Kubota M8540/M9540 Workshop Manual

About this manual

Kubota published this Workshop Manual for the M8540 and M9540 tractor models. It brings the documented service and technical-reference material for those named tractors into a single publication.

Its documented technical value includes torque settings, wear limits, fluid and system capacities, dimensions, and speed ratings for service checks and specification lookup. Use the values and conditions stated in the PDF for the applicable model and procedure.

Use the Manual Contents below to check that the exact repair, inspection, or maintenance procedure you need is included in this publication.

Manual details

Manufacturer

Kubota

Manual type

Workshop Manual

Equipment type

Tractor

Models

M8540 and M9540

Publication year

2007

Publication date

January 2007

Language

English

Page count

603

Product highlights

Electrical systems

The manual includes wiring diagrams and electrical troubleshooting.

Hydraulic systems

The manual includes hydraulic pressure-test material and hydraulic valve-adjustment material.

Specifications and settings

The manual includes reference information for torque specifications, wear limits, capacities, dimensions, and speed ratings.

Special tools

A special-tools section is included.

Maintenance

The manual includes a maintenance schedule.

Manual contents

Use these source headings to locate the task or system you need in the PDF.

• GENERAL — p. 24
  • TRACTOR IDENTIFICATION — p. G-1
  • [1] MODEL NAME AND SERIAL NUMBERS — p. G-1
  • [2] CYLINDER NUMBER — p. G-3
  • GENERAL PRECAUTIONS — p. G-4
  • HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING — p. G-5
  • [1] WIRING — p. G-5
  • [2] BATTERY — p. G-7
  • [3] FUSE — p. G-7
  • [4] CONNECTOR — p. G-7
  • [5] HANDLING OF CIRCUIT TESTER — p. G-8
  • TIGHTENING TORQUES — p. G-11
  • [1] GENERAL USE SCREWS, BOLTS AND NUTS — p. G-11
  • [2] STUD BOLTS — p. G-11
  • [3] HYDRAULIC FITTINGS — p. G-12
  • MAINTENANCE — p. G-13
  • CHECK AND MAINTENANCE — p. G-16
  • [1] DAILY CHECK — p. G-16
  • [2] CHECK POINTS OF INITIAL 50 HOURS — p. G-17
  • [3] CHECK POINTS OF EVERY 50 HOURS — p. G-20
  • [4] CHECK POINTS OF EVERY 100 HOURS — p. G-22
  • [5] CHECK POINTS OF EVERY 200 HOURS — p. G-27
  • [6] CHECK POINTS OF EVERY 400 HOURS — p. G-29
  • [7] CHECK POINTS OF EVERY 500 HOURS — p. G-30
  • [8] CHECK POINTS OF EVERY 600 HOURS — p. G-32
  • [11]CHECK POINTS OF EVERY 3000 HOURS — p. G-33
  • [12]CHECK POINTS OF EVERY 1 YEAR — p. G-33
  • [13]CHECK POINTS OF EVERY 2 YEARS — p. G-34
  • [14]CHECK POINTS OF EVERY 4 YEARS — p. G-37
