Kubota V Manual KX36 KX41 3V

W ORKSHOP MANUAL
KUBOTA EXCAVATOR
KX36-3
KX41-3S, KX41-3V
Mechanism Chapter
C ode N o.97899-60810
Record of Revisions
Symbol Date Main Revised Points & Corrective Measures Person-in-charge
EU - version machine models : KX36-3, KX41-3S, KX41-3V

KTC, KCL, KTA version machine model : KX41-3V
CONTENTS
I General
II Machine Body
III Electrical system
IV Hydraulic System
V Engine
I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
a. Sales feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
b. Difference between KX36-3 and KX41-3 . . . . . . . . . . . . . . . . . . . . . . I-2
c. Quick chart for selling points : KX41-3V . . . . . . . . . . . . . . . . . . . . . . . I-3
d. Comparison to competitors;EU - version . . . . . . . . . . . . . . . . . . . . . . I-4
e. New engineering feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
f. Compornents compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7
I-1
I. General
a. Sales feature
Product concept : Comfort in conpact
(1) Grade up the basic performance; Digging, filling back and lifting capacity
(2) Grade up product feature to differentiate competitor; Digital meter, upper boom cylinder, hose protec-
tion
Workability Bucket digging force improvement

Variable pump adoption
Boom and SP simultaneous operation
The maximum digging depth priority
High level stability
Maintenance Boom cylinder over a boom
Hoses arranged inner boom
Bucket hose/ SP hose inner Arm
Blade hose division
New digital meter adoption
Amenity Much easier access into cabin
Cabin width expansion
Operativity Straight travel adoption
Smoother operation
Safety Engine safety start
Travel lock system
ROPS, FOPS standard equipment
b. Difference between KX36-3 and KX41-3
Differentiation KX36-3 KX41-3 Remark

No1. Engine D782 (13 PS) D902 (16PS)
No2. Bucket digging forth 1276 kgf 1591 kgf Bucket cylinder is different
No3. Working area (Arm length) 950 mm 1100 mm
No4. New digital meter Not equipped Equipped
No5. Variable track specification Not adopted Adopted Fixed track is same parts
No6. Travel speed One speed Two speed
No7. Straight travel Not equipped Equipped KX41-3S, V : EU - version only
No8. Seat grade Standard seat High back seat
No9. Roof window of the cabin Not equipped Equipped
I-2
c. Quick chart for selling points : KX41-3V
Short stroke operating Digital panel High speed travel switch

lever and wrist rest with new navigation system on the dozer lever
Boom cylinder is installed

over upside of boom Best matching of displacement
hydraulic pump and Kubota new
Aux. Hydraulic hoses are diesel engine
routed inside of arm. D902, 17.0HP 2300rpm
I-3
Increased bucket pin diameter Separated boom swing pedal
Pin diameter : 30mm and auxiliary hydraulic pedal
d. Comparison to competitors;EU - version
1.5 t class
Sales features(Sample:EU - version) KUBOTA KUBOTA Bobcat VOLVO TAKEUCHI KOMATSU YANMAR
KX41-3V KX41-2αV 322D EC15B TB016 PC12 B15-3
Bucket digging forth (kgf) 1591 1270 1546 1541 1336 1350 1525
Workability Boom and SP simultaneous operation - - - - -
Maximum digging depth priority (mm) 2382 2336 2197 2300 2375 2180 2150
High level stability
Boom cylinder over boom
Maintenance ability
Bucket hose/SP hose inner Arm (bucket)
Divided blade hoses
Much easier access into cabin (485) (390) (420) (460) (400) (450) (345)
Operator comfort Cabin width expansion (915) (845) (850) (860) (902) (880) (960)
Straight travel adoption
Operativity Smoother operation
Wrist-controled lever
Engine starting check
Safety Travel lock system
ROPS/FOPS standard equipment
Others Tumbler distance extension (mm)
(for KX36-3) Shoes width extension (mm)
1.3 t class
Sales features(Sample:EU - version) KUBOTA KUBOTA JCB VOLVO
KX36-3 KX36-2α 8015 EC13
Bucket digging forth (kgf) 1276 1245 1122 1122
Workability Boom and SP simultaneous operation - -
Maximum digging depth priority (mm) 2230 2170 2102 2010
High level stability <Shown by demonstration>
Boom cylinder over boom
Maintenance ability
Bucket hose/SP hose inner Arm (bucket) (bucket)
Divided blade hoses -
Much easier access into cabin (440) (390) (550) -
Operator comfort Cabin width expansion
Straight travel adoption
Operativity Smoother operation -
Wrist-controled lever
Engine starting check -
Safety Travel lock system
ROPS/FOPS standard equipment
Others Tumbler distance extension (mm) 1090 1010 1008 1085
(for KX36-3) Shoes width extension (mm) 230 200 230 200
I-4
e. New engineering feature
1. Hydraulic system
1) New hydraulic circuit with downsized cylinder valve
(1) New Hydraulic Circuit
Despite the downsizing of the cylinder valve (with
an overall length reduced to 335 mm from 368.5
mm), the construction of the interflow circuit for the
upward and downward movement of the boom
along with the employment of the pump flow
unload valve interlocked with an unload lever
ensures the smooth operability and stability of the
hydraulic system.
(a) Boom Upward and Downward Interflow
When boom upward and downward pilot signal
is input, the inflow section will be switched and
the flow of pump number 3 will be guided to the
boom section. The total flow of pump number 1
and number 3 will drive the boom cylinder, thus
increasing the operation speed of the boom.
(b) Unload Section
When the safety lever beside the operator's
seat is set to the unload position, the spool of
the unload section will be switched and the
hydraulic oil in pump number 1 and number 2
will flow directly to the tank circuit, thus ensur-
ing safety and protecting the operator from
improper control.
2) Flow characteristic simulation for operability improvement

(2) Flow Characteristic Simulation
To ensure the smooth operability, a fine adjustment to the cylinder valve spool is essential. The flow
characteristics of the spool vary with the combination of the squeezed areas of three types of pas-
sages. Therefore, a computer simulation was conducted to grasp the flow characteristics, a proto-
type was manufactured, and a fine adjustment based on the feeling results of operability on an actual
model was made to achieve comfortable operability.
I-5
2. Improvement in user-friendliness and operator's range of vision
(1) Optimum positioning of levers and other attach-
ments
The optimum positioning of the respective levers,
pedal, meter, and key was considered in a 3D
(CATIA) simulation.
3. Electronic System
1) Digital Navigation System
(1) Information-intensive Display
The dot-type LCD provides a variety of alarms as
well as normal display items supporting 11 lan-
guages. Furthermore, the display incorporates a
service tester and other versatile functions for
improvement in ease of use.
(2) Integration of Functions
The integration of functions implemented at the
time of the development of the KX91-3, 101-3 Con-
struction Machine has been further developed to
include a variety of control functions into a meter
for a great decrease in the number of parts along
with an increase in functional performance and a
reduction in cost. The meter incorporates an auto
release, auto glow, finger control service port, auto
idling, and two-speed selection functions.
I-6
f. Compornents compatibility
Parent 100% compatible high compatible low compatible Original design
KX36-3 KX41-3(EU) KX41-3V

Location Main components
(EU) S V (US)
1 Track frame
2 Track roller, idler
Under carriage 3 Blade
4 Travel motor
5 Track shoe
6 Swivel bearing
7 Seat
8 Swivel frame
9 Hydraulic Pump
10 Control valve
9 stacks Ten stacks Ten stacks Ten stacks
Upper frame
11 Engine
12 Bonnet
13 Control box, cover, step
14 Cab
15 Electric parts
16 Control device
17 Swing bracket
Front attachment 18 Boom
19 Arm
I-7
I-8
II.Machine Body. . . . . . . . . . . . . . . . . . . . . . . II-2
a. Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2
b. Main component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-6
II-1
II.Machine Body
a. Quality Specifications
No Specificatios Items Unit KX36-3 EU KX41-3S KX41-3V EU KX41-3V US Remarks
Q1 Main Speed JIS A8404
mm 3670 ± 73 3665 ± 73 ← ←
1 Total length(Transport)
inch 144.5 ± 2.9 144.3 ± 2.9 ← ←
mm 990 ± 10 990 ± 10 1300/994 ± 13 ←
2 Total width
inch 39.0 ± 0.4 39.0 ± 0.4 51.2/39.1 ± 0.5 ←
1 Machine size
mm 2283 ± 23 ← ← ←
3 Total height(Canopy)
inch 89.9 ± 0.9 ← ← ←
mm 2283 ± 23 ← ←
4 Total height(Cabin)
inch 89.9 ± 0.9 ← ←
Machine weight kg 1440 ± 29 1450 ± 29 1595 ± 32 ←

1 Fuel tank
(Canopy) lbs 3174.6 ± 63.9 3197 ± 63.9 3516.337 ± 70.5 ←
kg 1540 ± 31 1550 ± 31 1705 ± 34
2 Machine weight(Cabin)
lbs 3395.1 ± 68.3 3417.13 ± 68.3 3759 ± 75.0
kPa
2 Weight Ground contact press.
3 psi
(Canopy)
kgf/cm2
kPa
Ground contact press. psi
4
(Cabin)
kgf/cm2
Rated engine
1 Swivel speed rpm 9.1 ± 0.9 ← ← ← RPM,
η = 100 %
km/h 2.2 ± 0.2 2.4 ± 0.2 2.2 ± 0.2 2.3 ± 0.2
2 F1
mph 1.37 ± 0.12 1.49 ± 0.12 1.37 ± 0.12 1.43 ± 0.12
km/h 4.3 ± 0.4 4 ± 0.4 4.1 ± 0.4
3 F2
3 Performance mph 2.67 ± 0.25 2.49 ± 0.25 2.55 ± 0.25
Travel speed
km/h 2.2 ± 0.2 2.4 ± 0.2 2.2 ± 0.2 2.3 ± 0.2
4 R1
mph 1.37 ± 0.12 1.49 ± 0.12 1.37 ± 0.12 1.43 ± 0.12
km/h 4.3 ± 0.4 4 ± 0.4 4.1 ± 0.4
5 R2
mph 2.67 ± 0.25 2.49 ± 0.25 2.55 ± 0.25
6 Gradeability deg 30 < ← ← ←
Rear end min. turning mm 1070 ± 21 ← ← ←

1
radius inch 42.1 ± 0.8 ← ← ←
Swivel frame rear mm 423 ± 8 ← ← 426 ± 8

2
ground clearance inch 16.7 ± 0.3 ← ← 16.8 ± 0.3
mm 1090 ± 33 ← 1230 ± 37 ←
3 Tambler center distance
inch 42.9 ± 1.3 ← 48.4 ± 1.5 ←
mm 1445 ± 43 ← 1587 ± 48 ←
4 4 Crawler total length
inch 56.9 ± 1.7 ← 62.5 ± 1.9 ←
mm 990 ± 20 ← 1300/994 ± 26 ←
5 Crawler total width
inch 39.0 ± 0.8 ← 51.2/39.1 ± 1.0 ←
mm 230 ± 5 ← ← ←
6 Crawler shoe width
inch 9.1 ± 0.2 ← ← ←
mm 167 ± 5 158 ± 5 ← ←
7 Min. ground clearance
inch 6.6 ± 0.2 6.2 ± 0.2 ← ←
II-2
1 Engine,SAE J1349 Gross Model name D782-BH D902-BH D902-BH D902-EBH
kw 9.00 ± 0.20 11.80 ± 0.30 ← ←
2 Rated output DIN 70020
ps 12.2 ± 0.3 16.0 ± 0.4 ← ←
5 3 Rated speed rpm 2300 ← ← ←
L 0.778 0.898 ← ←
4 Displacement cc 778 898 ← ←
Usgal 0.21 0.24 ← ←
1 Hydraulic pump type
16.6 x 2 17.3 x 2 ← ←
L
10.4, 6.2 10.4, 6.2 ← ←
2 Pump delivery
4.39 x 2 4.57 x 2 ← ←
Usgal
2.75, 1.72 2.75, 1.72 ← ←
Mpa 20.6 -0.2 21.6 -0.2 ← ←
kgf/cm2 210 +3, -2 220+3, -2 ← ←

p 1, p2
Bar 206 216 ← ←
6 psi 2986 3128 ← ←

Mpa 20.1 20.6 ← ←
Main relief pressure kgf/cm2 205 220 ← ←

3 p3 Valve bench set
(Bench set) Bar 201 216 ← ←
psi 2915 3128 ← ←
Mpa 3.9 +0.3 ← ← ←
kgf/cm2 40 ← ← ←
p4
Bar 39 ← ← ←
psi 569 ← ← ←
7 1 Swivel motor type
1 Travel motor type
8 2 Under carrage Parking brake type
3 Crawler shoe type
m3 0.035 ± 0.002 0.04 ± 0.002 ← ←

1 CECE
yd3 0.046 ± 0.052 ± ← ←
Bucket heaped capacity
3 0.035 ± 0.002 0.04 ± 0.002 ← ←
m
2 SAE, JIS
3 0.046 ± 0.052 ± ← ←
yd
mm 402 ± 10 450 ± 10 ← ← Without side
3 Bucket width
inch 15.8 ± 0.4 17.7 ± 0.4 ← ← cutter
4 L deg 73 ± 2 73 ± 2 ← ←
Swing angle
5 R deg 50 ± 2 ← ←
mm 3782 ± 57 3910 ± 59 ← ←
6 Max. digging radius
9 Front attachment inch 148.9 ± 2.2 153.9 ± 2.3 ← ←
Ground level Max. mm 3723 ± 56 3855 ± 58 ← ←

7
digging radius inch 146.6 ± 2.2 151.8 ± 2.3 ← ←
Ground level Min. mm 1237 ± 25 1231 ± 25 ← ← Bucket bottom

8
finish radius inch 48.7 ± 1.0 48.5 ± 1.0 ← ← horizontal
mm 2227 ± 45 2370 ± 47 ← ←
9 Max. digging depth
inch 87.7 ± 1.8 93.3 ± 1.9 ← ←
Max. vertical digging mm 1742 ± 35 1835 ± 37 ← ←

10
depth inch 68.6 ± 1.4 72.2 ± 1.5 ← ←
mm 3458 ± 69 3540 ± 71 ← ←
11 Max. digging height
inch 136.1 ± 2.7 139.4 ± 2.8 ← ←
II-3
mm 2366 ± 47 2455 ± 49 ← ←
12 Max. dump height
inch 93.1 ± 1.9 96.7 ± 1.9 ← ←
Max. dump height mm

13
(Arm vertical) inch
mm 1439 ± 43 1550 ± 47 ← ←
14 Mini. turning radius
inch 56.7 ± 1.7 61.0 ± 1.9 ← ←
Mini. turning radius mm 1147 ± 34 1245 ± 37 ← ←

15
(Left swing) inch 45.2 ± 1.3 49.0 ± 1.5 ← ←
9 Front attachment mm 512 ± 15 ← ← ←

16 L
inch 20.2 ± 0.6 ← ← ←
Off-set amount
mm 323 ± 10 ← ← ←
17 R
inch 12.7 ± 0.4 ← ← ←
kgf
18 Max. digging force N
lbw
m3
19 Optional bucket range JIS, SAE
yd3
mm 990 ± 5 ← 1300/994 ± 5 ←
1 Width
inch 39.0 ± 0.2 ← 51.2/39.0 ± 0.2 ←
mm 230 ± 5 ← ← ←
2 Height
inch 9.1 ± 0.2 ← ← ←
mm
3 Length
inch
10 Dozer
mm 180 ± 9 181 ± 9 201 ± 10 ←
4 Max. lift above GL
inch 7.1 ± 0.4 7.1 ± 0.4 7.9 ± 0.4 ←
mm 193 ± 10 ← 205 ± 11 ←
5 Max. below GL
inch 7.6 ± 0.4 ← 8.1 ± 0.4 ←
3
m
6 Displacement capacity
yd3
L
1 Radiator capacity
US gal
L
2 Reserve tank capacity
US gal
L
3 Engine crank case
US gal
Hydraulic oil L 21 ± 1.1 ← ← 20 ± 1

4 Full
(all amount) US gal 5.55 ± 0.29 ← ← 5.28 ± 0.26
Hydraulic oil L 14.5 ± 0.7 ← ← ←

5 Tank
(tank amount) US gal 3.83 ± 0.18 ← ← ←
11 Water & oil
Wheel L
6
motor US gal
Swivel L
7 reduction
case US gal
Gear oil
Track L
8
roller US gal
L
9 Front idler
US gal
L
10 Fuel tank
US gal
II-4
Q2 Main Specs JIS A8404
mm 53, 73 ← ← ←
1 Bucket tooth slaggish
inch 2.1, 2.9 ← ← ←
mm < 10 ← ← ←
1 2
inch < 0.39 ← ← ←
mm < 10 ← ← ←
3 Dozer's declination
inch < 0.39 ← ← ←
Eccentric amount from mm From swivel

1
swing center inch center
2
mm
2 Distance to swing center
inch
mm
1 Distance to boom pin
inch
mm exclude
2 Boom pin height
inch grouser
3
Min. clearance of bucket mm 62 -16/+34 167 -16/+34
3 teeth to boom cylinder
protector inch 2.4 -0.6/+1.3 6.6 -0.6/+1.3
Clearance of boom mm
4
cylinder to shoe inch
1 Approach angle deg 26.5 ± 2.7 25.5 ± 2.6
mm From swivel
2 Distance to dozer tip
inch center
4 Distance of crawler end mm

3
to dozer inch
Clearance of dozer to mm
4
weight inch
mm 357 ± 7 Include
1 Crawler height grouser on the
inch 14.06 ± 0.28 spocket
mm 358 ± 7
2 Max. crawler height
inch 14.09 ± 0.28
Clearance of swivel mm
5 3
frame to crawler inch
mm From swivel
4 Distance to idler center
inch centerl
Distance to sprocket mm
5
center inch
II-5
b. Main component
1. Swivel bearing
(4)
(1)
(2)
(3)
(1) Seal B
(2) S-mark
(3) Seal A
(4) Rp 1/8, for grease nipple
Number of teeth = 73
Backlash = 0.05 ~ 0.35 mm
(0.002 ~ 0.014 inch)
P.C.D. = φ 328.5
II-6
2. Track roller
(1) Packing, NBR

(2) Spring
(3) Reinforce, ring
(4) Sleeve
(5) Fill grease
(5)
Lub oil :Engine oil SAE #30CD class 40 cc
Plug :Apply screw lock agent and tightening
torque, 0.8 kgm
II-7
3. Idler and tension spring
3-1 Structure
(1) Support 1 (5) Floating seal (9) Wire (13) Retainer

(2) Support 2 (6) Bushing (10) Plug, R 1/8 (14) Nut
(3) shaft (7) O-ring (11) Yoke (15) Split pin
(4) Idler (8) Spring pin (12) Spring (16) Bolt
Pre-set length of spring : L

KX36-3 :
KX41-3 : 130 mm (5.12 inch)
KX41-3V :
OK NO
(Spring roll pin direction)
II-8
4. Pump coupling
4-1 EU - version : KX36-3, KX41-3, KX41-3V
4-2 North America & Oceania - version : KX41-3V

Two Point Pitch
II-9
5. Rubber track
Spec items KX36-3 KX41-3S, V EU KX41-3V US

Type 230 x 32 x 96 230 x 35 x 96
Circunference 3072 ± 10 mm 3360 ± 10 mm
Number of steel cords 48 +2
-0
48 ± 4
Thickness of crawler main part 25.0 mm 23.0 mm
Ditto joint parts 28.5 mm 26.5 mm
Core metal FCD1200 Austempering FCD450
Number of core metal (Links) 32 35 35
II-10
6. Swing bracket
(7)
(11)
(12)
(8)
(9)
(10)
(1) Swing bracket

(2) ~ (6) Bushing
(7) After installing the bush, pin of φ34.9 goes through smoothy.
(8) Dimension before bushing.
(9) Side of the bush (3) should flash the face.
(11) Side of the bush (2) should behind the surface.
II-11
7. Bucket link pin : North America & Oceanea
[Unit : mm]
Parts name Parts No. Specifications

(1) Bucket link 1 RB238-66713 Et 125.5 / Wb 40
(2) Bush A RB238-66781 φ38 x φ30 x W40
(3) Pin A dia RB238-66771 φ30 L : change
RB238-66722
(5) Bucket link 2, 3 φ30 - φ30
RB238-66732
(6) Arm boss RB238-67112 X85 Y2 / φ55 x φ38 x L125.5
(7) Bush B 68701-66661 φ38 x φ30 x W35
(8) Pin B dia RB238-66751 φ30 L : change
(10) Bucket cylinder L/S (stroke) RB238-67802 529 / 805.5 (276.5)
II-12
III.Electrical System. . . . . . . . . . . . . . . . . . . III-2
a. Development concept : KX41-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-2
b. Outline of Kubota ICS (Intelligent Control System) . . . . . . . . . . . . . . III-5
c. Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-8
d. Service mode menues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-12
e. Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-34
f. Circuit wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-47
g. Electrical component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-53
III-1
III.Electrical System
a. Development concept : KX41-3
1. Background of Adoption of New Meter
(1) The L1 (3-ton class) Series, which was released in Japan in 1999 for domestic users, adopted a new
meter of LCD type (called YUYU NAVI). Since then, this meter has been one of the sales points of
the Series.
(2) Presently, the new meter is applied to only models for domestic users. No models for overseas users
adopt this meter.
(3) The new meter has a stable reputation for providing advanced performance, convenience, and user-
friendliness. This sales point should be added to models for overseas users.
We would like to start adopting the new meter with KX41-3 first, and expand the application range to
include higher rank models systematically.
2. Features of New Meter

(1) Advanced performance:
Digital display (multi-language support), alarm sound, and design performance (see fig. 2 on the
right-hand side)
(2) Parts integration:
Relays and controllers supporting a variety of functions for conventional models are integrated into
the new meter for space saving and high cost performance. (Relays partly need to be installed exter-
nally.)
(3) Functions in a Wide Variety
1. Warning and self-diagnostic functions:
The following items are displayed on the LCD with graphics, failure (warning) numbers, and char-
acters along with an alarm sound.
ï Remaining fuel (see fig. 3 on the right-hand side)
ï Oil pressure (see fig. 4 on the right-hand side)
ï Charge (see fig. 5 on the right-hand side)
ï Overvoltage
ï Overheating
2. Inspection time instruction function:
"SERVICE HOURS" appears whenever the time has come for the inspection and replacement of
the oil filter as explained in the manual, and prompts the user to make an inspection.
3. Fuel replenishment assist function:
The meter beeps intermittently at the time of fuel replenishment, and the interval between beeps
is shortened when the tank is almost filled to prevent the fuel from overflowing.
The beep functions with the key turned OFF, but one of the switch needs to be pressed.
4. Service tester function:
This function allows the monitoring of the operation of electrical devices (e.g., an oil pressure
switch) connected to the meter and provides the history of failures resulted in the past (see figs.
6 and 7 on the right-hand side).
While in harness manipulation mode, it is possible to diagnose and single out harness compo-
nents that have internal failures (e.g., contact failures).
5. Other functions
ï Low Travel speed reset at the time of restarting the engine (if the engine is turned OFF with
high - low switch set to the high range).
ï Engine start check (preventing the engine from starting with the lever unlocked).
ï Starter motor automatic disconnection → Auto release
ï Auto glow
ï Built-in hour meter and display
ï Built-in tachometer and display
6. Expansion function for the future (Presently not scheduled to adopt for KX4I-3)
ï Monitoring with theft prevention set up
ï Service port (thumb) hand-held proportional control
ï Air-conditioner idling control
ï Auto idling
III-2
(Reference) LCD Display Examples of New Meter
Fig. 1
Normal screen
Key switch ON (Only the glowing moment)
Normal screen (with the tachometer selected)
Normal screen (with the hourmeter selected)
Fig. 2
Language selection
screen
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
III-3
3. Electrical system : Functional comparison : KX41-3S, V
North America &
No. Function EU-version
Oceanea
KICS;Kubota Intelligent Control System,

1 Yes Yes
LCD(liquid cristal display) with character and illustration
Yes (delete Yes (delete

2 Maintenance indication upon hour meter
method:manual) method:auto)
Yes (sample, date

3 Anti-theft system No
not fixed)
4 AI(Auto idle) function No No
5 Engine overheat warning Yes No
6 Starter motor auto release function Yes Yes
7 Glowplug auto glow function Yes Yes
8 Travel high-low switch at lever grip Yes Yes
9 Fuel feed assist sound Yes Yes
10 Heater Yes (cab version) No
Harness and switch

Harness is
11 Rotating lamp are equipped as
incorporated
standard
12
13
14
15
III-4
b. Outline of Kubota ICS (Intelligent Control System)
III-5
III-6
III-7
c. Operating Mode
1. Outline
In operating mode, normally LCD shows three types of information.
1) Key switch ON,
2) Normal display, hour meter
3) Normal display, tachometer
When in trouble, LCD shows warning and failure indications as shown below.
In the following list, item No.1, 2, 3, 4, 5, 11, 12, 13, 14, 21, 22, 23, 24, 25, 51, 52, 53, 54, 55, 61, will be
indicated according to the machine conditions.
III-8
2. LCD display list
Below list shows all LCD letter indications for both oparating mode and service mode.
In operating mode, data 003 ~ 022 will be on the display according to the machine condition.
In case of non AI, non S/P control machines, date 008 ~ 022 except 017, 019, 020, 021 wonít come up to
show.
name English meaning and explanation

This LCD display shows the following conditions;fuel amount, water temp., engine
data000
oil pressure, battery, glow plug, and operating hour meter.
This LCD display shows the following conditions;fuel amount, water temp., engine
data001
speed.
This LCD display shows the following conditions;fuel amount, water temp.,
data002
and operating hour meter.
data003 The letter on the LCD indicates the warning of each function;fuel amount shortage
data004 The letter on the LCD indicates the warning of low engine oil pressure
data005 The letter on the LCD indicates the warning of low charging voltage of alternator
The letter on the LCD indicates the warning of each function; higher voltage line
data006
connected for example, 24 V battery
The letter on the LCD indicates the warning thepossibility of engine overheating
data007
condition EU - version only : 124 ± C
data008 The letter on the LCD indicates the warning ofaccel sensor line break or shortage
The letter on the LCD indicates the warning of governor sensor line break or
data009
shortage
data010 The letter on the LCD indicates the warning of AI motor line shortage.
data011 The letter on the LCD indicates the warning of AI motor line break.
data012 The letter on the LCD indicates the amount of auxiliary port flow.
The letter on the LCD indicates the warning of electrical shortage of aux. solenoid
data013
valve left side.
The letter on the LCD indicates the warning of electrical line break of aux. sole-
data014
noid valve left side.
The letter on the LCD indicates the warning of electrical shortage of aux. solenoid
data015
valve right side.
The letter on the LCD indicates the warning of electrical line break of aux. sole-
data016
noid valveright side.
The letter on the LCD indicates the warning of coolant sensor or water temp. sen-
data017
sor fail.
data018 The letter on the LCD indicates the warning of fuel sensor fail.
data019 The letter on the LCD indicates the warning of 12V sensor supply line shortage.
data020 The letter on the LCD indicates the warning of 5V sensor supply line shortage.
data021 The letter on the LCD indicates the warning of controller error in the meter panel.
The letter on the LCD indicates the warning of AI motor being restricted by any
data022
means.
III-9
data023 Indicates the model name.
data035 Owner is expected to select the language he prefers.
data036
data037
data038
data039
data040
This means tester mode which test the following circuit conditions electrically on
data041
real time.
The letters and symbols indicate the real time conditions of the following items.
data042
engine speed , battery voltage
Engine oil pressure switch condition; on or off, Alternator charging circuit condi-
data043
tion; normal or abnormal
Water V indicates water temp. sensor voltage
data044
Fuel V indicates fuel sensor voltage
AI SW indicates on or off condition of AI switch. Press indicates AI pressure
data045 switch condition.
Motor A means current amount flowing to AI motor.
Accel V indicates voltage amount at accel sensor.
data046
Gover V indicates voltage amount at governer sensor.
data047 Compressor indicates the condition of air conditioner's compressure switch.
Aux. Is abbriviation of auxiliary port and indicates the switch condition, on or off.
data048
Breaker indicates the breaker switch condition ,on or off.
Aux. means in this case auxiliary port solenoid valve.
data049
L;left side, R; right side, A; current amount to each solenoid valve.
Fail record means machines' failure record are stored in the memory and can be
data050
shown up on the display. Delete record means you can delete if you want.
First h indicates the operating hours when first failure occurred, last means last
data051 fail occurred.
Count indicates the number of fail occurred.
data052 This means no failure occurred in the past.
Back tier indicates that you can return back to one upper tier or same tier by
data053
pressing the buttom, for either a long or a short time.
data054
III-10
data055 Literary it means other menus.

This means micro computor is ready to check electrical harness conditions, break
data056 or breaking.
In this case, for your sefety engine should be off.
This means micro computor is checking the harness conditions. Service person-
data057 nel is required to put hands on the suspected harness, then controller detects the
break of harness.
This display letter means that AI motor can be controlled by just pressing switches
on the panel board.
data058
Aim of this function is to adjust AI motor link to fit the cable not by the accel knob
but by switch.
Max(CW) means AI motor link moves toward engine speed Max. direction.
data059
Idle(CCW) means AI motor link moves toward engine speed idle direction.
data060 With this display on, all fail records will be shown up on LCD.
data061 This display means that data in the EEPROM will be shown up on LCD.
These figures and letters indicate the data of EEPROM.
data062
Data can be scrolled up by pressing the switch.
data063 This indication shows that micro computor is checking the LCD function.
data064 This shows LCD condition.
data067 This indicates the service hours of the machine.
data068 This indicates the hours of machine set up.
data069 This indicates the software version of main controller.
data070 This means initialization of the machine main controller.
data071 This indicates that operator is required to start engine.
data072 This means initialization of the AI system.

This indicates that operator is suggested to turn the accel knob to Max engine
data073
speed.
This indicates that operator is suggested to turn the accel knob to idle engine
data074
speed.
This means all initialization process has completed and operator is suggested to
data075
turn off key.
data076 This means initialization of the machine.
data077 This means initialization of the solenoid valve.
data078 This means initialization of the engine idle speed.
data079 This means initialization of engine overheat warning system.
data080 This indicates the overheat temp. setting value.
data081 This indicates service hour to conduct maintenance job.
data082 These indicates where machine was manufactured.

