rpm) M9960 Model F24/R24 Model Tire size (Rear) 18.4-30 Dual speed : H Dual speed : L Shuttle shift Range gear Main gear shift lever shift lever...
Page 31 INFORMATION M8560, M9960, WSM (At rated engine rpm) M9960 Model F24/R24 Model Tire size (Rear) 18.4-30 Dual speed : H Dual speed : L Shuttle shift Range gear Main gear shift lever shift lever lever km/h km/h 0.39 0.24 0.33 0.21...
Page 32: Dimensions
INFORMATION M8560, M9960, WSM 5. DIMENSIONS ROPS Model 9Y1210686INI0020US0 I-28 KiSC issued 08, 2012 A...
Page 33 INFORMATION M8560, M9960, WSM ROPS (Low Profile) Model 9Y1210686INI0022US0 I-29 KiSC issued 08, 2012 A...
Page 34 INFORMATION M8560, M9960, WSM CABIN Model 9Y1210686INI0021US0 I-30 KiSC issued 08, 2012 A...
Page 35 GENERAL KiSC issued 08, 2012 A...
Page 36 GENERAL CONTENTS 1. TRACTOR IDENTIFICATION....................... G-1 [1] MODEL NAME AND SERIAL NUMBERS ................G-1 (1) Tractor Number ........................ G-1 (2) Engine Number......................... G-2 (3) DPF Muffler Number......................G-3 [2] E4B ENGINE .......................... G-5 [3] CYLINDER NUMBER ......................G-5 2. GENERAL PRECAUTIONS......................G-6 3.
Page 37 [2] TREAD ADJUSTMENT ......................G-89 (1) Front Wheels (2WD Model) .................... G-89 (2) Front Wheels (4WD Model) .................... G-90 (3) Rear Wheels ........................G-91 [3] WHEEL HUB ........................G-92 [4] TIRE LIQUID INJECTION..................... G-92 10. IMPLEMENT LIMITATIONS ....................... G-96 KiSC issued 08, 2012 A...
Page 38: Tractor Identification
M8560, M9960, WSM 1. TRACTOR IDENTIFICATION [1] MODEL NAME AND SERIAL NUMBERS (1) Tractor Number When contacting your local KUBOTA distributor, always specify engine serial number, tractor serial number and hourmeter reading. (1) Tractor Identification Plate (5) CABIN Identification Plate...
Page 39: Engine Number
GENERAL M8560, M9960, WSM (2) Engine Number Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows. Year of manufacture...
Page 40: Dpf Muffler Number
GENERAL M8560, M9960, WSM (3) DPF Muffler Number The DPF muffler full assembly serial number is an identified number for the DPF muffler full assembly. It shows the month and year of manufacture as below. (1) DPF Muffler Full Assembly Part...
Page 41 GENERAL M8560, M9960, WSM (Continued) Year of manufacture Alphabet or Alphabet or Year Year Number Number 2001 2015 2002 2016 2003 2017 2004 2018 2005 2019 2006 2020 2007 2021 2008 2022 2009 2023 2010 2024 2011 2025 2012 2026...
Page 42: E4B Engine
Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission regulations depends on the engine output classification. Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the respective countries affected by Nonroad Emission regulations. For KUBOTA Engines, E4B will be the designation that identifies engine models affected by the next emission phase (See the table below).
Page 43: General Precautions
• When it is necessary to use special tools, use KUBOTA special tools. Refer to the drawings when you make special tools that you do not use frequently.
Page 44: Handling Precautions For Electrical Parts And Wiring
GENERAL M8560, M9960, WSM 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, obey the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
Page 45 GENERAL M8560, M9960, WSM • 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 46: Battery
GENERAL M8560, M9960, WSM [2] BATTERY • Be careful not to confuse positive and negative terminal posts. • When you remove battery cables, disconnect negative cable first. When you install battery cables, check for polarity and connect positive cable first.
Page 47: Handling Of Circuit Tester
GENERAL M8560, M9960, WSM • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make sure that there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust WSM000001GEG0075US1 • Make sure that there is no female connector being too open.
Page 48: Color Of Wiring
GENERAL M8560, M9960, WSM [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 49: Lubricant, Fuel And Coolant
KUBOTA SUPER UDT 2 fluid* 52.8 Imp.qts 6.0 L Front differential case 6.3 U.S.qts oil (4WD) 5.3 Imp.qts KUBOTA SUPER UDT 2 fluid* or SAE80-SAE90 gear oil 3.5 L Front axle gear case oil 3.7 U.S.qts (4WD) 3.1 Imp.qts * KUBOTA original transmission hydraulic fluid.
Page 50 JUN87). Transmission Oil: *KUBOTA SUper UDT-2 : For an enhanced ownership experience, we highly recommend Super UDT-2 to be used instead of standard hydraulic/transmission fluid. Super UDT-2 is a proprietary KUBOTA formulation that deliveries superior performance and protection in all operating conditions.
Page 51: Tightening Torques
GENERAL M8560, M9960, WSM 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Tighten screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual according to the table below. Indication on top of bolt No-grade or 4T...
Page 52: Hydraulic Fittings
GENERAL M8560, M9960, WSM [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 53: Metric Screws, Bolts And Nuts
GENERAL M8560, M9960, WSM [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 54: Maintenance
GENERAL M8560, M9960, WSM 6. MAINTENANCE Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 1 Engine start system Check G-23 � � � � �...
Page 55 GENERAL M8560, M9960, WSM Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 25 Front axle gear case oil Change G-38 � 600 Hr every 26 Front axle pivot...
Page 56 GENERAL M8560, M9960, WSM Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 1 Inner air filter Clean G-35 � � � 200 Hr every 2 Fresh air filter...
Page 57: Check And Maintenance
GENERAL M8560, M9960, WSM 7. CHECK AND MAINTENANCE CAUTION • Be sure to check and service the tractor on a flat place with engine shut off, the parking brake on and chock the wheels. 9Y1210686GEG0053US0 [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 58: Check Points Of Initial 50 Hours
9. Make sure that the transmission fluid doesn't leak through the seal. IMPORTANT • To prevent serious damage to the hydraulic system, use only a KUBOTA genuine filter. (1) Drain Plug (A) Oil level is acceptable within this (2) Hydraulic Oil Filter range.
Page 59 2. After draining reinstall the drain plug. 3. Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick (2). (See page G-12.) 4. After running the engine for a few minutes, stop it and check the oil level again;...
Page 60: Check Points Of Every 50 Hours
GENERAL M8560, M9960, WSM [3] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System CAUTION To avoid personal injury: • Do not allow anyone near the tractor while testing. • If the tractor does not pass the test, do not operate the tractor.
Page 61 GENERAL M8560, M9960, WSM Checking Wheel Mounting Nuts Tightening Torque CAUTION • Never operate tractor with a loose rim, wheel, or axle. • Any time bolts and nuts are loosened, retighten to specified torque. • Check all bolts and nuts frequently and keep them tight.
Page 62: Check Points Of Every 100 Hours
GENERAL M8560, M9960, WSM [4] CHECK POINTS OF EVERY 100 HOURS Checking Battery Condition DANGER To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below. • Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.
Page 63 GENERAL M8560, M9960, WSM (Continued) � Battery Charging CAUTION To avoid personal injury: • 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 64 GENERAL M8560, M9960, WSM 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. (1) Battery Terminals...
Page 65 GENERAL M8560, M9960, WSM (Continued) (5) Grease Fitting (Top Link Bracket) [C] CABIN Model (6) Grease Fitting (Lifting Rod) (7) Grease Fitting (Top Link) (8) Grease Fitting (Hydraulic Lift Cylinders Pin) (9) Steering Joint Shaft 9Y1210686GEG0064US0 G-28 KiSC issued 08, 2012 A...
Page 66 GENERAL M8560, M9960, WSM Adjusting Fan Belt Tension CAUTION • Be sure to stop the engine before checking belt tension. 10 to 12 mm Belt tension Factory specification 0.39 to 0.47 in. 1. Stop the engine and remove the key.
Page 67 GENERAL M8560, M9960, WSM Adjusting Brake Pedal CAUTION To avoid personal injury : • Stop the engine and chock the wheels before checking brake pedal. • To prevent uneven braking, the specification must be within the recommended limit. � Checking the brake pedal free travel 1.
Page 68 GENERAL M8560, M9960, WSM Cleaning Air Cleaner Element 1. Remove the air cleaner cover (3) and primary element (2). 2. Clean the primary element if: • When dry dust adheres to the element, blow compressed air from the inside turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm...
Page 69: Check Points Of Every 200 Hours
GENERAL M8560, M9960, WSM Checking Parking Brake CAUTION • Do not dismount the tractor while checking the parking brake. 1. Confirm the tractor (tractor unit only) can surely be parked on the slope of about 15 degrees (Slope that rises by 2.7 meters every 10 meters).
Page 70 GENERAL M8560, M9960, WSM 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 71 GENERAL M8560, M9960, WSM 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 hose clamp (2) securely.
Page 72 GENERAL M8560, M9960, WSM Cleaning Inner Air Filter (CABIN Model) 1. Remove the knob bolt (2) and pull out the filter (1). 2. Blow air from the direction opposite to the filter's normal air flow. Pressure of compressed air must be under 210 kPa (2.1 kgf/cm...
Page 73: Check Points Of Every 300 Hours
GENERAL M8560, M9960, WSM Checking Air Conditioner Condenser (CABIN Model) 1. Loosen the wing nut (4). 2. Hold the handle (3), slide out the air conditioner condenser (1) assembly toward yourself. CAUTION To avoid personal injury : • Be sure to stop the engine before removing the screen.
Page 74: Check Points Of Every 600 Hours
GENERAL M8560, M9960, WSM Cleaning Water Separator This job should not be done in the field, but in a clean place. 1. Close the fuel cock (1). 2. Remove the cup (2), and rinse the inside with kerosene. 3. Take out the element (4) and dip it in the kerosene to rinse.
Page 75: Check Point Of Every 800 Hours
GENERAL M8560, M9960, WSM Changing Front Axle Gear Case Oil 1. To drain the used oil, remove the right and left drain plugs (1) and filling plugs (2) at the front axle gear case and drain the oil completely into the oil pan.
Page 76: Check Points Of Every 3000 Hours
GENERAL M8560, M9960, WSM Replacing Oil Separator Element CAUTION To avoid personal injury: • Be sure to stop the engine before replacing the oil separator element. 1. Remove the cover and take out the element. Wipe off oil and the carbon in the case with a clean rag.
Page 77: Check Points Of Every 1 Year
GENERAL M8560, M9960, WSM Checking Intake Air Heater 1. See page 8-S18. 9Y1210686GEG0098US0 Cleaning DPF Muffler 1. Refer to the DPF handling manual (9Y111-08130). 9Y1210686GEG0099US0 [12] CHECK POINTS OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1.
Page 78: Check Points Of Every 2 Years
GENERAL M8560, M9960, WSM [13] CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Line 1. Replace the fuel hose and clamps. See page G-31. 9Y1210686GEG0108US0 Replacing Power Steering Line 1. Replace the hoses and clamps. See page 5-S9. 9Y1210686GEG0109US0 Replacing Radiator Hose (Water Pipes) 1.
Page 79 GENERAL M8560, M9960, WSM (Continued) � Anti-Freeze CAUTION • When using antifreeze, put on some protection such as rubber gloves (Antifreeze contains position). • If should drink antifreeze, throw up at once and take medical attention. • When antifreeze comes in contact with the skin or clothing, wash it off immediately.
Page 80 The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. NOTE •...
Page 81 GENERAL M8560, M9960, WSM Replacing PCV (Position Crankcase Ventilation) Valve Hose 1. See page G-39. 9Y1210686GEG0111US0 Replacing DPF Differential Pressure Sensor Hose 1. See page 1-S61. 9Y1210686GEG0112US0 Replacing Boost Sensor Hose 1. See page 8-S41. 9Y1210686GEG0113US0 Cleaning Master Cylinder Filter 1.
Page 82: Others
GENERAL M8560, M9960, WSM [14] OTHERS Bleeding Fuel System Air must be removed : 1. When the fuel filter or lines are removed. 2. When water is drained from water separator. 3. When tank is completely empty. 4. After the tractor has not been used for a long period of time.