  • [15]OTHERS — p. G-38
  • SPECIAL TOOLS — p. G-43
  • [1] SPECIAL TOOLS FOR ENGINE — p. G-43
  • [2] SPECIAL TOOLS FOR TRACTOR — p. G-58
  • [3] SPECIAL TOOLS FOR AIR CONDITIONER UNIT — p. G-71
  • TIRES — p. G-73
  • [1] TYPE OF TIRES — p. G-73
  • [2] TREAD ADJUSTMENT — p. G-74
  • (2) Rear Wheels — p. G-75
  • [3] WHEEL HUB — p. G-76
  • [4] TIRE PRESSURE — p. G-76
  • [5] TIRE LIQUID INJECTION — p. G-77
• 10. IMPLEMENT LIMITATIONS — p. G-80
• MECHANISM — p. 108
  • FEATURE — p. 1-M1
  • ENGINE BODY — p. 1-M2
  • [1] CYLINDER BLOCK — p. 1-M2
  • [2] HALF-FLOATING HEAD COVER — p. 1-M2
  • [3] CYLINDER HEAD — p. 1-M3
  • [4] CENTER DIRECT INJECTION SYSTEM (E-CDIS) — p. 1-M3
  • [5] PISTON — p. 1-M4
  • [6] BUILT-IN DYNAMIC BALANCER — p. 1-M4
  • LUBRICATING SYSTEM — p. 1-M5
  • [1] OIL COOLER — p. 1-M5
  • COOLING SYSTEM — p. 1-M6
  • [1] THERMOSTAT — p. 1-M6
  • FUEL SYSTEM — p. 1-M8
  • [1] GOVERNOR — p. 1-M8
  • [2] 2 STAGE DI NOZZLE — p. 1-M11
  • [3] INJECTION PUMP WITH F.S.P — p. 1-M12
  • INTAKE SYSTEM — p. 1-M13
  • [1] INTAKE AIR HEATER — p. 1-M13
• SERVICING — p. 122
  • TROUBLESHOOTING — p. 1-S1
  • SERVICING SPECIFICATIONS — p. 1-S5
  • TIGHTENING TORQUES — p. 1-S12
  • CHECKING, DISASSEMBLING AND SERVICING — p. 1-S14
  • [1] CHECKING AND ADJUSTING — p. 1-S14
  • (1) Engine Body — p. 1-S14
  • (3) Cooling System — p. 1-S16
  • (5) Turbocharger — p. 1-S22
  • [2] SEPARATING ENGINE (ROPS MODEL) — p. 1-S23
  • (1) Lubricant and Coolant — p. 1-S23
  • (2) Preparation for Engine Separating — p. 1-S23
  • (3) Separating Front Axle and Front Frame as a Unit — p. 1-S26
  • (4) Removing Engine from Tractor — p. 1-S27
  • [3] SEPARATING ENGINE (CABIN MODEL) — p. 1-S29
  • (1) Lubricant and Coolant — p. 1-S29
  • (2) Preparation for Engine Separating — p. 1-S29
  • (3) Air Conditioner System — p. 1-S33
  • (4) Separating Front Axle and Front Frame as a Unit — p. 1-S33
  • (5) Preparation for CABIN Side — p. 1-S34
  • (6) Separating Engine from Clutch Housing Case — p. 1-S35
  • [4] REMOVING EXTERNAL COMPONENTS — p. 1-S36
  • (2) External Parts — p. 1-S36
  • (3) Turbocharger — p. 1-S37
  • (2) Thermostat — p. 1-S42
  • (3) Injection Pump Unit — p. 1-S43
  • (4) Water Pump and Oil Cooler — p. 1-S52
  • (6) Piston and Connecting Rod — p. 1-S56
  • (7) Flywheel and Crankshaft — p. 1-S59
  • [6] SERVICING — p. 1-S62
  • (1) Cylinder Head — p. 1-S62
  • (2) Idle Gar and Camshaft — p. 1-S68
  • (3) Piston and Connecting Rod — p. 1-S71
  • (4) Crankshaft — p. 1-S73
  • (5) Cylinder — p. 1-S76
• MECHANISM — p. 201
  • TRAVELING CLUTCH — p. 2-M1
  • [1] HYDRAULIC SHUTTLE MODEL — p. 2-M1