These letters and signs indicate the switch conditions; safety lock lever, travel
data083
high speed and main key position at start or not.
data084 This indicates that operator is suggested to lift up unload lever(safety lock lever).
data085 Simple mode means that min. fail indications are shown up on LCD.
III-11
d. Service mode menues
1. Outline
Service mode is basically for dealerís service personel.
This mode is so designed to initialize machineís condition, additional attachment and control system.
and also diagnose machine trouble. Display indication items are listed in page 3-9 and 3-10, from data
number 023 ~ 085.
Following pages include ;

1) Service mode flow chart
2) Main menues in detail
2. Service mode flow chart

How to enter the service mode;
1. While pushing the display select switch.
2. Turn the main key switch to ON position.
3. Then you are in the service mode.
III-12
3. Main menues and functions
3-1 Selection Method of 11 Languages
If the key is turned ON with the display selector pressed, the name of the model presently selected will
appear. When the finger is off the display selector, the next language selection screen will appear. The infor-
mation on the selected model is important. Therefore, this method enables the confirmation of the model
first.
As explained above, the system is designed to support 11 languages, and the language selection screen will
appear first. (See fig. )
The selection screen of the 11 languages is written in each of the languages as shown in figure. When a lan-
guage is selected, a display corresponding to the language will appear.
Direction of arrow ;
Push the display selector switch
for long time
While pressing the display
selector switch, turn the main
Push the display selector switch
key ON.
for short time
Fig.1. Service Mode Language Selection Screen
III-13
3-2 Tester mode
Items such as the present battery voltage can be displayed by selecting Diagnosis and Tester. (See fig. 2.)
Fig.2. Tester menu
ï Engine -> Engine revolution XXXX rpm

A revolution sensor is mounted to the injection pump gear.
The gear ratio varies with the model as described below.
KX41-3's gear ratio: 46
KX61-3 and KX71-3's gear ratio: 54
KX91-3, KX101-3, KX121-3, and KX161-3 gear ratio: 68
Calculation Method
A single rotation of the injection pump corresponds to two engine rotations.
The revolution of the engine is calculated by measuring the passing period of the number of gear tooth
specified by the timer and obtaining the revolution under the same condition for 60 seconds.
ï Battery: Battery Voltage
The battery voltage is input into the meter through two diodes. Therefore, the voltage displayed is added
with 1.4 V in consideration of the potential drop caused by the diode.
ï E. oil: Engine oil switch ON and OFF.
ï Charge: Alternator L terminal ON and OFF.
These switches are turned ON with the engine stopped and turned OFF with the engine started while in
normal operation.
ï Lever: Lever lock.
ï Trave: Running in second gear.
ï Start: Start position of key switch.
ï Water: Water temperature voltage and water temperature ( C).
ï Fuel: Fuel voltage and fuel quantity (in liters).
The quantity of fuel (in litters) displayed is a reference value.
The fuel (in liters) is displayed from data measured according to the model.
ï Non anti-theft ver.: Not connected to theft prevention ECU (i.e., no communication is possible with the
theft prevention ECU).
III-14
3-3 Fail recoord dump
The fail record can be displayed by selecting Diagnosis and Fail record. (See fig. 3.)
By selecting the Fail record, the system reads the contents of the EEPROM and checks the information on
failures.
If failures are found, each failure item and the number of times on the hour meter can be scrolled at 1.5-sec-
ond intervals.
By pressing the display selector just once, the next failure point can be viewed.
If there is no failure, "No fail record" will be displayed.
(See the Section of Fail Safe for failures in detail.)
Fig. 3 Fail record dump
3-4 Deletion of Fail Record

The fail record can be deleted by selecting Diagnosis and Delete record. (See fig. 4.)
The message "Fail record deleted" will be displayed when the record is deleted.
By pressing the display selector while this message is displayed, the message to read the fail record will
appear again. The message to read the fail record will, however, appear automatically in 3 seconds without
pressing the display selector.
Fig. 4 Fail record delete
III-15
3-5 Machine model setup
Model settings can be made by selecting Set up and Set up machine. (See fig. 6.)
Here, information on the model and the country of manufacturer is selected.

By selecting the country of manufacturer, European specifications and North American specifications are
distinguished.
(If AI optional specifications are provided, the selection of AI as an optional item will appear as well.)
Fig.5 Machine model setu-up
Note:
By selecting the country of manufacturer, optional functions attached to the country - version, such as the
overheating and service auto manual items can be determined automatically.
Fig.6 Machine model set-up
3-6 Overheat set-up

Note:
By selecting Diagnosis , Set up , Engine start , Set up machine , and Set up overheat warning , overheat
warning settings can be made.
By turning the overheat warning ON, the overheating warning function will be enabled and the overheat
warning will be output when the preset temperature is reached.
The preset temperature can be adjusted in 10 C increments or decrements.
The value will be negative with the working lamp switch turned ON and positive with the center switch turned
ON. The entered value will be determined with the display selector continuously turned ON.
Overheat warning Adjustable in 10C

temperature increments/decrements
Fig. 7 Overheat Settings
In default condition, Overheat warning is OFF for North America and Oceania - version and ON for EU -
version.
III-16
3-7 Simple mode set-up --- Chinese-version only
Simple-mode settings can be made by selecting Set up, Engine start, Set up machine, and Simple mode.
(See fig. - .)
While in simple mode, the output will be turned OFF when the fail-safe function is activated, but no mes-
sages will be output. The fuel replenish mode will not be available.
No messages for failures including engine oil failures will be output while in simple mode. In this case, the
hour meter cannot be switched over to the tachometer while in normal mode. Therefore, only the hour meter
will be displayed. The reason is that the tachometer does not display the engine oil icon.
This meter is used for the U-50-3 meter for China, but the U-50-3 meter for China is shipped with a factory
setting made to simple mode.
3-8 Harness check Mode

By selecting Other menu and Circuit check Engine stop, the present conditions of the harness connector
can be checked (See fig. below.).
When the Circuit check Engine stop is selected, the message "Checking touch harness" will appear at the
moment the engine revolution drops below 800 rpm. This mode is available on the condition that the engine
is stopped. The mode cannot be selected when the engine revolution is 800 rpm or over.
While in harness check mode, the following items can be checked. Items in parentheses are error criteria.
ï Lever lock switch (OFF When lever is down).
ï Fuel sensor (Reading of 2 V or more, or 0.2 V or less.).
ï Water temperature (Water temperature of 140 C or more, or -30 C or lower.).
ï Oil switch (OFF When engine stops and Key is ON).
ï Charge circuit (OFF).
If there is any error, a message indicating the position of the error will flash automatically. Simultaneously,
the buzzer will beep.
When the error is restored, the buzzer will be turned OFF, but the flashing memory will be kept on hold.
If there are a number of errors, the screen will scroll.
III-17
3-9 All Fail Record
All the accumulated failure records can be shown by selecting Other menu, Other menu, and All fail record
(See Fig.6.).
By selecting All fail record, the first hour meter items generated after shipping through the last one will be
shown.
There are 19 types of failure diagnostic items, and the details of each type of item can be checked. The hour
meter will, however, remain even after the failure records are deleted.
Fig.6 All Fail Record

3-10 EEPROM read
The data of the EEPROM can be checked by selecting Other menu, Other menu, and EEPROM read. (See
Fig.7.)
Ten items are displayed on each page in hexadecimal, and 13 pages will be used in total.
The EEPROM consists of 128 x 16 bits.
Fig.7 EEPROM read

3-11 LCD inspection
The dot type of the LCD can be checked by selecting Other menu, Other menu, and LCD check. (See Fig. 8.)
Checkered pattern 1, checkered pattern 2, and the outer frame will be displayed. Checkered pattern 1 and
checkered pattern 2 are opposite to each other in dot ON-OFF pattern. Missing dots can be checked by
using this function. (See Figs.9 and 10.)
Fig.8 LCD check
Fig.9 Frame Display
Fig.10 Checkered Pattern
III-18
3-12 Servive hour meter check
The service hour meter can be checked and altered by selecting Other menu, Other menu, and Service hour
meter.
Only the display selector switch is used to make value changes. The service hour meter will be changed
when the meter is replaced, because the service hour meter will not be synchronized with the hour meter,
and warnings will not be displayed in a timely manner.
As you reach to this menu, first box is blinking to ready to change the digit. Push the
SW in short, the number will be incremented. Push the SW longer, the number will
be fixed and shifted to next box. After fixing all boxes, the beep sounds three times
and automatically returns to service hour meter with new service hours.
3-13 Servive hour meter delete

A deletion method of the service hour meter can be set by selecting Other menu, Other menu, and Service
warning selection.
Auto: North America & Oceania - version

The service hour meter will be turned off when the key is turned OFF and ON 10 times in total.
Manual: EU - version
The service hour meter will be turned off with the working lamp switch pressed continuously for 3 seconds.
Note:
Change in Service Hour Meter
North American specifications: By default set to auto.

European specifications: By default set to manual.
Turn off the service hour meter with the working lamp switch pressed.
3-14 Set-up time

The hour meter used for model settings can be checked by selecting Other menu, Other menu, and Set up
hour meter.
3-15 Software version

The software version can be checked by selecting Other menu, Other menu, and Soft version.
III-19
3-16 Auto glow control
The glow will be turned ON for an optimum time according to the temperature of engine cooling water.
3-16-1 Key-ON Processing

Water temperature: The glow-ON time is obtained from the glow time map (see Fig. 1, 2). The glow will not,
however, turn ON while the engine is working or the temperature is 81 C or over. The glow icon will appear
with the glow turned ON.
When the user confirms that the glow icon turns OFF and tries starting the engine, a delay in response (usu-
ally 0.5 to 1.5 seconds) will result, during which the temperature of the glow plug will drop. Therefore, the
actual glow will be kept turned ON for 2 seconds after the glow icon disappears. This will make a response
time lag between the display and glow time, thus making it possible to start the engine smoothly. (See Fig.
3.)
Water Glow Glow icon
tempera- time display time
ture ( C) (s) (s)
140 0.0 0.0
100 0.0 0.0
81 0.0 0.0
80 3.0 1.0
60 3.3 1.3
40 3.8 1.8
20 5.3 3.3
10 6.5 4.5
0 9.0 7.0
-10 11.0 9.0
-15 12.0 10.0
-40 12.0 10.0
Fig.1.Cooling Water Temperature vs. Glow Time Fig.2.Graph of Water Temperature vs. Glow Time
Glow continuing
Display
Glow completes
START
Starter switch ON
OFF
ON
Glow output
(new)
OFF Glow output holding period
ON
Glow output
(conventional)
OFF
The glow plug is cooled down during this period.
Time
Fig.3.Transition Diagram of Glow and Starter Key
III-20
Glow ON/OFF Conditions
The glow will turn ON under any of the following conditions: The engine revolution is 1000 rpm or below; the
engine oil pressure switch is OFF (the input terminal of the engine oil pressure switch is H); the charge is
OFF (the L input terminal is H). If these conditions are not satisfied, the glow will be turned OFF because
controller unit judges that the engine has started.
Relationship between Water Temperature and Dots

The gauge of the water temperature uses four dots vertically and 34 dots horizontally.
The relationship between the water temperature and dots is shown below.
Refreshment Cycle of Number of Dots

The average temperature of 721 samples obtained at 6.9344-ms intervals (6.9344 ms x 721 = 5 s) is con-
verted into the number of dots to refresh the display.
Enlarged view of water temperature gauge
Water temperature Dots

40 0
70 14
100 17
110 20
125 34
140 34
Relationship of Water Temperature and Number of Dots Relationship of Water Temperature and Number of Dots
(Graph)
Glow Control (Others)

1. If the grounding of the motor to the engine is improper, the voltage may sneak to the glow relay, thus
always turning the glow relay ON. Therefore, when the key is not at the start position, the glow relay will
be turned OFF.
2. If the battery is discharged while the key turned ON (In case operator left the key ON) and when the bat-
tery voltage is close to the level of triggering the CPU, the following operation may be repeated.
The microcontroller starts and turns the glow relay ON to perform auto glowing.
È
The glow current flows and the battery voltage drops because the glow relay is turned ON.
È
The microcontroller is reset.
È
The battery voltage rises because the microcontroller is reset and the glow relay is turned OFF, when
no current flows.
È
The microcontroller is triggered and the glow relay is turned ON because the battery voltage rises.
È
The above sequence is repeated. Then glow relay contact may have chattering and be damaged.
The glow relay will be always turned OFF in order to prevent the chattering of the above glow relay when the
voltage is 7.5 V or below. The similar process will be performed for the relay for the working lamp.
This know - how is to protect the relay itself.
III-21
3. FYI (For your information)
water [V] temp [C]

0.33 140
0.409 130
0.504 120
0.634 110
0.795 100
1 90
1.26 80
1.58 70
1.96 60
2.4 50
2.86 40
3.36 30
3.77 20
4.15 10
4.44 0
4.66 -10
4.8 -20
4.89 -30
4.94 -40
III-22
3-17 Travel high - low switch control
1. Change travel speed by pressing the high - low switch on the dozer control lever. Refer to the control
flow.
2. The travel mechanism will start in low gear to ensure safety when the key is turned ON.
3. With consideration of the change of the operator with the key kept turned ON, the frame mechanism will
be set into low gear to ensure safety when the lever lock is lifted up.
4. Control flow chart.
Note:
System will always ì Resetî to low speed when key is switched ì OFFî or safety lock lever is lifted.
III-23
3-18 Fuel amount control
1. Outline
A map indicating the voltage and fuel relationship has been prepared by plotting each determined input
voltage based on the float position of the fuel sensor and the remaining fuel.
The power supply voltage (5V) is input into the microcomputer according to the partial voltage varied
with the float position. Therefore, when calculating the actual quantity of remaining fuel, make a map
conversion with consideration of the power supply voltage.
The fuel shortage alarm will be displayed when the quantity of remaining fuel is between approximately
5 and 10 liters, the range of which, however, varies with the model. As a rule of thumb, the fuel will last
for approximately one hour after the alarm turns ON.
Fuel shortage alarm
Fuel residual
Model
amount [l]
KX41-3 5±3
KX61-3 7±3
KX71-3 7±3
Voltage and fuel map
Circuit diagram & function(Fuel sensor) (Water temp sensor)
(1)Fuel sensor (2)Water temp sensor (3)Meter (4)AD voltage

(Calculation example) Voltage value is 0.899 for example.
Theoretically, water sensorís resistance is 179.76 Ω
III-24
2. Meter display
1) The LCD with four vertical dots and 37 horizontal dots is used to display the fuel gauge.
Fuel level KX41-3 Amount L (us gal)

Full in tank 19 ± 3
Sensor upper limit 17 ± 3
Sensor lower limit 5±3
(Sample data)
2) A fuel shortage (0.899 V or over) is judged with 8,653 sampling times for 60 seconds. If a fuel short-
age is detected 7,780 times or more (i.e., a minimum of 90% of the total), the fuel shortage alarm will
be displayed.
3) If the fuel shortage alarm is displayed when the key is turned OFF, data on the alarm will be saved in
the microcomputer. If the voltage on average for 0.2 second indicates a fuel shortage (0.899 V or
over) when the key is turned ON again, the alarm will be displayed at once.
4) The alarm displayed will be canceled if the alarm cancel voltage (0.719 V or below) is detected 649
times or more (i.e., a minimum of 90% of the total) after the sensor signal is sampled 721 times for 5
seconds.
5) When the engine starts, the sensor float sways greatly, thus resulting in input voltage dispersion.
Therefore, the sampling cycle of the sensor signal is set to 25 seconds.
6) If fuel sensor disconnection occurs, the existence of fuel is not detectable, and the fuel shortage
alarm will not turn ON.
III-25
3. Fuel Replenishment Assist Function
While replenishing fuel by pressing any switch after the key is turned OFF, the buzzer interval will
change according to the quantity of fuel replenished. When the fuel in the tank is not much, the buzzer
will be heard at long intervals. When the quantity approaches the full tank level, the intermittent buzzer
continues at shorter intervals. When the tank is full, the buzzer will be heard continuously with no inter-
vals to prevent the fuel from overflowing from the tank.
ï Beep sound disappears approx 10 seconds after reaching to full of fuel.

ï If fuel fank isnít full, keep sound continues to sound for two minutes in order to alarm.
III-26
3-19 Startor auto release control
1. Outline
1) If the key freezed in the start position, the auto release relay is turned OFF to prevent damage to the
startor motor. At the same time, the glow relay will be turned OFF forcibly to prevent damage to the
glow plug. (Prevention of startor motor from key freezing)
2) The start of the engine is judged from the engine revolution sensor signal to turn OFF the auto
release relay. (Startor auto release)
3) If the key is turned OFF once and reset to the start position immediately while the engine is starting,
the pinion gear will engage while the ring gear rotates, which deteriorates the durability of the gears.
Therefore, the mechanism is designed to prevent of the engine from starting in two seconds after the
key is turned OFF. (Reentry prevention control)
4) The engine on the KX41-3 does not start at low temperature unless the revolution rises approxi-
mately 800 rpm. Therefore, the start of the engine is judged at 1,000 rpm.
(The judgment of the release of the starter has been raised by 200 rpm.)
5) If the key freezes while there is a failure in the engine revolution sensor, the auto release relay will be
automatically turned OFF in 30 seconds and power supply to the starter will be stopped. (Prevention
of starter burnout damage)
The reason the above period is set to 30 seconds is that it will be possible to start the engine by
energizing the starter three times for 10 seconds after auto glowing even in winter at a temperature
as low as -17 C.
START
AC(ON)
AUTO RELEASE RELAY (NO)

OFF
SAFETY SW
R&L
STARTER
MOTOR
5V
rpm
CONTROL UNIT
III-27
2. Auto release Circuit diagram & function
Auto release relay

(Starter relay)
NO - type
OFF
Key SW Key ON
Start Is the key switch set at "START"

longer than 30 seconds?
Engine speed sensor
Has the engine started?

Automatic release
control system
controller
1) Function chart
When in normal operation
a.Key switch start signal

About T1 sec
b.Engine speed sensor signal
c.Release relay solenoid
When the key switch is returned after the engine got started, the release relay functions as shown
below upon engine speed.
Engine speed Auto release relay (T1, T2)
1000 >
= Nx ON
ON (Within 6 seconds)
1001 ~ 1150
OFF (After 6 seconds)
> ON (Within 0.5 seconds)
1151 = Nx
OFF (After 0.5 seconds)
2) If the engine has started but the key switch fails to return (key switch failure)

T2 sec
c.Release relay solenoid S w itch turne d off
Suppose that the key switch fails to return and the key switch start signal stays on. But if the engine
speed sensor signal is fed, the automatic release control system regulates the transistor's base cur-
rent flow, which turns on the release relay solenoid ON or OFF.
III-28
3) If the key switch fails to return and the engine speed sensor is also in trouble

30 sec
S w itch
c.Release relay solenoid
tu rned off
If the key switch start signal is detected to have been on for 30 seconds, the automatic release con-
trol system (3) lets the transistor's base current flow, which turns on the release relay solenoid (1)
and turns off the relay switch.
a:Key switch status b:Engine speed sensor status c:Release relay solenoid action
(1) Normal: Normal Normal:
No particular action No particular action
(2) Start position Normal Relay deactivated 0.5 or 6 seconds
→ Failure to return according the engine speed.
(3) Start position Engine failure to start, or no engine Relay deactivated 30 seconds after
→ Failure to return speed sensor signal the key switch turn to "START"
3. Trouble shooting
If Engine Does Not Start
1) Check if the safety lock lever is lifted.

Make sure that the safety switch is turned OFF.
Take the following steps, set the unit to tester mode, and check the condition of the safety switch.
(Service mode)
KX41-3 English Diagnosis Tester Lever travel start
A manual check with a circuit tester is possible.
2) Check if the prevention of start mode reentry is working. (Wait two seconds or more.)
3) Check if the auto release relay is turned OFF.
Make a manual check with a circuit tester.
4) Check if the wrong model settings are made.
Depending on the model, the start of the engine is judged at 1,000 rpm or below. Therefore, the
release of the starter motor is judged before the startup revolution of the engine is reached.
5) The reason why detecting engine speed is set at 1000 rpm ;
If 800 rpm is set to detect the engine start - up speed, the controller stops supplying the current to the
startor motor.
Under the low ambient temperature, engine may not start up at around 800 rpm.
Therefor, in order to make sure the actual engine start, sensing engine speed is set higher by 200
rpm.
This varies according to the models.
III-29
4. Operational flow chart
4-1
III-30
4-2
III-31
4-3
< Engine speed and condition of auto release relay >

Engine speed : Nx Time : T1, T2 Auto release relay
1000 >
= Nx ON
Within 6 seconds ON
1001 ~ 1150
After 6 seconds O FF
> Within 0.5 seconds ON
1151 = Nx
After 0.5 seconds O FF
starter relay = Auto release relay
III-32
3-20 Service hour meter
A service maintenance message will appear when the preset hour meter item is activated.
The message will disappear in 10 seconds. Hereafter, whenever the key is turned OFF and ON, the mes-
sage will appear for the first 10 seconds.
There are two modes (i.e., auto mode and manual mode) to turn OFF the inspection icon perfectly, either of
which is selectable by the user's settings.
While the system is in auto mode, the icon will disappear when the key is turned OFF and ON 10 times in
total. Then icon will not appear again with the key further pressed. This is convenient because the icon will
disappear only with the key turned OFF and ON, in which case the actual maintenance of the equipment will
be up to the user's choice.
While in manual mode, the icon will disappear with the working lamp pressed continuously for 3 seconds. In
this case, the message will be eliminated after the user's maintenance work. Therefore, the problem of the
careless omission of maintenance will be prevented. This method is, however, complicated. Therefore, it is
necessary for each dealer to make maintenance management.
When all the described inspection items in the Operation Manual are considered, a message will be dis-
played at 50-hour intervals, which is not so meaningful. In view of the foregoing, important items (e.g., items
related to the engine oil, operating oil, air filter, and engine oil filter) should be targeted so that a message
will appear in the case of maintenance necessity for any of these items. The meter with North American
specifications and that with European specifications share the same software, but the timing of maintenance
varies with the specifications and the size of the system. Therefore, the displayed frequency of each item is
changed according to the specifications. Fig. 2 shows an example of the display of the KX41-3 with North
American specifications.
Usually, the service hour meter advances in synchronization with the hour meter, thus causing no problems.
If the hour meter is replaced, however, the new hour meter will start with zero hour. In that case, the service
hour meter will be asynchronous. Due to ethics reasons, the system cannot incorporate functions that allow
the alternation of the hour meter. There are, however, no problems in altering the service hour meter. There-
fore, items that can be input for the service hour meter have been prepared.
KX41-3 Service Hour Meter with North American Specifications
Fig. 2
EU - version machine
A message appears initial at 50-hour intervals and 250-hour intervals (i.e., every 250, 500, 750, and 1000
hours).
III-33
e. Failure Diagnosis
1. Failure display and diagnosis criteria
The following table 1 shows data on failure diagnosis, for operating mode and service mode.
Note:
ï Display items of the system in service mode can be checked with the fail record.
ï In the case of a warning for fuel scarcity, the buzzer will be turned ON for a moment at five-minute inter-
vals.
ï No.11 ~ 61 except 31, 32, 51, 52, 53, 54, 55 will be incorporatrd in future version machine, such as auto
idle (AI) model, anxilliary port (AUX) model and anti - theft system model.
Table 1. Failure diagnosis

Display
Function stop EEPROM
Buzzer Lamp Reset method Method of diagnosis
point address
Operating mode service mode
1 Fuel - 5-minute Yellow Replenish fuel --- --- Fuel scarcity rate is 90% min. after
intervals 60-s sampling
2 Engine oil 2 Engine oil Continu- Red Returns to nor- --- 66, 86 At 5 V (normal).
ally mal The following conditions continue
10 s: oil = L and 800 rpm min.
3 Charge 3 Charge Momen- Red Returns to nor- --- 65, 85 At 5 V (normal).
tarily mal The following conditions continue
10 s: charge = L and 800 rpm min.
4 High voltage 4 High voltage Continu- Red Turn key OFF AI AUX 67, 87 At 5 V (normal).
ally A power supply voltage of 18 V
min. continues 3 s.
5 Overheat 5 Overheat Continu- Red 112C±α max. AI AUX 77, 97 At 5 V (normal).
ally The following conditions continue:
Engine revolution of 800 rpm min.
with overheat warning
When the water temperature sen-
sor is normal, a water temperature
of (124 ± α) C min. continues 5 s.
(α : Adjustable between -10 C and
+10 C.)
11 Accel sensor 11 Accel sensor Momen- Red Turn key OFF AI 68, 88 At 5 V (normal).
tarily The accelerator sensor for AI spec-
ifications at 0.25 V max. or 4.75 V
min. continues for 0.2 s.
12 Governor sen- 12 Governor Momen- Red Turn key OFF AI 71, 91 At 5 V (normal).
sor sensor tarily The governor sensor for AI specifi-
cations at 0.25 V max. or 4.75 V
min. continues for 0.2 s.
13 AI motor short 13 AImotor short Momen- Red Turn key OFF AUX 69, 89 At 5 V (normal).
tarily AI specifications.
The specifications are presently
under consideration.
14 AI motor short 14 AI motor Momen- Red Turn key OFF AUX 70, 90 At 5 V (normal).
short tarily AI specifications.
III-34
Display Function stop EEPROM
Buzzer Lamp Reset method Method of diagnosis
point address
Operating mode service mode
21 AUX.volum 21 AUX volum Momen- Red Cancel AUX AUX 72, 92 At 5 V (normal).
tarily AUX specifications.
AUX mode turns ON.
The AUX sensor at 0.25 V max. or
4.75 min. continues for 0.2 s.
22 AUX.Sole- 22 AUX. Sole- Momen- Red Cancel AUX AUX 73, 93 At 5 V (normal).
noid L short noid L short tarily AUX specifications.
AUX mode turns ON.
23 AUX.Sole- 23 AUX.Sole- Momen- Red Cancel AUX AUX 74, 94 At 5 V (normal).
noid L break noid L break tarily AUX specifications.
AUX mode turns ON.
noid R short noid R short tarily AUX specifications.
AUX mode turns ON.
noid R short noid R short tarily AUX specifications.
AUX mode turns ON.
31 Lift up unload - Momen- Yellow Wait for 5 s, Engine does --- The key is shifted to the start posi-
lever tarily then disappear not start tion with the lever lock moved
down.
32 Service hour - Momen- Yellow Wait for 10 s --- --- The specified hour meter is set.
tarily
33 Key is wrong - Momen- Yellow Wait for 3 s Engine does --- Theft prevention specifications
tarily not start The wrong key is used to start the
engine.
34 Owner tag - Momen- Yellow Wait for 3 s Engine does --- Theft prevention specifications
tarily not start The owner tag is used to start the
engine.
- 51 Coolant sen- Momen- Red Turn key OFF --- 82, 102 At 5 V (normal).
sor tarily A water temperature of -30 C max.
or 140 C min. continues for 1 s.
- 52 Fuel sensor Momen- Red Turn key OFF --- 81, 101 At 5 V (normal).
tarily The fuel sensor at 2 V min. contin-
ues for 10 s.
53 Sensor supply 53 Sensor sup- Momen- Red Turn key OFF LCD turns OFF 79, 99 5-V short-circuiting detection termi-
short 5V ply short 5V tarily AI AUX 5-V out- nal at H level continues for 0.1 s.
put turns OFF
54 Sensor supply 54 Sensor sup- Momen- Red Turn key OFF AI AUX always 80, 100 At 5 V (normal).
short 12V ply short 12V tarily 0 rpm The 12-V short-circuiting detection
terminal at H level continues for 0.1 s.
55 Meter control- - Momen- Red Turn key OFF AI AUX 78, 98 The rightmost 16 bits of the added
ler error tarily value of addresses 36 through 50
do not coincide with the value of
address 64.
- 61 AI motor retri- Momen- Red Press accelera- --- 83, 103 At 5 V (normal).
crd tarily tor AI specifications
A motor current of 6 A min. contin-
ues for 3 s.
III-35
2. Fail record in EEPROM
If the sensor or actuator line has an error, the output of the actuator will stop and the LCD will display the
contents of the error while the error point is written to the EEPROM. Fig. 2 and fig. 3 show the address allo-
cation of the EEPROM.
2-1 Error Storage Method

If an error result, data in a corresponding EEPROM address will be overwritten. The data in the correspond-
ing address has a capacity of 2 x 16 bits. The first address (1 x 16 bits) has an hour meter record for the lat-
est error. The other address (1 x 16 bits) has an hour meter record of the first error along with the total
number of errors in the past. The data will be written to the EEPROM after rounding off all hour meter values
for less than one hour (see fig.1).
Hour meter data and the number of errors (1) will be written to both addresses if an error occurs for the first
time. The last hour meter data will be converted into present hour meter data for errors on and after the sec-
ond time. The count will remain 15 regardless of whether the actual number of errors exceeds 15, and only
data on the last hour meter data will be overwritten.
Address sample (Fig. ___ shows address numbers 85 to 103)
Address sample (Fig. ___ shows address numbers 65 to 83)
0 A A 7
0 A A 7 H
Fig. 1 Error Data Storage Method
2-2 Number of Errors

Data is stored in four bits. Therefore, the maximum number of errors is limited to 15. The count increases by
one if an error occurs after the key is turned ON. Once the key is turned ON, however, the count increases
only by one until the key is turned OFF.
(Example) Binary to decimal
1 0 1 0 1 0 1 0 Binary
0 x 20 = 0
1 x 21 = 2
0 x 22 = 0
1 x 23 = 8
0 x 24 = 0
1 x 25 = 32
0 x 26 = 0
+1 x 27 = 128
(decimal) 170 hrs
III-36
2-3 Erasing Method of Error Log
The error log will be deleted by selecting Error Log Delete in Diagnosis Mode. In the software, only the 0th to
third bits (the accumulated number of errors) in EEPROM addresses 85 through 103 will be zero cleared,
but hour meter data will not be zero cleared. Error Log Delete in Diagnosis Mode judges that there is no
error log if the number of errors is zero.
Hour meter data will not be deleted after executing Error Log Delete in Diagnosis Mode. Therefore, by
dumping the EEPROM, hour meter data for errors will be known. This will make troubleshooting possible if
the LCD meter is returned to the factory due to a failure after shipping.
The contents of addresses 65 through 103 are zero cleared with the PC before shipping.
Address No. Contents & purpose to use
0
Hour meter
~
35
36 Machine model (Ref.1)
37 Optional item (Ref.2)
38
AI control data
~
44
45
Thumb control data
~
50
51
Overheat control data
52
53 Language (Ref.3)
54
Machine hours & times
~
63
64
Machine failure warning
~
104
105
Original manufacturer use
~
Address No. 118 : Machine serial No.