Page 83 1. The slow blow fuse are intended to protect the electrical cabling. If any of them has blown out, be sure to pinpoint the cause. Never use any substitute, use only a KUBOTA genuine part. 2. Unscrew the bolt (6) from fuse box (5). (Bolt fixed slow blow fuse) Fuse I.D.
Page 84 GENERAL M8560, M9960, WSM Replacing Fuse (CABIN Model) 1. The tractor electrical system is protected from potential damage by fuses. 2. A blown fuse indicates that there is an overload or short somewhere in the electrical system. 3. If any of the fuses should blow, replace with a new one of the same capacity.
Page 85 1. The slow blow fuse are intended to protect the electrical cabling. If any of them has blown out, be sure to pinpoint the cause. Never use any substitute, use only a KUBOTA genuine part. � Replacement procedure Non bolt fixed slow blow fuse: 1.
Page 86 GENERAL M8560, M9960, WSM Replacing Light Bulb CAUTION • Be careful not to drop the bulb, hit anything against the lamp, apply excess force, and get the lamp scratched. If broken, glass may cause injury. Pay more attention to halogen lamps in particular, which have high pressure inside.
Page 87 GENERAL M8560, M9960, WSM Adding Washer Liquid (CABIN Model) 1. Add a proper amount of automobile washer liquid. 1.3 L Tank capacity 1.4 U.S.gals 1.1 Imp.gals (1) Washer Liquid Tank 9Y1210686GEG0127US0 Checking Refrigerant (Gas) (CABIN Model) CAUTION • Liquid contact with eyes or skin may cause frostbite.
Page 88: Special Tools
GENERAL M8560, M9960, WSM 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 89 GENERAL M8560, M9960, WSM 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...
Page 90 GENERAL M8560, M9960, WSM Small End Bushing Replacing Tool Application • Use to press out and to press fit the small end. NOTE • The following special tool is not provided, so make it referring to the figure. [Press out] 157 mm (6.1811 in.)
Page 91 GENERAL M8560, M9960, WSM Gear Case Oil Seal Replacing Tool Application • Use to press fit the oil seal. NOTE • The following special tool is not provided, so make it referring to the figure. 148.8 mm (5.8582 in.) 50 mm (1.9685 in.) 18.8 mm (0.7401 in.)
Page 92 GENERAL M8560, M9960, WSM 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. Rmax = 12.5 S 94.5 to 95.0 mm dia.
Page 93 GENERAL M8560, M9960, WSM Balancer Bushing Replacing Tool 1 Components Parts NOTE • The following special tools are not provided, so make them referring to the figure. 1) Shaft 498 mm (19.61 in.) 318.8 to 319.2 mm (12.5726 to 12.5669 in.) 102.8 to 103.2 mm (4.0472 to 4.0630 in.)
Page 94 GENERAL M8560, M9960, WSM 3) Piece 2 Chamfer 0.1 mm (0.004 in.) 1 mm (0.04 in.) Chamfer 1 mm (0.04 in.) 54.3 to 54.4 mm dia. (2.1378 to 2.1417 in. dia.) 34.025 to 34.05 mm dia. (1.3396 to 1.3406 in. dia.) 48.5 mm dia.
Page 95 GENERAL M8560, M9960, WSM Balancer Replacing Tools 3, 4, 5 Application • Use to press fit the bushing. NOTE • The following special tools are not provided, so make them referring to the figure. Name of Part Q'ty Bracket Flange Nut...
Page 96 GENERAL M8560, M9960, WSM 2) Shaft 44 mm dia. (1.73 in. dia.) 12 mm (0.47 in.) Chamfer 1 mm (0.04 in.) 3 mm (0.12 in.) 3 mm (0.12 in.) 30 mm (1.18 in.) 38 mm (1.38 in.) 35 mm (1.38 in.) M12 ×...
Page 97 GENERAL M8560, M9960, WSM 4) Joint 1 M12 × P1.25 Chamfer 1 mm (0.04 in.) 30 mm dia. (1.18 in. dia.) 13 mm dia. (0.51 in. dia.) Chamfer 3 mm (0.12 in.) R3 mm (0.12 in. radius) 45 mm (1.77 in.) 75 mm (2.95 in.)
Page 98 GENERAL M8560, M9960, WSM 7) Piece 3 26 mm (1.02 in.) 18 mm (0.71 in.) 16.5 to 17.0 mm (0.6496 to 0.6693 in.) 1.5 mm (0.06 in.) 53.0 to 53.2 mm dia. (2.0866 to 2.0945 in. dia.) 49.55 to 49.75 mm dia. (1.9508 to 1.9587 in. dia.) 16 mm (0.63 in.)
Page 99 GENERAL M8560, M9960, WSM Timer Gear Puller Application • Use for removing the timer gear from governor shaft. NOTE • The following special tools are not provided, so make them referring to the figure. 27 mm (1.1 in.) 130 mm (5.12 in.) 15 mm (0.59 in.)
Page 100 GENERAL M8560, M9960, WSM Nozzle Adaptor for Measuring Cylinder Compression Pressure Application • Use for measuring diesel engine compression pressure. NOTE • The following special tools are not provided, so make them referring to the figure. 5 mm (0.1969 in.) 3 mm dia., 44.5 to 45 mm depth (0.1181 in.
Page 101 GENERAL M8560, M9960, WSM 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 tool is not provided, so make it referring to the figure.
Page 102 GENERAL M8560, M9960, WSM Tool for Aligning the Crankcase 1 and 2 Application • Use for aligning the crankcase 1 and 2. NOTE • The following special tool is not provided, so make it referring to the figure. 115 mm (4.53 in.) 56 mm (2.2 in.)
Page 103: Special Tools For Tractor
GENERAL M8560, M9960, WSM [2] SPECIAL TOOLS FOR TRACTOR Tie-rod End Lifter Code No. • 07909-39051 Application • Use to remove the tie-rod end with ease. WSM000001GEG0029US0 Steering Wheel Puller Code No. • 07916-51090 Application • Use to remove the steering wheel without damage to the steering shaft.
Page 104 GENERAL M8560, M9960, WSM 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 105 GENERAL M8560, M9960, WSM Power Steering Adaptor Code No. • 07916-54021 Application • Use to measure the relief valve setting pressure for power steering. WSM000001GEG0038US0 Front Axle Rocking Restrictor NOTE • The following special tool is not provided, so make it referring to the figure.
Page 106 GENERAL M8560, M9960, WSM Sliding Hammer Application • Use to removing the bevel pinion shaft with adaptor for front axle. NOTE • The following special tool is not provided, so make it referring to the figure. 120 mm (4.72 in.) 14.5 mm dia.
Page 107 GENERAL M8560, M9960, WSM Adaptor (M6) for Sliding Hammer Application • Use to removing the front axle bevel pinion shaft with sliding hammer. NOTE • The following special tool is not provided, so make it referring to the figure. M6 × P1.0 25 mm (0.98 in.)
Page 108 GENERAL M8560, M9960, WSM LSD Adaptor Application • Use for measuring the turning torque of LSD. NOTE • The following special tool is not provided, so make it 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 109 GENERAL M8560, M9960, WSM 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 (M ×...
Page 110 GENERAL M8560, M9960, WSM (3) Tool 1 (Body) 140 mm dia. (5.51 in. dia.) Radius 50 mm (2.0 in.) Radius 3 mm (0.1 in.) 30 mm dia. (1.2 in. dia.) 2.09 rad (120 °) 17 mm dia. (0.67 in. dia.) 60 mm (2.4 in.)
Page 111 GENERAL M8560, M9960, WSM Locking Wrench Application • Use for locking pinion nut. NOTE • The following special tool is not provided, so make it referring to the figure. 170 mm (6.69 in.) 130 mm (5.12 in.) 63.5 mm (2.5 in.) 40 mm radius (1.57 in.
Page 112 GENERAL M8560, M9960, WSM Bevel Gear Shaft (8T) Tool Application • Use for measuring and tightening the bevel gear shaft. NOTE • The following special tool is not provided, so make it referring to the figure. 12.75 to 12.90 mm square (0.50 to 0.51 in. square) 32.500 to 32.525 mm dia.
Page 113 GENERAL M8560, M9960, WSM 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 tool is not provided, so make it referring to the figure.
Page 114 GENERAL M8560, M9960, WSM Hydraulic Cylinder Piston Sealing Tool Application • Tool (a): Use for installing the piston seals to the piston. • Tool (b): Use for installing the piston to the cylinder. NOTE • The following special tool is not provided, so make it referring to the figure.
Page 115 GENERAL M8560, M9960, WSM Cylinder Safety Valve Setting Pressure Adaptor Application • Use to adapt the safety valve to the nozzle tester to measure cracking pressure and test the check valve on the safety valves. NOTE • The following special tool is not provided, so make it referring to the figure.
Page 116 GENERAL M8560, M9960, WSM Oil Cooler Relief Valve Setting Pressure Adaptor Application • Use to adapt the oil cooler relief valve to the nozzle tester to measure cracking pressure and test check on the oil cooler relief valve. NOTE • The following special tool is not provided, so make it referring to the figure.
Page 117 GENERAL M8560, M9960, WSM Valve Adaptor Application • Use for measuring the system pressure of shuttle valve, system pressure relief pressure, 4WD valve, PTO valve and dual hi-lo valve. NOTE • The following special tool is not provided, so make it referring to the figure.
Page 118 GENERAL M8560, M9960, WSM Tools for Dismounting Cabin Application • Use to dismounting the cabin from tractor body. NOTE • This special tools are not provided, so make them referring to the figure. Q'ty Piece [A] Piece [B] Piece [C]...
Page 119 GENERAL M8560, M9960, WSM 1050 mm (41.34 in.) 1650 mm (64.96 in.) 4.5 mm (0.18 in.) 1200 mm (47.24 in.) 50.0 mm (1.97 in.) 6-11.0 mm dia. (0.433 in. dia.) 1362 mm (53.62 in.) (1) Material : STKR400 (50 × 50 × t45) 9Y1210686GEG0131US0 62.0 mm (2.44 in.)
Page 120 GENERAL M8560, M9960, WSM 30.0 mm (1.18 in.) 3.2 mm (0.13 in.) 11.0 mm dia. (0.433 in. dia.) 45.0 mm (1.77 in.) 15.0 mm (0.591 in.) 12.0 mm (0.472 in.) 70.0 mm (2.76 in.) 13.0 mm dia. (0.512 in. dia.) 60.0 mm (2.36 in.)
Page 121 GENERAL M8560, M9960, WSM 70.0 mm (2.76 in.) 77.0 mm (3.03 in.) 4.5 mm (0.18 in.) 100 mm (3.94 in.) 92.0 mm (3.62 in.) 3.0 mm (0.12 in.) 224 mm (8.82 in.) 11.0 mm (0.433 in.) 25.0 mm (0.984 in.) 264 mm (10.4 in.)
Page 122: Special Tools For Air Conditioner Unit
GENERAL M8560, M9960, WSM [3] SPECIAL TOOLS FOR AIR CONDITIONER UNIT Air Conditioner Service Tool Code No. • DENSO 95048-00063 Application • Use for charge, test or discharge of the air conditioning system. (1) Manifold Gauge Assembly (95048-10090) (2) Charging Hose (Red: HI) (95948-10270)
Page 123 GENERAL M8560, M9960, WSM 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 tool is not provided, so make it referring to the figure.
Page 124 GENERAL M8560, M9960, WSM Stopper Bolt (for A/C Compressor) Application • Use with the stopper magnet clutch. NOTE • The following special tool is not provided, so make it referring to the figure. 12 mm (0.47 in.) 5.5 mm dia. (0.22 in. dia.) 35 mm (1.38 in.)
Page 125: Tires
• Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure show in the operator's manual. IMPORTANT • Do not use tires other than those approved by KUBOTA. • Dual tires are not approved. NOTE • When optional different-diameter tires are fitted on the machine, the travel speed display mode must be changed.
Page 126: Tread Adjustment
GENERAL M8560, M9960, WSM [2] TREAD ADJUSTMENT CAUTION • When working on slopes or when working with trailer, set the wheel tread as wide as practical for maximum stability. • Support tractor securely on stands before removing a wheel. • Do not work under any hydraulically supported devices. They can settle, suddenly leak down, or be accidentally lowered.