  • (1) Structure — p. 2-M1
  • (2) Oil Flow — p. 2-M2
  • PTO CLUTCH — p. 2-M3
  • [1] STRUCTURE — p. 2-M3
  • [2] OIL FLOW — p. 2-M5
• SERVICING — p. 207
  • TROUBLESHOOTING — p. 2-S1
  • SERVICING SPECIFICATIONS — p. 2-S2
  • TIGHTENING TORQUES — p. 2-S3
  • CHECKING AND ADJUSTING — p. 2-S4
  • [1] CLUTCH PEDAL FREE TRAVEL — p. 2-S4
  • (1) ROPS Model — p. 2-S4
  • (2) CABIN Model — p. 2-S4
  • [2] PTO CLUTCH — p. 2-S5
  • (1) ROPS Model — p. 2-S7
  • [2] SEPARATING ENGINE (ROPS MODEL) — p. 2-S9
  • (1) Preparation for Engine Separating — p. 2-S9
  • (2) Separating Engine from Clutch Housing Case — p. 2-S12
  • [3] SEPARATING ENGINE (CABIN MODEL) — p. 2-S14
  • (1) Preparation for Engine Around — p. 2-S14
  • (2) Air Conditioner System — p. 2-S18
  • (3) Preparation for CABIN Side — p. 2-S18
  • (4) Separating Engine from Clutch Housing Case — p. 2-S20
  • [4] DAMPER DISC (HYDRAULIC SHUTTLE MODEL) — p. 2-S20
  • [5] PTO CLUTCH VALVE — p. 2-S21
  • (1) Removing PTO Clutch Valve — p. 2-S21
  • [6] PTO CLUTCH PACK — p. 2-S23
  • (1) Separating Clutch Housing Case from Transmission Case (ROPS Model) — p. 2-S23
  • (2) Separating Clutch Housing from Transmission Case (CABIN Model) — p. 2-S29
  • (3) Removing PTO Clutch Pack — p. 2-S30
  • [1] TRAVELING CLUTCH (HYDRAULIC SHUTTLE MODEL) — p. 2-S34
  • [2] PTO CLUTCH PACK — p. 2-S34
• MECHANISM — p. 245
  • STRUCTURE — p. 3-M1
  • (1) F12/R12 Speed with Creep Transmission Model — p. 3-M1
  • POWER TRAIN FOR TRAVELING GEAR — p. 3-M2
  • [1] SHUTTLE SHIFT SECTION — p. 3-M2
  • (1) Hydraulic Shuttle Model — p. 3-M2
  • [2] HYDRAULIC SHUTTLE VAL VE (HYDRAULIC SHUTTLE MODEL) — p. 3-M3
  • (1) Structure — p. 3-M3
  • (2) Operation — p. 3-M4
  • [3] MAIN GEAR SHIFT SECTION — p. 3-M9
  • (1) F12/R12 Speed Transmission Model — p. 3-M9
  • [4] HI-LO/CREEP SHIFT SECTION — p. 3-M10
  • (1) F12/R12 Speed with Creep Transmission Model — p. 3-M10
  • [5] SHIFT FORK ROD AND FORK — p. 3-M11
  • (1) F12/R12 Speed with Creep Transmission Model — p. 3-M11
  • [6] FOUR WHEEL DRIVE SECTION (4WD MODEL ONLY) — p. 3-M12
  • (1) 2WD-4WD Shift Section — p. 3-M12
  • (2) 2WD-4WD Shift Linkage — p. 3-M13
  • LUBRICATION FOR TRANSMISSION — p. 3-M14
  • [1] HYDRAULIC SHUTTLE MODEL — p. 3-M14
  • POWER TRAIN FOR PTO SYSTEM — p. 3-M15
  • [1] PTO GEAR SECTION — p. 3-M15
• SERVICING — p. 261
  • TROUBLESHOOTING — p. 3-S1
  • SERVICING SPECIFICATIONS — p. 3-S2
  • TIGHTENING TORQUES — p. 3-S4
  • CHECKING AND ADJUSTING — p. 3-S5
  • [1] SHUTTLE LEVER — p. 3-S5
  • (1) Hydraulic Shuttle Model — p. 3-S5
  • (2) Engine Start Condition — p. 3-S7