127
Fig.2.Address and contents of EEPROM
Ref.1 : 0:KX41-3, 1:KX61-3, 2:KC71-3, KX91-3, 4:KX101-3, 5:KX-121-3, 6:KX161-3,

Ref.2 : bit No : 8 7 6 5 4 3 2 1 0
0 : Made in Japan, 1 : made in Germany

1 : Chinese - version
0 : Non AI, 1 : AI - version
1 : Thumb - version
1 : Anti - theft - version
0 : Canopy, 1 : Cab
1 : K or U - version
1 : Japanese - version, 0 : Oversea's - version
1 : Long arm
III-37
Address No. Contents of failure Data bit
65 3 Charge
66 2 Engine oil
67 4 High voltage
68 11 Accel sensor
69 13 AI motor short
70 14 AI motor break
71 12 Governor sensor
72 21 Aux.volume
73 22 Aux.solenoid L short The leftmost 12 bits display the hour meter value of
74 23 Aux.solenoid L break the last error. The rightmost four bits display the
75 24 Aux.solenoid R short accumulated number of errors.
76 25 Aux.solenoid R break
77 5 Overheat
78 55 Meter controller error
79 54 Sensor supply short 5V
81 52 Fuel sensor
82 51 Coolant sensor
83 61 AI motor retricted
84 reserve
85 3 Charge
86 2 Engine oil
87 4 High voltage
88 11 Accel sensor
89 13 AI motor short
90 14 AI motor break
91 12 Governor sensor
92 21 Aux.volume
93 22 Aux.solenoid L short
The leftmost 12 bits display the hour meter value of
94 23 Aux.solenoid L break
the last error. The rightmost four bits are dummy bits.
95 24 Aux.solenoid R short
96 25 Aux.solenoid R break
97 5 Overheat
98 55 Meter controller error
101 52 Fuel sensor
102 51 Coolant sensor
103 61 AI motor retricted
Fig.3 EEPROM Addresses for Error Log
III-38
3. self-diagnosis of controller unit
3-1 Purpose
The error diagnosis of the meter is possible by using the self-diagnostic harness. The self-diagnostic
function of a conventional model provided with a microcontroller can detect failures in the microcontroller
only after all the failure diagnosis of the electrical devices other than the microcontroller is made. This
kind of method requires time. Furthermore, there is a fear in the accuracy of the diagnosis.
By connecting the self-diagnostic harness to the meter and applying voltage from the battery, the self-
diagnostic program built into the meter will run, thus making the self-diagnosis of the incorporated hard-
ware of the meter possible with the inputs and outputs of the meter automatically activated and checked.
Note:
It is not 100% possible to make the perfect self-diagnosis of the hardware of the meter, however,
because not all hardware components built into the meter are checked.
3-2 Operation Procedure

1. Dismount the meter from the main harness of
the equipment and connect the meter to the
self-diagnostic harness.
2. Connect the 12-V terminal and negative termi-

nal of the self-diagnostic harness to the battery.
3. Self-diagnosis starts automatically.
III-39
The red and yellow lamps flash alternately.
The LCD of the meter flashes black and white

alternately.
The lamp as shown in the illustration on the

right-hand side turns ON and OFF repeatedly.
The buzzer beeps.

The backlight of the meter turns ON and OFF
repeatedly.
4. If the following message appears in approxi-

mately one minute, the hardware in the meter is
considered normal.
Finish key off
5. If any one out of numbers 2 through number 15

specified in table 2 is displayed, the meter has a
failure.
6. If the lamp is kept turned ON while the three

switches as shown in the illustration on the
right-hand side are pressed, the switches and
lamp are in normal condition.
III-40
3-3 Failure Display Number of Self-diagnostic Function
Table 2. Self - diagnosis of controller, items and methods
Fail
Check item Check parts Check methods indication
No.
2 Check sum CPU ROM Implement self-checksum. 1
Turn OFF the glow relay and make sure that pin 29
Glow relay output
(RXD2 power 7.1) is set to low level.
Input & output RS-485 (negative) (positive) flash
Turn OFF the glow relay and make sure that flash
TXD, RXD input
RXD TXD input is set to high level.
3 2
Turn ON the glow relay and make sure that pin 29
Glow relay output
(RXD2 port 7.1) is set to low level.
Input & output RS-485 (negative) (positive) flash
Turn ON the glow relay and make sure that the
TXD, RXD input
flash RXD TXD input is set to low level.
Auto release relay output, lever Turn OFF the auto release relay and make sure
Input & output
lock switch input that the lever lock switch is set to high level.
4 3
Auto release relay output, lever Turn ON the auto release relay and make sure that
Input & output
lock switch input the lever lock switch is set to low level.
Working lamp relay output, start Turn OFF the working lamp relay and make sure
Input & output
switch input that the start switch is set to high level.
5
Working lamp relay output, start Turn ON the working lamp relay and make sure
Input & output
switch input that the start switch is set to low level.
Compressor clutch relay output, Turn OFF the compressor clutch relay and make
Input & output
engine rpm input sure that the engine rpm is set to low level.
6 4
Compressor clutch relay output, Set the compressor clutch relay to high level and
Input & output
engine rpm input make sure that the engine rpm is set to high level.
Turn OFF the AUX LED and make sure that the
Input & output AUX LED output, charge input
aircon switch is set to high level.
7 5
Turn ON the AUX LED and make sure that the air-
Input & output AUX LED output, charge input
con switch is set to low level.
Turn OFF the AI LED and make sure that the oil is
Input & output AI LED output, oil input
set to low level.
8 6
Turn ON the AI LED and make sure that the oil is
Input & output AI LED output, oil input
set to low high level.
Travel sol output, aircon switch Turn OFF the travel sol and make sure that the
Input & output
input charge is set to low level.
9 7
Travel sol output, aircon switch Turn ON the travel sol and make sure that the
Input & output
input charge is set to high level.
III-41
Fail
Check item Check parts Check methods indication
No.
Motor Tr1, Tr2, Tr3, and Tr4 are set to low output
Motor Tr1, Tr2, Tr3, and Tr4 output
level.
Input & output AI operation switch input, travel
The AI operation switch is set to low level. The
switch input
travel switch is set to low level.
Motor Tr1 is set to high output level and Tr2, Tr3,
and Tr4 are set to low output level.
The AI operation switch is set to high level. The
switch input
travel switch is set to high level.
Motor Tr1 and Tr4 are set to high output level and
Tr2 and Tr3 are set to low output level.
10 Input & output AI operation switch input, travel 8
switch input
travel switch is set to low level.
Motor Tr2 is set to high output level and Tr1, Tr3,
and Tr4 are set to low output level.
switch input
Motor Tr2 and Tr3 are set to high output level and
Tr1 and Tr4 are set to low output level.
The AI operation switch is set to low level. The
switch input
Turn OFF the AUX sol (positive) (R) and make
AUX sol (positive) (R) output,
Input & output sure that the compressor clutch switch is set to low
compressor clutch switch input
level.
Turn ON the AUX sol (positive) (R) and make sure
that the compressor clutch switch is set to high
11 level. 9
AUX sol (positive) (R) output,
The AN2_7 AD value varies more by 25 mV or
Input & output compressor clutch switch input
more from the value with the input turned OFF.
AN2_7 input
From theoretical values, 12 V and 240 Ω: 50 mA
Voltage fluctuation corresponding to 50 mA: 50
mV
AUX sol (negative) (L) output, Turn OFF the AUX sol (negative) (L) and make
Input & output
AI pressure switch input sure that the AI pressure switch is set to low level.
12 10
AUX sol (negative) (L) output, Turn ON the AUX sol (negative) (L) and make sure
Input & output
AI pressure switch input that the AI pressure switch is set to high level.
Turn OFF the AI self-hold relay and make sure that
AI self-hold relay output, breaker
Input & output the breaker switch and AUX switch are set to low
switch and AUX switch input
level.
13 11
Turn ON the AI self-hold relay and make sure that
AI self-hold relay output, breaker
Input & output the breaker switch and AUX switch are set to high
switch and AUX switch input
level.
AD (Analog and Check with the microcomputer that the AD value is
14 fuel sensor
digital conversion) 1.8 V ± 0.15.
15 water temp sensor
16 motor potention sensor 12
17 accel potention sensor
18 AUX potention sensor
III-42
FYI (For your information)
Check Sum Error
1. A check sum error is checked to see if the contents of the program for microcomputer control are cor-
rupted.
2. The control program is saved in the ROM of the CPU. Once data is written to the ROM and shipped to
the market, the data cannot be written in the market.
3. The total sum of the data in each address of the control program is obtained in advance and stored as
check sum data prepared while in normal operation.
4. When the key is ON, the microcomputer calculates the total sum of the data in each address of the
control program in self-control of the microcomputer. The microcomputer checks if the results coincide
with the check sum data prepared while in normal operation (i.e., at the time of writing the program).
The microcomputer will go to the next step after the microcomputer checks if the results are found nor-
mal.
5. If the data does not coincide, the microcontroller judges that the program is illegal. In that case, a
check sum data error will result and an error alarm will be output. Error No. = 55
6. The program data can be reversed if the LSI in the controller partly fails to operate due to external envi-
ronmental factors, such as abnormal temperatures or excessive shock. That is the reason the micro-
computer makes this check when the key is turned ON, thus preventing the microcomputer resulting in
out-of-control conditions due to program failures.
III-43
3-4 Functions of Self-diagnostic Harness
The harness short-circuits the input and output terminals of the meter in advance, switches the respec-
tive inputs of the meter ON and OFF in sequence, and checks if the data on the output side is normal.
Self-diagnosis
Yazaki I/O
Check if the signal changes in synchronization

with the output when the power is turned ON.
Goes into aging mode. Yazaki aging
Always select input mode.

Check that the input potential is inverted with the
transistor turned ON and OFF.
III-44
4. Electrical component layout
(2) (1) (4) (3) (5) (8)
(1) Main key SW (17) Couper
(2) Hi - Low SW (18) Cab relay
(3) Meter coupler (19) Light relay
(9) (6) (10) (11)
(4) Hi - Low lamp (20) Horn relay
(5) Selector SW (21) Starter relay
(6) Coil commander (22) Glow relay (12)
(7) Work lamp SW (23) Fuse box
(8) Fuel pump (24) Fusible link (50A) (13)
(9) Engine emergency stop (Fusible link) (25) Battery
(10) Engine stop solenoid (26) Ground
(11) Glow piug (27) Travel Hi - Low solenoid (4)
(12) Fusible link (28) Unload solenoid
(13) Alternator (29) Power outlet
(14) Starter Motor (30) Horn
(15) Engine lock SW (31) Working lamp
(16) Lever lock SW
(29)
(30)
(31)
(17) (16) (15)
(21) (20) (19) (18)
(25) (24) (23) (22)

(28) (27) (26)
III-45
5. Service Mode KX41-3(Non-AI Non- anti-theft Non-S/P) ver 1.13
Note:
1. push switch for short time
2. push switch for long time
III-46
f. Circuit wiring diagram
1. KX36-3 EU
III-47
KX-41-3 Export standard type
III-48
KX-41-3 Export (EU) (US)
III-49
2. Main electrical compornents
III-50
3. Covering circuit by controller
III-51
III-52
g. Electrical component
1. Battery
Code NO. RB238-53231
Type 75D23L
Capacity, 5RH 52 Ah
Discharge, 300A at -15 C 8.9 V after 5 sec
Weigh, wet 17.0 kg
Specific gravity 1.280
Size L x W x H 230 x 171 x 225 mm
2. Fuel sensor
(1)
(2)
(3)
(1) (2) (3) ï Flange bolt tightening torque :98.1 ~ 196 Ncm
KX36-3 99.8 188.3 240.2
(10.0 ~ 20.0 kgcm)
(0.72 ~ 1.45 ftlbs)
KX41-3 EU 99.3 189.6 241.6
ï Insulation : 3M Ω or more
KX41-3 US 38.6 99.0 143.0 (D500V megatester)
III-53
KX36-3
(1)
(1) Meter Sender resistance
(2)
(2) Fuel gauge Level Ω
(5) (3) Sender Full 3.0 ± 2
(4) Thermistor 1/2 (32.5)
(4) (3)
(5) Warning lamp Empty 110.0 ± 2
(6)
(6) Fuel sender
(7) tank earth
(7)
3. Fuse box
KX41-3 : EU - version
III-54
4. Heater : EU - version
1.
1-1 Structure, Maker : Siroco
(1)
(1) Electric cable exit

(2) Fuse 5 Amps
(3) Motor side
(4) Duct,
(5) Duct,
(2) 1-2 Specifications

Heating capacity : 4.1 kw
(3)
Nominal air flow : 239 m3/h
Rated voltage : 13 V
Consumption current : 5.6 A
(4)
(5)
(1) Connector
(1) 12 V (Black)
(2) HIgh speed (red)
(3) (2)
Low speed
(3)
(orange)
III-55
III-56
IV.Hydraulic System . . . . . . . . . . . . . . . . . . IV-2
a. Hydraulic components Specifications . . . . . . . . . . . . . . . . . . . . . . . .IV-2
b. Hydraulic circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-5
c. Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-9
d. Control valve assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-13
e. Pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-19
f. Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-20
g. Swivel motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-29
h. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-30
i. Rotary joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-34
j. Unload valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-37
k. Selector valve : KX41-3V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-39
l. Accessaries of hydraulic compornents . . . . . . . . . . . . . . . . . . . . . .IV-40
m. Service port performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-41
IV-1
IV.Hydraulic System
a. Hydraulic components Specifications
1. EU - version; KX36-3,
KX36-2 KX36-3 KX41-2㱍 KX41-3 KX41-2V㱍 KX41-3V
1 Supplier Casappa Nachi Nachi Nachi Nachi Nachi
2 Parts No. RG108-6111-2 RG038-6111-1 RG118-6111-1 RG138-6111-1 RG118-6111-1 RG138-6111-1
3 type Gear 2Vp+Gear 2Vp+Gear 2Vp+Gear 2Vp+Gear 2Vp+Gear
4 q1 cc/rev 6.5 7.2 7.2 7.5 7.2 7.5
5 q2 cc/rev 6.5 7.2 7.2 7.5 7.2 7.5
6 q3 cc/rev 4.5 4.5 5.2 4.5 5.2 4.5
7 q4 cc/rev supply unit 2.7 supply unit 2.7 supply unit 2.7
8
Pump 9 Engine model D1105-BH-8 D782-BH D782-BH D902 D782-BH D902
10 rated rev rpm 2100 2300 2200 2300 2200 2300
11 rated output
12 relief q1 kgf/cm2 210 205 210 220 210 220
13 q2 kgf/cm2 210 205 210 220 210 220
14 q3 kgf/cm2 210 205 210 210 210 210
15 q4 kgf/cm2 46 40 46 40 46 40
16 C/V supplier KYB Hydrocontrol KYB Hydrocontrol KYB Hydrocontrol
1 Supplier Trasmital B Trasmital B Trasmital B Trasmital B Nachi Trasmital B Trasmital B Nachi

3 type MAG10V MAG10V MAG10V MAG12V PHV-120 MAG12V-2 MAG12V PHV-120
4 Motor cap. cc/rev 10.92 10.92 10.92 6.88 12.46 6.88 10.92 6.0 12.46 6.27 12.46 6.88 11.36 6.21
5 Motor torque kgf䍃m 3.65 3.56 3.65 2.30 4.36 2.41 3.82 2.10 4.16 2.10 4.36 2.41 3.98 2.17
6 Motor rev. rpm 1250 1516 1451 2302 1384 2507 1580 2875 1271 2526 1384 2507 1518 2778
7
8 Supplier GB Trasmital B Trasmital B Trasmital B Trasmital B Nachi Trasmital B Trasmital B Nachi
9 Reduction ratio 31.8 37.22 31.8 31.8 36.96 34.2 34.2 36.96
IV-2
Travel Motor
10 Equivalent cap. cc/rev 347.3 406.4 347.3 218.8 396.2 218.8 403.6 221.8 426.1 214.4 426.1 235.3 419.9 229.5
11 Output torque kgf䍃m 116.1 132.6 116.1 73.12 138.7 76.61 141.3 77.6 142.4 71.7 149.2 82.4 147 80.4
12 Schaft rev. rpm 39.3 40.7 45.6 72.4 43.54 78.84 42.7 77.8 37.2 73.9 40.5 73.3 41.1 75.2
13 PCD sprocket mm
14 fixing pitch mm 157 155 157 155 155 157 155 155
15 Sprocket teeth pcs 19 19 19 19 19 19 19 19
16 Pitch rubber tracks. mm 96 96 96 96 96 96 96 96
17 Travel speed km/h 2.15 2.23 2.50 3.96 2.38 2.03 2.03 4.26 2.03 4.04 2.22 4.01 2.25 4.11
AVON BS Bilbao BS Bilbao BS Bilbao BS Bilbao BS JPN BS Bilbao BS Bilbao

RG001-2231-0 RG038-2232-1 RG108-2232-2 RG038-2232-1 RG038-2232-1 RA211-2231-0 RG136-2231-1 RG136-2231-1
200x30x96 230x32x96 230x32x96 230x32x96 230x32x96 230x32x96 230x32x96 230x32x96
Wire distance mm 146.4 146.4 146.4 146.4 146.4 146.4 146.4 146.4
Rubber Track Tangential force kgf 792.8 905.9 792.8 947.7 965.4 972.9 1019 1004
Wire qty 30(36) 48 40 48 48 48 48 48
Wire strength kg 580(670) 400 400 400 400 400 400 400
Strength ratio >20 21.9(30.4) 21.2 20.2 20.3 19.9 19.7 18.8 19.1
1 Supplier Sumitomo Eaton Sumitomo Eaton Sumitomo Eaton Sumitomo Eaton Sumitomo Eaton Sumitomo Eaton
3 type Orbit Orbit Orbit Orbit Orbit Orbit
4 Motor cap. cc/rev 195 195 195 195 195 195
5 Brake pressure kgf/cm2 135 135 135 135 135 135
Swing Motor 6 Motor torque kgf䍃m 41.9 41.9 41.9 41.9 41.9 41.9
7 Motor rev. rpm 51.7 53.1 58.7 53.1 58.7 53.1
8 Teeth Pinion pcs 12 12 12 12 12 12
9 Teeth S race pcs 73 73 73 73 73 73
10 Swivel Torque kgf䍃m 254.9 254.9 254.9 254.9 254.9 254.9
11 Swivel Speed rpm 8.5 8.7 9.6 8.7 9.6 8.7
2. Cylinder Specifications; EU - version
parts No. RG038-67601 RG038-67801

bore 㱢 mm 55 55
rod 㱢 mm 30 30
KX36-3 㹣㹣㹣
stroke mm 343.5 276.5
S length mm 588.5 529
supplier Pacoma Pacoma
parts No. RG138-67701 RG138-67601 RG138-67801 RG138-75101 RG138-67401
bore 㱢 mm 60 60 60 60 55
rod 㱢 mm 30 35 35 30 30
KX41-3
stroke mm 469 335.5 276.5 111 340
S length mm 675 589 529 348 610
supplier Pacoma Pacoma Pacoma Pacoma Pacoma
parts No. RG138-22301
bore 㱢 mm 55
rod 㱢 mm 30
KX41-3V 㹡㹡㹡㹡㹡
stroke mm 310
S length mm 528
supplier Pacoma
IV-3
IV-4
b. Hydraulic circuit diagram
1. KX36-3: EU - version
IV-5
2. KX41-3: EU - version
IV-6
3. KX41-3V: EU - version
IV-7
4. KX41-3V: North America & Oceania - version
(1) Running left

(2) Running left
(3) Flexible leg and dozer switching valve
(4) Left
(5) Right
(6) Ascent
(7) Decent
(8) Right
(9) Left
(10) Low
(11) High
(12) Bolting
(13) Dump
(14) Forward
(15) Backward
(16) Forward
(17) Backward
(18) Decent
(19) Ascent
(20) Bolting
(21) Dump
(22) Swing
(23) Dozer flexible leg
(24) Rotation
(25) Interflow valve
(26) Service port
(27) Arm
(28) Running right
(29) Inlet
(30) Running left
(31) Boom
(32) Bucket
(33) Arm bolting
(34) Arm dump
(35) Rotation left
(36) Rotation right
(37) Boom ascent
(38) Boom descent
(39) Bucket bolting
(40) Bucket dump
IV-8
c. Main pump
1. Outer view
(1) (2)
(3) (4)
(4)
(5)
(4) (4)
(1) Suction port (2) 4 - M10 (3) Oil inlet (4) Discharge port
(5) Rotation direction, Clockwise
IV-9
2. structure
(1) Body S (10) Swash plate (21) Rod G (35) Snap ring (62) Seal washer
(2) Body H (11) Needle (24) Retainer (39) O - ring (65) Gear pump
(3) Shaft (12) Swing pin (25) Stopper pin (40) O - ring (66) Coupling
(4) Cylinder barrel (13) Packin (27) Pin (44) Hex bolt (67) Collar
(5) Valve plate (14) Spring C (30) Ball bearing (49) Hex plug (68) Bolt
(6) Piston (15) Spring T (31) Needle bearing (51) Plug (69) O - ring
(7) Shoe (18) Spring holder (32) Oil seal (56) Spring pin (70) Washer
(8) Shoe holder (19) Spring guide (33) Belleville spring (60) Hex screw (71) O - ring
(9) Barrel holder (20) Pin (34) Snap ring (61) Nut (72) O - ring
IV-10
3. P-Q performance curve
Discharge: q1=q2 (cc/rev)
Pressure: P1+P2 (kgf/cm2)

Tedt condition Remark
Oil ISOVG46 3.77 kgfm
Oil temp 50 ± 5 C (at P3=5 kgf/cm2)
RPM 2300 rpm 3.98 kgfm
Direction Clockwise Pump intake torque (at P3=210 kgf/cm2)
q3 4.5 cc/rev
q4 2.7 cc/rev
P4 40 kgf/cm2
4. Pump Specifications, Type : PVD-00B-15P-5G3-4982A

1.Capacity P1, P2: 7.5 x 2 cm3/rev P3: 4.5 cm3/rev P4: 2.7 cm3/rev
2.Pressure P1, P2: 21.6 MPa P3: 20.6 MPa P4: 3.9 MPa
at bench 2
(220 kgf/cm ) (210 kgf/cm ) 2
(40 kgf/cm2)
Rated Speed: 2300 min-1 Rotation Direction: Clockwise
3.Speed
Max. Speed: 2600 min-1
4.Suction pressure -0.02 ~ ±0.04 MPa (-0.2 ~ ±0.4 kgf/cm2)
5.Oil ISO VG 32, 46, 68 Anti - Wear hydraulic fluid
6.Oil temp Temp range : -20 ~ +100 C
7.Control Constant torque control
at P3= 0.49 MPa T=37.0 Nm
8.Torque
at P3= 20.6 MPa T=39.0 Nm
P1, P2: 17.25 l/min x 2 P3: 10.35 l/min P4: 6.21 l/min
9.Pump discharge
(4.56 ug gal/min) (2.73 ug gal/min) (1.64 ug gal/min)
IV-11
5. Function1
1) Outline
Discharge groove P2
This compact, lightweight hydraulic pump has a Suction groove (1)
mechanism that provides for the performance of Discharge groove P1
two variable pumps. Yet it needs as small a space Suction groove (2)
as for just one conventional pump. This pump is
also equipped with a pilot gear pump.
The pump features a constant horsepower control
function for making most of the engine power. The
greater the pump load becomes, the lesser the
discharge rate becomes. As a result, when the
pump discharge pressures P1 and P2 have risen
and the resultant force of the piston higher, the (a) Valve plate
swash plate exceeds the spring force and tilts
from the oscillating center of the oscillating pin. In Discharge groove
this way, the discharge rate can be kept low. P1 and opening Discharge groove
P2 and opening
6. Function2
An even number of pistons are used in this swash
plate variable piston pump. This is to produce the
performance of two same-capacity pumps in one
pump casing.
Conventional valve plates have one suction
groove and one discharge groove, as shown in
Fig. 4. The new system, on the other hand, is pro-
vided with two suction grooves and two discharge (b) Cylinder barrel
grooves, as shown in Fig. 3. The discharge
Fig. 3 Operating principle
grooves P1 and P2 are located in the outer and
inner sides, respectively. Every other piston cham-
ber of cylinder barrel gets open to either of these
discharge grooves in the valve plate. In other
words, both the inner and outer suction grooves
behave just the same way, whereas the inner and Suction groove
outer discharge grooves work independently from Discharge groove
each other.
In this design with an even number of pistons, the
same number of pistons gets open outward and
inward of the valve plate. Because all the pistons
are of the same diameter, located in a same-pitch
circle and slide over the same swash plate, the
discharge rates of the discharge grooves P1 and (a) Valve plate
P2 are the same.
There is another advantage in employing just a
single swash plate. Even though the swash plates
tilting angle varies according to the variable con-
trol, the discharge rates of P1 and P2 ports change
accordingly and equally.
(b) Cylinder barrel

Fig. 4 Conventional swash plate piston pump
IV-12
d. Control valve assy
1. KX36-3: EU - version, Code No:RG038-61131, Maker: Hydro control
IV-13
2. KX41-3: EU - version, Code No:RG138-61131, Maker: Hydro control
IV-14
3. Control valve section : KX41-3S ; RG138-61131
(Swing section)
IV-15
(Dozer section)
(Slew section)
(Inlet section, P3)
IV-16
(Service section)
(Arm section)
(Travel section, L & R)
IV-17
(Inlet section, P1 & P2)
(Boom section)
(Bucket section)
IV-18
e. Pilot valve
1. EU - version
Maximum permissible operating torque at lever: 8 daN.m
IV-19
f. Travel motor
1. EU - version; KX36-3, KX41-3S, KX41-3V
Maker: Transmital Bonfiglioli
(1) Structure
P1 G 3/8 19 TPI
(JIS B 2351 ì0î RING BOSS)
P2 SERVICE PORT
T1 G 1/4 19 TPI
(JIS B 2351 ì0î RING BOSS)
T2 DRAIN PORT
1 M10x1 FILLING AND DRAINING OIL PLUG
2 M10x1 OIL LEVEL PLUG

Mark to identify gearbox
Black:KX41-3V
White:KX41-3
Blue:KX36-3
IV-20
(2) Circuit diagram : EU
KX36-3 KX41-3S, KX41-3V
(3) Technical data : EU
No. Machine model KX36-3 KX41-3S KX41-3V
Low speed 12.46 cm3/rev

1 Motor Displacement 10.92 cm3/rev
High speed 6.88 cm3/rev
2 Gearbox ratio 1 : 37.22 1 : 31.8 1 : 34.2
3 Max, pressure 206 bar 216 bar
4 Max, flow 16.6 l/min 17.3 l/min
Continous 1 bar
5 Max, drain pressure
Peak 5 bar
Max, motor output torque High speed 273 Nm at 216 bar
6 35.8 Nm at 206 bar
(theoretical) Low speed 428 Nm at 216 bar
Max, motor output speed High speed 2515 rpm
7 1520 rpm
(theoretical) Low speed 1388 rpm
Max, gearbox output torque High speed 751 Nm 810 Nm
8 1333 Nm
(theoretical) Low speed 1361 Nm 1467 Nm
Max, gearbox output speed High speed 73.4 rpm
9 40.8 rpm
(theoretical) Low speed 40.6 rpm
10 Counter balance spool opreating pressure 3 bar 6 -7 bar
11 Check valve cracking pressure less than 0.3 bar
12 Hydraulic motor oil ISO VG 46
ISO VG 150 E.P./SAE 80W90
13 Gearbox oil type API GL5/MIL-L-2105
14 Gearbox oil: quantity 1 lt ± 10 % 0.3 lt ± 10 %

15 Oil temperature -20 C / +100 C
16 Total weight 17 Kg ± 10%
IV-21
2. KTC, KCL, KTA - version : KX41-3V
(1) Motor type ID mark
PHV - 120 - 37 - 9 - 8158C
R & D No.
Paint class
Reduction ratio
Nominal output torque
NACHI travel motor PHV series
(2) Specifications
Max. output torque 1443 Nm (147 kgfm)
Gear box Max. output speed 41.2 / 75.4 min-1
Reduction ratio 1 / 36.96
Displacement 11.36 / 6.21 cm3/rev
Max. pressure 21.6 MPa (220 kgf/cm2)
Motor Max. speed 1523 / 2786 min-1
Max oil flow 17.3 l/min
Hi - Low change pressure 0.5 MPa (5 kgf/cm2)
Equivalent capacity for one turn of motor assy. 419.9 / 229.5 cm3/rev
Operating oil ISO - VG46 or equivalent
Temperature -20 ~ 100 C
Others Filtering 10 μm
Gear box oil SAE -30 -CD
Gear box oil amount 330 cm3
Weight 17 kg
IV-22
3. Structure
(1)
(2)
(3)
(5)
(4)
(1)
(1)
(2)
(5) (4)
(1) Counter balance valve (4) Selector valve

(2) HI - Lo change valve (5) Hi - Lo piston
(3) Selector valve
IV-23
4. Principle of operation
(1) Operating principle of wheel motor
(1) (2)
(6)
(7)
(5)
(3)
(5)
(4)
(1) Stationary part (5) Hydraulic motor

(2) Rotating part (6) Symple planetary gear reducer (two - step)
(3) Counter balance valve (7) Carrier 2
b1 : four planet gears,
(4) Two - speed spool (8)
b2 : three planet gears
Description of operation
The PHV series travelling motor has a stationary main body composed of a hydraulic motor and hydrau-
lic valve and a rotating main body composed of a simple planetary gear reducer.
IV-24
(2) Reducer
1) Function
The PHV series travelling motor reducer, which is a simple two-step planetary gear reducer, converts
the high-speed revolution of the hydraulic motor to low-speed high torque to obtain case rotation.
2) Description of operation
In the figure shown to the right, the gear S2 is (1) (2)
spline-coupled with the hydraulic motor output
shaft (or they are combined). The revolution
of the gear S2 is single-reduced through the
gears (S2, b2, a2). This single-reduced revo-
lution is double-reduced through the gears
(S1, b1, a1) spline-coupled with the carrier 2.
The reduced revolution is transmitted to the
rotating main body through the annular gears (4)
a1 and a2, providing travelling driving force.
The reduction ratio of a simple two-step plane-
tary gear reducer is generally expressed as
shown below.
Zs1 Zs2
R= ×
Zs1 + Za1 Zs2 + Za2
Where
Zs1, Zs2: Number of teeth of gears s1 and s2
(3)
Za1, Za2: Number of teeth of gears a1 and a2
Because the PHV series travelling motor is of (1) Stationary part
the main body rotating type, the reduction ratio (2) Rotating part
is expressed as shown below.
(3) Symple planetary gear reducer (two - step)
1 (4) Carrier 2
R' =
1-1/R
IV-25
(3) Hydraulic motor
1) Function of motor
The hydraulic motor, which is an axial piston motor (rotating cylinder and swash plate type), converts
the hydraulic energy supplied from the pump to revolving movement.
2) Structure of motor and operating principle (See the figure below.)
(4) Cylinder barrel (a) The motor shaft and gear S2 are combined or coupled through splines
(5) Valve plate (b) Port A
(6) Piston (c) Port B
(7) Swash plate
(8) Shaft
The pressure oil flowing in through the hydraulic valve is supplied to the valve plate (5). When the
pressure oil is supplied to the port A, the oil flows into the cylinder port, which corresponds to the port
A, in the cylinder barrel (4) and presses the piston (6). This pressing force is converted to turning
force through the swash plate (7) and the resulting turning force is transmitted to the shaft (3) spline-
coupled with the cylinder barrel (4). The return oil in the cylinder port flows out through the port B of
the valve plate (5).
In the case of reverse rotation, the pressure oil flows in through the port B and flows out through the
port A.
IV-26
3) Operating principle of two-speed motor
The swash plate has two faces I and II on the surface opposite to the shoe-sliding surface and sup-
ported by the two balls fixed in the body 2 .
The ball is positioned eccentrically above the central axis. In the 1st speed state, therefore, the face
II is pressed against the body 2 by hydraulic oil force applied to the piston and the spring force in the
cylinder barrel and the swash plate angle becomes α. At this time, the motor is of large capacity.
When the speed selector lever is switched to the g2nd speed position, the operating pressure is con-
ducted through the two-speed spool to the control room and the control piston moves until the face II
of the swash plate touches the body 2, fixing the swash plate angle at β. At this time, the motor is of
small capacity.
When the engine is stopped, the control room is connected to the drain port through the two-speed
spool and the swash plate is returned to the 1st speed position by the spring force. At the time of
starting, therefore, the motor is always in the 1st speed state.
(1) Swash plate (7) Body 2

(2) Shoe (8) Face II
(3) Piston (9) Face I
(4) Spring (10) Control room
(5) Cylinder barrel (11) Control piston
(6) Ball (12) Operating pressure
IV-27
(4) Hydraulic valve (counter balance valve)
When the pressure oil is supplied through the port A, the pressure oil pushes open the check valve (3)
and flows into the inlet-side port Aí of the hydraulic motor. At the same time, the pressure oil flows
through the choke hole C into the room D and slides the spool valve (2) to the right, overcoming the force
of spring (4). As a result, the hydraulic motor return oil flows in through the port Bí, passes through the
opening E of the main body (1) and spool valve (2) and returns to the port B. These processes make the
hydraulic motor rotate. When the pressure oil is supplied through the port B, the above-mentioned pro-
cesses are reversed and the hydraulic motor rotates reversely.
When the pressure oil supplied through the port A is made unpressurized, the spring force works to
return the spool valve to the left. At this time, the oil in the room D controls the speed at which the spool
valve returns to the left, utilizing the choking effect of the choke hole C. Even if the pressure oil supplied
through the port A is made unpressurized, the hydraulic motor continues rotating using an inertial force.
At this time, the return oil is gradually controlled through the sliding speed of the spool valve and the
helix shape, thus stopping the hydraulic motor smoothly.
IV-28
g. Swivel motor
1. EU - version; KX36-3, KX41-3, KX41-3V
Maker: Eaton Fluid Power Ltd.
(1)Structure
(1) SMOTOR,ASSY(SWING)
(2) ADAPTER
(3) ADAPTER
(4) BOLT
(2)Circuit diagram
(3)Specifications
IV-29
h. Cylinder
1. Structure
1-1 EU - version
(KX36-3, KX41-3S, KX41-3V, Bucket)
(2)
(3)
(1)
(4)
(1) (2) (3) (4)
KX36-3 65 φ 55 φ 30 62
KX41-3S,V 70 φ 60 φ 35 64
(KX36-3, KX41-3S, KX41-3V, Arm)
(8) (4) (6)

(5)
(7)
(1) (2) (3)
(1) (2) (3) (4) (5) (6) (7) (8)
KX36-3 62 62 343.5 ± 2 φ 65 φ 55 φ 30 M22 x 1.5 M58 x 1.5
KX41-3S,V 72.5 60 335.5 ± 2 φ 70 φ 60 φ 35 M27 x 2 M63 x 1.5
(KX36-3, KX41-3S, KX41-3V, Boom)
IV-30
(KX36-3, KX41-3S, KX41-3V, Swing)
(KX36-3, KX41-3S, KX41-3V, Blade)
Retracted length = 348 ± 1.5, Stroke = 111mm
(KX41-3V, Truck)
DU-bushing ; Inner dia = φ 30 +0.09

0 , Length = 34.75 ± 0.25
IV-31
1-2 North America and oceanea
(KX41-3V, Bucket, Arm)
T.T.
(20) (21)
(17)
(18) (19)
T.T.
[mm]
(1) Cylinder tube (6) Backup-ring (11) DU-bushing Bucket Arm
(2) Cylinder rod (7) Scraper (12) Piston (17) Stroke 276.5 335.5
(3) Bushing (8) O-ring (13) Piston seal (18) Retracted L 529 ± 1.5 589 ± 1.5
(4) Cylinder head (9) Backup-ring (14) Wear-ring (19) Extended L 805.5 ± 2.5 924.5 ± 2.5
(5) Packing (10) O-ring (15) Lock nut, M24 (20) 328.5 387.5
(16) grease nipple (21) 75.5 76.5
(KX41-3V, Boom)
T.T.
(3)
(1) (2)
T.T.
(1)Retracted L = 765 ± 1.5 (2)Extended L = 1234 ± 2.5 (3)Stroke = 469
(KX41-3V, Blade)
(1) (2)
(3)
T.T.
T.T.
IV-32
(KX41-3V, Swing)
(1) (2)
(3)
T.T.
T.T.
(KX41-3V, Truck)
T.T.
(1) (2)
(3)
T.T.