Page 127: Front Wheels (4Wd Model
GENERAL M8560, M9960, WSM (2) Front Wheels (4WD Model) Front tread width can be adjusted as shown with the standard equipped tires. To change the tread width 1. Remove the wheel rim and disk mounting bolts. 2. Change the position of the rim and disk (right and left) to the desired position, and tighten the bolts.
Page 128: Rear Wheels
GENERAL M8560, M9960, WSM (3) Rear Wheels Rear tread width can be adjusted as shown with the standard equipped tires. To change the tread width 1. Remove the wheel rim and / or disk mounting bolts. 2. Change the position of the rim and disk (right and left) to the desired position, and tighten the bolts.
Page 129: Wheel Hub
GENERAL M8560, M9960, WSM [3] WHEEL HUB Rear wheel Front wheel hub – Screw circle diameter 152.4 mm 203.2 mm 203.2 mm (6.000 in.) (8.000 in.) (8.000 in.) Number of screws Screws M14 × P1.5 M16 × P1.5 M18 × P1.5 114.0 mm...
Page 130 GENERAL M8560, M9960, WSM Attaching Injector 1. Lift the rear tires off the ground. 2. Turn the tire so that the air valve is at the top. 3. Remove the air valve, and attach the injector. (Code No. 07916-52501) (1) Injector...
Page 131 GENERAL M8560, M9960, WSM Injection CAUTION • When a calcium chloride solution is used, cool it before pouring it into the tire. • Do not fill tires with water or solution more than 75 % of full capacity (to the valve stem level).
Page 132 GENERAL M8560, M9960, WSM Draining Water or Solution 1. Lift the rear tires off the ground. 2. Turn the tire so that the air valve is at the bottom. 3. Remove the air valve, and drain liquid (liquid can only be drained to the level of the valve and liquid under that level remains inside).
Page 133: Implement Limitations
KUBOTA. Use with implements which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Tractor may result in malfunctions or failures of the tractor, damage to other property and injury to the operator or others. [Any malfunctions or failures of the tractor resulting from use with improper implements are not covered by the warranty.]...
Page 134 GENERAL M8560, M9960, WSM M8560 M9960 Implement Remarks Max. Tank 4000 L (1060 U.S.gals, 880 Imp.gals) Capacity Slurry Tank Max. Load 5000 kg (11000 lbs) Capacity Max. Load 5000 kg 6000 kg 5000 kg 6000 kg Capacity (11000 lbs) (13200 lbs)
Page 135 • Implement size may vary depending on soil operating conditions. *1 : Must remove front weight with this implement. *2 : Need subframe. *3 : The valve contains the weight of KUBOTA standard bucket. 9Y1210686GEG0148US0 G-98 KiSC issued 08, 2012 A...
Page 136 ENGINE KiSC issued 08, 2012 A...
Page 137 MECHANISM CONTENTS 1. ENGINE ............................1-M1 [1] CYLINDER BLOCK ......................1-M1 [2] HALF-FLOATING HEAD COVER ..................1-M1 [3] CYLINDER HEAD ........................ 1-M2 [4] PISTON ..........................1-M2 [5] CENTER DIRECT INJECTION SYSTEM (E-CDIS) ............. 1-M2 2. LUBRICATING SYSTEM......................1-M4 [1] OIL COOLER........................1-M4 3.
Page 138: Engine
ENGINE M8560, M9960, WSM 1. ENGINE [1] CYLINDER BLOCK The engine utilizes a split crankcase to produce greater durability and operate more quietly; the crankcase is split into two parts, crankcase 1 (1), which houses the parts for combustion and crankcase 2 (2), which completes crankcase 1 and produces low-noise.
Page 139: Cylinder Head
ENGINE M8560, M9960, WSM [3] CYLINDER HEAD We have improved the helical shaped 2-valve, 2-stage ports in order to generate an ideal swirl and intake air inertia at the intake port and to gain a greater amount of intake air for the air/fuel mixture.
Page 140 ENGINE M8560, M9960, WSM V3 series DI engine has two intake valves and two exhaust valves per each cylinder. The rocker arm (1) contacts a bridge arm (2) instead of the valves stem tip. The bridge arm then contacts both intake valves or both exhaust valves and causes two valves to open simultaneously.
Page 141: Lubricating System
ENGINE M8560, M9960, WSM 2. LUBRICATING SYSTEM [1] OIL COOLER V3 series engine has a water-cooled oil cooler that not only cools hot oil, but also warms the cool engine oil shortly after start up. As shown in the figure, the oil flows inside the...
Page 142: Cooling System
ENGINE M8560, M9960, WSM 3. 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 143: Bottom Bypass System
ENGINE M8560, M9960, WSM [2] BOTTOM BYPASS SYSTEM In addition, to improving the cooling performance of the radiator by utilizing a bottom bypass system, the mechanism utilizes a 3-stage thermostat valve that reduces thermal shock considerably compared to previous radiators.
Page 144: Common Rail System (Crs)
ENGINE M8560, M9960, WSM 4. COMMON RAIL SYSTEM (CRS) [1] OVERVIEW (1) Injector (2) Rail (3) Supply Pump (4) Different Sensors (5) Engine ECU Common rail system not only complies with strict emission regulations, it enables multiple, precise high-pressure injections that do not vary with engine RPM.
Page 145: Fuel System
ENGINE M8560, M9960, WSM [2] FUEL SYSTEM (1) Injector (5) SCV (Suction Control Valve) (9) Fuel Feed Pump Engine ECU (2) Rail (6) Fuel Cooler (10) Water Separator Tractor ECU (3) Supply Pump (7) Check Valve (11) Fuel Tank Sensor...
Page 146: Supply Pump
ENGINE M8560, M9960, WSM [3] SUPPLY PUMP The supply pump is equivalent to previously used injection pumps and it delivers fuel to the rail at a pressure more than double that of previous pumps. It consists of feed pump (10), regulating valve (6), SCV (suction control valve) (2), pump unit, delivery valve (3) and fuel temperature sensor (1).
Page 147 ENGINE M8560, M9960, WSM SCV (suction control valve) (1) Drive Voltage (2) Amperage (3) Average Current Differential (4) Plunger (5) Feed Pump (6) Regulating Valve (7) Cylinder (8) SCV (Suction Control Valve) Low Suction Volume High Suction Volume By regulating the amount of fuel supplied to the plunger (4), the SCV (8) controls the pressure of fuel in the rail.
Page 148 ENGINE M8560, M9960, WSM Pump Unit The pump unit works to increase the pressure of fuel received from the SCV and is composed of a drive shaft (1), ring cam (3) and two plungers (5). A ring cam (3) is mounted on the outside of the eccentric cam (2), which is on the same axle as the drive shaft;...
Page 149: Rail
ENGINE M8560, M9960, WSM [4] RAIL The common rail (2) stores fuel at the high pressure applied by the supply pump and supplies the shared pressure to the injectors of each cylinder. The rail incorporates control parts a rail pressure sensor (3) and a pressure limiter (1).
Page 150: Injector
ENGINE M8560, M9960, WSM [5] INJECTOR The injectors inject high-pressure fuel from the rail into the combustion chamber of the engine, using signals from the engine ECU (1) to produce the ideal timing, amount of fuel, mixture and spray. The injector injects a finely tuned spray in three pulses during the combustion stage.
Page 151 ENGINE M8560, M9960, WSM Injector Operation (1) Solenoid (2) TWV (Two-way Valve) (3) Discharge Orifice (4) Command Piston (5) Needle Valve (6) Leak Passage (7) Intake Orifice (8) Control Chamber Injection Stop Injection Start Injection Finish From Rail To Fuel Tank The injector uses the signal output from the engine ECU to control the injection with the fuel pressure in the control chamber.
Page 152 ECU (1). When replacing an engine ECU, as it is necessary to write all of the data, including the injector (2) corrections, only KUBOTA can write the data to the engine ECU. (1) Replacement Engine ECU (2) Injector...
Page 153: Engine Control System
ENGINE M8560, M9960, WSM [6] ENGINE CONTROL SYSTEM (1) Key Switch ON Signal (9) Rail Pressure Sensor (21) Camshaft Position Sensor (26) Exhaust Gas Temperature (2) Starter Switch Signal (10) Rail (22) Diesel Particulate Filter Sensor0 (T0) (DOC Inlet (3) CAN Communication for...
Page 154: Engine Ecu
ENGINE M8560, M9960, WSM (1) Engine ECU The engine ECU (1) controls the amount, timing, mixture and pressure of fuel that is injected. The engine ECU (1) operates each kind of control based on the signals from each type of sensor.
Page 155 ENGINE M8560, M9960, WSM Camshaft Position Sensor The camshaft position sensor (1) is mounted near the camshaft gear and the sensor functions in the same way as the crankshaft position sensor. This sensor detects the extra teeth (two teeth) of the camshaft pulsar gear (2) and the engine ECU uses the signal to calculate the piston position.
Page 156 ENGINE M8560, M9960, WSM These sensors utilize thermistors detect temperature. A characteristic of thermistors is that their electrical resistance varies with temperature, this characteristic is used by the different sensors to detect temperature via voltage. Intake Air Temperature Sensor The intake air temperature sensor "A" measures the intake temperature after it passes through the turbocharger.
Page 157: Egr System
ENGINE M8560, M9960, WSM 5. EGR SYSTEM [1] OVERVIEW (1) Intake Throttle Valve (2) Intake Air Heater (3) Intake Manifold (4) Exhaust Manifold (5) EGR Valve (6) EGR Cooler Intake Air Exhaust Gas Coolant Inlet Coolant Outlet An EGR (exhaust gas recirculation) system takes out a portion of the exhaust gas and recirculates it to the intake side, thus reducing the amount of available oxygen and lowering the temperature of combustion, which suppresses the generation of nitrogen oxide (NOx).
Page 158: Intake And Exhaust System
ENGINE M8560, M9960, WSM [2] INTAKE AND EXHAUST SYSTEM (1) Mass Air Flow Sensor (5) Exhaust Gas Temperature (10) EGR DC Motor Intake Air Flow (2) Exhaust Gas Temperature Sensor2 (T2) (DPF Outlet (11) EGR Lift Sensor Exhaust Gas Flow...
Page 159: Egr Valve
ENGINE M8560, M9960, WSM [3] EGR VALVE Water Cooled EGR Valve This is a device that regulates EGR gas flow. The degree the valve is open is detected using a lift sensor and a motor is used to set this to the degree of open calculated using signals including the engine speed.
Page 160: After Treatment System
ENGINE M8560, M9960, WSM 6. AFTER TREATMENT SYSTEM [1] AFTER TREATMENT DEVICES (1) Common Rail System (10) Temperature Sensor (DOC (13) Temperature Sensor (DPF (a) EGR Valve Opening (2) Engine ECU Inlet Exhaust Temperature) Outlet Exhaust Temperature) (b) Injection Pattern...
Page 161: Dpf Regeneration Process
ENGINE M8560, M9960, WSM [2] DPF REGENERATION PROCESS (1) Auto Mode Auto Mode Engine Engine Buzzer Required procedure Regenera- Parked re- Engine Output Accumulates RPM in- tion indica- generation warning crease in- indicator indicator dicator PM Warning Level: 0 (No Need...
Page 162 ENGINE M8560, M9960, WSM Auto Mode Engine Engine Buzzer Required procedure Regenera- Parked re- Engine Output Accumulates RPM in- tion indica- generation warning crease in- indicator indicator dicator • Immediately move the tractor to a safe place and PM Warning...
Page 163: Inhibit Mode
ENGINE M8560, M9960, WSM (2) Inhibit Mode Inhibit Mode Engine Engine Buzzer Required procedure Regenera- Parked re- Engine Output Accumulates RPM in- tion indica- generation warning crease in- indicator indicator dicator PM Warning Level: 0 (No Need 100 % Normal Condition...
Page 164 ENGINE M8560, M9960, WSM Diesel Oxidation Catalyst (DOC) An oxidizing catalyst positioned in front of the Diesel Particulate Filter (DPF) step that uses post injection unburned fuel to actively regenerate the DPF. (1) Diesel Oxidation Catalyst (DOC) 9Y1210686ENM0039US0 1-M27 KiSC issued 08, 2012 A...
Page 165 ENGINE M8560, M9960, WSM Diesel Particulate Filter (DPF) The Diesel Particulate Filter (DPF) is a device that captures and combusts PM in the exhaust gas. Physically captures the PM using a filter which spontaneously combusts when exhaust gas temperature is high.