  • DISASSEMBLING AND ASSEMBLING — p. 3-S12
  • [1] HYDRAULIC SHUTTLE VALVE — p. 3-S12
  • (1) Removing Fuel Tank (ROPS Model) — p. 3-S12
  • (2) Removing Fuel Tank (CABIN Model) — p. 3-S13
  • [2] PREPARATION (ROPS MODEL) — p. 3-S16
  • (1) Lubricant and Fuel — p. 3-S16
  • (2) External Parts — p. 3-S16
  • (3) Steering Support Unit — p. 3-S24
  • [3] PREPARATION (CABIN MODEL) — p. 3-S25
  • (1) Separating Cabin from Tractor — p. 3-S25
  • (2) Fuel Tank and External Parts — p. 3-S26
  • [4] SEPARATING EACH BLOCK — p. 3-S27
  • (1) Clutch Housing Case — p. 3-S27
  • (2) Transmission Case — p. 3-S27
  • [5] SHUTTLE SECTION — p. 3-S29
  • (1) Hydraulic Shuttle — p. 3-S29
  • [6] SHIFT COVER — p. 3-S34
  • [7] DISASSEMBLING CLUTCH HOUSING CASE — p. 3-S40
  • (1) Removing 1st Shaft, 2nd Shaft and 3rd Shaft — p. 3-S40
  • (2) 1st Shaft (Hydraulic Shuttle Model) — p. 3-S42
  • (3) 2nd Shaft and 3rd Shaft (F12/R12 Speed Transmission Model) — p. 3-S43
  • (4) DT Propeller Shaft — p. 3-S44
  • (5) Creep Gear — p. 3-S44
  • [8] DISASSEMBLING TRANSMISSION CASE — p. 3-S46
  • (1) Hydraulic Pump Holder — p. 3-S46
  • (2) PTO Section — p. 3-S47
  • (3) Differential Gear — p. 3-S48
  • SERVICING — p. 3-S51
  • [1] BEARING — p. 3-S51
  • [2] SHUTTLE CLUTCH PACK (HYDRAULIC) — p. 3-S52
  • [3] SHIFT FORK AND SYNCHRONIZER — p. 3-S53
  • [4] HYDRAULIC PUMP DRIVE GEAR — p. 3-S54
  • [5] DIFFERENTIAL GEAR — p. 3-S55
• MECHANISM — p. 322
  • FEATURES — p. 4-M1
• SERVICING — p. 324
  • TROUBLESHOOTING — p. 4-S1
  • SERVICING SPECIFICATIONS — p. 4-S2
  • TIGHTENING TORQUES — p. 4-S3
  • DISASSEMBLING AND ASSEMBLING — p. 4-S4
  • [1] SEPARATING REAR AXLE (ROPS MODEL) — p. 4-S4
  • (1) Preparation — p. 4-S4
  • (2) Preparation for Removing Rear Axle (Left Side) — p. 4-S9
  • (4) Removing Rear Axle — p. 4-S11
  • [3] DISASSEMBLING REAR AXLE — p. 4-S12
  • (2) Planetary Gear — p. 4-S12
  • (3) Rear Axle — p. 4-S13
  • SERVICING — p. 4-S15
  • [1] BEARING — p. 4-S15
  • [2] PLANETARY GEAR — p. 4-S15
• MECHANISM — p. 342
  • TRAVELING BRAKE — p. 5-M1
  • [1] STRUCTURE — p. 5-M1
  • [2] MASTER CYLINDER ASSEMBLY — p. 5-M2
  • PARKING BRAKE — p. 5-M3
  • [1] STRUCTURE — p. 5-M3
• SERVICING — p. 347
  • TROUBLESHOOTING — p. 5-S1
  • SERVICING SPECIFICATIONS — p. 5-S2
  • TIGHTENING TORQUES — p. 5-S3
  • [2] DISASSEMBLING AND ASSEMBLING — p. 5-S10
  • (1) Removing Master Cylinder (ROPS Model) — p. 5-S10
  • (2) Removing Master Cylinder (CABIN Model) — p. 5-S11
  • (3) Master Cylinder — p. 5-S14
  • (4) Brake Pedal — p. 5-S14
  • (5) Brake Piston — p. 5-S15
  • (6) Brake Disc and Plate — p. 5-S16