T.T. : Tightening torque
[Cylinder essential quality] 6. Withstanding external force :

1. Seal durability: Any damages, distortions, oil leakage, permanent defor-
Must conform to class ìAî (0.05 ml / 100m) of ìJIS B 8354î mations must not occur in any parts when external force 2
under following conditions. times as high as the main relief pressure 43.1 MPa (440
Oil pressure : 21.6 MPa (220 kgf / cm2), kgf / cm2) the cylinder thrust force (12240 kgf) is applied by
Oil temperature : 100 deg, Speed : 16.6 m / min, 30000 times or more.
Sliding distance : 300km
2. Dust Seal properties : 7. Rust prevention of plating :
Dust enter must be 11 mg or less under following condi- Must be rating number 9 or higher after 4 cycles (64 hour)
tions. of CASS testing. Thickness of platinf must be kept more
Speed : 16.6 m / min, Stroke : 150 mm, than Ep-ICr30 (0.03 mm)
Number of repetitions : cycles, 8. Cushion performance : (Cushion type cylinder only)
Vibration applied to facility : 7.4 Hz Cushion facility must be set in bottom side for contraction
3. Internal oil leakage : with following performance.
Must be within 1 cm3 for 3 min under the condition of the Oil temperature : 30 deg / cushion time : 2 seconds or less
main relife pressure 21.6 MPa (220 kgf / cm2) applied to Oil temperature : 50 deg / cushion time : 1 ± 0.3 seconds
the stroke end (Oil temperature 50 ± 5 deg). Oil temperature : 80 deg / cushion time : 0.3 seconds or more
4. Minimum operating pressure :
Must be within 4 % of the main relief pressure 0.86 MPa 9. Piston rod surface treatment :
(8.8 kgf / cm2) applied to the bottom port after 3 or more Piston rod rubbing part : Ni-Hcr or Hcr plating
cycles with full stroke sliding under none load (Oil tempera- Thickness 9.03 mm or more
ture 50 ± 5 deg). Hardness HV (25g) 700 or more
5. Withstanding pressure : Induction hardening : HRC 50 to 56, Depth 2 to 3 mm
Permanent deformation and oil leakage must not occur
after pressure 2 times as high as the main relief pressure
43.1 MPa (440 kgf / cm2) is applied by 40000 time or more.
IV-33
i. Rotary joint
1. Structure
1-1 KX36-3
(17)
(14) (15)
(16)
(13) (17)
(17)
(13)
(14)
(19) (18)
(20)
(18)
(15)
(16)
(14)
(1) Shaft (8) Plug (R 1/8) (15) F:Travel R, upper

(2) Back-up ring (9) Collar (16) D:Travel, drain
(3) D-ring (10) Circlip (17) C:Blade, bottom
(4) Back-up ring (11) O-ring (18) B:Blade, rod
(5) O-ring (12) Plug (R 1/8) (19) I:Travel L, upper
(6) Collar (13) H:Travel L, lower (20) Each port must be free from painting
(7) Body (14) E:Travel R, lower
IV-34
1-2 KX41-3S
(17)
(14) (15)
(16)
(13) (16)
(21)
(19)
(13)
(17)
(21)
(18)
(19)
(20)
(18)
(15)
(16)
(14)
(21)

(7) Body (14) E:Travel R, lower (21) G:Travel high speed
Note:
1. Applied pressure:
B, C, E, F, H, I = 24.5 MPa (250 kgf/cm2) G = 3.9 MPa (40 kgf/cm2) D = 1.5 MPa (15 kgf/cm2)
2. Leakage from ports of both sides is 1 cc or less after pressuring for 2 min.
IV-35
1-3 KX41-3V
(17)
(22)
(14) (15)
(16)
(13) (16)
(21)
(19)
(13)
(23)
(17)
(21)
(19) (18)
(22)
(20)
(18)
(15)
(16)
(14) (23)
(21)

(7) Body (14) E:Travel R, lower (21) G:Travel high speed
(22) I:Track cylinder, rod
(23) J:Track cylinder, bottom
Note:
1. Proof pressure strength must be 34.3 MPa (350 kgf/cm2).
2. Turning forgue, without load : 127 Nm (13 kgfm) or less.
IV-36
j. Unload valve
1. North America and Oceanea version
1-1 Structure
Maker : Nishina
Red
Black
(1) Shim (11) Plug

(2) spring (12) Hollow bolt
(3) Name plate (13) Washer
(4) Plunger (14) Screw
(5) Spring (15)
(6) Spool (16) O-ring
(7) Body (17)
(8) Solenoid (18) Cable clamp
(9) Cover (19) Protection tube
1-2 Specifications
(1) Alow voltage: DC 10.8 ~ 14.4V
(2) Current: 1.2 A at 20 C
Red (3) Insulation: JIS C 4003 H
(4) Coil resistance: Ω
(5) Surge killer: Diode
Black
Relief valve set 2
(6) 3.9 +0.2 +0.2
0 MPa (40 0 kgf/cm )
pressure: at 6l/min
(7)
Cracking 3.4 MPa (35kgf/cm2)
pressure: at 2l/min
p → A, B
Valve pressure
(8)
loss: 0.5 MPa (5.1 kgf/cm2) or
less at 6l/min
A, B, G = G 1/4
(9) Port size:
P, T = G 3/8
(19)
IV-37
2. EU - version
2-1 Structure
Maker : Hydro control
(1) VALVE,ASSY(UNLOAD) (6) ADAPTER

(2) VALVE,ASSY(UNLOAD) ONLY FOR KX36-3 (7) ADAPTER
(3) ADAPTER (8) ADAPTER ONLY FOR KX41-3
(4) ONLY FOR KX41-3 (9) BOLT M10 x 1.5
(5) ADAPTER
2-2 SpecificationsStructure
1. Pilot oil flow : 6.2 l/min
2. Max. allowable oil flow : 16 l/min
3. Rated voltage and output : 12V - 18W
4. Coil resistance : 8 Ω
IV-38
k. Selector valve : KX41-3V
1. Structure
2. Function
This valve is to select the oil flow direction for blade cylinder or track cylinder.
3. Specifications
1) Operating pressure and flow : Main relief pressure (20.6 MPa) at 10.4 l/min.
2) Inside leakage : 8 cc/min at 20.6 Mpa, 50 C
IV-39
l. Accessaries of hydraulic compornents
1. Check valve assy
(6)
(7) (8)
(1) Shim
(2) spring
(3) Name plate
(4) Plunger
(10) (11)
(5) Spring
(9)
[mm]
(11)
(6) (7) (8) (9) (10)
HEX
KX36-3
KX41-3 EU 67 55 G 1/2 φ26 30.02 27
KX41-3V
KX41-3V US 65 53 G 3/8 φ18.6 25.4 22
Cracking pressure : 343 ± 29 MPa (3.5 ± 0.3 kgf/cm2)
2. Hydraulic filter
Specifications items Suction filter, all models Return filter : EU
1.Filtration area 1650 cm 2 1850 cm2
2.Filtration level 105 μm (150 mesh) 10 μm nominal
3.Oil flow 80 l/min 70 l/min
4.Hex.spanner 41 mm 36 mm
5.Filter dia. φ 85 φ 90
6.Filter length 105 140
7.Relief opening pressure 0.1MPa
IV-40
m.Service port performance
1. Test sample : KX36-3 GL
IV-41
2. Test sample : KX41-3V GL
IV-42
V.Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-3
a. Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-3
b. Performance curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-5
c. Function & structure of coil commander . . . . . . . . . . . . . . . . . . . . . . V-7
V-1
V-2
V.Engine
a. Engine Specifications
Machine model KX36-3 EU KX41-3S, V EU KX41-3V US
Engine Model D782-BH-3 D902-BH D902-EBH

No. of cylinder 3 3
mm 67 x 73.6 72 x 73.6
Bore x Stroke
in 2.64 x 2.90 2.83 x 2.90
cc 778 898
Displacement
in3 47.5 54.8
kW/rpm 9.3/2300 11.6/2300
Max. output/rpm PS/rpm 12.6/2300 15.8/2300
HP/rpm 12.5/2300 15.5/2300
Compression ratio 24 24
> >
Nm 41.8 = 49.9 = 52.6
> >
Max. torque kgfm 4.26 = 5.10 = 5.36
ftlbf 38.8
> >
30.8 = 36.8 =
mm 449 x 402 x 538 473 x 402 x 546
Dimensions:L x W x H
in. 17.7 x 15.8 x 21.2 18.6 x 15.8 x 21.5
kg 64 72
Dri weight
lbs 141 159
mm 0.145-0.185 0.145-0.185
Valve clearance
in. 0.0057-0.0073 0.0057-0.0073
Firing sequence 1-2-3 1-2-3
Combustion chamber E-TVCS E-TVCS
Mpa 2.84-3.24
Compression pressure
(A)/(B) kgf/cm2 29-33
psi 412-469
Fan belt RPF2325
g/kWh 286 286
Fuel consumption ratio g/Psh 210 210
lbs/Hph 0.47 0.47
l/h 3.2 4.1
Fuel consumption
gal/h 0.85 1.08
Max.speed without load rpm 2650 >
= 2650 >
=
Speed with 2 pumps relief rpm
>
2300 =
Speed with idling rpm 1200--1300 1200--1300
kPa 196-441 196-441
Engine oil pressure
with rated engine rpm kgf/cm2 2.0-4.5 2.0-4.5
psi 28.4-64.0 28.4-64.0
MPa 13.7
Injection pressure kgf/cm2 140
psi 1991
Cooling system Pressurized radiator(0.088Mpa, 0.9kgf/cm2), water pump
g/kWh 0.95
Engine oil consumption ratio g/Psh 0.7
lbs/Hph 0.0016
V-3
Engine electric components
Machine model KX36-3 EU KX41-3 EU KX41-3 US
Engine Model D782-BH-3 D902-BH D902-EBH

Fuel injection pump type Bosch M Dtype m ini-pump
Nozzle type DN4PD62 mini-nozzle
Mpa 13.7
Injection pressure kgf/cm2 140
psi 1991
Dynomo 12V480W
Manufacturer P/N 100211-4730 100211-1670
Regulator adjusting voltage V 14.2-14.8 14.2-14.8
Battery type
Nominal capacity of 5hrs rating Ah
Specific gravity of electrolite
Starter motor 12V1.2KW 12V1.4KW
Manufacturer P/N 228000-0951 228000-0991
Glow plug Ω 1.5 1.5
V-4
b. Performance curve
KX36-3; D782-BH-3
Net value; D1546
V-5
KX41-3S, KX41-3V; D902-EBH(-BH)
Net value; D1545
V-6
c. Function & structure of coil commander
1. Circuit diagram
Hold
(Red)
Pull
(white)
Pull Hold
coil coil
Timer
circuit
FE Transistor
Gnd
(Black)
Coil commander Solenoid (pull in type)
2. Function
Under some condition, such as low temp, large current flows to pull coil and may cause to cut the coil.
Coil commander is to regulate the current flow to pull coil by controlling the current time according to the
temperature
Temperature vs Current Time
V-7
3. Inspeetion & troubleshooting
1) Check the continuity of hold coil.
2) Check pull in coil function after wiring 12V to red and while terminal and ground to black color termi-
nal.
Then engine solenoid functions and pull in the plunger head.
Photo : pull in condition Photo : hold condition
V-8
KUBOTA Corporation
CONSTRUCTION MACHINERY DIVISION
1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN
EDITOR:
CONSTRUCTION MACHINERY MANUFACTURING DEPT.
SERVICE SECTION
HIRAKATA PLANT
PHONE :+81-72-840-1195
FAX :+81-72-890-2886
K U B O TA C orporation P rinted in Japan 0403.C M C .e.10 C ode N o.97899-60810

WORKSHOP MANUAL
KUBOTA EXCAVATOR
KX36-3
KX41-3S, KX41-3V
Service Chapter
Code No.97899-60860
Record of Revisions
Symbol Date Main Revised Points & Corrective Measures Person-in-charge
EU - version machine models : KX36-3, KX41-3S, KX41-3V

KTC, KCL, KTA version machine model : KX41-3V
(PP - version, Pan-Pacific - version)
CONTENTS
I General
II Machine Body
III Engine
IV Hydraulic System
V Electrical system
I. General
A.Body and engine identification marks . . . . . . . . . . . . . . . . I-S-3
B.Safety precautions for servicing, disassembly and reassembly. . . . I-S-4
a. Safety measures before starting work. . . . . . . . . . . . . . . . . . . . . . . I-S-4
b. Safety measures during work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-4
c. Preparation for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5
d. Precautions for disassembly and reassembly. . . . . . . . . . . . . . . . . I-S-5
C.Important Safety process and critical functional process . . . I-S-6
a. Essential Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6
b. Important Safety Process .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6
c. Important Critical Functional Process . . . . . . . . . . . . . . . . . . . . . . I-S-6
D.Important inspection items after reassembling . . . . . . . . . I-S-6
a. Operate the Machine and check for Unusual Noise and Vibrations.I-S-6
b. Make Sure the Safety decals and Wireharness Clamps are in their
Specified Positions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6
c. With the Machine Front in a Specified Posture, Check the Amount of
Hydrauric Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6
d. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-7
E.Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12
a. PP (KTC, KCL, KTA) - version . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12
b. Hydraulic Oil Check for machines with Hydraulic Breakers . . . . . I-S-14
c. EU version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-15
F. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-16
a. Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-16
b. Machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-17
c. Lever stroke and operating force . . . . . . . . . . . . . . . . . . . . . . . . . I-S-19
d. Dimensions of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-20
Note : PP - version = Pan Pacific - version = KTC, KCL, KTA - version
I-S-1
I-S-2
A.Body and engine identification marks
If trouble should occur during use, or if servicing is
necessary, contact the dealer who handles the
machine. At that time please inform the machine
model and engine type and serial numbers.
KTC, KCL, KTA version
2-47, Shikitsuhigasi 1-Chome, Naniwa-ku, Osaka, 556-8601 JAPAN

No. Items Contents ; Example
MODEL 1
1 Machine model KX41-3V
2 Serial No. 20001
SERIAL No. 2
3 Engine No.
ENGINE No. 3
PRODUCT 4 PRODUCT IDENTIFICATION No. >JKUK1613CO1H20001<
IDENTIFICATION
NUMBER
4
Example : S/N 20001
RA018-5772
Name plate : Code No. RA018-57721
(1) Machine serial number
(2) Engine serial number

e.g. D1503-2L0025
“2” indicates year of 2002 and “L” indicates June.
So, 2L indicates that the engine was manufactured
in June 2002.
Engine serial number
I-S-3
B.Safety precautions for servicing, disassembly and reassembly
Safety precautions for servicing
Most accidents during servicing arise from carelessness. Please remember that Safety involves both the
welfare of the employees and improved work efficiency.
Safety precautions for Disassembly and reassembly

Machines must be diassembled and assembled efficiently and safely.
It is very important to thoroughly understand the construction and function of the machine, to make all appro-
priate preparations, and start operations according to the specified working procedures.
a. Safety measures before starting work

(1) Work clothes (2) Team work
1. Wear specified work cap and clothed. 1. When working with two or more people,
(Under no circumstances may workers wear divide the work and maintain close commu-
undershirts only.) nication.
Cuffs must be kept buttoned, and any tears 2. Clane work must be carried out using prede-
must be mended.) termined signals.
2. Wear safety shoes.
3. Do not wear cotton gloves when working on (3) Disassembly and assembly
the internal section of engine, reduction 1. Do not wear gloves when using hammers.
gears or hydrauricunits for repair or others, 2. Use rods of the specified soft material for
or when using a hammer. Wear leather removing pins. Do not use a hammer as a
gloves, however, when hoisting wires. pad.
3. Do not place fingers in holes when center-
(2) Inspecting equipment and tools ing.
1. Prepare equipment (cranes, fork lifts, tool, 4. Heavy parts must be adequately supported
etc.) required for servicing and inspect for before removingbolts.
any problems before starting work.
2. Hammer heads (metal parts) must be firmly (4) Cranes
secured to their handles. 1. In principle, use a crane for objects heavier
3. Check hosting tools (wire ropes, hoisting than 44lb (20kg).
chains, etc.) before use. 2. Crane operation and hoisting must be per-
formed only by qualified personal.
(3) Keep workshop in order 3. Pay careful attention to the center of gravity
1. Secure appropriate space needed for disas- when hoisting, and do not stand under the
sembly to the job. lifted objects.
2. Secure a clean, safe place for arranging dis-
assembled parts. (5) Others
3. Store volatile substances (gasoline, light oil, 1. To work under a jacked-up carrier, be sure to
thinner, oily articles, etc.) in appropriate con- place wood pieces under it.
tainers at selected locations to prevent fire 2. When charging batteris, make sure there
hazards. are no open flames in the immediate vicinity.
3. All electric tools must be grounded.
b. Safety measures during work 4. Before welding the machine, remove the
(1) Protectors battery.
• When removing the battery, be sure to dis-
1. Wear goggles when using chisels for chip- connect negative (-) cord first.
ping. • When mounting the battery, be sure tp
2. Use appropriate protectors during welding. connect the positive (+) cord first.
3. Wear a helmet when working with a crane or
at elevated locations.
I-S-4
c. Preparation for disassembly
(1) Cleaning
Remove mud and dirt from the body before disassembly.
(2) Acceptance inspection

The machine must be checked before it is disassembled to record existing conditions, such as those
listed below.
Model, serial number, and hourmeter reading
• Reason for repair and repair history
• Element stains
• Fuel and oil condition
• Parts damage *(Take photographs if necessary.)
(3) Equipment and tools

prepare equipment, tools, cranes and parts storage racks as required.
d. Precautions for disassembly and reassembly

(1) Disassembly
1. Follow the specified disassembly procedures.
2. Make alignment marks to insure correct reassembly.
3. Arrange disassembled parts in an orderly way, and attach identification tags or put marks if needed.
(2) Reassembly
1. Clean all parts before assembly. Repair any scratches or dents. Take special precautions against dirt
and dust.
2. Parts with rust-preventive coatings must be assembles only after removing the corting.
3. Separated parts must be correctly reassembled using alignment marks.
4. As a rule, use a press to reassembled bearings, bushing and oil seals. Use pads when using a ham-
mer.
I-S-5
C.Important Safety process and critical functional process
The following instructions are related to essential adhesives, important safety process S and critical func-
tional process A .Pay special attention in servicing these process. (Pay also close attention in reconnecting
the electrical cables.)
a. Essential Adhesives
Type of screw adhesive
• Unless otherwise specified, use Three-Bond 1324 adhesive (medium-duty type).
Keep the screw threads free of oil and water.
Type of instantaneous adhesive
• Use Three-Bond 1733 or Three-Bond 1741E adhesive.
Keep the bond areas free of oil and water.
b. Important Safety Process S .

1. Reconnecting the fuel hose (clearance, hose routes, clamps, etc.)
2. Electrical cabling (engine, instrument panal, controls, etc.) (wiring routes, clamps and couplers)
c. Important Critical Functional Process A .

1. Setting up the travel wheel motor (tightening torque)
2. Reassembling the rotary joints (joint direction and shaft set-up)
3. Installing the swivel base bearing and the swivel motor (tightening torque)
4. Fitting the pump couplings (tightening torque)
D.Important inspection items after reassembling

a. Operate the Machine and check for Unusual Noise and Vibrations.
b. Make Sure the Safety decals and Wireharness Clamps are in their
Specified Positions.
c. With the Machine Front in a Specified Posture, Check the Amount of
Hydrauric Oil
Checking the oil level (For further datails, refer to the Operator’s Manual of each model.)
1) Park the machine on a level ground.
2) Make sure the hydrauric oil temperature is in the range of 10-30°C (50-86°F) and see if the oil level is
within the specified zone of the oil level gauge.
3) Keep the machine front as shown as following posture.
Posture: Extend the rods of the arm and bucket cylinders to max.
Place the bucket link on the ground, the offset swing at the
center, and the dozer also on the ground.
I-S-6
d. Piping
(1) General precautions
• Tightening the pipe socket to the specified torque. If too tight, the socket itself or a hydraulic component
may get damaged. It too loose, an oil leak may result.
• In connecting a new hose or pipe, tighten its nut first to the specified torque and then turn it back (about
45°). Then tighten it again to the specified torque. (Do not this to the sealing tape-applied hose or pipe.)
• When disconnecting a vertical hose or pipe, separate its bottom connection first.
• In desconnecting and reconnecting the hose and pipe, be sure to use two wrenches. With one wrench,
restrain the mating part to allow no twist.
• Check the mating connector’s sleeve and the hose’s taper for dust deposits and scratches.
• When the pipe socket has been tightened up, wipe the joint clean. Apply the maximum operating pres-
sure 2 or 3 times to make sure there is no oil leak.
(2) Hydraulic hose

Check the hydraulic hose for too tight a connect or twist.
* Excessivly tight contact
Let’s suppose that a hose is in contact with another hose or other part. If the hose is pulled away by a force
of 2 kg but still in contact, it means the contact is too tight.
(3) Precautions in tightening the bolts and nuts

• Use bolts of specified length.
• Do not over tighten the bolts: Its threads may get deformed or the fixed part may get damaged. Do not
undertighten the bolt either: It may get loose.
• In other words, tighten the bolt to the specified torqoe.
• Tighten the bolts and nuts diagonally for even tightness.
Nut
Joint body
Sleeve
R (Tapered thread) Steel pipe Union nut Tapered thread

G (Straight thread)
I-S-7
(4) Hose screw Metric Size Hose
Tightening torque Torque
N·m Thread size N·m
Thread size kgf·m Wrench size (piping screw) kgf·m
(piping screw) ft·lbf (reference) ft·lbf
Taper thread 20 ~ 30
Union nut section
section M12 × 1.5 2.0 ~ 3.1
14.75 ~ 22.13
7.8 ~ 11.8 N·m 14.71 ~ 19.61 N·m
17 mm 20 ~ 30
1/8” 0.8 ~ 1.2 kgf·m 1.5 ~ 20 kgf·m
0.67 in M14 × 1.5 2.0 ~ 3.1
5.8 ~ 8.7 ft·lbf 10.85 ~ 14.47 ft·lbf 14.75 ~ 22.13
24.5 ~ 29.4 36.3 ~ 44.1 30 ~ 50
19 mm
1/4” 2.5 ~ 3.0 3.7 ~ 4.5 M16 × 1.5 3.1 ~ 5.1
0.75 in
18.1 ~ 21.7 26.8 ~ 32.5 22.13 ~ 36.9
49.0 ~ 53.9 49.0 ~ 68.6 30 ~ 50
22 mm
3/8” 5.0 ~ 5.5 5.0 ~ 7.0 M18 × 1.5 3.1 ~ 5.1
0.87 in
36.2 ~ 39.8 36.2 ~ 50.6 22.13 ~ 36.9
58.8 ~ 63.7 83.4 ~ 88.3 40 ~ 60
27 mm
1/2” 6.0 ~ 6.5 8.5 ~ 9.0 M22 × 1.5 4.1 ~ 6.1
1.06 in
43.4 ~ 47.0 61.5 ~ 65.1 29.5 ~ 44.25
117.7 ~ 127.5 127.5 ~ 147.1
36 mm
3/4” 12.0 ~ 13.0 13.0 ~ 15.0
1.42 in
86.8 ~ 94.0 94.0 ~ 108.5
137.3 ~ 147.1 147.1 ~ 166.7
41 mm
1” 14.0 ~ 15.0 15.0 ~ 17.0
1.61 in
101.3 ~ 108.5 108.5 ~ 123.0
(5) Joint bodies

Tightening torque
N·m
Thread size kgf·m Spanner size Remarks
(piping screw) ft·lbf (reference) Steel pipe (OD)
R (tapered thread) G (straight thread)
19.6 ~ 29.4 N·m

17 mm 8 mm
1/8” 2.0 ~ 3.0 kgf·m -
0.67 in 0.31 in
14.5 ~ 21.7 ft·lbf
W/O-ring
36.3 ~ 44.1 Joint Torque
19 mm 12 mm
1/4” 3.7 ~ 4.5 58.8 ~ 78.5
0.75 in 0.47 in
26.8 ~ 32.5 6~8
43.4 ~ 57.9 When in
W/O-ring steel pipe is
39.2 ~ 49.0 Joint Torque in use.
23 mm 15 mm
3/8” 4.0 ~ 5.0 78.5 ~ 98.1
0.91 in 0.59 in
28.9 ~ 36.2 8 ~ 10
57.9 ~ 72.3
W/O-ring
49.0 ~ 68.6 Joint Torque
26 mm 16 mm
1/2” 5.0 ~ 7.0 117.7 ~ 137.3
1.02 in 0.63 in
36.2 ~ 50.6 12 ~ 14
86.8 ~ 101.3
I-S-8
(6) Tightening torque table for hose clamp (Screw type)
Tightening torque
N·m
No. Dia. (mm) Code No.
kgf·m
ft·lbf
1 Ø12 ~ 16 09318-89016
2 Ø19 ~ 25 09318-89024 2.5 ~ 3.4
25 ~ 35
3 Ø31 ~ 40 09318-89039 1.84 ~ 2.51
4 Ø36 ~ 46 09318-89045
5 Ø15 ~ 25 RC101-64580 4.9 ~ 5.9
50 ~ 60
6 Ø26 ~ 38 68311-72820 3.61 ~ 4.35
3.4 ~ 4.4
7 Ø13 ~ 20 RB101-63630 35 ~ 45
2.58 ~ 3.31
8 Ø40 ~ 55 RC411-63180
9 Ø77 ~ 95 69284-63170 4.9 ~ 5.9
50 ~ 60
10 Ø50 ~ 60 RC401-63190 3.61 ~ 4.35
11 Ø32 ~ 44 RD411-63820
(7) Nuts for piping