Page 166 ENGINE M8560, M9960, WSM Mass Air Flow Sensor The amount of air intake required for control of the EGR valve used to reduce NOx is measured. This sensor calculates temperature of intake air and intake mass air flow. This sensor communicates to engine ECU.
Page 167 ENGINE M8560, M9960, WSM Oil Separator Removes oil in the blowby gases that pass through the element (1) and the oil is returned to the oil pan. Blowby gases that pass through the element (1) are mixed into the intake upstream from the turbo charger.
Page 168 SERVICING CONTENTS 1. TROUBLESHOOTING.........................1-S1 2. SERVICING SPECIFICATIONS ....................1-S4 3. TIGHTENING TORQUES......................1-S9 4. CHECKING, DISASSEMBLING AND SERVICING ..............1-S11 [1] CHECKING AND ADJUSTING....................1-S11 (1) Engine Body ........................1-S11 (2) Lubricating System ......................1-S13 (3) Cooling System ......................1-S13 (4) Turbocharger .........................1-S15 (5) EGR System........................1-S16 (6) DPF System ........................1-S17 [2] PREPARATION FOR SEPARATING ENGINE ..............1-S18 (1) Lubricant and Coolant ....................1-S18 (2) Bonnet and Cover......................1-S19...
Page 169: Troubleshooting
ENGINE M8560, M9960, WSM 1. TROUBLESHOOTING This troubleshooting shows only mechanical failures. The failures related to the common rail system (CRS), and DPF, refer to the diagnosis manual (DM) for common rail system engine (9Y120-01740). Reference Symptom Probable Cause Solution...
Page 170 ENGINE M8560, M9960, WSM Reference Symptom Probable Cause Solution Page The engine revolution The fuel filter is clogged Replace G-31 is not smooth The air cleaner is clogged Clean or replace the G-31 air cleaner element Fuel leakage because of loose injection pipe...
Page 171 ENGINE M8560, M9960, WSM Reference Symptom Probable Cause Solution Page The lubricant oil The gap of the piston ring points to the same Move the ring gap 1-S54 consumption is too direction direction much The oil ring is worn out or cannot move...
Page 172: Servicing Specifications
ENGINE M8560, M9960, WSM 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.005 mm 0.002 in. Top Clearance 0.70 to 0.90 mm – 0.028 to 0.035 in. Compression Pressure 3.09 to 3.28 MPa / 2.41 MPa /...
Page 173 ENGINE M8560, M9960, WSM Item Factory Specification Allowable Limit Intake Valve Timing Open 0.24 rad (14 °) – before T.D.C. Close 0.63 rad (36 °) – after B.D.C. Exhaust Valve Timing Open 0.79 rad (45 °) – before B.D.C. Close 0.30 rad (17 °)
Page 174 ENGINE M8560, M9960, WSM Item Factory Specification Allowable Limit Camshaft Side Clearance 0.070 to 0.22 mm 0.30 mm 0.0028 to 0.0086 in. 0.012 in. Alignment – 0.01 mm 0.0004 in. Cam Height Intake 37.64 mm 37.14 mm 1.482 in. 1.462 in.
Page 175 ENGINE M8560, M9960, WSM Item Factory Specification Allowable Limit Piston Ring Gap Top Ring 0.30 to 0.45 mm 1.25 mm 0.012 to 0.017 in. 0.0492 in. Second Ring 0.30 to 0.45 mm 1.25 mm 0.012 to 0.017 in. 0.0492 in.
Page 176 ENGINE M8560, M9960, WSM LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed – 50 kPa 0.5 kgf/cm 7 psi At Rated Speed 200 to 390 kPa 150 kPa 2.0 to 4.0 kgf/cm 1.5 kgf/cm 29 to 56 psi...
Page 177: Tightening Torques
ENGINE M8560, M9960, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to G-14.) NOTE • For the screws, bolts and nuts with the mark "*", apply engine oil to their threads and seats before you tighten.
Page 178 ENGINE M8560, M9960, WSM Dimension × Item N·m kgf·m lbf·ft Pitch Crankcase 2 mounting screw M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41 *Main bearing case screw M14 × 1.5 138 to 147 14.0 to 15.0...
Page 179: Checking, Disassembling And Servicing
ENGINE M8560, M9960, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. After warming up the engine, stop it and remove the air cleaner, the DPF assembly, the muffler, high pressure pipes, cylinder head cover, overflow pipe, all nozzle holders and all nozzle gaskets.
Page 180 ENGINE M8560, M9960, WSM Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when the engine is cold. 1. Remove the high pressure pipes and the head cover. 2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (gear case side) comes to the compression top dead center.
Page 181: Lubricating System
ENGINE M8560, M9960, WSM (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 182 ENGINE M8560, M9960, WSM Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
Page 183: Turbocharger
ENGINE M8560, M9960, WSM Opening-temperature of Thermostat Valve 1. Push down the thermostat valve and insert a string between the valve and the valve seat. 2. Place the thermostat and a thermostat in a container with water and gradually heat the water.
Page 184: Egr System
ENGINE M8560, M9960, WSM (5) EGR System 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. 3. Start the engine and go to check 1) immediately.
Page 185: Dpf System
ENGINE M8560, M9960, WSM 2) If the coolant temperature is over 70 °C (158 °F), the surface temperature of EGR pipe must be over 100 °C (212 °F). 9Y1210686ENS0039US0 (6) DPF System Check the DPF Accumulate Level 1. Refer to the electrical section (see page 8-S27).
Page 186: Preparation For Separating Engine
ENGINE M8560, M9960, WSM [2] PREPARATION FOR SEPARATING ENGINE (1) Lubricant and Coolant Draining Engine Oil CAUTION • Before draining oil, be sure to stop the engine. • Allow engine to cool down sufficiently, oil can be hot and can burn.
Page 187: Bonnet And Cover
ENGINE M8560, M9960, WSM (2) Bonnet and Cover Bonnet and Cover (ROPS Model) 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the 3P connector (5) for head lights. 3. Remove the muffler pipe mounting screws (2) and then muffler pipe (4).
Page 188 ENGINE M8560, M9960, WSM Bonnet and Cover (CABIN Model) 1. Open the bonnet (1) and disconnect the battery (2) negative terminal. 2. Remove the muffler pipe mounting screws 1 (7) and the muffler pipe (6). 3. Remove the cover (3), the side panel (4) and the side cover guide (5) on both sides.
Page 189: Dpf Muffler
ENGINE M8560, M9960, WSM (3) DPF Muffler DPF Muffler 1 CAUTION • After running the engine, DPF muffler is very hot. When disconnecting the connectors, wait the cooling down. 1. Disconnect the connector 1 (1) and connector 2 (2). 2. Remove the screws (3) of between the DPF muffler and the mount stay.
Page 190: Propeller Shaft And Power Steering Hose
ENGINE M8560, M9960, WSM (4) Propeller Shaft and Power Steering Hose 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.
Page 191: Separating Engine
ENGINE M8560, M9960, WSM [3] SEPARATING ENGINE (1) ROPS Model Power Steering Hose and Wire Harness for L.H. Side 1. Remove the power steering hose bands (1) with the power steering hose (2). 2. DIsconnect the wire harness (3) from the alternator (4), the starter (5), the coolant temperature sensor (6), the engine oil pressure switch (7) and the intake air flow sensor (8).
Page 192 ENGINE M8560, M9960, WSM Oil Cooler Pipe, Fuel Hoses and Wire Harness for R.H. Side 1. Disconnect the oil cooler pipe retaining nuts (1). 2. Remove the slow blow fuse box (3) from the battery support and disconnect the connectors 1 (4) for the battery.
Page 193 ENGINE M8560, M9960, WSM Axle Support as a Unit 1. Make sure the clutch housing case and front frame are securely mounted on the disassembling stands. 2. Install the front axle rocking restrictor (1) (see page G-68) to the front axle bracket.
Page 194 ENGINE M8560, M9960, WSM Separating Engine from Clutch Housing WARNING • For safety, when separating the engine, use the hoist. Ensure that the hoist is fixed to the engine securely before separating the engine. You may be injured by dropping down the engine.
Page 195: Cabin Model
ENGINE M8560, M9960, WSM (2) CABIN Model Wire Harness for Tractor Front Side 1. Remove the engine ECU cover (1). 2. Let the red handles of engine ECU be rotated 0.79 rad (45 °) and disconnect the 96P connector (2) and 58P connector (3).
Page 196 ENGINE M8560, M9960, WSM Wire Harness for L.H. Side 1. DIsconnect the wire harness (5) from the alternator (1), the starter (2), the coolant temperature sensor (3), the engine oil pressure switch (4). 2. Disconnect the wire harness (6) from the camshaft position sensor (6) and the crankshaft position sensor (7).
Page 197 ENGINE M8560, M9960, WSM Condenser and Compressor � Without discharging the refrigerant from system 1. Remove the screw 1 (1) from the condenser (2) and slide out the condenser (2). 2. Remove the hose clamps (3). 3. Disconnect 1P connector (4) of magnetic clutch.
Page 198 ENGINE M8560, M9960, WSM (Continued) � With discharge the refrigerant from system 1. See page 9-S18. 2. Disconnect the low pressure hose (8) and high pressure hose (9) from compressor (5). (When reassembling) • Charge the refrigerator to the air conditioner system. (See page 9-S20.)
Page 199 ENGINE M8560, M9960, WSM Heater Hose, Steering Hose, Steering Pipe and Steering Joint Shaft 1. Remove the hose clamps (1). 2. Slide the hose clamp 2 (3) and disconnect the heater hoses (2) from the heater hose couples. 3. Remove the steering hose (4).
Page 200 ENGINE M8560, M9960, WSM Fuel Hose and Wire Harness for R.H. Side 1. Disconnect the wire harness (9) from the heater relay (1), the intake air temperature sensor (2), the intake air pressure sensor (3), the intake air heater (4), the EGR DC motor (5), the fuel temperature sensor (6), the SCV (7), the rail pressure sensor (8) and the connector (10).
Page 201 ENGINE M8560, M9960, WSM Step, Floor Mats and Wiring Harness for Cabin Side 1. Remove the auxiliary step on both sides. 2. Remove the fuel filling port (2). 3. Remove the floor mat 1 (3) and mat 2 (4). 4. Remove the floor cover (5), the duct band (11) and the front duct (12).
Page 202: Disassembling And Assembling
ENGINE M8560, M9960, WSM Separating Engine from Clutch Housing 1. Hoist the engine using the hoist and chain. 2. Remove the engine mounting screws and nut, and separate the engine from the clutch housing. NOTE • When you replace the engine with a new one, please record the serial number of new engine and the parts number and serial number of "DPF Full Assembly"...
Page 203: External Parts
ENGINE M8560, M9960, WSM (2) External Parts Fan, Starter, Alternator and Power Steering Controller 1. Remove the air conditioner drive belt (7). 2. Remove the fan (1) and fan belt (6). 3. Remove the alternator (2) and starter motor (5).
Page 204: Common Rail
ENGINE M8560, M9960, WSM Intake Throttle Valve and Intake Air Heater 1. Remove the air cleaner flange (1). 2. Remove the intake throttle valve (2). 3. Remove the intake air heater (3). NOTE • Do not disassemble the intake throttle valve.
Page 205 ENGINE M8560, M9960, WSM Coolant Temperature Sensor 1. Remove the coolant temperature sensor (1). (When reassembling) • Replace the gaskets with new ones. 16 to 23 N·m Coolant Temperature Tightening torque 1.6 to 2.4 kgf·m Sensor taper screw 12 to 17 lbf·ft...
Page 206 ENGINE M8560, M9960, WSM Crankshaft Position Sensor 1. Remove the crankshaft position sensor mounting screw (2). 2. Remove the crankshaft position sensor (1). (When reassembling) • Replace the O-ring with a new one. IMPORTANT • If you drop the sensor, do not reuse it.
Page 207 ENGINE M8560, M9960, WSM Intake Air Temperature Sensor and Boost Sensor IMPORTANT • Be careful not to damage the sensor when removing the hose from the boost sensor. 1. Remove the intake air temperature sensor (4). 2. Remove the hose (3) from the boost sensor (2).
Page 208: Cylinder Head And Valves
ENGINE M8560, M9960, WSM (5) Cylinder Head and Valves Cylinder Head Cover 1. Remove cylinder head cover 2 (1). 2. To prevent miswiring during reassembly, mark the injector terminals (2) and the leads (4). 3. Remove the injector harness from the injectors.