  • (7) Parking Brake Gear — p. 5-S17
  • [3] SERVICING — p. 5-S19
• MECHANISM — p. 368
  • STRUCTURE — p. 6-M1
  • [1] 4 WHEEL DRIVE — p. 6-M1
  • [2] LIMITED SLIP DIFFERENTIAL (LSD) — p. 6-M2
• SERVICING — p. 371
  • TROUBLESHOOTING — p. 6-S1
  • SERVICING SPECIFICATIONS — p. 6-S2
  • TIGHTENING TORQUES — p. 6-S4
  • (3) Removing Differential Gear and Bevel Pinion Shaft — p. 6-S11
  • (4) Disassembling Differential Gear (LSD) — p. 6-S12
  • [3] SERVICING — p. 6-S14
  • (1) 4WD Model — p. 6-S14
• MECHANISM — p. 395
  • STEERING MECHANISM — p. 7-M1
  • STEERING CYLINDER — p. 7-M2
• SERVICING — p. 398
  • TROUBLESHOOTING — p. 7-S1
  • SERVICING SPECIFICATIONS — p. 7-S2
  • TIGHTENING TORQUES — p. 7-S3
  • CHECKING, DISASSEMBLING AND SERVICING — p. 7-S4
  • [1] CHECKING AND ADJUSTING — p. 7-S4
  • (2) Hydraulic Pump — p. 7-S4
  • (1) Removing Steering Controller (ROPS Model) — p. 7-S5
  • (2) Removing Steering Controller (CABIN Model) — p. 7-S8
  • [3] DISASSEMBLING AND ASSEMBLING — p. 7-S10
  • (2) Removing Steering Cylinder (4WD Model) — p. 7-S12
  • (3) Disassembling Steering Cylinder — p. 7-S14
  • [4] SERVICING — p. 7-S14
• MECHANISM — p. 414
  • STRUCTURE — p. 8-M1
  • HYDRAULIC CIRCUIT — p. 8-M3
  • [1] TOTAL HYDRAULIC CIRCUIT — p. 8-M3
  • (1) Hydraulic Shuttle Model — p. 8-M3
  • [2] OIL COOLER RELIEF VALVE (ROPS MODEL) — p. 8-M4
  • THREE POINT HYDRAULIC SYSTEM — p. 8-M5
  • [2] HYDRAULIC BLOCK — p. 8-M6
  • [3] LINKAGE MECHANISM — p. 8-M7
  • (2) Draft Control — p. 8-M9
  • (3) Mixed Control — p. 8-M12
  • [4] HYDRAULIC CYLINDER — p. 8-M13
• SERVICING — p. 428
  • TROUBLESHOOTING — p. 8-S1
  • SERVICING SPECIFICATIONS — p. 8-S2
  • TIGHTENING TORQUES — p. 8-S5
  • CHECKING, DISASSEMBLING AND SERVICING — p. 8-S6
  • [1] CHECKING AND ADJUSTING — p. 8-S6
  • (1) Hydraulic Pump — p. 8-S6
  • (4) Auxiliary Control Valve Linkage (ROPS Model) — p. 8-S16
  • (5) Auxiliary Control Valve Linkage (CABIN Model) — p. 8-S17
  • (6) Oil Cooler Relief Valve — p. 8-S19
  • [2] DISASSEMBLING AND ASSEMBLING — p. 8-S20
  • (1) Hydraulic Pump — p. 8-S20
  • (2) Removing Top Cover (3-Point Hitch Hydraulic Block) (ROPS Model) — p. 8-S21
  • (3) Removing Top Cover (3-Point Hydraulic Block) (CABIN Model) — p. 8-S23
  • (4) Hydraulic Linkage — p. 8-S24
  • (6) Hydraulic Cylinder — p. 8-S30
  • (7) Relief Valve — p. 8-S31
  • (8) Safety Valve — p. 8-S32
  • (9) Top Link Bracket — p. 8-S32
• MECHANISM — p. 465
  • WIRING DIAGRAM — p. 9-M1
  • [1] MAIN HARNESS (ROPS MODEL) — p. 9-M1
  • [2] MAIN HARNESS (CABIN MODEL) — p. 9-M2
  • [3] CABIN HARNESS (CABIN MODEL) — p. 9-M3
  • [4] ENGINE HARNESS (CABIN MODEL) — p. 9-M4