Tightening torque
Steel pipe size
N·m Spanner size
(O.D. × I.D. × Remarks
kgf·m (reference)
Thickness)
ft·lbf
29.4 ~ 39.2
8 × 6 × 1 mm 17 mm
3.0 ~ 4.0
0.31 × 0.24 × 0.04 in 0.67 in
21.7 ~ 28.9
39.2 ~ 44.1
10 × 7 × 1.5 mm 19 mm
4.0 ~ 4.5
0.39 × 0.28 × 0.06 in 0.75 in
28.9 ~ 32.5
53.9 ~ 63.7
12 × 9 × 1.5 mm 21 mm
5.5 ~ 6.5
0.47 × 0.35 × 0.06 in 0.83 in
39.7 ~ 47.0 When sleeve nut is
88.3 ~ 98.1 in use.
16 × 12 × 2 mm 29 mm
9.0 ~ 10.0
0.63 × 0.47 × 0.08 in 1.14 in
65.1 ~ 72.3
127.5 ~ 137.3
18 × 14 × 2 mm 32 mm
13.0 ~ 14.0
0.71 × 0.55 × 0.08 in 1.26 in
94.0 ~ 101.3
235.4 ~ 254.97
27.2 × 21.6 × 2.8 mm 41 mm
24.0 ~ 16.0
1.07 × 0.85 × 0.11 in 1.61 in
173.6 ~ 188.1
I-S-9
(8) Tightening torque of bolts and nuts
Refer to the tightness torque table below.
Bolts, Nuts 4T 7T 9T
Nomial Dia.
SS41 S40C, S45C SCr4
7.8 ~ 9.3 N·m 9.8 ~ 11.3 N·m 12.3 ~ 14.2 N·m
M6 0.80 ~ 0.95 kgf·m 1.00 ~ 1.15 kgf·m 1.25 ~ 1.45 kgf·m
5.8 ~ 6.9 ft·lbf 7.2 ~ 8.3 ft·lbf 9.0 ~ 10.5 ft·lbf
17.7 ~ 20.6 N·m 23.5 ~ 27.5 N·m 29.4 ~ 34.3 N·m
M8 1.80 ~ 2.10 kgf·m 2.40 ~ 2.80 kgf·m 3.00 ~ 3.50 kgf·m
39.2 ~ 45.1 N·m 48.0 ~ 55.9 N·m 60.8 ~ 70.6 N·m
M10 4.00 ~ 4.60 kgf·m 4.90 ~ 5.70 kgf·m 6.20 ~ 7.20 kgf·m
62.8 ~ 72.6 N·m 77.5 ~ 90.2 N·m 103.0 ~ 117.7 N·m
M12 6.40 ~ 7.40 kgf·m 7.90 ~ 9.20 kgf·m 10.50 ~ 12.00 kgf·m
46.3 ~ 53.5 ft·lbf 57.1 ~ 66.5 ft·lbf 75.9~ 86.8 ft·lbf
107.9 ~ 125.5 N·m 123.6 ~ 147.1 N·m 166.7 ~ 196.1 N·m
M14 11.00 ~ 12.80 kgf·m 12.60 ~ 15.0 kgf·m 17.00 ~ 20.00 kgf·m
166.7 ~ 191.2 N·m 196.1 ~ 225.6 N·m 259.9 ~ 304.0 N·m
M16 17.00 ~ 19.50 kgf·m 20.00 ~ 23.00 kgf·m 26.50 ~ 31.00 kgf·m
245.2 ~ 284.4 N·m 274.6 ~ 318.7 N·m 343.2~ 402.1 N·m
M18 25.00 ~ 29.0 kgf·m 28.00 ~ 32.50 kgf·m 35.00 ~ 41.00 kgf·m
333.4~ 392.2 N·m 367.7 ~ 431.5 N·m 519.8 ~ 568.8 N·m
M20 34.00 ~ 40.00 kgf·m 37.50 ~ 44.0 kgf·m 53.00 ~ 58.00 kgf·m
(9) Types and materials of bolts and nuts

[ex. bolts]
Types Material Tensile strength Hardness Bolt head marking
Over 392 MPa
HRB
4T SS41 4000 kgf/cm2 No mark or marked 4
62 ~ 98
56892 lbf/in2
Over 686 MPa
S40C HRC
7T 7000 kgf/cm2 Marked 7
S45C 20 ~ 28
99561 lbf/in2
Over 882 MPa
HRC
9T SCr4 9000 kgf/cm2 Marked 9
28 ~ 34
128007 lbf/in2
I-S-10
(10)Washer-equipped elbow
Tightening torque
Size N·m kgf·m ft·lbs

G1/4 25 ~ 30 2.5 ~ 3.0 18 ~ 22
G3/8 49 ~ 54 5.0 ~ 5.5 36 ~ 40
G1/2 59 ~ 64 6.0 ~ 6.5 43 ~ 47
G3/4
118 ~ 127 12.0 ~ 13.0 87 ~ 94
G1
Tightening procedure
1) Connecting with the valve
• Screw in the elbow by hand until the washer comes
into contact.
Note:Clean up hte mating seal boforehand.
2) Positioning
• Turn the elbow back to its set position.
Note:Do not make any more than one turn back.
3) Fixing
• Tighten up the lock nut with a wrench.
• Lock nut tightening torque
G1/4:25 ~ 30 N·m (2.5 ~ 3.0 kgf·m, 18 ~ 22 ft·lbs)
G3/8:50 ~ 55 N·m (5.0 ~ 5.5 kgf·m, 36 ~ 40 ft·lbs)
G1/2:60 ~ 65 N·m (6.0 ~ 6.5 kgf·m, 43 ~ 47 ft·lbs)
G3/4:118 ~ 127 N·m (12.0 ~ 13.0 kgf·m, 87 ~ 94 ft·lbs)
G1:118 ~ 127 N·m (12.0 ~ 13.0 kgf·m, 87 ~ 94 ft·lbs)
I-S-11
E.Maintenance intervals
a. PP (KTC, KCL, KTA) - version
Hour meter indicator
No. Check points Intervals Consequently
50 100 150 200 250 300 350 400 450
check Daily check
1 Coolant
change every 2 years
2 Fuel check Daily check
check Daily check
3 Engine oil
change every 250 hrs
check Daily check
4 Hydraulic oil
change every 1000 hrs *1
5 Lubrication points - Daily check
6 Radiator and oil cooler check Daily check
7 Engine and electrical wiring check Daily check every year
8 Fuel tank, Fuel filter drain every 50 hrs
9 Battery condition check every 50 hrs
10 Greasing swing bearing teeth - every 50 hrs
11 Fan belt tension adjust every 200 hrs
check every 200 hrs
12 Radiator hoses and clamps
replace every 2 years
clean every 200 hrs *2
Outer element
13 Air filter element replace every 1000 hrs *2 @
Inner element replace every 1000 hrs *2
14 Greasing swing ball bearings - every 200 hrs
15 Fuel filter element replace every 400 hrs @
16 Engine oil filter replace every 250 hrs
17 Drive unit oil change every 500 hrs
18 Hydraulic return filter element replace every 500 hrs
19 Hydraulic suction filter element replace every 1000 hrs
20 Fuel injection nozzle injection check every 1500 hrs *4 @

pressure
21 Front idler and track roller oil change every 2000 hrs
22 Alternator and starter motor check every 2000 hrs
23 Injection pump check every 3000 hrs *4 @
24 Radiator system rinse every 2 years
check every 200 hrs
25 Fuel line and Intake air line @
replace every 2 years *3
* 500 thru 1000 continued to the following table.
I-S-12
500 550 600 650 700 750 800 1000
check Daily check
1 Coolant
change every 2 years
2 Fuel check Daily check
check Daily check
3 Engine oil
change every 250 hrs
check Daily check
4 Hydraulic oil
change every 1000 hrs *1
5 Lubrication points - Daily check
6 Radiator and oil cooler check Daily check
7 Engine and electrical wiring check Daily check every year
8 Fuel tank, Fuel filter drain every 50 hrs
9 Battery condition check every 50 hrs
10 Greasing swing bearing teeth - every 50 hrs
11 Fan belt tension adjust every 200 hrs
check every 200 hrs
12 Radiator hoses and clamps
replace every 2 years
clean every 200 hrs *2
Outer element
13 Air filter element replace every 1000 hrs *2 @
Inner element replace every 1000 hrs *2
14 Greasing swing ball bearings - every 200 hrs
15 Fuel filter element replace every 400 hrs @
16 Engine oil filter replace every 250 hrs
18 Hydraulic return filter element replace every 500 hrs
19 Hydraulic suction filter element replace every 1000 hrs
20 Fuel injection nozzle injection check every 1500 hrs *4 @

pressure
21 Front idler and track roller oil change every 2000 hrs
22 Alternator and starter motor check every 2000 hrs
23 Injection pump check every 3000 hrs *4 @
24 Radiator system rinse every 2 years
check every 200 hrs
25 Fuel line and Intake air line @
replace every 2 years *3
First operation
*1 When using a hydraulic breaker, change hydraulic oil and return filter according to the table on "Hydraulic Oil Change
(Including Exchange of the Suction Filter in the Hydraulic Tank) under "EVERY 1000 SERVICE HOURS" in the chapter
"REGULAR CHECKS AND MAINTENANCE WORK".
*2 Clean and replace the air filter more frequently if used under dusty conditions. By heavy soiling, replace the filter.
*3 Replace only if necessary.
*4 Consult your local KUBOTA Dealer for this service.
A The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA non-
road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance
on the engine according to the above instruction. Please see the Warranty Statement in detail.
I-S-13
b. Hydraulic Oil Check for machines with Hydraulic Breakers
The Hydraulic oil change after 1000 operating hours in

the operator’s manual is based on the type of work
done. Following inspection measure are valid when
hydraulic breakers are used:
1. Changing and filling up of hydraulic oil
1) The hydraulic oil must be changed more often
when breakers are used because the machine is
subject to harder conditions than at normal
excavating work.
2) Use only the recommended oils mentioned in
the operator’s manual when changing or fill oil.
3) When filling up oil, never mix oils of different
makes.
2. Changing the return filter and oil
1) The filter must be changed more often because
of contamination resulting from the frequent
assembly and disassembly of the hoses.
2) Use the correct replacement filter.
3) Oil change according to operating hours.
Hydraulic oil Return Filter Suction Filter

Normal excavator work every 1000 Hrs. 500 Hrs.
20% every 800 Hrs.
300 Hrs.
40% every 400 Hrs.
Breaker 1000 Hrs.
work 60% every 300 Hrs.
portion More 100 Hrs.
than every 200 Hrs.
80%
I-S-14
c. EU version
Operator Ser vices
* The services identified with must be carried out at the specified service hours after initial operation.
1.) Under dusty conditions the air filter must be cleaned more frequently or renewed.
2.) When using a hydraulic hammer over 20 % every 800 h. When using a hydraulic hammer over 60 % every 300 h.
When using a hydraulic hammer over 40 % every 400 h. When using a hydraulic hammer over 80 % every 200 h.
3.) When using a hydraulic hammer up to 50 % every 200 h. When using a hydraulic hammer over 50 % every 100 h.
4.) Earlier if necessary.
5.) At least annually.
Servicing by skilled personnel or KUBOTA dealer
I-S-15
F. Specifications
a. Machine Weight
Iron crawler isn’t available for these models.
(1) KE, KDG, KUK version
unit KX36-3 KX41-3S KX41-3V
Canopy Long arm kg 1490 1520 1630
Cabin Long arm kg 1580 1610 1720
(2) PP (KTC, KCL, KTA) version

KX41-3V
kg 1595
4 post Rops Rubber crawler
lbs 3516
Long arm is installed in standard version.
I-S-16
b. Machine specifications
(1) EU version
Unit KX36-3 KX41-3S KX41-3V
Engine
Type Vertical, water-cooled 4 cycle, 3 cylinders diesel
Model D782-BH-3 D902-BH D902-EBH
Output power (ISO3046) kW 9.3/2300 11.6/2300 m
PS 12.6/2300 15.8/2300
Displacement cc 778 898 m
Dimensions
Overall length mm 3670 3665 m
Overall width mm 990 m 1300/994

Overall crawler width mm 990 m 1300/994
Overall height Canopy/cab mm 2283/2283 m m
Min. ground clearance mm 167 158 m
Max. digging depth STD. Arm mm - - -

Long Arm mm 2227 2370 m
Max. digging height STD. Arm mm - - -

Max. digging radius STD. Arm mm - - -

Max. dumping height STD. Arm mm - - -

Swing angle (left/right) deg 73/50 m m
Travel speed Low speed km/h 2.2 2.4 2.2

High speed km/h - 4.3 4.0
Swivel speed rpm 9.1 m m
Max. traction force Low speed kN

kgf
High speed kN
kgf
Performance
Tumbler distance mm 1090 m 1230
Tread mm 760 m 1000
Crawler width × No. of shoe × pitch (Rubber) mm 230 × 32 × 96 230 × 35 × 96 m
Bucket
Capacity CECE heaped m3 0.035 0.04 m
Width mm 402 450 m
Dozer
Width × height mm 990 × 230 m 1300 x 230
Lift above GL / below GL mm 180/193 m 201/205
I-S-17
(2) PP version
KX41-3V
Engine
Vertical, water-cooled 4 cycle, 3 cylinders die-
Type
sel
Model D902-EBH
11.6 kW / 2300 rpm
Gross engine output (SAE J1349)
15.8 PS / 2300 rpm
Displacement 898 cc in3
Dimensions
Overall length 3665 mm 144.3 in
Overall width 1300/994 mm 51.2/39.1 in
Overall crawler width 1300/994 mm 51.2/39.1 in
Canopy 2283 mm 89.9 in
Overall height
Cabin - -
Min. ground clearance 158 mm 6.2 in
Max. digging depth Long (STD). Arm 2370 mm 93.3 in
Max. digging height Long (STD). Arm 3540 mm 139.4 in
Max. digging radius Long (STD). Arm 3910 mm 153.9 in
Max. dumping height Long (STD). Arm 2455 mm 96.7 in
Swing angle (left/right) 73 / 50 m
Low speed 2.3 km/h 1.43 mph

Travel speed
High speed 4.1 km/h 2.55 mph
Swing speed 9.1 rpm
kN
Low speed lbf
kgf
Max. traction force
kN
High speed lbf
kgf
Performance
Tumbler distance 1230 mm 48.4 in
Tread 1000 mm 39.4 in
Crawler width × No. of shoe × pitch
230 mm × 35 × 96 mm 9.01 in × 35 × 3.78 in
(Rubber crawler)
Bucket
Capacity heaped SAE 0.04 m3 0.052 yd3
Width 450 mm 17.7 in
Dozer
Width × height 1300 × 230 mm 51.2 × 9.1
Lift above GL / below GL 201 / 205 mm 7.9 / 8.1 in
Remarks : PP version is for KTC, KCL, and KTA
I-S-18
c. Lever stroke and operating force
Unit KX36-3 (EU) KX41-3S,V (EU) KX41-3V (PP) Remarks
mm 75 ± 10 72 ± 10 Up, Down
Stroke m
in. 3.0 ± 0.4 2.8 ± 0.4 (1)
Boom N 12.7 ± 4.9 13.7 ± 4.9
Up, Down
Force kgf 1.3 ± 0.5 m 1.4 ± 0.5
(1)
lbs 2.9 ± 1.1 3.1 ± 1.1
mm 75 ± 10 72 ± 10 Crowd, Dump
Stroke m
in. 3.0 ± 0.4 2.8 ± 0.4 (1)
Arm N 12.7 ± 4.9 13.7 ± 4.9
Crowd, Dump
Force kgf 1.3 ± 0.5 m 1.4 ± 0.5
(1)
lbs 2.9 ± 1.1 3.1 ± 1.1
mm 75 ± 10 74 ± 10 Crowd, Dump
Stroke m
in. 3.0 ± 0.4 2.9 ± 0.4 (1)
Bucket N 12.7 ± 4.9 13.7 ± 4.9
Crowd, Dump
Force kgf 1.3 ± 0.5 m 1.4 ± 0.5
(1)
lbs 2.9 ± 1.1 3.1 ± 1.1
mm 75 ± 10 74 ± 10 Right, Left
Stroke m
in. 3.0 ± 0.4 2.9 ± 0.4 (1)
Swivel N 12.7 ± 4.9 13.7 ± 4.9
Right, Left
Force kgf 1.3 ± 0.5 m 1.4 ± 0.5
(1)
lbs 2.9 ± 1.1 3.1 ± 1.1
mm 90 ± 10 80 ± 10 F, R
Stroke m
in. 3.5 ± 0.4 3.1 ± 0.4 (1)
Travel N 18.6 ± 4.9 114.7 ± 4.9
F, R
Force kgf 1.9 ± 0.5 m 1.5 ± 0.5
(1)
lbs 4.2 ± 1.1 3.3 ± 1.1
mm 70 ± 10 Up, Down
Stroke m m
in. 2.8 ± 0.4 (1)
Dozer N 20.6 ± 4.9
Up, Down
Force kgf 2.1 ± 0.5 m m
(1)
lbs 4.6 ± 1.1
N 49 ± 9.8 / 39.2 ± 9.8 53.9 ± 14.7 / 44.1 ± 14.7
Up, Down
Acceleration Force kgf 5.0 ± 1.0 / 4.0 ± 1.0 m 5.5 ± 1.5 / 4.5 ± 1.5
(2)
lbs 11.0 ± 2.2 / 8.8 ± 2.2 12.1 ± 3.3 / 9.9 ± 3.3
mm 25 ± 10 23 ± 10
Stroke m
in. 1.0 ± 0.4 0.91 ± 0.4
Swing pedal N 47.0 ± 9.8 39.2 ± 9.8
Force kgf 4.8 ± 1.0 m 4.0 ± 1.0 R, L
lbs 10.6 ± 2.2 8.8 ± 2.2
N 11.8 ± 9.8 / 33.3 ± 9.8
Safety lock lever (Left) Force kgf 1.2 ± 1.0 / 3.4 ± 1.0 m m Up, Down
lbs 2.64 ± 2.2 / 7.48 ± 2.2
N 4.9 ± 2.0 / 4.9 ± 2.0
Safety lock lever (Right) Force kgf 0.5 ± 0.2 / 0.5 ± 0.2 m m Up, Down
lbs 1.1 ± 0.4 / 1.1 ± 0.4
mm 15 ± 10
Stroke m m
in. 0.6 ± 0.4
Service port pedal N 62.7 ± 10 49.0 ± 10
Force kgf 6.4 ± 1.0 m 5.0 ± 1.0 R, L
lbs 14.1 ± 2.2 11.0 ± 2.2
(1) Measured at 20 mm lower from grip tip.

(2) Measured at 30 mm lower from grip tip.
I-S-19
d. Dimensions of Parts
(1) Front pins
No. Unit KX36-3 (EU) KX41-3S, V (EU) KX41-3V (PP) Remarks
mm 35 × 160
1 Pin diameter × length m m
in. 1.38 × 6.30
mm 35 × 257
in. 1.38 × 10.1
mm 35 × 160
in. 1.38 × 6.30
mm 30 × 118
in. 1.18 × 4.65
mm 30 × 86.5
in. 1.18 × 3.41
mm 50 × 109
in. 1.97 × 4.29
mm 50 × 109
in. 1.18 × 6.30
Service limit
mm 30 × 160
8 Pin diameter × length m m Pin dia : 1.0 mm
in. 1.18 × 5.59
(0.04 in)
mm 30 × 142
in. 1.18 × 7.52
mm 30 × 191
in. 1.18 × 5.59
mm 30 × 142
in. 1.18 × 7.19
mm 30 × 182.5
in. 1.18 × 7.19
mm 30 × 182.5
in. 1.18 × 7.19
mm 25 × 169 30 × 181
14 Pin diameter × length m
in. 0.98 × 6.65 1.18 x 7.13
mm 25 × 169 30 × 181
15 Pin diameter × length m
in. 0.98 ×6.65 1.18 x 7.13
O.D.
Length
O.D.
Length
New pin tolerance : 25I -0.05

0.07 , 30I -0.08 , 35I -0.08
- -
0.05 -
0.05
-0.002 -0.002 -
(0.98 -0.003 , 1.18 -0.003 , 1.37 -0.002
0.003 )
Material : S43C-D, S45C-D

Effective hard depth : 2 ~ 4 mm (0.08 ~ 0.16in.)
Surface hardness : HRC52 ~ 59HRC
I-S-20
(2) Bush Dimansion
Outer dia. × inner dia. × width
No. Unit Remarks
KX36-3 (EU) KX41-3S, V (EU) KX41-3V (pp)
mm 43 × 35 × 48
1 m m
in. 1.69 x 1.38 x 1.89
mm 43 × 35 × 32
1 m m
in. 1.69 x 1.38 x 1.26
mm 45 × 35 × 35
2 m m
in. 1.77 x 1.38 x 1.38
mm 60 × 50 × 37
6, 7 m m
in. 2.36 x 1.97 x 1.46
mm 60 × 50 × 23
6, 7 m m Service limit
in. 2.36 x 1.97 x 0.91
bush inner dia :
mm +1 mm (0.04 in)
9, 10
in.
mm 38 × 30 × 40
12 m m
in. 1.50 x 1.18 x 1.57
mm
13
in.
mm
14
in.
mm
15
in.
material : Normalizing, Hardness 170 to 229 HB
Surface treatment : Induction hardening & tempering

Effective case depth : 1 ~ 2 mm (0.04 ~ 0.08 in.)
Surface hardness : HRC52 ~ 59
I-S-21
(3) Track toller, idler, sprocket
Unit KX36-3 (EU) KX41-3S, V (EU) KX41-3V (PP) Remarks
mm 23 / 20
A : Guide width (A)/(B) m m
in 0.91 / 0.79
mm 80 / 76
B : Outer diameter (A)/(B) m m
in 3.15 / 2.99
mm 135 /
C : Roller width (A)/(B) m m
in 1.38 /
mm 15 /
D : Guide Hight (A)/(B) m
in 0.59 /
mm
E : Upper roller diameter (A)/(B) - - -
in
mm 10 /
F : Sliding plate thickness (A)/(B) m m
in 0.39 /
C (A)New machine reference value

(B)Allowable limit
D
A B

mm 202 / 196
1) Idler O.D. (A)/(B) m m
in 7.52 / 7.72
mm 27 / 23
2) Guide width (A)/(B) m m
in 1.06 / 0.91
mm 60 / 55
3) Idler width (A)/(B) m m
in 2.36 / 2.17
mm 290 / 284
4) Sprocket wheel O.D.. (A)/(B) m m
in 11.4 / 11.2
mm 23 / 18
5) Sprocket wheel width (A)/(B) m m
in 0.91 / 0.71
mm 19
6) Number of theeth
in 0.75
3) (A)New machine reference value

(B)Allowable limit
5)
6)
1)
4)
2)
I-S-22
(4) Dozer
Assy code No RG038-74511 RG138-7441 RB238-7441
mm 30 × 93
A : Pin diameter × length m m
in 1.18 x 3.66
mm 30 × 93
B : Pin diameter × length m m
in 1.18 x 3.66
mm 30 × 75
C : Pin diameter × length m m
in 1.18 x 2.95
mm 990 990 / 1300
D : Dozer width m
in 39.0 39.0 / 51.2
mm 225.5 277
E : Dozer height m
in 8.88 10.9
mm 624 662
F : Dozer length m
in 24.6 26.1
mm
G : Dozer tip plate height × thickness -
in
mm 434
H : Length between dozer arm center m m
in 17.1
mm 155
I : Extension blade length - m
in 6.10
mm 25 × 135
J : Pin diameter × length m m
in 0.98 x 5.31
Pin dia. service limit : -1 mm (0.04 in.)
C B
H
F
E
D
I-S-23
(5) Bucket
1) Bucket dimensions
No. Unit KX36-3 (EU) KX41-3S, V (EU) KX41-3V (PP) Remarks
mm 600 650
1
in. 23.6 25.6
mm 624 674
2
in. 24.6 25.6
mm 101.6 × t0.5
3 m
in. 4.00 × t0.33
mm 204 215
4
in. 8.03 8.46
mm 134 145
5
in. 5.28 5.71
mm 12 16
6
in. 0.47 0.63
mm 35
7 m
in. 1.38
mm 67 72.5
8
in. 2.64 2.85
mm 83
9
in. 2.95 3.27
mm 100
10
in. 3.54 3.94
mm 40 45
11
in. 1.57 1.77
mm 40 45
12
in. 1.57 1.77
mm 670 725
13
in. 26.4 28.5
mm 617 652
14
in. 24.3 25.7
mm 89 113
15
in. 3.50 4.45
mm 175 150
16
in. 6.89 5.91
mm 180 230
17
in. 7.09 9.06
mm 10 20
18
in. 0.39 0.79
NOTE: KUBOTA JAPAN BUCKET
I-S-24
(6) Arm
f
l g
c e
a b
C E
k
B
A D
i m
j h
mm (inch)
KX36-3 (EU) KX41-3S, V (EU) KX41-3V (US)

A 38 +0.025 (1.50 +0.001 ) m m
Arm boss inner dia.
0 0
B 38 +0.025
0 (1.50 +0.001
0 ) m m
C 30 +0.10
+0.05 (1.18 +0.004
+0.002 ) m m
D 38 +0.025
0 (1.50 +0.001
0 ) m m
E 30 +0.10 (1.18 +0.004 m m
+0.05 +0.002 )
a 95.5 -0.3
-
(3.76 -0.01
-
m m
0.5 0.02 )
b -
125.5 -0.15 0.006 -
m m
0.30 (4.94 -0.012 )
c 137 ± 0.5 (5.39 ± 0.02) m m

d 116 -0.2
- 0.008 -
m m
0.5 (4.57 -0.02 )
e 137 ± 0.5 (5.39 ± 0.02) m m

Arm boss width
f 735 ± 1 (28.9 ± 0.04) 125.7 ± 1 (4.95 ± 0.04) m

g 368.5 (14.5) 522 (20.6) m
h 153 ± 1 (6.02 ± 0.04) 157 ± 1 (6.18 ± 0.04) m
i 85 ± 1 (3.35 ± 0.04) m m
j 950 ± 2 (37.5 ± 0.08) 1100 ± 2 (43.3 ± 0.08) m
k 122.5 ± 1 (4.82 ± 0.04) m m
l 735 ± 1 (28.9 ± 0.04) m
m 1015 (40.0) m
nl
I-S-25
(7) Parts weight
Pilot valve kg 1.9 1.9 2.0
lbs 4.2 4.2 4.4
Track frame, side kg - 70 71.2
lbs 154 157.0
Track frame, center kg 148.9 87 84
lbs 328.3 192 185.2
Swivel frame kg 188 186 180
lbs 414.5 410 396.8
Swing bracket kg 28 28.0 29.8
lbs 61.7 61.7 65.7
Boom kg 64 64 63.9
lbs 141.1 141 140.9
Arm (1600) kg 35.0 35.0 36.7
lbs 77.0 77.0 80.9
Bucket kg 77 28 local content
lbs 59.5 61.7
Dozer (1700) kg 42 42 60 59.9
lbs 92.6 92.6 132.2 132.1
Protector (left) kg 24.5 m 30
lbs 54 66.1
Protector (right) kg 23.8 m 30.3
lbs 52.5 66.8
Protector (rear) kg 29.2 m 30.3
lbs 64.4 66.8
Rubber crawler kg 47 47 52 49.3
lbs 103.6 103.6 114.6 108.7
Iron crawler kg - - -
lbs
Arch kg 24 24 23
lbs 52.9 52.9 50.7
Engine kg 64 72 m Dry condition
lbs 141 159
Hydraulic tank kg 13.6 m 16
lbs 30.0 35.3
Fuel tank kg 2.9 m m
lbs 6.4
Swivel bearing kg 37 m 16.7
lbs 81.6 36.8
Battery with electrolite kg 14 m 17.0
lbs 30.9 37.5
Track roller kg 4.3 m m
lbs 9.5
Upper roller kg - - -
lbs
Rops/Fops canopy kg 62.4 62.0 62.7
lbs 137.6 136.7 138.2
Rops/Fops cabin kg 167 m -
lbs 368.2
Pump kg 13 m m
lbs 28.7
I-S-26
Traveling motor kg 17 m m
lbs 37.5
Swivel motor kg 15 m m
lbs 33.1
Swivel frame cover, L kg 8.4 m 7.95
lbs 18.5 17.5
Swivel frame cover, R kg 6.8 m 6.55
lbs 15.0 14.4
Pump housing kg 5.9 m m
lbs 13.0
Rear bonnet kg 7.7 m 8.5
lbs 17.0 18.7
Rubber mat kg 2.7 m 23
lbs 6.0 5.1
Unload valve kg 3.7 5.2 1.3
lbs 8.2 11.5 2.9
Sprocket 4.5 m 4.6
9.9 10.1
Idler assy 17.8 m m
39.2
Control valve without adaptor kg 14 m m
lbs 30.9
Boom cylinder kg 11.6 m 14.5 With protector
lbs 25.6 32.0
Arm cylinder kg 10 11 11.5
lbs 22.0 24.3 25.4
Bucket cylinder kg 9 10.2 10.5
lbs 19.8 22.5 23.1
Swing cylinder kg 9.5 m 9.4
lbs 20.7
Dozer cylinder kg 7.3 m 7.4
lbs 20.9 16.3
Rotary joint kg 12.6 m 12.7
lbs 27.8 28.0
Track cylinder kg - 8.6 8.2
lbs 19.0 18.1
The weights listed above is mostly based on calculations and slightly different from actual ones.
I-S-27
(8) Water and Oil Quantity
L 2.7 / 2.9 2.7 / -
Radiator Canopy / Cab m
US gal 0.71 / 0.77 0.71 / - Kubota LLC-N-50F
L 0.56 50%
Reserve tank m m
US gal 0.15
L 2.6 3.6
Engine Crank case m SAE10W30(CD)
US gal 0.69 0.95
L 27
Hydraulic oil Full m m ISO 46
US gal 7.1
L 14
Hydraulic oil Tank m m ISO 46
US gal 3.7
L 0.25
Wheel motor m m SAE90 (API GL-4)
US gal 0.07
cc 40
Track roller m m SAE30(CD)
US gal 0.01
cc
Upper roller - - - SAE30(CD)
US gal
cc 30
Front idler m m SAE30(CD)
US gal 0.01
L 19
Fuel tank m m
US gal 5.1
(9) Rubber crawler

Unit KX36-3, 41-3(EU) KX41-3V(EU) KX41-3V(PP) Remarks
Crawler assy code No. RG038-22321 RB238-22310
Identification mark 230 × 32 × 96 230 × 35 × 96
m
(Core steel rapping position) (f) (f)
mm 25 23
A : Lug height m
in 0.98 0.91
mm 24.5 26.5
B : Link height m
in 0.96 1.04
mm 230
C : Crawler width m m
in 9.06
mm 10 ~ 15
D : Crawler sag distance m m
in 0.39 ~ 0.59
mm 74.5 72.5
E : Crawler height m
in 2.93 2.85
Number of Core Iron 32 35 m FCD450T
Rubber crawler center round mm 3072 ± 10 3360 ± 10
m
length in 120.9 ± 0.39 132.3 ± 0.39
mm 96
Core Iron pitch m m
in 3.78
mm 25.0 / 28.5 23.0 / 26.5
Rubber thickness m
in 0.98 / 1.12 0.91 / 1.04
I-S-28
(10)Product inspection specifications : KBM products to EU-version
Nr. Inspection KX36-3 KX41-3S, V
1 ( stroke ) lever boom lifting 65 - 85 mm ditto
2 ( stroke ) " down 65 - 85 mm ditto
3 ( stroke ) lever arm crowd / dump 65 - 85 mm ditto
4 ( stroke ) lever bucket " " 65 - 85 mm ditto
5 ( stroke ) lever swing lh / rh 65 - 85 mm ditto
6 ( stroke ) lever dozer up / down 60 - 80 mm ditto
7 ( stroke ) speed levers lh/rh 80 - 100 mm ditto
8 clearance lh/rh-knob steering lever (inside) 511 ± 10 mm ditto
9 ( clearance ) lever dozer 10 - 21 mm ditto
10 ( clearance ) lever Boom/Bucket < 2mm ditto
11 ( clearance ) lever arm/swivel < 2mm ditto
12 ( clearance ) speed levers lh / rh 5 - 20 mm ditto
13 Clearance between the speed levers 5 - 20 mm ditto
14 parallel offset speed lever speed lever forward / backwards < 5 mm 5mm/15mm
15 Max. rpm w/o loading < 2600 rpm ditto
16 load rpm with1 pump > 2300 rpm ditto
17 Load rpm with 2 pumps > 2300 rpm ditto
18 Load rpm with 3 pumps > 2300 rpm ditto
19 Engine stop - with 3 pumps load kein Stopp
20 Idle speed ( measurement ) 1200 - 1350 rpm ditto
21 Accumulator - function checkedauf Funktion überprüfen > 3 min ditto
22 P1 load pressure ( bucket ) bar a1 206 -5
+10
a1 216 -5
+10
23 P2 load pressure ( arm ) bar a2 206 -5