Page 209 ENGINE M8560, M9960, WSM Overflow Pipe and Injectors 1. Remove the overflow pipe (1). 2. Remove the injector clamp (2). 3. Remove the injector (3) and its gasket (7). IMPORTANT • Do not disassemble the injector (3). • Do not remove the injector QR code tag (8).
Page 210 ENGINE M8560, M9960, WSM Check the Fuel Leakage of the Overflow Pipe 1. Connect the fuel pipe joint (7) of air pressure adjustment equipment to the eye joint bolt (3). 2. Tighten the valve (4). 3. Connect the air hose to the air pressure adjustment equipment.
Page 211 ENGINE M8560, M9960, WSM Rocker Arms and Push Rods 1. Remove the rocker arm (1). 2. Remove the push rod (3). 3. Remove the valve bridge arm (2). (When reassembling) • Face the pad (5) R face (4) up and install it on the bridge arm.
Page 212 ENGINE M8560, M9960, WSM Cylinder Head and Tappet 1. Loosen the pipe clamp and remove the water return hose (3). 2. Remove the inlet manifold (1) and exhaust manifold (2). 3. Remove the cylinder head mounting screw in the sequence of 18 to 1, and remove the cylinder head (4).
Page 213 ENGINE M8560, M9960, WSM To Select the Cylinder Head Gasket � Replacement of Cylinder Head Gasket 1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket in advance. 2. Replace the same notch (a), (b) or (c) as the original cylinder head gasket (1).
Page 214: Thermostat
ENGINE M8560, M9960, WSM Valve 1. Push the valve spring (5) with the valve spring retainer (4) and remove the valve spring collets (3). 2. Remove the valve spring (5) and valve (1). (When reassembling) • Install the valve spring with its small pitch (7) end downward (at the head side).
Page 215: Supply Pump
ENGINE M8560, M9960, WSM (7) Supply Pump Supply Pump CAUTION • Do not loosen the injection pipe when the fuel is under high pressure (within five minutes of stopping the engine). 1. Remove the supply pump's gear cover (1). 2. Put the piston of the number 4 cylinder at TDC.
Page 216 ENGINE M8560, M9960, WSM (Continued) (When reassembling) • Align the alignment marks of the supply pump gear (4) and idle gear 2 (7). • Replace the O-ring of the supply pump (10) with a new one. • Replace the gasket of supply pump gear cover with a new one.
Page 217: Water Pump And Oil Cooler
ENGINE M8560, M9960, WSM (8) Water Pump and Oil Cooler Water Pump 1. Remove the pipe band and the water pipe (water pump side) (1). 2. Remove the water pump (2). (When reassembling) • When mounting the water pump, take care not to forget mounting the O-ring and not to let it out of position.
Page 218: Gear Case And Timing Gear
ENGINE M8560, M9960, WSM (9) Gear Case and Timing Gear Fan Drive Pulley and Gear Case Cover 1. Mount a flywheel stopper on the flywheel. 2. Remove the crankshaft screw (2). 3. Remove the fan drive pulley (1). 4. Remove the gear case cover (3).
Page 219 ENGINE M8560, M9960, WSM Idle Gear 1, 2, Oil Pump Drive Gear and Crank Gear 1. Remove the idle gear mounting screw (1). 2. Remove the idle gear 1 (2) and idle gear 2 (5). 3. Remove the idle gear 1 (2).
Page 220: Piston And Connecting Rod
ENGINE M8560, M9960, WSM Plate (Gear Case) 1. Remove the plate mounting screws (1) and detach the plate (2). (When reassembling) • Apply liquid gasket (3) (Three Bond1217H) on the surface of the crankcase side where the plate will be installed to.
Page 221 ENGINE M8560, M9960, WSM Connecting Rod Cap 1. Remove the connecting rod screws (1). 2. Remove the connecting rod cap. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the supply pump.) • Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.
Page 222 ENGINE M8560, M9960, WSM Piston Ring and Connecting Rod 1. Remove the piston rings with a piston ring tool. 2. Remove the piston pin (8) to disconnect the connecting rod (7) from the piston (6). (When reassembling) • Be sure the crank pin bearing and the connecting rod are same I.D.
Page 223: Flywheel And Crankshaft
ENGINE M8560, M9960, WSM (11) Flywheel and Crankshaft Flywheel 1. Attach the stopper to the flywheel. 2. Remove the flywheel screws. 3. Remove the flywheel (1). NOTE • Do not use an impact wrench. Serious damage will occur. IMPORTANT • The flywheel is very heavy, so securely hold the flywheel when removing.
Page 224 ENGINE M8560, M9960, WSM Measuring Angular Deviation between Crankshaft TDC and Crank Position Sensor Detected TDC 1. Remove the cylinder head cover, an injector and rocker arm. 2. Bring the piston of cylinder 4 to TDC. 3. Remove the #4 exhaust valve bridge arm and valve spring.
Page 225 ENGINE M8560, M9960, WSM (Continued) 9. Connect the engine harness and the main switch. 10. Connect the battery. 11. Attach a tester (10) to the output terminal (13) and ground terminal (12) of the crankshaft position sensor (11). 12. Turn the main switch "ON".
Page 226 ENGINE M8560, M9960, WSM Flywheel Housing 1. Remove the flywheel housing (1). (When reassembling) • Apply liquid gasket (Three Bond 1217H) to flywheel housing. • Confirm that the liquid gasket coating surface is free of water, dust and oil in order to maintain sealing effect.
Page 227 ENGINE M8560, M9960, WSM Crankcase 2 1. Remove the crankcase 2 (1). (When reassembling) IMPORTANT • Make sure the crankcase 1 and 2 are clean. • Apply liquid gasket (2) (Three Bond 1217H) to the crankcase 2 as shown in the figure.
Page 228 ENGINE M8560, M9960, WSM Crankshaft 1. Remove the main bearing case (1). 2. Remove the crankshaft (2). (When reassembling) • Reassemble the main bearing case having the same number as the one engraved on the crankcase, and set the casting mark "F / W SIDE"...
Page 229: Intake Air Heater
ENGINE M8560, M9960, WSM (12) Intake Air Heater Intake Air Heater 1. Remove the inlet hose. 2. Disconnect the lead. 3. Remove the air cleaner flange (1) and intake throttle valve (2). 4. Remove the intake air heater (3). 3.5 to 5.3 N·m...
Page 230 ENGINE M8560, M9960, WSM (Continued) (When reassembling) CAUTION • When you install the temperature sensors, be sure that the temperature sensors are installed to the original positions. IMPORTANT • Replacing the gaskets (14) with new ones. • If the differential pressure tube is damaged or cracked, replace it.
Page 231: Servicing
ENGINE M8560, M9960, WSM (Continued) 49 to 55 N·m Filter comp (DPF) mounting 5.0 to 5.7 kgf·m bolts 37 to 41 lbf·ft 25 to 34 N·m Temperature sensor 2.5 to 3.5 kgf·m 18 to 25 lbf·ft Tightening torque 16 to 22 N·m Differential pressure pipe 1.6 to 2.3 kgf·m...
Page 232 ENGINE M8560, M9960, WSM Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head's four sides "A", "B", "C" and "D" and two diagonal "E" and "F" as shown in the figure. Measure the clearance with a feeler gauge.
Page 233 ENGINE M8560, M9960, WSM Valve Lapping 1. Apply the compound equally to the valve lapping surface. 2. Put the valve into the valve guide. Lap the valve on its seat with a valve lapping tool. 3. After you lap the valve, clean away the compound and apply oil, then lap the valve again with oil.
Page 234 ENGINE M8560, M9960, WSM Replacement of Valve Guide (When removing) 1. Press out the used valve guide with the valve guide replacing tool. (When installing) 1. Clean the new valve guide and valve guide bore, and apply engine oil to them.
Page 235 ENGINE M8560, M9960, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with a vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, and put a square on the side of the valve spring.
Page 236 ENGINE M8560, M9960, WSM Oil Clearance between Rocker Arm and Rocker Arm Shaft 1. Measure the rocker arm I.D. with an internal micrometer. 2. Measure the rocker arm shaft O.D. with an external micrometer. Calculate the oil clearance. 3. If the oil clearance is more than the allowable limit, replace the rocker arm and measure the oil clearance again.
Page 237: Timing Gears
ENGINE M8560, M9960, WSM Oil Clearance between Tappet and Tappet Guide Bore 1. Measure the tappet O.D. with an external micrometer. 2. Measure the tappet guide bore I.D. with a cylinder gauge. 3. Calculate the oil clearance. 4. If the oil clearance is more than the allowable limit or the tappet has a damage, replace the tappet.
Page 238 ENGINE M8560, M9960, WSM Camshaft Alignment 1. Hold the 2 end journals of camshaft with V blocks on the surface plate. 2. Set a dial indicator with its point on the middle journal. 3. Turn the camshaft slowly and read the variation on the indicator.
Page 239: Piston And Connecting Rod
ENGINE M8560, M9960, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an external micrometer. 2. Measure the cylinder block bore I.D. for the camshaft with a cylinder gauge. 3. Calculate the oil clearance. 4. If the oil clearance is more than the allowable limit, replace the camshaft.
Page 240 ENGINE M8560, M9960, WSM Oil Clearance between Piston Pin and Small End Bushing 1. Measure the O.D. of the piston pin where it contacts the bushing with an outside micrometer. 2. Measure the I.D. of the piston pin bushing at the connecting rod small end with a cylinder gauge.
Page 241 ENGINE M8560, M9960, WSM Oil Clearance between Piston Pin and Small End Bushing 1. Measure the O.D. of the piston pin where it contacts the bushing with an outside micrometer. 2. Measure the I.D. of the piston pin bushing at the connecting rod small end with a cylinder gauge.
Page 242 ENGINE M8560, M9960, WSM Connecting Rod Alignment NOTE • Make sure that the oil clearance of the small end bushing is less than the allowable limit. 1. Remove the piston pin from the piston. 2. Install the piston pin into the connecting rod.
Page 243: Crankshaft
ENGINE M8560, M9960, WSM (4) Crankshaft Side Clearance of Crankshaft 1. Set a dial indicator with its point on the end of the crankshaft. 2. Move the crankshaft to the front and rear to measure the side clearance. 3. If the measurement is more than the allowable limit, replace the thrust bearings.
Page 244 ENGINE M8560, M9960, WSM Oil Clearance between Crank Pin and Crank Pin Bearing 1. Clean the crank pin and crank pin bearing. 2. Put a strip of Plastigauge on the center of the crank pin. 3. Install the connecting rod cap.
Page 245 ENGINE M8560, M9960, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1. Clean the crankshaft journal and crankshaft bearing. 2. Put a strip of Plastigauge on the center of the journal. IMPORTANT • Do not put the Plastigauge into the oil hole of the journal.
Page 246: Cylinder
ENGINE M8560, M9960, WSM (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the 6 positions (see figure) with a cylinder gauge and find the maximum and minimum inner diameters. 2. Find the difference between the maximum and the minimum inner diameters.
Page 247 ENGINE M8560, M9960, WSM Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 2. If the clearance exceeds the allowable limit, replace the oil pump rotor assembly.
Page 248 TRANSMISSION KiSC issued 08, 2012 A...
Page 249 MECHANISM CONTENTS 1. STRUCTURE..........................2-M1 [1] F8/R8 SPEED TRANSMISSION MODEL ................2-M1 [2] F12/R12 SPEED TRANSMISSION MODEL ................ 2-M2 [3] F24/R24 SPEED TRANSMISSION MODEL ................ 2-M3 2. POWER TRAIN FOR TRAVELING GEAR ................. 2-M4 [1] HYDRAULIC SHUTTLE SHIFT SECTION ................2-M4 (1) Structure .........................