  • [1] ROPS MODEL — p. 9-M5
  • (1) Starting System, Charging System and Working Light — p. 9-M5
  • (2) Lighting System — p. 9-M6
  • (2) Lighting System — p. 9-M9
  • (3) Instrument Panel Board (Meter Panel) — p. 9-M10
  • (4) Working Light, Radio and Defogger — p. 9-M11
  • (5) Air Conditioner — p. 9-M12
  • (6) Wiper System — p. 9-M13
  • [3] WIRING COLOR — p. 9-M14
  • STARTING SYSTEM — p. 9-M15
  • [1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT — p. 9-M15
  • (1) ROPS Model — p. 9-M15
  • (2) CABIN Model — p. 9-M16
  • [2] COMPONENTS — p. 9-M17
  • (1) Air Heater — p. 9-M17
  • INSTRUMENT PANEL — p. 9-M18
  • [1] INDICATION ITEMS OF METER PANEL — p. 9-M18
  • [2] EASY CHECKER (TM) — p. 9-M19
  • [3] LCD MONITOR INDICATION — p. 9-M20
  • (1) Display Mode — p. 9-M20
  • (2) Setting Mode — p. 9-M21
  • (3) Checking Mode — p. 9-M22
  • OPC (OPERATOR PRESENCE CONTROL) — p. 9-M23
  • [1] SYSTEM OUTLINE AND ELECTRICAL CIRCUIT — p. 9-M23
  • LIGHTING SYSTEM — p. 9-M24
  • [1] COMPONENTS — p. 9-M24
  • TRAILER SOCKET — p. 9-M25
• SERVICING — p. 491
  • TROUBLESHOOTING — p. 9-S1
  • SERVICING SPECIFICATIONS — p. 9-S5
  • TIGHTENING TORQUES — p. 9-S6
  • CHECKING AND ADJUSTING — p. 9-S7
  • [1] BATTERY, FUSE, GROUNDING AND CONNECTOR — p. 9-S7
  • [2] MAIN SWITCH — p. 9-S12
  • (1) Main Switch (ROPS Model) — p. 9-S12
  • (2) Main Switch (CABIN Model) — p. 9-S13
  • [3] AIR HEATER — p. 9-S15
  • [4] STARTER MOTOR — p. 9-S15
  • [5] ENGINE STOP SOLENOID — p. 9-S16

Capabilities

The source outline indexes maintenance tasks, checking and adjustment, mechanism explanations, servicing instructions, troubleshooting, and disassembly and assembly. Use these source-backed headings to locate the applicable task or system in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out service work.

Keep the source's safety sequence, prerequisite steps, labels, units, configuration notes, and footnotes with the selected task; do not apply an isolated value outside the conditions stated in the manual.

Technical reference

Reference tables include torque settings, wear limits, fluid and system capacities, dimensions, and speed ratings for service checks, adjustment work, and specification lookup. Use the values and conditions in the PDF for the applicable model and procedure.

• Service limits and settings: torque settings and wear limits.
• Fluid reference: fluid and system capacities.
• Machine specifications: dimensions and speed ratings.

Delivery

This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.

References

Kubota Workshop Manual for Tractor, PDF edition.