+10
a2 216 -5
+10
24 P3 load pressure ( dozer ) bar a2 201 -5

+10
a3 206 -5
+10
25 Primary pressure ( P 4 ) +A3/B5

39 -0 bar
+A3/B5
39 -0 bar
26 ( control force ) lever boom up 0,8 - 1,80 kg ditto
27 " ( handhold-middle ) " down 0,8 - 1,80 kg ditto
28 " lever arml crowd/dump 0,8 - 1,80 kg ditto
29 " lever bucket dump / crowd 0,8 - 1,80 kg ditto
30 " rotation lever ( lh / rh ) 0,8 - 1,80 kg ditto
31 " lever dozer up / down 1,6 - 2,6 kg ditto
32 " speed lever lh / rh 1,4 - 2,4 kg ditto
33 Speed lever idle-max 4,0 - 6,0 kg ditto
34 Speed lever max - idle 3,0 - 5,0 kg
35 Ratched lever (top/down) 1,0 - 5,0 1,0 - 3,0
Canopy rh. 3,0 - 7,0 2,4 - 4,4
36 cushion time boom up ( 50 °C ) 0,4 - 1,3 s. 0,4 - 1,3 s.
37 Speed boom up (until cushion) 2,3 - 2,9 s. 2,0 - 2,6 s.
38 " down ( ground ) 2,8 - 3,4 s. 2,7 - 3,3 s.
39 " arm crowd 2,8 - 3,4 s. 3,1 - 3,7 s.
40 " arm dump 1,9 - 2,5 s. 2,1 - 2,7 s.
41 ( Speed. ) bucket crowd 2,1 - 2,7 s. 2,5 - 3,1 s.
42 ( Speed ) bucket dump 1,6 - 2,2 s. 1,7 - 2,3 s.
43 Swivel speed ( 3 rotations ) lh / rh 17,8 - 21.8 s. 17,8 - 21,8 s.
44 Starting speed swivel 1,9 - 2,3 s. 1,9 - 2,3 s.
I-S-29
Nr. Inspection KX36-3 KX41-3S, V
45 Speed swing lh ( until the stopper ) 4,4- 5,0 s. 4,3- 4,9 s.
46 Speed swing rh 3,7 - 4,3 s. 3,6 - 4,2 s.
47 Speed dozer ( full stroke ) up 1,0 - 1,6 s. 1,0 - 1,6 s.
48 " ( full stroke ) down 1,4 - 2,0 s. 1,4 - 2,0 s.
49 1.speed rubber crawler 2,2 ± 0,2 km/h (10 m) 15 - 18 s. ditto
50 2. speed rubber crawler 4,0kh/h ± 0,4 (10m) --------- 8,1-9,9s.
51 straight travel1. speed ( forwards / backwards ) ( 10 m ) < 600 mm ditto
52 straight travel 1. speed with dozer < 600 mm ditto
53 Impermeability boomcyl. ( 10 min ) 0,035 m3 63 kg < 15 mm ditto
54 " ( 10 min ) armcyl. 50 ± 5 °C < 10 mm ditto
55 " ( 10 min ) bucketcyl. < 4 mm ditto
56 Dozercyl. ( machine up dozer front ) < 13 mm ditto
57 Clearancel of the mounting Nut -> Front parts < 1 mm ditto
58 Parallelism of the crawler ( front / rear ) < 10 mm ditto
59 Crawler tension ( rubber / steel ) 10 - 15 mm ditto
60 Distance roller guides / joint ( lh/rh ) iron > 2 mm ditto
61 Offset crawler edge / dozer edge ± 10 mm ditto
62 crawler shoe width / 230 mm / ditto
63 Arm-break at dump 1500 rpm/63 kg/72kg no / 0 mm ditto
64 Incline of the dozers at the ground < 10mm ditto
65 vertical reference line of the machineat the front part < 10mm ditto
66 clearance sideward from the end of the bucket < 73 mm 53 - 73 mm
67 Distance Boom / Bucket-teeth 62
+34
-16 mm
+34
167 -16 mm
68 clearance bonnet / arch 5-10 / h2 mm ditto
69 Distance - weight / protector 4-10 / h3 mm ditto
70 Distance fan / radiator 38 ± 10 mm ditto
71 Distance fan / protector > 10 mm ditto
72 Distance between muffler pipe and weight hole > 20 mm middle
73 Tension of fan belt 7-13 mm / 5 kg ditto
74 Routing of breather and suction cooling hoses no kink ditto
75 Collision / Twist of fuel piping no ditto
76 Collision electrical wiring no ditto
77 Cooling fluid anti-freeze - 40 ±5
°C ditto
78 Hyd. oil qty: boom down / Arm crowd Tank 14,5l ± 0,7 ditto
79 Bucket close / dozer at ground Glas 1/2 - 3/4 ditto
80 Travel motor 0,25 l filler plug ditto
81 Tightening torque travel motor 60,8 - 70,6 Nm ditto
82 Sealing of track rollers and idlers i.O. ditto
83 Cross routing R / J ~ travel and dozer hoses no ditto
84 Mounting of control box (looseness) i.O. ditto
85 Fuse (reserve) 1x15A, 1x10A, 1x5A, 1x20A ok ditto
86 Battery fluid qty / density > 1,26 kg / dm3 ditto
87 Battery mounting (grease at terminals) i.O. ditto
88 Noise at operator's ear (canopy 4P) < 78 dB ditto
89 Noise at operator's ear (cabin) 78 +2 dB < 78 dB
I-S-30
II.Machine Body
A.Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3
a. Pin, bush and shim installation . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3
b. Instruction to press in the bushing . . . . . . . . . . . . . . . . . . . . . . . . II-S-8
c. Greasing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-13
B.Upper Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-16
a. Swivel bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-16
b. Travel lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-17
c. Accelarator lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-19
d. Dozer lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-21
e. Swing & SP pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-23
f. Control valve links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-25
g. Limit switch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-26
h. Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-27
C.Undercarrige . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-28
a. Track tension device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-28
b. Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-30
II-S-1
II-S-2
A.Front attachment
a. Pin, bush and shim installation
(1) Swing cylinder, swing bracket, boom
52 51
53 50
43 42 41 40
72 71 70
60
61 62
21
22
20
23 24
Swing bracket - swivel frame

Code No. Q’ty Part No. Remarks 12
RG1386645 2 Pin 10 I50
13
RG1386639 2 Bush 11 506037
35 34
RG1386638 2 Bush 12 506028
11
RG1384113 2 Bush 13 506040
30 32 10
0117361204 2 Bolt 14
0257250120 2 Nut 15
14 15
Swing bracket - boom cylinder
Code No. Q’ty Part No. Remarks
RG1386664 1 Pin 20 I35
RG1386659 1 Bush 21 354332 31 33 36
RG1386637 1 Bush 22 354348
0117361080 1 Bolt 23
Swing bracket - Swing cylinder
0257450100 1 Nut 24
Swing bracket - boom RG1386744 1 Pin 50 I30
RG1386745 1 Key plate 51
0113361016 1 Bolt 52
RG1386656 1 Pin 30 I35 0541100825 1 Spring pin 53
RG1386646 2 Bush 31 354535
RB2376657 1 Bush 32 354344
RB2376658 1 Bush 33 354344 Boom - boom cylinder
0117361204 1 Bolt 34 Code No. Q’ty Part No. Remarks
0257450100 1 Nut 35 RG1386664 1 Pin 60 I35
0661115010E 1 Grease nipple 36 0117361080 2 Bolt 61
0257450100 1 Nut 62
Swing bracket - Swing cylinder
Boom - arm cylinder
RG1386746 1 Pin 40 I30 Code No. Q’ty Part No. Remarks
0113361020 1 Bolt 41 RG1386654 1 Pin 70 I30
691816644 1 Spacer 42 0117361080 2 Bolt 71
RG2012179 1 Washer 43 0257450100 1 Nut 72
II-S-3
(2) Arm, bucket link
114 111
125 124 123 90
121 92 91
100
126
122 102 101
110
120
112113
133 132 83 82 81
131 130
134
80 84
146 140
142
145 144 143 141
Arm - bucket
Boom - arm Code No. Q’ty Part No. Remarks
Code No. Q’ty Part No. Remarks RG1386676 1 Pin 120 I30 KX41-3
RG1386663 1 Pin 80 I30 694216691 1 Pin 120 I25 KX36-3
687216652 2 Bush 81 303835 694216652 2 Bush 121 303835 KX41-3
0117361080 1 Bolt 82 RG0386674 2 Bush 121 303835 KX36-3
0257450100 1 Nut 83 RA1116733 2 Dust seal 122 KX41-3
0661115010E 1 Grease nipple 84 RB1376733 2 Dust seal 122 KX36-3
0113361225 1 Bolt 123
Arm - arm cylinder
0401560120 1 Plain washer 124
Code No. Q’ty Part No. Remarks 694416692 1 Spacer 125
RG1386665 1 Pin 90 I30 0661115010E 1 Grease nipple 126
0117361065 1 Bolt 91
0257450100 1 Nut 92 Bucket link1 - link2, 3
Arm - bucket cylinder RG1386677 1 Pin 130 I30
Code No. Q’ty Part No. Remarks RG1386678 2 Bush 131 303840
RG1386665 1 Pin 100 I30 0117361080 1 Bolt 132
0117361065 1 Bolt 101 0211860100 2 Nut 133
0257450100 1 Nut 102 0661115010E 1 Grease nipple 134
Bucket link1 - bucket

Arm - bucket link2, 3
RG1386676 1 Pin 140 I30 KX41-3
RG1386675 1 Pin 110 I30
694216691 1 Pin 140 I25 KX36-3
694216652 2 Bush 111 303835
694216652 2 Bush 141 303835 KX41-3
0117361080 1 Bolt 112
RG0386674 2 Bush 141 303835 KX36-3
0211860100 2 Nut 113
RA1116733 2 Dust seal 142 KX41-3
0661115010E 1 Grease nipple 114
RB1376733 2 Dust seal 142 KX36-3
0113361225 1 Bolt 143
0401560120 1 Plain washer 144
694416692 1 Spacer 145
0661115010E 1 Grease nipple 146
II-S-4
(3) Blade, blade cylinder and truck cylinder
153 152 151 150 154
170
171172173
160 181182
163 162 161 180
191 192 190
Truck frame - blade Truck frame - truck cylinder

Code No. Q’ty Part No. Remarks Code No. Q’ty Part No. Remarks
RG1088905 2 Pin 150 I30 RG1088812 2 Pin 180 I30
0113361020 2 Bolt 151 691912129 2 Bolt (Stopper) 181
RG2016686 2 Collar 152 0451260120E 2 Washer 182
RG2012179 2 Washer 153
0661625010 2 Grease nipple 154 Blade - extention blade
Truck frame - blade cylinder
RG1387747 2 Pin 190 I25
0552551000 2 Split pin 191
RG1387446 1 Pin 160 I30 RG1088948 2 Pin 192
0113361020 1 Bolt 161
RG2016686 1 Collar 162
RG2012179 1 Washer 163
Blade - blade cylinder

RG1387446 1 Pin 170 I30
0113361020 1 Bolt 171
RG2016686 1 Collar 172
RG2012179 1 Washer 173
II-S-5
154
153 152 151 150
160 161162163
Truck frame - blade

RG1088905 2 Pin 150 I30
0113361020 2 Bolt 151
RG2016686 2 Collar 152
RG2012179 2 Washer 153
0661625010 2 Grease nipple 154
Truck frame - blade cylinder

RG1387446 1 Pin 160 I30
0113361020 1 Bolt 161
RG2016686 1 Collar 162
RG2012179 1 Washer 163
II-S-6
(4) Clearance adjustment
(1)
(6)
(7) (2)
(8)
(3)
(9)
(4)
(5)
(1) 68721-6697 Shim (0.5, 60-31) SPCC 1. Front Play 0.6 mm max.
68051-6633 Shim (1.0, 60-31) SPCC Selective use * Pin on fulcrum * If the play exceeds 0.6
68051-6634 Shim (1.6, 60-31) SPCC Thrust direction mm, add some shims
* Insert a number of shims according to the clearance on the Clearance and make adjustments.
swing cyl bottom side. (Use the shims shown in
the illustration.)
(2) 68741-6686 Shim (1.0, 60-36) SPCC
68741-6687 Shim (1.6, 60-36) SPCC }
Selective use 2. Vertical clearance
between swivel frame
+ 0.3 ~ +1.3 mm
(3) RG138-6644 Thrust collar (2.3, 92-51) SK5M and swing bracket.
* Refer to the mounting method of thrust collar. 3. Use the shim and
(4) RG138-6644 Thrust collar (2.3, 92-51) SK5M thrust collar selec-
RG138-6649 Thrust collar (2.5, 92-51) SK5M

}
RG138-6648 Thrust collar (2.0, 92-51) SK5M Selective use tively with each part.
4. Installation of thrust Apply grease on both sur-
* Refer to the mounting method of thrust collar. collar face.
(5) RG246-6762 Shim (0.5, 70-36) SPCC
(6) 68741-6686 Shim (1.0, 60-36) SPCC
68741-6687 Shim (1.6, 60-36) SPCC } Selective use Apply grease
(7) 68741-6686 Shim (1.0, 60-36) SPCC

68741-6687 Shim (1.6, 60-36) SPCC } Selective use
(8) 68741-6686 Shim (1.0, 60-36) SPCC
(9) 68741-6686 Shim (1.0, 60-36) SPCC
II-S-7
b. Instruction to press in the bushing
(1) Bush installation steps
Part where bushing and dust seal are inserted. 1. Bushing insertion Insert the bushing by using an
(Completed assembly with bushing press-fit is excluded.) appropriate steel plate.
* Do not directly hit the bushing.
2. Bushing insertion 1) If no dust seals are used,
dimension check that the bushing does
(2) not protrude from either side.
(2) 2) Maintain room for a dust seal
on each side if it is used.
(2) (Only the dimension manage-
(1) (1) ment of the press-fit direction
(1) Both bushing and dust seal can be enough.)
(2) Only bushings 3. Dust seal mounting Mount as shown in the illustration.
direction
4. Bushing insertion Insert the bushing from the 15°
direction chamfer side.
(2) Installing direction of dust seal

Bush Dust Seal Install the dust seals in the direction as shown
at left. If in the wrong direction, the sealing
effect is adversely affected, which may get the
pins worn out earlier.
(Enlarged view of dust seal)
OutSide
Toward the Bushing
Press in Jig
Bush
Bush
Dust seal 3 5 5 3 Dust seal

15 15
5
0.
C
Bush direction Bush direction

5
0.
C
II-S-8
(3) Installation of thrust collar on the swing bracket
Thrust collar
1. Install the thrust collar, with its grooved face downward, on top of the swivel frame.
2. Select and install a 0.5 or 1.0 mm(0.02 ~ 0.04”) thick shim to have the clearance smaller than 0.5
mm(0.02”).
Thrust collar
090 : 2.3 mm
095 : 2.3, 2.0, 2.5 selective
Shim
200 : 0.5, 1.0, 1.6 selective
II-S-9
(4) Swing bracket pin & bush.
(1)
(1) Attention to the bush driving direction (align the holes). Make
sure later that the shaft goes through smoothly.
(2) Keep flush with the end face.
(3) Keep the collar upward.
(4) Attention to the bush driving direction (align the holes). Make
sure later that the shaft goes through smoothly.
(2)

(3)
(4)

(2) Bush
Dust seal
Collar
(3)
Specifications, New pin and bushing

[ Unit : mm]
Model KX008-3, U10-3 KX36-3, KX41-3S, V U20-3, U25-3 Remarks
Pin outer dia. o 35 --0.05 o 50 --0.05 o 60 --0.05
0.08 0.08 0.08
Pin material S45C-D, S43C-D m m

Bush inner dia. 35 +0.07
+0.04 50 +0.07
+0.04 60 +0.07
+0.04
Bush outer dia. 43 +0.09

+0.06 60 +0.09
+0.06 72 +0.09
+0.06
Bush material STKM16A

S43C m m
S45C
Thrust washer, shims thickness Thrust collar Thrust collar
: 2.0, 2.3, 2.5 : 2.8, 3.2
Shim : 0.5, 1.0, 1.6 Shim : 0.5, 1.0, 1.6
Swing bracket material FCD500-7 m
Test pin, to go through smoothly - o 49.95 -
pin : High frequency induction surface hardening/

Effective hardened depth : 2 ~ 4mm
Surface hardness : 52 ~ 59 HRC
Diameter value is for single part before installation.
II-S-10
(5) Measuring the swing bracket looseness
Set a dial gauge as shown below and note the height of the pointer. Lift the machine front until the swing
bracket tilts to maximum frontward. Now set the dial gauge reading to zero.
Next move the boom and arm until the swing bracket tilts to maximum backward. Now take the dial
gauge reading.
There is no specifications yet. This measuring data is just for your reference.
Swing bracket looseness measuring procedure photos
II-S-11
(6) Service tip to ease customer complain
Front slaggishness caused by pin-bushing worn-out largely depends on the following facters.
1. Maintenance: Daily maintenance, frequent applying of grease to renew, proper type of

grease.
2. Attachment installed: Weight of front attachment more than expected affects the excessive wear
of pin and bushing.
3. Application and operation:Heavy load digging operation and high rate of vibration work, such as
breaker also causes the abrasive wear than ordinary digging work.
4. Job site and strage: Dust, sand, moisture, salt or chemical acid accelerate the surface abrasive
and corrosion.
5. Total operation hours: Operating hour is the basic factor to evaluate the wear. Bushing wear-
curve is basically depended on the operation hours. And varies one by one
according to the ratio of oparating condition, attachment weight, applica-
tion and maintenance level mentioned-above.
6. Service limit: Allowable service limit to all pins and bushings is 1.0mm wear from the
new diameter size.
II-S-12
c. Greasing points
1) Keep applying grease until it comes out of the circumference at the
A-type: Straight type
other end surface of each rotating part.
(06611-15010)
2) Apply grease to the end surfaces of all the rotating parts and their
related shims.
B-type: 67°C
(06616-25010)
C-type: 90°C
(06616-35010)
(1)
(2) (3) (4)
(5)
(5)
(4) (5)
(3) (5) (8)
(5)
(6)
(5)
(6)
(6)
(5)
(7)
(1) View from the front (5) A - type (Boss - greasing)

(2) Swing cylinder, bottom (6) A - type (Pin - greasing)
(3) Swivel bearing, ball (7) B - type (Boss - greasing)
(4) Swivel bearing, teeth (8) C - type (Boss - greasing)
II-S-13
(5)
(7)
(7) (7)
(5) A - type (Boss - greasing) (7) B - type (Boss - greasing)
II-S-14
1 4 5
Q’ty 1. Stopper and bolt tight- 77.2 ~ 90.2 N·m

(1) Frame (Truck, center) 1 ening torque. (7.9 ~ 9.2 kgf·m)
* Screw tightening agent
(2) Frame (Truck, L) 1 applied (LockTight 271)
(3) Frame (Truck, R) 1
2. Coupling truck frames Apply grease to the right
(4) Bolt, stopper 4 left and right and truck and left circumferences of
frame center. the track frames.
(5) Spring washer 4
(6) Apply grease on all surfaces of truck frame
L & R as shown by hatching lines.
II-S-15
B.Upper Structure
a. Swivel bearing
(1)
3
1
(2)
2
Upper angle 10 (5)
Front
Ｓ
A (6)
Direction of adapter
Swing Ball Teeth (swing cylinder)
(view right side og machine)
(4)
(3)
(1) Machine rear

(2) Marked “S“ (Soft zone of inside gear)
(3) Machine front
(4) Grease supply port (Must be faced to the
swivel frame hole)
(5) The ball inlet (Soft zone of outer race)
(6) Greace supply to teeth
1. Innerring soft zone: S mark.

• Set “S” mark at its right position.
2. Outer-ring soft zone: Ball inlet
• This soft zone should be at its left sode.
3. Align the grease nipple hole of the swivel frame with the nipple on the bearing.
A 4. Swivel Bearing Tightening
• Apply Locktite #271 on the bolts.
• Tightening torque: 103 ~ 117.7 N·m
10.5 ~ 12 kgf·m
75.9 ~ 86.8 ft·lbs
• Apply grease to the entire surface of the bearing teeth uniformly.
• Mounting bolts: Truck frame side, 01138-51230, 18 pcs
Swivel frame side, 01138-51230, 19 pcs
II-S-16
b. Travel lever
(2)
1. Adjustments of Mount the levers Improper position
lever to neutral as shown in the p
(6) position illustration. Improper control
(3) Mounting direc-
tion and angle
(1)
2. Travel lever The levers must Improper return
rotation return to the neu- p
tral position Improper action
promptly after
operation.
(4) 3. Travel lever Levers not aligned
adjustments p
1) Forward/ o 5 mm (max.) Contact between
Backward (0.2 in) levers
(5) tolerance of Improper action
left and right
levers
2) Clearance of o 5 ~ 25 mm (EU)
left and right 5 ~ 14 mm (KTC)
levers (0.2 ~ 0.55 in)
4. Grip mounting Mount the grips Improper assem-
Mounting direc- securely. bly
tion and angle The grips must be p
in backward/for- Grips rotate
ward directions.
5. Check items The valve spool Improper action
after mounting must operate full p
stroke. Increase in
The valve spool required opera-
must operate tional power
smoothly.
Adjust the traveling lever as shown below table.

No. Items Dimensions Remarks
(1) Gap between left and right lever to longitudinal direction. under 5 mm
under 0.2 in
(2) Clearance between left and right lever. 15 ~ 25 mm(EU), 5 ~ 14 mm(KTC)
0.43 ~ 0.67 in(EU), 0.2 ~ 0.55 in
(3) Distance beween bracket front end and newtral position center of 180 mm
Reference valve
Traveling lever grip. 7.09 in
(4) Travel lever, L
(5) Travel lever, R
(6) Grip
(7) Check points after assembly : Control valve spool should smoothly shift to full stroke.
II-S-17
(8) Apply grease on bearing, DU - bushing.
Rotating parts should function smoothly.
EU - type
(5) Lever (Traveling, left) 1
(6) Lever (Traveling, left 3) 1
(7) Pin, spring 2
(8) Lever (Traveling, right) 1
(9) Bearing, needle 2
(10) Bolt 4 (MB 7T)
(11) Nut 4 (MB 4T)
(12) Shaft, traveling
(13) Washer, plain

(28) Bearing, ball
(29) Bush
PP - type
(1) Clearance: 0.3 mm or less

(2) Bolt @ torque: 23.5 ~ 27 N·m

2.4 ~ 2.8 kgf·m

(11)

II-S-18
c. Accelarator lever
1. idle speed : 1250 ± 50 rpm KX36-3, 41-3S, V Adjust it by stopper bolt.
2. Max. speed setting : Check if the accel lever link plate contacts to stopper bolt.
3. Lever stroke 99 mm (3.9”)
8 7 Acceleration
Deceleration
55 5 mm (2.17 0.2 in)
D
) (Ref. value)
value
(Ref. ( 0.59
in) 15 mm(0.59 in)
D- D m m
15
4
6
D
5
Plate
Accel cable
1") Idle Acceleration

m (3.1 Deceleration
79m
x
Ma
60 5 mm (2.36 0.2 in)
3 2
1
)
value (Ref. value)
(Ref. (0.98 in)
m 13 mm(0.51 in)
25 m
Plate
(1) Cable, accel 1
(2) Washer, olain 1
(3) Splint 1
(4) Pin 1
Accel cable
(5) Pin, snap 1
(6) Washer, plain 1
(7) Support, accel 1
(8) Bolt, w sems 2 (MB 7T)
II-S-19
4. Apply grease on DU - bush.
5. Install spring, shim and plate and tighten with washer and bolt.
accel lever should slide smoothly.
8 6 7 10 9
3 2 5 12 11
(2) Lever, accel 1

(3) Bush 1
(5) Grip, lever 1
(6) Splint 1
(7) Plate 1
(8) Pin, Shim 1
(9) Washer, spring lock 1
(10) Hex, box 2 M10 x 1.25 7T
(11) Hex, box 2 M10 x 1.25 7T
(12) Nut 2 M10 x 1.25 7T
Accel cable route
(1) Go through the arch guide

(2) Go through the slit
(1) (3) (2) (3) Accel cable
II-S-20
d. Dozer lever
(6) 1 2 1. Outer part of the cable shouldn’t be bent.
Straight length : 200 mm (7.78”) or more.
2. Allowable cable radius :
R = 150 mm (5.91”) or more.
3. Cable shouldn’t be twisted when fixing
(7) 4. Check points after installation
Control valve spool should shift smoothly
at full stroke.
4)
(144.
3 4 5
4 5
(1) Glip 1
(2) Screw, pan hed 2
(3) Cable (blade) 1
(4) Washer, plain 2
(5) Pin, snap 2
(6) Dozer lever shouldn’t contact with upper cover at its full stroke.
(7) Cover (R, upper)
II-S-21
13 14 15
(15)
(15)
(15) 17 16
5)
(1
(13) Assy, lever (Blade) 1 (8) Apply grease on DU - bush.

(14) Lever (blade) 1 (9) Stopper bolt setting length should be as
showen in Fig.
(15) Bush 2
l = 15 mm (0.59”)
(16) Washer, plain 1
(17) Pin, snap 1
Dozer Cable route
(1)
(2)
(3) (1) Go above the horn harness

(2) Go inside the frame
(4)
(3) Dozer cable
(4) Go through the Groove
(2) (5) Inside : Fuel hose
(6) Outside : Cable
(5) (6)
II-S-22
e. Swing & SP pedal
(1) Pedal adjustment (3) Tightening torque of link ball :

To be symmetrical right and left 17.7 ~ 20.6 N·m
(Horizontal at the center) (1.8 ~ 2.1 kgf·m)
Right-and-left: Swing 13.0 ~ 15.2 ft·lbs
(2) Pedal operation
Both spools of service port and swing port to
move over their entire strokes smoothly.
Each pedal should return to its newtral position
smoothly.
19 20 21 22
269.5
(1)
(2) (3)
‫ޓ‬
(4)
(5)
(1) Link rod (19) Lever (swing) 1

(2) Pedal upper face should be horizontal at neutral. (20) Bush 2
(3) Pedal (21) Washer, plain 1
(4) Washer and snap pin (22) Pin, snup 1
(5) Lever and bush
II-S-23
<Service port pedal>
(2)
(2) Pedal upper face should be horizontal at neutral.
24 25 26 27
(24) Lever (sp pedal) 1

(25) Bush 2
(26) Washer, plain 1
(27) Snup pin 1
II-S-24
f. Control valve links
(1) Installation of each link (3) Tightening torque of control valve mounting
Each link should rotate smoothly. bolt (2).
(2) Installation of DU-bush and shaft Apply screw - lock agent.
Apply grease. 23.5 ~ 27.5 N·m
(2.4 ~ 2.8 kgf·m)
17.4 ~ 20.3 ft·lbs
2 4 5 3 1 5 6 3 13 14 15 10 11 12 7 8 9
(1) Bolt 4 M12 x 1.25 7T (10) Link (plate2) 1

(2) Bolt 3 M8 7T (11) Pin, joint 1 Dozer
(3) Link 2 (12) Snap pin 1
(4) Pin, joint 2 (13) Link (plate2) 1
Traveling
(5) Snap pin 4 (14) Pin, joint 1 Service port
(6) Pin, joint 2 (15) Snap pin 1
(7) Link (plate1) 1
(8) Pin, joint 1 Swing
(9) Snap pin 1
II-S-25
g. Limit switch installation
(1) Limit switch performance (3) Squeeze of the seat support rubber 2
Limit switch setup 1 ~ 2 mm (0.04 ~ 0.08 in)
Limit switch to perform as specified (4) DU-bush
* Apply screw loctite (Three Bond TB1401B). Apply grease.
No gap at points (A), (B) and (C) with limit (5) Safety lock switch tightening torque:
switch activated 3.9 ~ 4.9 N·m
(2) Tension spring fitting on the unload lever 0.4 ~ 0.5 kgf·m)
(left) 2.9 ~ 3.6 ft·lbs
Hook tip of the spring (to hook on the unload
lever) to face the machine's outside.
(Unload lever LH)

(1) (2)
A (3)
(4) (5)
(Unload lever LH)
(3)
(2)
(6)
(1) Lock lever, (L), bush

(2) Safety lock switch
(3) Spring
(4) Trim 1 (Seat support rubber 2)
(5) Hook tip of the spring to outerward B
(6) Lock lever, (R)
II-S-26
h. Seat belt
4 3
(5)
(1) Seat belt assy 1

(2) Bolt 2
(3) Bracket 1
(4) Bolt 2
(5) Meet to the corner
II-S-27
C.Undercarrige
a. Track tension device
(1) Assembling procedure
1. Make sure the unit slides smoothly in the track frame.
2. Tightening torque of idler assy and tension spring plate : 77.5 ~ 90.0 N·m
(7.9 ~ 9.2 kgf·m)
57.1 ~ 66.5 ft·lbs
Apply screw lock agent (Loctite 271)
3. Idler lubricant amount
Engine oil : SAE # 30 CD class, 30 cc (0.008 us gal.)
4. Spring pre - set length :
l = 130 ± 0.5 mm (5.12 ± 0.02 inch)
Set the split pin at the nearest position.
5. Track sag distance : Rubber track : 10 ~ 15 mm (0.39 ~ 0.59 inch) at the lower center.
2 3
(5)
(4)
(1) Sddy idler 2

(2) Assy cylinder, left 1 Track (left)
Assy cylinder, Right
(3) Nipple, grease cylinder 1 Track (Right)
(4) Overlap area
(5) In case of rubber track, seam mark (f) should be positioned at the upper center as shown in Fig.
II-S-28
(2) Grease cylinder installation
1. Apply grease on dust seal,
O - ring and backup ring.
(3) 2. Mating surface of backup
ring should be in side direc-
tion.
3. Nipple assy (2) should be
installed after ram is inserted
to its end (A - port).
4. Fail symptom :
Improper installation of ram
causes air in the tube and
results in track looseness.
5. Tightening torque of nipple
assy (2).
98.0 ~ 108.0 N·m
(9.0 ~ 11.0 kgf·m)
65.1 ~ 79.6 ft·lbs
6. Apply grease and adjust the
rubber track sag distance.
1 2 7. Rubber track sag distance :
(4) 10 ~ 15 mm
(0.39 ~ 0.59 inch)
8. Precaution :
Rotate track for 5 to 6 times
and measure the distance
with “f“ mark at top position.
(3) A - part (4) Mating surface of backup ring
II-S-29
b. Track Roller
3 4 1
(1) Assy roller, truck 6