Page 250: Structure
TRANSMISSION M8560, M9960, WSM 1. STRUCTURE [1] F8/R8 SPEED TRANSMISSION MODEL (1) Hydraulic Shuttle Section (3) Hydraulic Pump and Drive Section (5) PTO Gear Section (540 Type) (7) PTO Gear Section (8) Range Gear Shift Section (10) Creep Gear Section (Cassette Type) (Option)
Page 251: F12/R12 Speed Transmission Model
TRANSMISSION M8560, M9960, WSM [2] F12/R12 SPEED TRANSMISSION MODEL (1) Hydraulic Shuttle Section (3) Hydraulic Pump and Drive Section (5) PTO Gear Section (540 Type) (7) PTO Gear Section (8) Range Gear Shift Section (10) Creep Gear Section (Cassette Type) (Option)
Page 252: F24/R24 Speed Transmission Model
TRANSMISSION M8560, M9960, WSM [3] F24/R24 SPEED TRANSMISSION MODEL (1) Hydraulic Shuttle Section (3) Hydraulic Pump and Drive Section (5) PTO Gear Section (540 Type) (7) PTO Gear Section (8) Range Gear Shift Section (10) Dual Speed Section (2) Main Gear Shift Section...
Page 253: Power Train For Traveling Gear
TRANSMISSION M8560, M9960, WSM 2. POWER TRAIN FOR TRAVELING GEAR [1] HYDRAULIC 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...
Page 254: Oil Flow
TRANSMISSION M8560, M9960, WSM (2) Oil Flow (1) Shuttle Valve (3) Forward Clutch (5) Clutch Pedal (A) Pump (2) Reverse Clutch (4) Shuttle Lever (6) Spool (B) Power Steering Controller (C) Oil Cooler (D) PTO Clutch and Other Clutches When the shuttle lever (4) shifts to the forward or reverse, the oil flows to the forward or reverse clutch (2), (3) respectively.
Page 255: Hydraulic Clutch Pack
TRANSMISSION M8560, M9960, WSM (3) Hydraulic Clutch Pack Shuttle Shift Section The shuttle shift section allows the operators to change forward and reverse with a shuttle lever. It is using hydraulic clutch shifting. When the shuttle lever is moved to the F or R position, clutch is engaged to the front or rear by the hydraulic.
Page 256: Hydraulic Shuttle Valve Section
TRANSMISSION M8560, M9960, WSM [2] HYDRAULIC SHUTTLE VALVE SECTION (1) Structure (1) Shuttle Shift Spool (a) Shuttle Forward Position Pressure Check Port To Clutch Body (Forward) (Forward, Reverse) (b) Shuttle Neutral Position (Modulation) P Port (Pump) (2) Inching Valve Spool...
Page 257: Operation
TRANSMISSION M8560, M9960, WSM (2) Operation Shuttle Lever at Neutral Position (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever (8) Clutch Pedal Check Port (Modulation)
Page 258 TRANSMISSION M8560, M9960, WSM When Shuttle Lever is Shifting Neutral to Reverse or Forward Position (Clutch Pedal is Released) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve...
Page 259 TRANSMISSION M8560, M9960, WSM When Lever at Forward Position (Clutch Pedal is Released) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever (8) Clutch Pedal...
Page 260 TRANSMISSION M8560, M9960, WSM When Lever at Reverse Position (Clutch Pedal is Released) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever (8) Clutch Pedal...
Page 261 TRANSMISSION M8560, M9960, WSM When Clutch Pedal is Depressed (with Shuttle Lever at Reverse or Forward Position) (1) Proportionally Reducing Valve (2) Shuttle Valve (3) Shuttle Shift Spool (Forward, Reverse) (4) Inching Valve (5) Modulating Valve (6) Accumulate Valve (7) Shuttle Lever...
Page 262: Main Gear Shift Section
TRANSMISSION M8560, M9960, WSM [3] MAIN GEAR SHIFT SECTION (1) F8/R8 Speed Transmission Model (1) 1st Shaft (6) 21T Gear (11) 30T Gear (16) Center Ring (2) 31T Gear (7) Coupling (12) 14T Gear Shaft (17) Outer Synchronizer Ring (3) Shifter...
Page 263: F12/R12 And F24/R24 Speed Transmission Model
TRANSMISSION M8560, M9960, WSM (2) F12/R12 and F24/R24 Speed Transmission Model (1) 1st Shaft (6) 35T Gear (11) Coupling (16) 27T Gear (2) 27T Gear (7) Coupling (12) Shifter (17) 14T Gear Shaft (3) Shifter (8) Shifter (13) 17T Gear...
Page 264: Range Gear Shift Section
TRANSMISSION M8560, M9960, WSM [4] RANGE GEAR SHIFT SECTION (1) F8/R8 Speed Transmission Model (1) 30T Gear (2) 14T Gear Shaft (2nd Shaft) (3) 3rd Shaft (4) 25T Gear (5) Coupling (6) Shifter (7) 45T-22T Gear H : Hi Speed Range...
Page 265: F12/R12 And F24/R24 Speed Transmission Model
TRANSMISSION M8560, M9960, WSM (2) F12/R12 and F24/R24 Speed Transmission Model (1) 33T Gear (2) 14T Gear Shaft (2nd Shaft) (3) 24T Gear (4) 3rd Shaft (5) Coupling (6) Shifter (7) 45T-22T Gear H : Hi Speed Range L : Lo Speed Range...
Page 266: Creep Gear Shift Section (Option)
TRANSMISSION M8560, M9960, WSM (3) Creep Gear Shift Section (Option) (1) 33T Gear (2) 14T Gear Shaft (2nd Shaft) (3) 24T Gear (4) 3rd Shaft (5) Coupling (6) Shifter 1 (7) 45T-22T Gear (8) 48T Gear (9) 53T Gear (10) 17T Gear...
Page 267: Shift Fork Rod And Fork
TRANSMISSION M8560, M9960, WSM [5] SHIFT FORK ROD AND FORK (1) F8/R8 Speed Transmission Model (1) 3rd-4th Shift Fork (7) Main Shift Lever (A) Select 1st-2nd Shift Fork (C) Engage to Hi Position (2) H-L Fork (8) 3rd-4th Shift Fork Rod...
Page 268: F12/R12 And F24/R24 Speed Transmission Model
TRANSMISSION M8560, M9960, WSM (2) F12/R12 and F24/R24 Speed Transmission Model (1) 3rd-4th Shift Fork (8) H-L Lever (15) Interlock Ball 2 (C) Select 5th-6th Shift Fork (2) H-L Fork (9) Main Shift Lever (3) 5th-6th Shift Fork (10) 3rd-4th Shift Fork Rod...
Page 269: Creep Gear Shift Section (Option)
TRANSMISSION M8560, M9960, WSM (3) Creep Gear Shift Section (Option) (1) 3rd-4th Shift Fork (9) Main Shift Lever (A) Select 1st-2nd Shift Fork (E) Engage to Lo Position (2) Select Arm (10) 1st-2md Shift Fork Rod (F) Engage to Creep Position...
Page 270: Dual Speed Shift Section
TRANSMISSION M8560, M9960, WSM [6] DUAL SPEED SHIFT SECTION (1) Hydraulic Clutch Pack Dual Speed Section The dual speed section is operated hydraulic clutch, solenoid valve and dual speed switch. When operate the lo to H position, travelling speed increase approx. 18 %.
Page 271: Dual Speed Valve
TRANSMISSION M8560, M9960, WSM (2) Dual Speed Valve This valve change the oil flow to the dual speed HI clutch or LO clutch. As the pilot valve DS (solenoid valve) (5) operates by energizing the solenoid, the flow of oil is switched to the HI side (B) or LO (C) side of dual speed clutch with DS spool (2).
Page 272: Lubrication For Transmission
TRANSMISSION M8560, M9960, WSM 3. LUBRICATION FOR TRANSMISSION [A] F8/R8 Speed Transmission [B] F12/R12 Speed [C] F24/R24 Speed Transmission Transmission Hydraulic shuttle section, main shift change synchromesh gears, hydraulic pump drive / driven gear, PTO hydraulic pack and PTO brake are forcibly lubricated.
Page 273: Power Train For Pto System
TRANSMISSION M8560, M9960, WSM 4. POWER TRAIN FOR PTO SYSTEM [1] PTO GEAR SECTION (1) PTO Propeller Shaft 1 (2) PTO Clutch (3) PTO Propeller Shaft 2 (4) Coupling (5) 13T Gear Shaft (6) 16T Gear (7) PTO Shaft (8) 45T Gear...
Page 274: Pto Hydraulic Clutch Section
TRANSMISSION M8560, M9960, WSM [2] PTO HYDRAULIC CLUTCH SECTION (1) PTO Hydraulic Clutch The PTO clutch pack has five clutch disks (5), five drive plates (6), a belleville washer (cupped spring washer) (9) and one pressure plate (4). The clutch piston...
Page 275: Pto Solenoid Valve, Relief Valve And Oil Flow
TRANSMISSION M8560, M9960, WSM (2) PTO Solenoid Valve, Relief Valve and Oil Flow When the PTO switch is at the OFF position, the oil flows is stopped by the PTO solenoid valve (3). When the PTO switch is at ON position, the solenoid...
Page 276: Power Train For 4Wd
TRANSMISSION M8560, M9960, WSM 5. POWER TRAIN FOR 4WD [1] 4WD SHIFT SECTION (1) 2WD-4WD Section 2 wheel drive or 4 wheel drive is selected by changing the position of shifter (4) on the propeller shaft 1 (5) using the front wheel drive lever.
Page 277: 2Wd-4Wd Shift Linkage
TRANSMISSION M8560, M9960, WSM (2) 2WD-4WD Shift Linkage When operating the front wheel drive lever (1) from 2WD to 4WD, the shift lever (4) turn and push down the 4WD (2) to engage the shifter (7) via shift arm (3).
Page 278: 4Wd Hydraulic Clutch Section (Dual Speed Model)
TRANSMISSION M8560, M9960, WSM [2] 4WD HYDRAULIC CLUTCH SECTION (DUAL SPEED MODEL) (1) 4WD Hydraulic Clutch (1) 4WD Propeller Shaft (2) 33T Gear (3) Cylinder Case (4) 4WD Piston (5) Spring (6) Clutch Body (7) 4WD Shaft (8) 35T Gear The 4WD clutch is controlled by the solenoid valve and the hydraulic flow.
Page 279: 4Wd Oil Flow
TRANSMISSION M8560, M9960, WSM (2) 4WD Oil Flow Oil pressure-fed from the power steering hydraulic pump is flowed to the 4WD solenoid valve (3) 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 280: Differential Lock
TRANSMISSION M8560, M9960, WSM 6. DIFFERENTIAL LOCK [1] PIN TYPE When resistances to the right and left tires are different due to ground conditions or type of work, the wheel with less resistance slips and prevents the tractor from moving ahead. To compensate for this the differential lock restricts the differential function and causes both rear axles to rotate as a unit.
Page 281: Hydraulic Actuated Type (Dual Speed Model)
TRANSMISSION M8560, M9960, WSM [2] HYDRAULIC ACTUATED TYPE (DUAL SPEED MODEL) (1) Structure (1) Shaft L.H. (2) Piston (3) Differential Lock Pin (4) Shaft R.H. (5) Differential Case (6) Spring (7) Pin (8) Piston Support The differential lock can be operated easily with an electric switch.
Page 282: Oil Flow
TRANSMISSION M8560, M9960, WSM (2) Oil Flow Oil pressure-fed from the power steering hydraulic pump is flowed to the differential lock solenoid valve (3) through the steering controller and oil cooler. When the differential lock switch turned on, the differential lock solenoid valve is electrified, the oil flow is switched and engage the differential lock pin to lock position.
Page 283 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 2. SERVICING SPECIFICATIONS ....................2-S3 3. TIGHTENING TORQUES......................2-S6 4. CHECKING AND ADJUSTING....................2-S8 [1] HYDRAULIC SHUTTLE LEVER....................2-S8 (1) Hydraulic Shuttle Lever ....................2-S8 (2) Engine Start Condition....................2-S10 [2] CLUTCH PEDAL FREE TRAVEL..................2-S11 [3] GEAR SHIFTING LINKAGE ....................2-S12 (1) Main Gear Shift......................2-S12 (2) Range Gear Shift......................2-S14 [4] ACCELERATOR SECTION....................2-S16 (1) Checking Accelerator Lever ..................2-S16...
Page 284 [9] DISASSEMBLING TRANSMISSION CASE ................2-S89 (1) Removing PTO Clutch Pack ..................2-S89 (2) Disassembling PTO Clutch Pack...................2-S90 (3) Removing 4WD Clutch (Dual Speed Model) ..............2-S91 (4) Disassembling 4WD Clutch Pack ..................2-S92 (5) Removing Differential Gear and Bevel Pinion Shaft ............2-S94 (6) Differential Gear......................2-S96 (7) Differential Lock Piston (Dual Speed Model) ..............2-S98 [10]PTO GEAR CASE .......................2-S98 (1) 540 Type........................2-S98...
Page 285: Troubleshooting
TRANSMISSION M8560, M9960, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Shuttle Clutch Slip Operating pressure is low Adjust 2-S20 Shuttle clutch valve malfunctioning Replace 2-S29 Clutch disk or steel plate excessively worn Replace 2-S59, 2-S103 Deformation of piston or steel plate Replace –...
Page 286 TRANSMISSION M8560, M9960, WSM Reference Symptom Probable Cause Solution Page Front Wheel Does 4WD shift malfunctioning Repair or replace 2-S87, Not Rotate 2-S91 4WD clutch malfunctioning Repair or replace 2-S87, 2-S91 4WD propeller shaft coupling disengaged Engage – 4WD Operating...
Page 287: Servicing Specifications
TRANSMISSION M8560, M9960, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Clutch Pedal (ROPS Model) Free Travel 15 to 20 mm – 0.59 to 0.79 in. Total Stroke 145 to 155 mm – 5.71 to 6.10 in. Clutch Pedal (CABIN Model)
Page 288 TRANSMISSION M8560, M9960, WSM Item Factory Specification Allowable Limit Valve Lever Pin to Lever Bushing Clearance 0.0490 to 0.156 mm 0.5 mm 0.00193 to 0.00614 in. 0.02 in. • Lever Pin O.D. 13.957 to 13.984 mm – 0.54959 to 0.55055 in.
Page 289 TRANSMISSION M8560, M9960, WSM Item Factory Specification Allowable Limit Differential Case Bore to Differential Side Clearance 0.0700 to 0.189 mm 0.35 mm Gear Boss 0.00276 to 0.00744 in. 0.014 in. • Differential Case Bore I.D. 49.07 to 49.15 mm –...
Page 290: Tightening Torques
TRANSMISSION M8560, M9960, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to G-14.) Item N·m kgf·m lbf·ft Rear wheel mounting nut 344 to 392 35.0 to 40.0...
Page 291 TRANSMISSION M8560, M9960, WSM Item N·m kgf·m lbf·ft Shuttle case and shuttle holder mounting screw and nut 48 to 55 4.9 to 5.7 36 to 41 Speed change cover mounting screw 78 to 90 7.9 to 9.2 58 to 66...
Page 292: Checking And Adjusting
TRANSMISSION M8560, M9960, WSM 4. CHECKING AND ADJUSTING [1] HYDRAULIC SHUTTLE LEVER (1) Hydraulic 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 293 TRANSMISSION M8560, M9960, WSM (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 294: Engine Start Condition
TRANSMISSION M8560, M9960, WSM (2) Engine Start Condition Engine Start Condition IMPORTANT • Before starting the engine, make sure the gear shift lever at the neutral position. • Place the PTO lever to the OFF position. • Apply the parking brake.
Page 295: Clutch Pedal Free Travel
TRANSMISSION M8560, M9960, WSM [2] CLUTCH PEDAL FREE TRAVEL Clutch Pedal Free Travel 1. Measure the clutch pedal free travel "L". 2. If adjustment is needed, change with clutch wire cable (3) retaining nut (2) so that the free travel becomes 15 to 20 mm (0.59 to 0.79 in.).
Page 296: Gear Shifting Linkage
TRANSMISSION M8560, M9960, WSM [3] GEAR SHIFTING LINKAGE (1) Main Gear Shift Checking Function of Main Gear Shift 1. Check the function of the main gear shift. • Neutral position to 1st gear position. • Neutral position to 2nd gear position.
Page 297 TRANSMISSION M8560, M9960, WSM Adjusting Main Gear Shift 1. If the main gear shift lever 1 (1) is loose or does not shift smoothly, tighten the lock nut (3) to adjust. Make sure that there are sufficient grease applied to the sliding position 1 "a"...
Page 298: Range Gear Shift
TRANSMISSION M8560, M9960, WSM (2) Range Gear Shift Checking Function of Range Shift 1. Check the function of the range gear shift. • H, L and C (Option) position. 2. If feeling abnormal shifting, adjust the range shift following 2-S15.
Page 299 TRANSMISSION M8560, M9960, WSM Adjusting Range Gear Shift 1. Adjust the range gear shift rod (1) so that when the range gear shift lever (2) is shifted to the high speed range position, the clearance is "a" in the table below. (ROPS Model) 2.
Page 300: Accelerator Section
TRANSMISSION M8560, M9960, WSM [4] ACCELERATOR SECTION (1) Checking Accelerator Lever Checking Accelerator Lever (ROPS Model) 1. Check that grease is applied to between the accelerator plate (1) and the hand accelerator lever (2). If grease is not applied, apply grease to there.
Page 301 TRANSMISSION M8560, M9960, WSM Checking Accelerator Lever (CABIN Model) 1. Check the grease is applied to between the accelerator plate (3) and the hand accelerator lever (2). If grease is not applied, apply grease to there. 2. Check the hand accelerator lever (2) operating force.
Page 302: Adjusting Accelerator Lever And Wire
TRANSMISSION M8560, M9960, WSM (2) Adjusting Accelerator Lever and Wire Adjusting Accelerator Lever (ROPS Model) 1. When shifting the hand accelerator lever (1) to low engine speed and the accelerator pedal (4) is neutral position, adjust the turnbuckle (2) with accelerator rod (3) to hold the engine speed to minimum.
Page 303 TRANSMISSION M8560, M9960, WSM Adjusting Accelerator Wire (CABIN Model) 1. Apply grease to the bushes (1) with accelerator pedal (2). 2. When touching the accelerator pedal (2) to the bolt (5), adjust length of bolt "L2", so that the accelerator sensor lever (3) touches link pin (4).
Page 304: Hydraulic Clutch Valve
TRANSMISSION M8560, M9960, WSM [5] HYDRAULIC CLUTCH VALVE Shuttle Clutch Valve System Pressure 1. Prepare a can (3) for fuel and put in the fuel hose (1) and fuel return hose (2). 2. Remove the each plugs of F, R, M and install the adaptor (4) (see page G-80), threaded joint, cable, and pressure gauge (Code No.: 07916-52961).
Page 305 TRANSMISSION M8560, M9960, WSM PTO Clutch Valve Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the shuttle lever in Neutral position. • Set the parking brake lever in parking position.
Page 306 TRANSMISSION M8560, M9960, WSM 4WD Clutch Valve Operating Pressure (Dual Speed Model) IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the shuttle lever in Neutral position. • Set the parking brake lever in parking position.
Page 307 TRANSMISSION M8560, M9960, WSM Dual Speed Clutch Valve Operating Pressure IMPORTANT • Do not connect the universal joint of the implement to the tractor PTO shaft while testing. • Set the shuttle lever in Neutral position. • Set the parking brake lever in parking position.
Page 308: Disassembling And Assembling
Transmission fluid Capacity 63.4 U.S.qts 52.7 Imp.qts IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oil may damage the transmission or hydraulic system. (Refer to G-12.) • Do not mix different brands fluid together. (1) Drain Plug...
Page 309 TRANSMISSION M8560, M9960, WSM Disconnecting buttery negative terminal 1. Open the bonnet 2. Disconnect the buttery negative terminal (1) (1) Negative terminal 9Y1210686TRS0166US0 Front Axle Rocking Restrictor 1. Chock the wheels and install the front axle rocking restrictor (1) to the front axle bracket on both sides. (See page G-68)
Page 310 TRANSMISSION M8560, M9960, WSM Fuel Filling Port, Fender and Auxiliary Step [Low Profile Model] 1. Remove the fuel filling port (1) fixing screw. 2. Remove the harness cover (2) and disconnect the 4P connector (3). 3. Remove the auxiliary lever bracket (4).
Page 311 TRANSMISSION M8560, M9960, WSM Fuel Tank [Low Profile Model] 1. Remove the fuel sensor 2P connector (1). 2. Place the disassembling stand under the fuel tank (2). 3. Remove the fuel tank band (3). 4. Remove the fuel tank stay (4).
Page 312 TRANSMISSION M8560, M9960, WSM Auxiliary Step and Fuel Tank (CABIN Model) 1. Remove the cover mounting screws (1). 2. Remove the fuel filling port mounting screw (2). 3. Remove the auxiliary step (3) and disconnect the wire harness from fuel level sensor (4).
Page 313: Hydraulic Shuttle Valve
TRANSMISSION M8560, M9960, WSM (2) 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 314: Dual Speed Solenoid Valve
TRANSMISSION M8560, M9960, WSM Solenoid Valve Assembly (F24/R24 Speed Transmission Model) 1. Remove the l-joint screws and then remove delivery pipe (2) and differential lock pipe (1). 2. Disconnect the connector (3). 3. Remove the solenoid valve assembly (4). (When reassembling) •...
Page 315: Propeller Shaft (4Wd Model) And Power Steering Hose
TRANSMISSION M8560, M9960, WSM (3) Propeller Shaft (4WD Model) and Power Steering Hose 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.
Page 316: Bonnet And Cover
TRANSMISSION M8560, M9960, WSM (4) Bonnet and Cover Bonnet and Cover (ROPS Model) 1. Open the bonnet (1) and disconnect the battery negative terminal. 2. Disconnect the 3P connector (5) for head lights. 3. Remove the muffler pipe mounting screws (2) and then muffler pipe (4).
Page 317 TRANSMISSION M8560, M9960, WSM Bonnet and Cover (CABIN Model) 1. Open the bonnet (1) and disconnect the battery (2) negative terminal. 2. Remove the muffler pipe mounting screws 1 (7) and the muffler pipe (6). 3. Remove the cover (3), the side panel (4) and the side cover guide (5) on both sides.
Page 318: Dpf Muffler
TRANSMISSION M8560, M9960, WSM (5) DPF Muffler Disconnecting Connectors for DPF Muffler CAUTION • After running the engine, DPF muffler is very hot. When disconnecting the connectors, wait the cooling down. 1. Disconnect the connectors 1 (1) for the exhaust gas temperature sensor.
Page 319 TRANSMISSION M8560, M9960, WSM Oil Cooler Pipe, Fuel Hoses and Wire Harness for R.H. Side 1. Disconnect the oil cooler pipe retaining nuts (1). 2. Remove the slow blow fuse box (3) from the battery support and disconnect the connectors 1 (4) for the battery.
Page 320 TRANSMISSION M8560, M9960, WSM Separating Engine from Clutch Housing 1. Make sure the engine and clutch housing case are securely mounted on the disassembling stands. 2. Remove the steering support mounting screw (1) for front side. 3. Remove the engine mounting screws and nut, and separate the engine from the clutch housing.
Page 321: Cabin Model
TRANSMISSION M8560, M9960, WSM (2) CABIN Model Wire Harness for Tractor Front Side 1. Remove the engine ECU cover (1). 2. Let the red handles of engine ECU be rotated 0.79 rad (45 °) and disconnect the 96P connector (2) and 58P connector (3).
Page 322 TRANSMISSION M8560, M9960, WSM Wire Harness for L.H. Side 1. DIsconnect the wire harness (5) from the alternator (1), the starter (2), the coolant temperature sensor (3), the engine oil pressure switch (4). 2. Disconnect the wire harness (6) from the camshaft position sensor (6) and the crankshaft position sensor (7).
Page 323 TRANSMISSION M8560, M9960, WSM Condenser and Compressor � Without discharging the refrigerant from system 1. Remove the screw 1 (1) from the condenser (2) and slide out the condenser (2). 2. Remove the hose clamps (3). 3. Disconnect 1P connector (4) of magnetic clutch.
Page 324 TRANSMISSION M8560, M9960, WSM (Continued) � With discharge the refrigerant from system 1. See page 9-S18. 2. Disconnect the low pressure hose (8) and high pressure hose (9) from compressor (5). (When reassembling) • Charge the refrigerator to the air conditioner system. (See page 9-S20.)
Page 325 TRANSMISSION M8560, M9960, WSM Heater Hose, Steering Pipe and Steering Joint Shaft 1. Remove the hose clamps (1). 2. Slide the hose clamp 2 (3) and disconnect the heater hoses (2) from the heater hose couples. 3. Disconnect the breather hose (4) and steering pipe 1 (5).
Page 326 TRANSMISSION M8560, M9960, WSM Fuel Hose and Wire Harness for R.H. Side 1. Disconnect the wire harness (9) from the heater relay (1), the intake air temperature sensor (2), the intake air pressure sensor (3), the intake air heater (4), the EGR DC motor (5), the fuel temperature sensor (6), the SCV (7), the rail pressure sensor (8) and the connector (10).
Page 327 TRANSMISSION M8560, M9960, WSM Step, Floor Mats and Wiring Harness for CABIN Side 1. Remove the auxiliary step on both sides. 2. Remove the fuel filling port (2). 3. Remove the floor mat 1 (3) and mat 2 (4). 4. Remove the floor cover (5) and seat under cover (6).
Page 328: Separating Clutch Housing Case And Transmission Case
TRANSMISSION M8560, M9960, WSM Separating Engine from Clutch Housing 1. Check the engine and clutch housing case are securely mounted on the disassembling stands. 2. Remove the engine mounting screws and nuts. 3. Separate the engine from the clutch housing.
Page 329 TRANSMISSION M8560, M9960, WSM ROPS, Lower Link, Lift Rod and Rear Wheel (Low Profile Model) 1. Hook the upper frame (1). 2. Remove the damper mounting nut (2). 3. Remove the lunch pin (5) and set bolt (4). 4. Remove the upper frame (1) using a hoist.
Page 330 TRANSMISSION M8560, M9960, WSM Fender (R.H.) and ROPS Under (R.H.) 1. Remove the cover (1) and then disconnect 3P connector for PTO clutch control switch. 2. Loosen the retaining nut (2). 3. Remove the pin (3) and then disconnect the auxiliary control valve wire (4).
Page 331 TRANSMISSION M8560, M9960, WSM Fender (L.H.), ROPS Under (L.H.), Seat, 4WD Lever Grip and Hydraulic Lowering Speed Rod 1. Unscrew the fender mounting screws (1) and then remove the fender (2). 2. Disconnect the 4P connector and two 1P connectors for combination lamp (4) and hazard lamp (3).
Page 332 TRANSMISSION M8560, M9960, WSM Fender, ROPS Under, Seat, 4WD Lever Grip and Hydraulic Lowering Speed Rod (Low Profile Model) 1. Remove the fuel filling port (1) fixing screw. 2. Remove the harness cover (2) and disconnect the 4P connector (3) and 1P connector (4) and remove the wire harness from ROPS under.
Page 333 TRANSMISSION M8560, M9960, WSM Hydraulic Control Rods, Differential Lock Rod, Accelerator Rod and Connectors 1. Disconnect the position control rod (1) and draft control rod (2). 2. Disconnect the differential lock rod (3) and the accelerator rod (4). 3. Disconnect the 2P connector (5) for OPC buzzer and the 4P connector (6) for speed sensor.
Page 334 TRANSMISSION M8560, M9960, WSM Accelerator Rod and Step 1. Disconnect the accelerator rod. 2. Remove the step (2) mounting bolts, and then remove the step (2). 3. Remove the step (2). NOTE • After assembling check the speed change lever movement and adjust them if necessary (see page 2-S18).
Page 335 TRANSMISSION M8560, M9960, WSM Step, Covers, Fuel Tank and Wire Harness 1. Remove the auxiliary step (1) and fuel tank (2). (See page 2-S25, 2-S27.) 2. Disconnect the 1P connectors (3) for hydraulic shuttle valve, the 3P connector (4) for revolution sensor and the 2P connector (5) for 4WD safety switch.
Page 336 TRANSMISSION M8560, M9960, WSM Hydraulic Pipe, Parking Lever Spring and Hydraulic Pump 1. Remove the brake pipe clamps (3), and both brake pipes (1), (2). 2. Remove the 3-point hitch delivery pipe (4), (5) with the 3-point hitch delivery pipe 3 (6).
Page 337: Preparation For Cabin Model
TRANSMISSION M8560, M9960, WSM (2) Preparation for CABIN Model Removing Cabin from Body 1. Refer to 9-S34. 9Y1210686TRS0056US0 Fuel Tank 1. Remove the fuel tank (1). (See page 2-S28.) (1) Fuel Tank 9Y1210686TRS0057US0 2-S53 KiSC issued 08, 2012 A...
Page 338 TRANSMISSION M8560, M9960, WSM Wire Cables and Wire Harness 1. Remove the shuttle cable (1) and the clutch cable (2). 2. Remove the 4WD lever rod (3). 3. Disconnect the 1P connector (3) for hydraulic shuttle valve, the 3P connector (4) for revolution sensor and the 2P connector (5) for 4WD safety switch.
Page 339 TRANSMISSION M8560, M9960, WSM Differential Lock Rod, Parking Gear Brake Spring, Hydraulic Pipe and Hydraulic Pump 1. Remove the oil cooler return pipe (1). 2. Remove the solenoid valve pipe (2), the power steering pipe (3) and the brake return hose (4).
Page 340: Clutch Housing Case
TRANSMISSION M8560, M9960, WSM (3) Clutch Housing Case Separating Clutch Housing Case from Engine 1. Remove the clutch housing mounting screws and nuts. 2. Separate the clutch housing case. (When reassembling) • Apply molybdenum disulphide (Three Bond 1901 or equivalent) to spline of input shaft.
Page 341 TRANSMISSION M8560, M9960, WSM Removing Main Shift Lever 1. Disconnect the range gear shift rod (1) and the parking gear brake rod (2). 2. Remove the main shift lever bracket assembly (3). 3. Tap out the roll pin and then pull out the main gear shift lever 1 (4).
Page 342: Transmission Case
TRANSMISSION M8560, M9960, WSM (4) Transmission Case 3-Point Linkage and Hydraulic Cylinder 1. Remove the lower link (7) and lift rod (6). 2. Remove the cylinder cover (1). 3. Disconnect the cylinder hose (4) and return hose (3). 4. Remove the hydraulic cylinder (2).
Page 343: Damper Disk
TRANSMISSION M8560, M9960, WSM [5] DAMPER DISK Damper Disk 1. Remove the damper disk (1). (When reassembling) • Direct the shorter end of the damper disk boss toward the flywheel. • Apply molybdenum disulphide (Three Bond 1901 or equivalent) to the spline.
Page 344 TRANSMISSION M8560, M9960, WSM Removing Shuttle Case Assembly 1. Remove the oil seal (1). 2. Remove the external circlip (2). 3. Tap out the input shaft (3) with shuttle clutch and 26T, 24T gear with shuttle shaft (4) together. (When reassembling) •...
Page 345: Removing Hydraulic Shuttle Clutch (F24/R24 Speed Transmission Model)
TRANSMISSION M8560, M9960, WSM (2) Removing Hydraulic Shuttle Clutch (F24/R24 Speed Transmission Model) Removing Shuttle Case Assembly CAUTION • The shuttle case assembly is heavy, so that take care it when handling. 1. Remove the shuttle holder (1). 2. Remove the shuttle case mounting screws and nuts.
Page 346 TRANSMISSION M8560, M9960, WSM Removing Shuttle Clutch Pack 1. Remove the external circlip (2) and 30T gear (1). 2. Remove the spacer (4), collar (5) and 27T gear (3). 3. Pull the shuttle clutch pack (7) and lower the shuttle clutch pack (7) in the housing case.
Page 347: Shuttle Clutch Assembly
TRANSMISSION M8560, M9960, WSM (3) Shuttle Clutch Assembly Shuttle Clutch Assembly (F8/R8 and F12/R12 Speed Transmission Model) (1) Seal Ring (2) Shuttle Shaft (3) Key (4) 28T Gear (5) Internal Circlip (6) Belleville Washer (Cupped Spring Washer) (7) Pressure Plate...
Page 348 TRANSMISSION M8560, M9960, WSM Shuttle Clutch Assembly (F24/R24 Speed Transmission Model) (1) Bearing (2) 32T Gear (3) Spacer (4) 29T Gear (5) Seal Ring (6) Shuttle Shaft (7) Bearing (8) Internal Circlip (9) 27T Gear (10) Internal Circlip (11) Belleville Washer (Cupped...
Page 349 TRANSMISSION M8560, M9960, WSM Shuttle Shaft 1. Remove the bearing (4) and washer (3). 2. Remove the gear (2). 3. Tap out the shuttle shaft (1) with gear (5) to the forward. � NOTE F8/R8 and F12/R12 F24/R24 speed speed transmission...
Page 350 TRANSMISSION M8560, M9960, WSM Shuttle Clutch Pack 1. Remove the internal circlip (1). 2. Remove the belleville washer (2), pressure plate (3), steel plate (5), (7) and clutch disks (6). (When reassembling) • Install the clutch disks (6) and steel plate (5), (7) mutually.
Page 351 TRANSMISSION M8560, M9960, WSM Piston 1. Press the thrust collar (4) lightly by the hand made jig (see page G-72), and remove the external circlip (3). 2. Remove the springs (7). 3. Draw out the piston (5) using a air pressure.
Page 352: Removing Dual Speed Clutch
TRANSMISSION M8560, M9960, WSM (4) Removing Dual Speed Clutch Dual Speed Clutch Assembly 1. Remove the holder (10). 2. Remove the oil seal (12),external circlip (1) and internal circlip (13). 3. Tap out the dual speed shaft (7) with clutch pack (5).
Page 353 TRANSMISSION M8560, M9960, WSM Dual Speed Clutch Pack 1. Remove the internal circlip (1). 2. Take out the pressure plate (2), clutch disks (4) and steel plates (3). (When reassembling) • Install the clutch disks (4) and steel plate (3) mutually.
Page 354 TRANSMISSION M8560, M9960, WSM Piston 1. Press the washer (4) lightly by the hand made jig (see page G-72), and remove the external circlip (3). 2. Remove the springs (7). 3. Draw out the piston (5) using a air pressure.
Page 355: Shift Cover
TRANSMISSION M8560, M9960, WSM [7] 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 Creep speed range position (F). 3. Remove the shift cover (1) mounting screws.
Page 356 TRANSMISSION M8560, M9960, WSM Main Shift Fork (F8/R8 Speed Transmission Model) 1. Remove the roll pin (8), (13), fork rod (11) and 3rd-4th fork (7). 2. Remove the roll pin (6), fork rod (5) and 1st-2nd fork (4). NOTE • Take care not to lose the balls and springs.
Page 357 TRANSMISSION M8560, M9960, WSM Main Shift Fork (F12/R12 and F24/R24 Speed Transmission Model) 1. Remove the roll pins (8), (13), fork rod (11), shifter (12) and 5th-6th fork. 2. Remove the roll pins (15), (21), fork rod (19), shifter (20) and 3rd-4th fork.
Page 358 TRANSMISSION M8560, M9960, WSM Range Gear Shift Fork 1. Remove the roll pin (1), (6), fork rod stopper collar (7), fork rod (3) and range shift fork (2). 2. Remove the ball (4) and spring (5). NOTE • Take care not to lose the detent ball (4) and spring (5).
Page 359 TRANSMISSION M8560, M9960, WSM Main Shift Arm 1. Remove the roll pin (1) and main shift arm (2). 2. Remove the internal circlip (3) and collar (4) then remove the spring 1 (7). 3. Remove the external circlip (5) and collar (8) then remove the spring 2 (9) and collar (10).
Page 360 TRANSMISSION M8560, M9960, WSM Range Shift Arm 1. Remove the roll pin 1 (2), roll pin 2 (3) and stopper plate (4). 2. Draw out the range shift arm (5). (When reassembling) • Be sure to assemble the range shift lever (1) as an original direction as shown in photo.
Page 361 TRANSMISSION M8560, M9960, WSM Creep Gear Assembly (If Equipped) 1. Remove the creep holder mounting screw (1) and the creep gear assembly. (1) Creep Holder Mounting Screw (5) Creep Shaft (2) Creep Holder (6) 48T Gear (3) Shifter (7) Shift Cover...
Page 362: Disassembling Clutch Housing Case
TRANSMISSION M8560, M9960, WSM [8] DISASSEMBLING CLUTCH HOUSING CASE (1) Removing 1st Shaft, 2nd Shaft and 3rd Shaft 30T Gear (27T Gear) 1. Remove the external circlip 1 (3). 2. Remove the 30T gear (1) or 27T gear (5). (When reassembling) •...

Kubota M9960 Workshop Manual

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