(2) Bush 12 M12 x 1.25 x L30
(3) Washer 12
(4) Plain washer 12
1. Remove the stuck oil and paint on the track roller and track frame for mounting track roller.
2. Tightening torque for mounting track roller.
103 ~ 117.7 N·m
10.5 ~ 12 kgf·m
75.9 ~ 86.8 ft·lbf
Apply threebond #1305 on the femail thread.
3. Seating face clearance of track frame and track roller should be 1.5 mm (0.06 inch) or less.
4. Center line dislocation to tamber line should be ± 2 mm (0.08 inch) or less
(Idler should be placed at the center of gap.)
II-S-30
III.Engine
A.Engine accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3
a. Engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3
b Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-4
c. Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-6
d. Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-10
e. Pump coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-12
f. Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-13
g. Fuel tank cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-14
h. Fuel hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-15
B.Engine WSM : D902 -E . . . . . . . . . . . . . . . . . . . . . . . . . III-S-17
C.Engine WSM : D782 -B . . . . . . . . . . . . . . . . . . . . . . . . III-S-119
III-S-1
III-S-2
A.Engine accessories
a. Engine mount
(1) Shock absorber installation
Install as shown in Fig.
1. R part should be down to swivel frame side.
2. Tighten to torque from swivel frame side.
3. Tighten to torque at engine side.
Nut : 02118 - 60100
Tightening torque : 39.2 ~ 45.1 N·m
(4.0 ~ 4.6 kgf·m)
28.9 ~ 33.3 ft·lbs
Apply screw locktite agent.(Locktite 271)
(1)
(2)
(3)
(4)
(5)
(6)
D (1) Cover
(7) (2) Shock absorber
(3) R part
(4) Engin bracket, front
(5) Shock absorber
(6) Engin bracket, rear
(7) Harness
(9) (8) Temp sensor
(8) (9) Joint
III-S-3
b Air cleaner
<Outer element> P/N=6C060-99411
Filtering area: 0.45m2, nominal, 10P
El element paper:
Clean efficiency: 99% (JIS 8 class)
<Inner element> P/N=T0270-93221
Filtering area: 135cm2
250mesh
(1)Outer element
(2)Inner element (safety element)
(3)Case
(4)Dust cover
(5)Clamps
<Inner element>
(2) (6) (4) (1) (3)
(12) (8) (10) (13) (11) (9) (7)
(1) Element, 2nd filter

(2) Pipe
(3) Plate
(4) Tube
(5) Clip
(6) Seal
(7) Element
(8) End cap
(9) End cap
(10)Protector
(11)Inner tube
(12)Gasket
(13)Clip
III-S-4
9 10 8 6 7 1 2
(11)
(11)
5 3 4
(1) Assy cleaner, air

(2) Band, air cleaner
(3) House, inlet
(4) House, clamp
(5) House, clamp
(6) House, inlet
(7) House, clamp
(8) Band, pipe
(9) House, inlet
(10)Band, pipe
(11)Hose inlet should be vertical.
III-S-5
c. Radiator
(1) Stretch of fan out of fan shroud (3) Bracket fitting on the radiator cushion
Part (A) Rubber catch to hook on tightly
Refer to the Fig.
Fan to stretch uniformly out of its shroud
(2) Clearance between fan and fan shroud
Part (B)
10mm, 0.39 inch or more to be ensured
A
B 50
(1) (1) (20)
(1)
(1)
(1) 10 mm (0.39”) or more.
III-S-6
5 6
13 11 4 2 3 1 22 20 9 7 8 21 22
15
17 16 10
18
(1) Assy radiator 1
19 (2) Shroud, fan 1
(3) Trim (1150) 1
(4) Bolt 4 M6 x 1 4T
(5) Cover, fan 1
(6) Bolt 2 M6 x 1 4T
(7) Bracket : oil cooler 1
(8) Bolt 4 M6 x 1 4T
(9) Oil cooler 1
(10) Bolt 4 M6 x 1 4T
(11) Hose (upper) 1
(12) Hose (bottom) 1 For canopy
14 12 13 (13) Hose clamp 3
(14) Hose clamp 1
(15) Hose (drain, radiator) 1
(16) Hose clamp 2
(17) Adapter (drain) 1
(18) Washer, seal 1
(19) Plug 1
(20) Stay (L, radiator) 1
(21) Stay (R, radiator) 1
(22) Bolt 2 M6 x 1 4T
III-S-7
5
3 4 6 7 (10)
(8)
(9)
(1) Bolt 2 M10 x 1.25 7T

(2) Assy tank, reserve 1
(3) Bracket, radiator 1
(4) Bolt 3 M10 x 1.25 7T
(5) Cushion, radiator 2
(6) Shroud, fan 1
(7) Cover, fan 1
(8) Swivel frame
(9) Hose on drain side
Pass through the crena of the weight.
(10) Pass between the cover (fan) and shroud (Fan)
III-S-8
(4)Thermostat
P/N=19434-73011
Identify with black marking
ink on the shaded spot.
Applied model=
Preformance:
8mm
Mark the
Mark the valve opening manufacturing Lift
temperature here. date here.
Mark the
manufacturer
logo here.
71°C 85°C
(8) Approx. 10°C
(6) (5)
Valve opening temp. Full lift temp.
(1)
(3) (1)Seat
(2) (2)Body
(3)Valve
(4) (4)Spring
(7) (5)Stopper
(6)Shaft
(7)Pellet
(8)Adjust pin
III-S-9
d. Muffler
(1) Clamping the muffler pipe (3) Assembling order
Tightening torque : 3.9 ~ 5.9 N·m * Temporarily tighten the bolts (A), (B) and
(0.4 ~ 0.6 kgf·m) (C).
2.9 ~ 4.3 ft·lbs No gaps at the tightened faces (a, b and c)
(2) Ensuring the clearance between muffler * (A): First to tighten up
pipe outlet and weight hole * (B): Second to tighten up
(1) Clearance to be over 15 mm(0.59 inch) * (C): Third to tighten up
(2) Tail pipe * (D): Fourth to tighten up
(3) Weight
(4) Tail pipe not to stretch out of the weight end Tightening torque : (A)(B) : 48.1 ~ 55.9 N·m
(4.9 ~ 5.7 kgf·m)
(2) (1)
35.4 ~ 41.2 ft·lbs
Tightening torque : (C) : 3.9 ~ 5.9 N·m
(0.4 ~ 0.6 kgf·m)
2.9 ~ 4.3 ft·lbs
(3)
(4)
3 1 2 4 5 6 14 11 10 9 8 7
12
B 13
2
A 13
3
(234) (11)
(1) Gasket, muffler na 1 (424) (8) Bolt 2 M8 7T

(2) Flange (muffler) 1 (9) Plain washer 4
(3) Bolt 3 M8 7T (10) Spring washer 2
(4) Nut 3 4T (11) Nut 2 M8 7T
(5) Spring washer 3 (12) Bracket, muffler 1
(6) Muffler 1 (13) Bolt 5 M10 x 1.25 7T
(7) Band pipe muffler 2 (14) Pipe, muffler 1
III-S-10
(3) Applying the thermal insulators (1, muffler) (RB237-4247U) and, (2, muffler) (RB237-4248U), (3,
muffler) (RB237-4249U)
Apply the thermal insulator (2, 3 muffler) on both sides of the muffler first and then another thermal insu-
lator (1, muffler).
Finally bind the muffler's both ends with the wires (07811-10984).
2 4
(6)
262
(17.5) (204)
(1) Insulation (1, muffler) 1

(4) Muffler 1 (424)
(5) Wire 2
(6) Wire fix direction
III-S-11
e. Pump coupling
(1) Apply grease on spline section
Proper amount to be applied (No overflow allowed)
No grease to be stuck on the rubber
Wipe off grease immediately as required.
(1)
(2) Tighten coupling bolts
(01138-61016) A
Tightening torque : 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) (2)
Apply screw lock agent.
(3)
(4)
(1) Pump housing

(2) Coupring
(3) Bolt
(4) Apply grease on the spline area.
010 Housing, pump

020 Bolt
030 Bolt
050 Pin, Straight
070 Coupling
080 Assy pump, Piston
090 Bolt
III-S-12
f. Fuel tank
(1) Fuel sensor assembly KX41-3S, V : RB237-5114U

KX36-3 : RB137-5114U
Tightening torque : 3 ~ 4 N·m (0.3 ~ 0.4 kgf·m)
(2) Fuel tank
Push the tank foward machine rear direction and fix to tight.
(11) (10)
6 4 5
2 1 7 9
8
(12)
(1) Fuel tank

(2) Fuel sensor KX41-3
(2) Fuel sensor KX36-3
(3) Flange bolt : M5 x 14 M5
(4) Tank retainer
(5) Cushion
(6) Bolt M8 7T
(7) Tank stay
(8) Cushion
(9) Bolt M10 x 1.25 7T
(10) Front
(11) Rear
(12) Pushing direction
III-S-13
g. Fuel tank cushion
(1) Cushion application

Push and stick the cushion in place.
* Clean up the surface cushion applying the cushion.
(1)
(2)
(45)
(4)
Fig.1
(3)

(7)
(6)
(5)
(1) Align the hole centers and paste the cushion in the longitudinal direction of the equipment.
(2) Align the edge of the cushion with the inner edge of the equipment.
(3) See Fig.1.
(4) Align the edge of the cushion with the rear edge.
(5) Align the hole centers and paste the cushion in the longitudinal direction of the equipment.
(6) Align the edge of the cushion with the upper edge of the vertical rib of the swivel frame.
(7) Align the edge of the cushion with the outer edge of the equipment.
III-S-14
h. Fuel hoses
(1) S Fuel hose route

No contact with sharp edge, hot surface and moving part
No clamping with the fuel hose and electrical cables
Over-tightness and local slack not allowed
Hose not to be flattened
* Be careful when clamping the hose.
Specified dimensions to be strictly followed
Type of pipe clip
(1) * mark RG008-5198U

# mark RG008-5199U
(9)
(7) (10)
(6) (2)
(8) (11)
(13) (4)
(5)
(12)
(3)
(14)
(1) Joint to fuel tank (8) Fuel tank

L = 675, 26.6” (I 4)
(Protection tube 580 mm, 22.8”)
(2) Engin to joint (9) Fuel filter assy
L = 150, 5.9” (I 4)
(3) Joint to engin (10) T - joint
L = 260, 10.2” (I 4)
(4) Joint to joint (11) Fuel return (Engin)
L = 90 (I 8)
(5) Pump to joint (12) Pipe joint (T - 9)
L = 100, 3.9”
(6) Fuel tank to filter (13) Fuel pump
L = 1150, 45.3
(Protection tube 1050 mm, 41.3”)
(7) Filter to pump (14) Rotate 90 degrees and mount the joint so that the
L = 250, 9.8” left and right directions will be cross shaped.
III-S-15
III-S-16
B.Engine WSM : D902 -E
To the best Service Personnels of Kubota Construction Machinery Dealers.
This engine WSM contains and covers Engine model D902 - E
As for D782 - B, only pages that contain different data and contents were added from page III-S-119.
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism,
service and maintenance of Z602-E and D902-E. It is divided into two parts, "Mechanism" and "Servicing".
B Mechanism
Information on the construction and function are included. This part should be understood before proceeding with
troubleshooting, disassembling and servicing.
Refer to Diesel Engine Mechanism Workshop Manual (Code No. 97897-01872) for the one which has not been
described to this workshop manual.
B Servicing
The heading "General" includes general precautions, check and maintenance and special tools. Other section,
there are troubleshooting, servicing specification lists, checking and adjusting, disassembling and assembling, and
servicing which cover procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on the latest product information
available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
July 2003
KUBOTA Corporation 2003

0000003172E
III-S-17
Z602-E · D902-E, WSM SAFETY INSTRUCTIONS
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.It is essential that you read the
instructions and safety regulations before you attempt to repair or use this unit.
A Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
A Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
A Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
A Indicates that equipment or property damage could result if instructions are not followed.
A Gives helpful information.
0000001386E
BEFORE SERVICING AND REPAIRING
A Read all instructions and safety instructions in this
manual and on your engine safety decals.
A Clean the work area and engine.
A Park the machine on a firm and level ground.
A Allow the engine to cool before proceeding.
A Stop the engine, and remove the key
A Disconnect the battery negative cable
0000001387E
SAFETY STARTING
A Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
A Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
0000001388E
III-S-18
SAFETY WORKING
A Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
A Wear close fitting clothing and safety equipment
appropriate to the job.
A Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
A When servicing is performed together by two or
more persons, take care to perform all work safely.
A Do not touch the rotating or hot parts while the
engine is running.
A Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
A Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
A Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
0000001389E
AVOID FIRES
A Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
A To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
A Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
A Make sure that no fuel has been spilled on the
engine.
0000001390E
III-S-19
VENTILATE WORK AREA

A If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
0000001391E
DISPOSE OF FLUIDS PROPERLY

A Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, electrolyte and other
harmful waste.
0000001393E
PREVENT ACID BURNS

A Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
0000001392E
PREPARE FOR EMERGENCIES

A Keep a first aid kit and fire extinguisher handy at all
times.
A Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
0000001394E
III-S-20
Z602-E · D902-E, WSM SPECIFICATIONS
SPECIFICATIONS
Model Z602-E D902-E
Number of Cylinders 2 3
Type Vertical, water-cooled, 4-cycle IDI diesel engine
Bore x Stroke mm (in.) 72 x 73.6 (2.83 x 2.90)
Total Displacement (cu.in.) 599 (36.55) 898 (54.80)
SAE Net Continuous kW/ (rpm)

8.8 / 3200 (11.8 / 3200) 13.4 / 3200 (18.0 / 3200)
(HP/ (rpm))
SAE Net Intermittent kW/ (rpm)

10.1 / 3200 (13.5 / 3200) 15.4 / 3200 (20.6 / 3200)
(HP/ (rpm))
Maximum Bare Speed ( (rpm)) 3450
Minimum Bare Idling Speed

900 to 1000
( (rpm))
Combustion Chamber Spherical Type (E-TVCS)
Fuel Injection Pump Bosch MD Type mini pump
Governor Centrifugal ball mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch throttle type
Injection Timing 0.30 to 0.33 rad (17 to 19 ) before T.D.C.
Firing Order 1-2 1-2-3
Injection Pressure 13.73 MPa (140 , 1991 psi)
Compression Ratio 24 : 1
Lubricating System Forced lubrication by pump
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Cell starter (with glow plug)
Starting Motor 12 V, 1.0 kW 12 V, 1.2 kW
Recommended Battery Capacity

12 V, 36AH, equivalent 12 V, 52AH, equivalent
(5 Hr capacity)
Charging Alternator 12 V, 480 W
Fuel Diesel Fuel No.2-D
Class CF lubricating oil as per API classification is recommended.

Lubricating Oil If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil.
For details on recommended lubricating oils, see page S-16, 20.
Lubricating Oil Capacity 2.5 L (2.64 U.S.qts) 3.7 L (3.91 U.S.qts)
Weight (Dry) BB spec. kg (lbs) 57.0 (125.7) 72.0 (158.7)
A Specifications are subject to change without notice.

A The battery capacity is indicated in 5-hour ratio.
0000003173E
III-S-21
Z602-E · D902-E, WSM PERFORMANCE CURVES
PERFORMANCE CURVES
B Z602-E
(1) Brake Horsepower (6) Net Intermittent Torque (11) Net Intermittent B.S.F.C. (15) Gross B.H.P.
(2) Engine Speed (7) Net Continuous Torque (12) Gross Torque (16) Overload B.H.P.
(3) B.S.F.C. (8) Gross Intermittent B.H.P. (13) Overload Torque (17) Continuous B.H.P.
(4) Torque (9) Net Intermittent B.H.P. (14) Continuous Torque (18) Overload B.S.F.C.
(5) Gross Intermittent Torque (10) Net Continuous B.H.P.
0000003174E
III-S-22
Z602-E · D902-E, WSM PERFORMANCE CURVES
B D902-E
(1) Brake Horsepower (6) Net Intermittent Torque (11) Net Intermittent B.S.F.C. (15) Gross B.H.P.
(2) Engine Speed (7) Net Continuous Torque (12) Gross Torque (16) Overload B.H.P.
(3) B.S.F.C. (8) Gross Intermittent B.H.P. (13) Overload Torque (17) Continuous B.H.P.
(4) Torque (9) Net Intermittent B.H.P. (14) Continuous Torque (18) Overload B.S.F.C.
(5) Gross Intermittent Torque (10) Net Continuous B.H.P.
0000003301E
III-S-23
Z602-E · D902-E, WSM DIMENSIONS
DIMENSIONS
B Z602-E
0000003175E
III-S-24
Z602-E · D902-E, WSM DIMENSIONS
B D902-E
0000003176E
III-S-25
CONTENTS
1. ENGINE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-27
[1] HALF-FLOATING HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . .III-S-27
[2] PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-28
[3] OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-28
2. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-29
[1] COOLING FIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-29
III-S-26
Z602-E · D902-E, WSM ENGINE
1. ENGINE BODY
[1] HALF-FLOATING HEAD COVER
The rubber packing is fitting in to maintain the head
cover 0.5 mm or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover [a] Z602-E
(2) Rubber Packing [b] D902-E
0000003177E
III-S-27
[2] PISTON
Piston's skirt is coated with molybdenum isulfide ,
which reduces the piston slap noise and thus the entire
operating noise.
Molybdenum disulfide (MoS )

The molybdenum disulfide serves as a solid lubricant,
like a Graphite or Teflon. This material helps resist
metal wears even with little lube oil.
(1) Molybdenum Disulfide
0000001272E
[3] OIL PAN

The oil pan is expanded under the gear case.
Therefore, the height of the engine can be lowered more
than so far while securing a necessary amount of oil.
(1) Gear Case [a] Z602-E
(2) Oil Pan [b] D902-E
(3) Crank Case
0000003178E
III-S-28
2. COOLING SYSTEM
[1] COOLING FIN
The cooling fin is set up around the oil passage in the
gear case.
Therefore, the temperature of oil is decreased by the
wind generated by the cooling fan.
(1) Cooling Fin [a] Z602-E
[b] D902-E
0000003302E
III-S-29
CONTENTS
1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-32
[1] ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-32
(1) Model Name and Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . III-S-32
(2) Cylinder Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-33
[2] GENERAL PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-34
[3] TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-35
(1) Tightening torques for special use screws, bolts and nuts . . . . . . . . . . III-S-35
(2) Tightening torques for general use screws, bolts and nuts . . . . . . . . . . III-S-36
[4] TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-37
[5] SERVICING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .III-S-40
[6] MAINTENANCE CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-46
[7] CHECK AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-48
(1) Daily Check Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-48
(2) Check Points of Every 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-50
(3) Check Points of Every 100 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-51
(7) Check Points of Every Year or Every Sixth Cleanings of Air Cleaner Element
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-55
(9) Check Points of Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-57
(10) Check Points of Every 3000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-57
(11) Check Points of Every 2 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-57
[8] SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-58
2. ENGINE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-64
[1] CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-64
[2] DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . .III-S-65
(1) Draining Coolant and Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-65
(2) External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-66
(3) Cylinder Head, Valves and Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-66
(4) Timing Gear, Camshaft and Fuel Camshaft . . . . . . . . . . . . . . . . . . . . . III-S-73
(5) Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-76
(6) Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-78
[3] SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-81
(1) Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-81
(2) Timing Gear, Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-87
(3) Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-89
III-S-30
(4) Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-93
(5) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-97
3. LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . III-S-99
[1] CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-99
[2] SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-99
4. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-101
[1] CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . III-S-101
[2] DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . III-S-103
5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-104
[1] CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . III-S-104
(1) Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-104
(2) Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-107
6. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . III-S-109
[1] CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-109
(1) Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-109
(2) Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-109
(3) Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-110
[2] DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . III-S-110
(1) Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-110
(2) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-111
[3] SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-113
(1) Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-113
(2) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-116
III-S-31
1. GENERAL
[1] ENGINE IDENTIFICATION
(1) Model Name and Engine Serial Number
When contacting the manufacture, always specify your engine
model name and serial number.
The engine model and its serial number need to be identified
before the engine can be serviced or parts replaced.
B 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.
A Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
A: Engine Model Name and [a] Z602-E

Serial Number [b] D902-E
0000003179E
III-S-32
A Month of manufacture
Engine Serial Number
Month
0001 ~ 9999 10000 ~
January A0001 ~ A9999 B10000 ~
February C0001 ~ C9999 D10000 ~
March E0001 ~ E9999 F10000 ~
April G0001 ~ G9999 H10000 ~
May J0001 ~ J9999 K10000 ~
June L0001 ~ L9999 M10000 ~
July N0001 ~ N9999 P10000 ~
August Q0001 ~ Q9999 R10000 ~
September S0001 ~ S9999 T10000 ~
October U0001 ~ U9999 V10000 ~
November W0001 ~ W9999 X10000 ~
December Y0001 ~ Y9999 Z10000 ~
e.g. Z602-3A0001
"3" indicates 2003 and "A" indicates January.
So, 3A indicates that the engine was manufactured on January,
2003.
0000001298E
(2) Cylinder Number

The cylinder numbers of KUBOTA diesel engine are designated
as shown in the figure.
The sequence of cylinder numbers is given as No.1, No.2 and
No.3 starting from the gear case side.
0000003180E
III-S-33
[2] GENERAL PRECAUTION

A During disassembly, carefully arrange removed parts in a
clean area to prevent confusion later. Screws, bolts and nuts
should be replaced in their original position to prevent
reassembly errors.
A When special tools are required, use KUBOTA genuine
special tools. Special tools which are not frequently used
should be made according to the drawings provided.
A Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
A Remove oil and dirt from parts before measuring.
A Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.
A Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
A When reassembling external or internal snap rings, position
them so that the sharp edge faces against the direction from
which force is applied.
A Be sure to perform run-in the serviced or reassembled engine.
Do not attempt to give heavy load at once, or serious damage
may result to the engine.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Place the Sharp Edge against
the Direction of Force
0000001277E
III-S-34
[3] TIGHTENING TORQUES

Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and
nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.
0000001286E
(1) Tightening torques for special use screws, bolts and nuts
A For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
A The letter "M" in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is
the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between
two threads.
Item Size x Pitch ft-lbs

*Cylinder head cover screw M6 x 1 6.86 to 11.3 0.7 to 1.15 5.1 to 8.3
Injection pipe retaining nut M12 x 1.5 24.5 to 34.3 2.5 to 3.5 18.1 to 25.3
Overflow pipe retaining nut M12 x 1.5 19.6 to 24.5 2.0 to 2.5 14.5 to 18.1
Nozzle holder assembly M20 x 1.5 49.0 to 68.6 5.0 to 7.0 36.2 to 50.6
Glow plug M8 x 1 7.85 to 14.7 0.8 to 1.5 5.8 to 10.8
*Rocker arm bracket screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Cylinder head screw M8 x 1.25 37.3 to 42.2 3.8 to 4.3 27.5 to 31.1
*Fan drive pulley screw M12 x 1.5 98.1 to 107.9 10.0 to 11.0 72.3 to 79.6
*Idle gear shaft mounting screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Connecting rod screw M7 x 0.75 26.5 to 30.4 2.7 to 3.1 19.5 to 22.4
*Flywheel screw M10 x 1.25 53.9 to 58.8 5.5 to 6.0 39.8 to 43.4
Bearing case cover mounting screw M6 x 1 9.8 to 11.3 1.00 to 1.15 7.2 to 8.3
*Main bearing case screw 2 M7 x 1 26.5 to 30.4 2.7 to 3.1 19.5 to 22.4
*Main bearing case screw 1 M6 x 1 12.7 to 15.7 1.3 to 1.6 9.4 to 11.6
Nozzle holder - 34.3 to 39.2 3.5 to 4.0 25.3 to 28.9
Oil pressure switch PT 1/8 14.7 to 19.6 1.5 to 2.0 10.8 to 14.5
Starter (C terminal nut) - 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7
0000001287E
III-S-35
(2) Tightening torques for general use screws, bolts and nuts
When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below.
Grade Standard Screw and Bolt Special Screw and Bolt
Nominal
Diameter Unit ft-lbs ft-lbs
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32
M8 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 17.4 to 20.3
M10 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 35.4 to 41.2
M12 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2 57.1 to 66.5
Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening,
be sure to check out the numbers as shown below.
Punched number Screw and bolt material grade
None or 4 Standard screw and bolt SS41, S20C
7 Special screw and bolt S43C, S48C (Refined)
0000001288E
III-S-36
[4] TROUBLE SHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not Start A No fuel Replenish fuel
A Air in the fuel system Bleed III-S-50
A Water in the fuel system Change fuel and
repair or replace fuel
system
A Fuel hose clogged Clean
A Fuel filter clogged Change III-S-53
A Excessively high viscosity of fuel or engine oil Use specified fuel III-S-51
at low temperature or engine oil
A Fuel with low cetane number Use specified
fuel
A Fuel leak due to loose injection pipe retaining Tighten retaining nut III-S-67
nut
A Incorrect injection timing Adjust III-S-104
A Fuel camshaft worn Replace III-S-75
A Injection nozzle clogged Repair or replace III-S-107,108
A Injection pump malfunctioning Replace III-S-73
A Seizure of crankshaft, camshaft, piston, Repair or replace
cylinder or bearing
A Compression leak from cylinder Replace head gasket, III-S-64
tighten cylinder head
screw, glow plug and
nozzle holder
A Improper valve timing Correct or replace III-S-74
timing gear
A Piston ring and cylinder worn Replace III-S-77, 91,
97, 98
A Excessive valve clearance Adjust III-S-56
(Starter Does Not A Battery discharged Charge
Run)
A Starter malfunctioning Repair or replace III-S-110
A Wiring disconnected Connect
Engine Revolution Is A Fuel filter clogged or dirty Replace III-S-53
Not Smooth
A Air cleaner clogged Clean or replace III-S-51
A Fuel leak due to loose injection pipe retaining Tighten retaining nut III-S-67
nut
A Injection pump malfunctioning Replace III-S-73
A Incorrect nozzle injection pressure Adjust III-S-107,108
A Injection nozzle stuck or clogged Repair or replace III-S-68,108,109
A Governor malfunctioning Repair III-S-75
III-S-37
Reference
Page
Either White or Blue A Excessive engine oil Reduce to specified III-S-48
Exhaust Gas Is level
Observed
A Piston ring and cylinder worn or stuck Repair or replace III-S-77, 91,
97, 98
A Deficient compression Adjust top clearance III-S-65
Either Black or Dark A Overload Reduce the load
Gray Exhaust Gas Is
A Low grade fuel used Use specified fuel
Observed
A Fuel filter clogged Replace III-S-53
A Air cleaner clogged Clean or replace III-S-51
A Deficient nozzle injection Repair or replace III-S-68,107,
nozzle 108
Deficient Output A Incorrect injection timing Adjust III-S-104
A Engine's moving parts seem to be seizing Repair or replace
A Uneven fuel injection Replace injection III-S-73
pump
A Deficient nozzle injection Repair or replace III-S-68, 107,
nozzle 108
A Compression leak Replace head gasket, III-S-64
tighten cylinder head
screw, glow plug and
nozzle holder
Excessive Lubricant A Piston ring's gap facing the same direction Shift ring gap III-S-76
Oil Consumption direction
A Oil ring worn or stuck Replace III-S-77, 91
A Piston ring groove worn Replace piston III-S-77, 91
A Valve stem and valve guide worn Replace III-S-71, 82
A Oil leaking due to defective seals or packing Replace
Fuel Mixed into A Injection pump's plunger worn Replace injection III-S-73
Lubricant Oil pump
A Deficient nozzle injection Repair or replace III-S-68, 107,
nozzle 108
A Injection pump broken Replace III-S-73
Water Mixed into A Head gasket defective Replace III-S-70
Lubricant Oil
A Cylinder block or cylinder head flawed Replace
III-S-38
Reference
Page
Low Oil Pressure A Engine oil insufficient Replenish III-S-48
A Oil strainer clogged Clean III-S-72
A Oil filter cartridge clogged Replace III-S-53
A Relief valve stuck with dirt Clean
A Relief valve spring weaken or broken Replace
A Excessive oil clearance of crankshaft bearing Replace III-S-80,
95 to 97
A Excessive oil clearance of crankpin bearing Replace III-S-77, 94
A Excessive oil clearance of rocker arm Replace III-S-85
A Oil passage clogged Clean
A Different type of oil Use specified type of III-S-51
oil
A Oil pump defective Repair or replace III-S-75,99,100
High Oil Pressure A Different type of oil Use specified type of III-S-51
oil
A Relief valve defective Replace
Engine Overheated A Engine oil insufficient Replenish III-S-48
A Fan belt broken or tensioned improperly Replace or adjust III-S-55, 101
A Coolant insufficient Replenish III-S-49
A Radiator net and radiator fin clogged with dust Clean
A Inside of radiator corroded Clean or replace III-S-54
A Coolant flow route corroded Clean or replace III-S-52
A Radiator cap defective Replace III-S-102
A Radiator hose damaged Replace III-S-52
A Overload running Reduce the load
A Head gasket defective Replace III-S-70
A Unsuitable fuel used Use specified fuel
0000003183E
III-S-39
[5] SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Valve Clearance (Cold) 0.145 to 0.185 mm
0.00571 to 0.00728 in.
Compression Pressure 3.53 to 4.02 MPa 2.55 MPa
36.0 to 41.0 26.0
512 to 583 psi 370 psi
Variance Among
10 % or less
Cylinder
Top Clearance 0.50 to 0.70 mm
0.0197 to 0.0276 in.
Cylinder Head Surface Flatness 0.05 mm
0.0020 in.
Valve Recessing (Intake and Exhaust) -0.10 to 0.10 mm 0.30 mm
-0.0039 to 0.0039 in. 0.0118 in.
Valve Stem to Valve Guide Clearance 0.030 to 0.057 mm 0.10 mm
0.00118 to 0.00224 in. 0.0039 in.
Valve Stem 5.968 to 5.980 mm
(O.D.) 0.23496 to 0.23543 in.
Valve Guide 6.010 to 6.025 mm
(I.D.) 0.23661 to 0.23720 in.
Valve Face Angle 0.785 rad
45
Valve Seat Angle 0.785 rad
45
Width 2.12 mm
0.0835 in.
Valve Spring Free Length 31.3 to 31.8 mm 28.4 mm
1.232 to 1.252 in. 1.118 in.
Tilt 1.2 mm
0.047 in.
Setting Load / 64.7 N / 27.0 mm 54.9 N / 27.0 mm
Setting Length 6.6 kgf / 27.0 mm 5.6 kgf / 27.0 mm
14.6 lbs / 1.063 in. 12.3 lbs / 1.063 in.
0000001278E
III-S-40
ENGINE BODY (Continued)

Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm
0.00063 to 0.00177 in. 0.0059 in.
Rocker Arm Shaft 10.473 to 10.484 mm
(O.D.) 0.41232 to 0.41276 in.
Rocker Arm 10.500 to 10.518 mm
(I.D.) 0.41339 to 0.41410 in.
Push Rod Alignment 0.25 mm
0.0098 in.
Tappet to Tappet Guide Bore Oil Clearance 0.016 to 0.052 mm 0.10 mm
0.00063 to 0.00205 in. 0.0039 in.
Tappet 17.966 to 17.984 mm
(O.D.) 0.70732 to 0.70803 in.
Tappet Guide Bore 18.000 to 18.018 mm
(I.D.) 0.70866 to 0.70937 in.
Timing Gear Crank Gear to Idle 0.043 to 0.124 mm 0.15 mm
Gear (Backlash) 0.00169 to 0.00488 in. 0.0059 in.
Idle Gear to Cam 0.047 to 0.123 mm 0.15 mm
Gear (Backlash) 0.00185 to 0.00484 in. 0.0059 in.
Idle Gear to
0.046 to 0.124 mm 0.15 mm
Injection Pump
0.00181 to 0.00488 in. 0.0059 in.
Gear (Backlash)
Crank Gear to Oil
0.041 to 0.123 mm 0.15 mm
Pump Drive Gear
0.00161 to 0.00484 in. 0.0059 in.
(Backlash)
Idle Gear Side Clearance 0.20 to 0.51 mm 0.80 mm
0.0079 to 0.0201 in. 0.0315 in.
Camshaft Side Clearance 0.15 to 0.31 mm 0.5 mm
0.0059 to 0.0122 in. 0.0197 in.
Alignment 0.01 mm
0.0004 in.
Cam Height (Intake 26.88 mm 26.83 mm
and Exhaust) 1.0583 in. 1.0563 in.
Camshaft Journal to Cylinder Block Bore Oil Clearance 0.050 to 0.091 mm 0.15 mm
0.00197 to 0.00358 in. 0.0059 in.
Camshaft Journal 32.934 to 32.950 mm
(O.D.) 1.29661 to 1.29724 in.
Cylinder Block Bore 33.000 to 33.025 mm
(I.D.) 1.29921 to 1.30020 in.
0000001279E
III-S-41

Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.020 to 0.084 mm 0.10 mm
0.00079 to 0.00331 in. 0.0039 in.
Idle Gear Shaft 19.967 to 19.980 mm
(O.D.) 0.78610 to 0.78661 in.
Idle Gear Bushing 20.000 to 20.051 mm
(I.D.) 0.78740 to 0.78941 in.
Piston Pin Bore I.D. 20.000 to 20.013 mm 20.05 mm
0.78740 to 0.78791 in. 0.7894 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm
0.00055 to 0.00150 in. 0.0039 in.
Piston Pin 20.002 to 20.011 mm
(O.D.) 0.78748 to 0.78783 in.
Small End Bushing 20.025 to 20.040 mm
(I.D.) 0.78839 to 0.78897 in.
Piston Pin to Small End Bushing Oil Clearance 0.015 to 0.075 mm 0.15 mm
(Spare Parts) 0.00059 to 0.00295 in. 0.0059 in.
Small End Bushing 20.026 to 20.077 mm
(I.D.) 0.78845 to 0.79043 in.
Piston Ring Gap Top Ring 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.0138 in. 0.0492 in.
Second Ring 0.35 to 0.50 mm 1.25 mm
0.0138 to 0.0197 in. 0.0492 in.
Oil Ring 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.0138 in. 0.0492 in.
Piston Ring to Piston Ring Groove Second Ring 0.090 to 0.120 mm 0.15 mm
(Clearance) 0.00354 to 0.00472 in. 0.0059 in.
Oil Ring 0.04 to 0.08 mm 0.15 mm
(Clearance) 0.0016 to 0.0031 in. 0.0059 in.
Connecting Rod Alignment 0.05 mm
0.0020 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
0.0059 to 0.0122 in. 0.0197 in.
Alignment 0.02 mm
0.0008 in.
0000001280E
III-S-42

Crankpin to Crankpin Bearing Oil Clearance 0.020 to 0.051 mm 0.15 mm
0.00079 to 0.00201 in. 0.0059 in.
Crankpin 33.959 to 33.975 mm
(O.D.) 1.33697 to 1.33760 in.
Crankpin Bearing 33.995 to 34.010 mm
(I.D.) 1.33893 to 1.33898 in.
Crankshaft Journal to Crankshaft Bearing 1 Oil Clearance 0.034 to 0.106 mm 0.20 mm
0.00134 to 0.00417 in. 0.0079 in.
Crankshaft Journal 43.934 to 43.950 mm
(O.D.) 1.72968 to 1.73031 in.
Crankshaft Bearing 43.984 to 44.040 mm
1 (I.D.) 1.73165 to 1.73386 in.
(Flywheel Side) 0.00110 to 0.00232 in. 0.0079 in.
(O.D.) 1.72968 to 1.73031 in.
2 (I.D.) 1.73142 to 1.73201 in.
(Intermediate) 0.00110 to 0.00232 in. 0.0079 in.
(O.D.) 1.72968 to 1.73031 in.
3 (I.D.) 1.73142 to 1.73201 in.
Cylinder Liner I.D. 72.000 to 72.019 mm 72.169 mm
[Standard] 2.83464 to 2.83539 in. 2.84129 in.
Cylinder Liner I.D. 72.500 to 72.519 mm 72.669 mm
[Oversize : 0.25 mm (0.0098 in.)] 2.85433 to 2.85507 in. 2.86098 in.
0000001281E
III-S-43
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed More than 49 kPa
0.5
7 psi
At Rated Speed 196 to 441 kPa 147 kPa
2.0 to 4.5 1.5
28 to 64 psi 21 psi
Inner Rotor to Outer Rotor Clearance 0.03 to 0.14 mm
0.0012 to 0.0055 in.
Outer Rotor to Pump Body Clearance 0.07 to 0.15 mm
0.0028 to 0.0059 in.
Inner Rotor to Cover Clearance 0.075 to 0.135 mm
0.00295 to 0.00531 in.
0000001282E
COOLING SYSTEM
Fan Belt Tension 7.0 to 9.0 mm / 98 N
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbs)
Thermostat Valve Opening
69.5 to 72.5
Temperature
157.1 to 162.5
(At Beginning)
Valve Opening
85
Temperature
185
(Opened Completely)
Radiator Cap Pressure Falling Time 10 seconds or more
88 59 kPa
0.9 0.6
13 9 psi
Radiator Weak Leakage Test No leaks at specified
Pressure pressure
157 kPa
1.6
23 psi
0000001283E
III-S-44
FUEL SYSTEM
Injection Pump Injection Timing 0.30 to 0.33 rad
(17 to 19 )
before T.D.C.
Pump Element Fuel Tightness 13.73 MPa
140
1991 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
13.73 12.75 MPa 13.73 12.75 MPa
140 130 140 130
1991 1849 psi 1991 1849 psi
Fuel Injection Nozzle Injection Pressure 13.73 to 14.71 MPa
140 to 150
1991 to 2134 psi
Valve Seat When the pressure is
Tightness 12.75 MPa
(130 , 1849 psi),
the valve seat must be
fuel tightness
0000001284E
ELECTRICAL SYSTEM
Glow Plug Resistance Approx. 0.9
Starter Commutator (O.D.) 30.0 mm 29.0 mm
1.181 in. 1.142 in.
Difference of O.D.'s Less than 0.02 mm 0.05 mm
0.0008 in. 0.0020 in.
Mica Undercut 0.50 to 0.80 mm 0.20 mm
0.0197 to 0.0315 in. 0.0079 in.
Brush Length 14.0 mm 9.0 mm
0.551 in. 0.354 in.
Alternator Stator Resistance Less than 1.0
Rotor Resistance 2.9
Slip Ring O.D. 14.4 mm 14.0 mm
0.5669 in. 0.5512 in.
Brush Length 10.0 mm 1.5 mm
0.3937 in. 0.0591 in.
0000001285E
III-S-45
[6] MAINTENANCE CHECK LIST

To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following
the table below.
The lubricating oil change intervals listed in the table below are for Classes CF, CE and CD lubricating oils of API
classification with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change
the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition.
Service Interval
Refer-
Item Every Every Every Every Every Every Every Every ence
Initial Every Every
100 200 400 500 800 1500 3000 2 page
50 hrs 50 hrs 1 year
hrs hrs hrs hrs hrs hrs hrs years
Checking fuel hose and

III-S-50
clamp bands
Changing engine oil III-S-51
Replacing oil filter

III-S-53
cartridge
Checking fan belt tension

III-S-51
and damage
Cleaning air cleaner

III-S-51
element
Cleaning fuel filter III-S-52
Checking radiator hoses

III-S-52
and hose clamp bands
Checking intake air line III-S-52
Replacing fuel filter III-S-53
Cleaning fuel tank inside III-S-54
Cleaning water jacket and

III-S-54
radiator interior
Replacing fan belt III-S-55
*Replacing air cleaner

III-S-55
element
Checking valve clearance III-S-56
**Checking fuel injection

III-S-57
nozzle condition
Checking injection pump III-S-57
Replacing intake air line III-S-57
Replacing radiator hoses

III-S-57
and clamp bands
Replacing fuel hoses and

III-S-57
clamp bands
Changing radiator coolant

III-S-57
(L.L.C.)
* Or, every sixth cleanings of air cleaner element.

**Maintenance interval as per EPA instructions.
0000003184E
III-S-46
A When changing or inspecting, be sure to level and stop the engine.
A Lubricating Oil
With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-
sulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to
employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used
with a high-sulfur fuel, change the lubricating oil at shorter intervals.
A Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed.
Fuel
Low sulfur
High sulfur Remarks
Lubricating (0.5 % )
oil class
CF O O TBN 10
CF-4 O X
CG-4 O X
O : Recommendable X : Not recommendable

0000001294E
III-S-47
[7] CHECK AND MAINTENANCE

(1) Daily Check Points
Checking Engine Oil Level
1. Level the engine.
2. To check the oil level, draw out the dipstick (1), wipe it clean,
reinsert it, and draw it out again.
Check to see that the oil level lies between the two notches.
3. If the level is too low, add new oil to the specified level.
A When using an oil of different maker or viscosity from the

previous, drain old oil. Never mix two different types of
oil.
A Be sure to inspect the engine, locating it on a horizontal

place. If placed on gradients, accurately, oil quantity may
not be measured.
A Be sure to keep the oil level between upper and lower
limits of the dipstick. Too much oil may cause a drop in
output or excessive blow-by gas. On the closed breather
type engine in which mist is sucked through port, too
much oil may caused oil hammer. While too little oil, may
seize the engine's rotating and sliding parts. (The closed
breather is an option.)
(1) Dipstick
0000003437E
III-S-48
Checking and Replenish Coolant

1. Without recovery tank ;
Remove the radiator cap (1) and check to see that the coolant
level is just below the port.
With recovery tank (2) ;
Check to see that the coolant level lies between FULL (A) and
LOW (B).
2. If coolant level is too low, check the reason for decreasing
coolant.
(Case 1)
If coolant is decreasing by evaporation, replenish only fresh,
soft water.
(Case 2)
If coolant is decreasing by leak, replenish coolant of the same
manufacture and type in the specified mixture ratio (fresh, soft
water and L.L.C.). If the coolant brand cannot be identified,
drain out all of the remaining coolant and refill with a totally
new brand of coolant mix.
A Do not remove the radiator cap until coolant temperature

is below its boiling point. Then loosen the cap slightly to
relieve any excess pressure before removing the cap
completely.
A During filling the coolant, air must be vented from the

engine coolant passages. The air vents by jiggling the
radiator upper and lower hoses.
A Be sure to close the radiator cap securely. If the cap is
loose or improperly closed, coolant may leak out and the
engine could overheat.
A Do not use an antifreeze and scale inhibitor at the same
time.
A Never mix the different type or brand of L.L.C..
(1) Radiator Cap (A) FULL
(2) Recovery Tank (B) LOW
0000001296E
III-S-49
(2) Check Points of Every 50 Hours

Checking Fuel Hose and Clamp Bands
1. If the clamp (1) is loose, apply oil to the threads and securely
retighten it.
2. The fuel hose (2) is made of rubber and ages regardless of the
period service.
Change the fuel hose together with the clamp every two years.
3. However, if the fuel hose and clamp are found to be damaged
or deteriorate earlier than two years, then change or remedy.
4. After the fuel hose and the clamp have been changed, bleed
the fuel system.
A Stop the engine when attempting the check and change

prescribed above.
(When bleeding fuel system)

1. Fill the tank with fuel and open the cock (4).
2. Loosen the air vent plug (3) of the fuel filter a few turns.
3. Screw back the plug when bubbles do not come up any more.
4. Open the air vent cock (5) on top of the fuel injection pump.
5. If equipped electrical fuel feed pump, turn the key to AC
position and pump the fuel up for 10 to 15 seconds.
If equipped mechanical fuel feed pump, set the stop lever on
stop position and crank the engine for 10 to 15 seconds.
6. Close securely the air vent cock after air bleeding.
A Always keep the air vent cock on the fuel injection pump
closed except when air is vented, or it may cause the
engine to stop.
(1) Clamp [A] Cartridge Type
(2) Fuel Hose [B] Element Type
(3) Air Vent Plug
(4) Fuel Cock
(5) Air Vent Cock
0000001297E
III-S-50

Changing Engine Oil
A Be sure to stop engine before changing engine oil.

1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. To drain the used oil, remove the drain plug (1) at the bottom
of the engine and drain the oil completely.
4. Screw the drain plug (1).
5. Fill new oil up to upper line on the dipstick (2).
A When using an oil of different maker or viscosity from the

previous one, remove all of the old oil.
A Never mix two different types of oil.
A Engine oil should have properties of API classification
CD/CE/CF/CF-4/CG-4.
A Use the proper SAE Engine Oil according to ambient
temperature.
SAE30 or SAE10W-30
Above 25 (77 )
SAE10W-40
SAE20 or SAE10W-30
0 to 25 (32 to 77 )
SAE10W-40
SAE10W or SAE10W-30
Below 0 (32 )
SAE10W-40
Model Z602-E D902-E
Oil pan depth 101 mm (3.98 in.)
2.5 L 3.7 L
Engine oil capacity
2.64 U.S.qts 3.91 U.S.qts
(1) Drain Plug (2) Dipstick
0000003303E
Checking Fan Belt Tension and Damage

See page III-S-101.
0000003185E
Cleaning Air Cleaner Element
1. Remove the air cleaner element.
2. Use clean dry compressed air on the inside of the element.
Pressure of compressed air must be under 205 kPa
(2.1 , 30 psi).
Maintain reasonable distance between the nozzle and the
filter.
A The air cleaner uses a dry element. Never apply oil to it.
A Do not run the engine with filter element removed.
A Change the element once a year or every 6th cleaning.
0000001301E
III-S-51
Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the cup (5), and
rinse the inside with kerosene.
3. Take out the element (4) and dip it in the kerosene to rinse.
4. After cleaning, reassemble the fuel filter, keeping out dust and
dirt.
5. Bleed the fuel system.
A If dust and dirt enter the fuel, the fuel injection pump and
injection nozzle will wear quickly. To prevent this, be sure
to clean the fuel filter cup periodically.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring
0000001302E

Checking Radiator Hoses and Clamp Bands
1. Check to see if the radiator hoses are properly fixed every 200
hours of operation or every six months, whichever comes first.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The water hose is made of rubber and tends to age. It must
be replaced every two years. Also replace the clamp and
tighten it securely.
(1) Upper Hose (2) Lower Hose
0000001303E
Checking Intake Air Line

1. Check to see if the intake air hose(s) are properly fixed every
200 hours of operation.
2. If the clamp is loose, apply oil to the threads and retighten it
securely.
3. The intake air hose(s) is made of rubber and tends to age. It
must be change every two years. Also change the clamp and
tighten it securely.
A To prevent serious damage to the engine, keep out any

dust inside the intake air line.
(1) Intake Air Hose (2) Clamp
0000001304E
III-S-52
Replacing Oil Filter Cartridge
A Be sure to stop the engine before replacing filter

cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a slight coat of oil onto the new cartridge gasket.
3. To install the new cartridge, screw it in by hand. Over
tightening may cause deformation of rubber gasket.
4. After the new cartridge has been replaced, the engine oil
normally decrease a little. Thus see that the engine oil does
not leak through the seal and be sure to read the oil level on
the dipstick. Then, replenish the engine oil up to the specified
level.
A To prevent serious damage to the engine, replacement

element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Engine Oil Filter Cartridge
0000001305E

Replacing Fuel Filter Cartridge (Cartridge Type)
Water and dust in fuel are collected in the filter cartridge. So,
change the filter cartridge every 400 hours service.
1. Remove the used filter cartridge with filter wrench.
2. Apply a thin film of fuel to the surface of new filter cartridge
gasket before screwing on.
3. Then tighten enough by hand.
4. Loosen the air vent plug to let the air out.
5. Start engine and check for fuel leakage.
(1) Fuel Filter Cartridge
0000001306E
Replacing Fuel Filter Element (Element Type)
1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the cup (5), and
rinse the inside with kerosene.
3. Replace the filter element (4).
4. Reassemble the fuel filter, keeping out dust and dirt.
5. Bleed the fuel system.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring
0000001307E
III-S-53

Cleaning Fuel Tank Inside
0000001308E
Cleaning Water Jacket and Radiator Interior
A Do not remove the radiator cap when the engine is hot.

Then loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
1. Stop the engine and let cool down.
2. To drain the coolant, open the radiator drain plug (2) and
remove the radiator cap (1). Then radiator cap (1) must be
removed to completely drain the coolant. And open the drain
cock (3).
3. After all coolant is drained, close the drain plug.
4. Fill with clean water and cooling system cleaner.
5. Follow directions of the cleaner instruction.
6. After flushing, fill with clean water and anti-freeze until the
coolant level is just below the port. Install the radiator cap (1)
securely.
7. Fill with coolant up to "FULL" (A) mark on the recovery tank
(4).
8. Start and operate the engine for few minutes.
9. Stop the engine and let cool. Check coolant level of radiator
and recovery tank (4) and add coolant if necessary.
A Do not start engine without coolant.

A Use clean, fresh, soft water and anti-freeze to fill the
radiator and recovery tank.
A When the anti-freeze is mixed with fresh, soft water, the
anti-freeze mixing ratio must be less than 50 %.
A Securely tighten radiator cap. If the cap is loose or
improperly fitted, water may leak out and the engine could
overheat.
(1) Radiator Cap A: Full
(2) Drain Plug B: Low
(3) Drain Cock
(4) Recovery Tank
0000001309E
III-S-54
Replacing Fan Belt

1. Remove the alternator.
2. Remove the fan belt (1).
3. Replace new fan belt.
4. Install the alternator.
5. Check the fan belt tension.
7.0 to 9.0 mm
/ 98 N or 10 kgf
Deflection (A) Factory spec.
0.28 to 0.35 in.
/ 98 N or 22 lbs
(1) Fan Belt (A) Deflection
0000001310E
(7) Check Points of Every Year or Every Sixth Cleanings of Air Cleaner Element
Replacing Air Cleaner Element
See page III-S-51.
0000003438E
III-S-55

Checking Valve Clearance
A The valve clearance must be checked and adjusted when

engine is cold.
1. Remove the cylinder head cover (1) and the glow plugs.
2. Align the "1TC" mark (2) on the flywheel and alignment mark
(3) on the rear end plate so that the No. 1 piston comes to the
compression top dead center.
3. Check the following valve clearance marked with " " using a
thickness gauge.
4. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
5. Then turn the flywheel 6.28 rad (360 ), and align the "1TC"
mark (2) on the flywheel and alignment mark (3) on the rear
end plate so that the No.1 piston comes to the overlap
position.
6. Check the following valve clearance marked with " " using a
thickness gauge
Engine model valve Z602-E D902-E
arrangement
Intake Exhaust Intake Exhaust
Adjustable cylinder valve valve valve valve
location of piston
No.1
No.2
No.3 - -
: When No.1 piston is at the compression top dead center

position.
: When No.1 piston is at the overlap position.
7. If the clearance is not within the factory specifications, adjust
with the adjusting screw.
Intake and exhaust 0.145 to 0.185 mm
Factory spec.
valve clearance (Cold) 0.00571 to 0.00728 in.
A The sequence of cylinder numbers is given as No.1, No.2

and No.3 starting from the gear case side.
A After adjusting the valve clearance, secure the adjusting
screw with the lock nut.
(1) Cylinder Head Cover A: Gear Case Side
(2) "1TC" Mark [a] Z602-E
(3) Alignment Mark [b] D902-E
0000003187E
III-S-56

Checking Fuel Injection Nozzle Condition
See page III-S-107, 108.
0000003188E
(10)Check Points of Every 3000 Hours

Checking Injection Pump
See page III-S-104, 105, 106.
0000003189E
(11)Check Points of Every 2 Years

Replacing Intake Air Line
See page III-S-52.
0000003190E
Replacing Radiator Hoses and Clamp Bands

See page III-S-52.
0000003191E
Replacing Fuel Hoses and Clamp Bands

See page III-S-50.
0000003192E
Changing Radiator Coolant (L.L.C.)

See page III-S-49, 54.
0000003193E
III-S-57
[8] SPECIAL TOOLS

Special Use Puller Set
Code No : 07916-09032
Application : Use exclusively for pulling out bearing, gears and
other parts with ease.
0000000677E
Piston Ring Compressor

Code No : 07909-32111
Application : Use exclusively for pushing in the piston with
piston rings into the cylinder.
0000000678E
Piston Ring Tool

Code No : 07909-32121
Application : Use exclusively for removing or installing the
piston ring with ease.
0000000679E
Diesel Engine Compression Tester

Code No : 07909-30208 (Assembly) 07909-31251 (G)
07909-30934 (A to F) 07909-31271 (I)
07909-31211 (E and F) 07909-31281 (J)
07909-31231 (H)
Application : Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1) Gauge (7) Adaptor F
(2) L Joint (8) Adaptor G
(3) Adaptor A (9) Adaptor H
(4) Adaptor B (10) Adaptor I
(5) Adaptor C (11) Adaptor J
(6) Adaptor E
0000000680E
III-S-58
Diesel Engine Compression Tester (for Glow Plug)

Code No : 07909-39081 (Assembly) 07909-31301 (L)
07909-31291 (K) 07909-31311 (M)
Application : Use to measure diesel engine compression and
diagnostics of need for major overhaul.
(1) Gauge (4) Adaptor L
(2) L Joint (5) Adaptor M
(3) Adaptor K
0000001398E
Oil Pressure Tester

Code No : 07916-32032
Application : Use to measure lubricating oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
0000000681E
Valve Seat Cutter

Code No : 07909-33102
Application : Use to reseat valves.
Angle : 0.785 rad (45 )
0.262 rad (15 )
Diameter : 28.6 mm (1.126 in.) 38.0 mm (1.496 in.)
31.6 mm (1.244 in.) 41.3 mm (1.626 in.)
35.0 mm (1.378 in.) 50.8 mm (2.000 in.)
0000000682E
Radiator Tester
Code No : 07909-31551
Application : Use to check of radiator cap pressure, and leaks
from cooling system.
Remarks : Adaptor (1) BANZAI Code No. RCT-2A-30S.
0000000815E
III-S-59
Connecting Rod Alignment Tool

Code No : 07909-31661
Application : Use to check the connecting rod alignment.
Applicable : Connecting rod big end I.D.
range 30 to 75 mm (1.18 to 2.95 in.) dia.
Connecting rod length
65 to 300 mm (2.56 to 11.81 in.)
0000000684
Nozzle Tester
Code No : 07909-31361
Application : Use to check the fuel injection pressure and spray
pattern of nozzle.
Measuring : 0 to 50 MPa
range (0 to 500 , 0 to 7000 psi)
0000000685E
Plastigage
Code No : 07909-30241
Application : Use to check the oil clearance between
crankshaft and bearing, etc..
Measuring : Green.....0.025 to 0.076 mm (0.001 to 0.003 in.)
range Red.........0.051 to 0.152 mm (0.002 to 0.006 in.)
Blue.........0.102 to 0.229 mm (0.004 to 0.009 in.)
0000000686E
Red Check
Code No : 07909-31371
Application : Use to check cracks on cylinder head, cylinder
block, etc..
0000000687E
III-S-60
Injection Pump Pressure Tester

Application : Use to check fuel tightness of injection pumps.
Pressure gauge full scale : More than 29.4 MPa (300 , 4267
A
psi)
B Copper gasket
C Flange (Material : Steel)
D Hex. nut 27 mm (1.06 in.) across the plat
E Retaining nut
F PF 1/2
G 5 mm (0.20 in.)
H 17 mm dia. (0.67 in.dia.)
I 8 mm dia. (0.31 in.dia.)
J 1.0 mm (0.039 in.)
K 17 mm dia. (0.67 in.dia.)
L 6.10 to 6.20 mm dia. (0.2402 to 0.2441 in.dia.)
M 8 mm (0.31 in.)
N 4 mm (0.16 in.)
O 11.97 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)
P PF 1/2
Q 23 mm (0.91 in.)
R 17 mm (0.67 in.)
S 4 mm (0.16 in.)
T 12.00 to 12.02 mm dia. (0.4724 to 0.4732 in.dia.)
U 100 mm (3.94 in.)
V M12 x P1.5
a Adhesive application
b Fillet welding on the enter circumference
0000001341E
III-S-61
Valve Guide Replacing Tool

Application : Use to press out and press fit the valve guide.
A 20 mm dia. (0.79 in. dia.)
B 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in.dia.)
C 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in.dia.)
D 200 mm (7.87 in.)
E 80 mm (3.15 in.)
F 40 mm (1.58 in.)
G 15 mm (0.59 in.)
H 5 mm (0.197 in.)
I 6.0 to 6.1 mm dia. (0.236 to 0.240 in.dia.)
J 18 mm dia. (0.71 in.dia.)
K 10.6 to 10.7 mm dia. (0.417 to 0.421 in.dia.)
L 7 mm (0.276 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C2 Chamfer 2.0 mm (0.079 in.)
C0.3 Chamfer 0.3 mm (0.012 in.)
0000000816E
Bushing Replacing Tools
Application : Use to press out and to press fit the bushing.
1. For small end bushing
A 145 mm (5.71 in.)
B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95 mm (0.7835 to 0.7854 in.)
E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F 25 mm (0.98 in.)
a 6.3 (250 .)
b 6.3 (250 .)
2. For idle gear bushing

A 150 mm (5.91 in.)
B 20 mm (0.79 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95 mm (0.7835 to 0.7854 in.)
E 21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)
F 25 mm (0.98 in.)
a 6.3 (250 .)
b 6.3 (250 .)
0000003194E
III-S-62
Flywheel Stopper
Application : Use to loosen and tighten the flywheel screw.
A 200 mm (7.87 in.)
B 20 mm (0.79 in.)
C 30 mm (1.18 in.)
D 8 mm (0.31 in.)
E 10 mm dia. (0.39 in. dia.)
0000000818E
Crankshaft Bearing 1 Replacing Tool

Application : Use to press out and press fit the crankshaft
bearing 1.
[Press Out]
A 135 mm (5.31 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 10 mm (0.39 in.)
E 22 mm (0.87 in.)
F 20 mm dia. (0.79 in. dia.)
G 47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)
H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)
[Press Fit]
A 130 mm (5.12 in.)
B 72 mm (2.83 in.)
C 40 mm radius (1.57 in. radius)
D 9 mm (0.35 in.)
E 24 mm (0.95 in.)
F 20 mm dia. (0.79 in. dia.)
G 68 mm dia. (2.68 in. dia.)
H 43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)
0000000819E
III-S-63
2. ENGINE BODY
[1] CHECKING AND ADJUSTING
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine.
3. Remove the air cleaner, the muffler, the head cover and all
glow plugs.
4. Set a compression tester (Code No. 07909-30208) with the
adaptor (Adaptor K, code No. 07909-291) to the glow plug
hole.
5. After making sure that the stop lever is set at the stop position
(non-injection), run the engine with the starter and measure
the compression pressure.
6. Repeat steps 4 and 5 for each cylinder.
7. If the measurement is below the allowable limit, apply a small
amount of oil to the cylinder wall through the glow plug hole
and measure the compression pressure again.
8. If the compression pressure is still less than the allowable limit,
check the top clearance, valve clearance and cylinder head.
9. If the compression pressure increases after applying oil, check
the cylinder wall and piston rings.
A Check the compression pressure with the specified valve

clearance.
A Always use a fully charged battery for performing this
test.
A Variances in cylinder compression values should be
under 10 %.
3.53 to 4.02 MPa
Factory spec. 36 to 41
512 to 583 psi
Compression pressure
2.55 MPa
Allowable limit 26
370 psi
0000001289E
III-S-64
Top Clearance
1. Remove the cylinder head. (Do not attempt to remove the
cylinder head gasket.).
2. Move the piston up, and stick a strip of fuse [1.5 mm dia.
(0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the
piston head at three positions with grease so as to avoid the
intake and exhaust valves and the combustion chamber ports.
3. Lower the piston, and install the cylinder head and tighten the
cylinder head screws to the specified torque.
4. Turn the flywheel until the piston exceeds its top dead center.
5. Remove the cylinder head, and measure the thickness of the
squeezed fuses.
6. If the measurement is not within the factory specifications,
check the oil clearance between the crankpin and crankpin
bearing and between the piston pin and small end bushing.
A After checking the top clearance, be sure to assemble the

cylinder head with a new cylinder head gasket.
0.50 to 0.70 mm
Top clearance Factory spec.
0.0197 to 0.0276 in.
37.3 to 42.2
Tightening torque Cylinder head screw 3.8 to 4.3
27.5 to 31.1 ft-lbs
(1) Fuse
0000000844E
[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Coolant and Engine Oil
Draining Coolant
A Never remove radiator cap while operating or immediately

after stopping. Otherwise, hot water will spout out from
the radiator. Wait for more than ten minutes to cool the
radiator, before opening the cap.
1. Prepare a bucket. Open the coolant drain cock.
(1) Coolant Drain Cock
0000001290E
III-S-65
Draining Engine Oil

1. Start and warm up the engine for approx. 5 minutes.
2. Place an oil pan underneath the engine.
3. Remove the drain plug (1) to drain oil.
4. After draining, screw in the drain plug.
(When refilling)
A Fill the engine oil up to the upper line on the dipstick (2)
A Never mix two different type of oil.

A Use the proper SAE Engine Oil according to ambient
temperature.
(1) Drain Plug (3) Oil Inlet Plug
(2) Dipstick
0000001291E
(2) External Components

Alternator, Starter and Others
1. Remove the air cleaner and muffler.
2. Remove the engine stop solenoid (1).
3. Remove the cooling fan (2), fan pulley and fan belt (3).
4. Remove the alternator.
5. Remove the starter.
(When reassembling)
A Check to see that there are no cracks on the belt surface.
A Keep the engine stop lever (5) to touch the stopper (4).
Tighten the engine stop solenoid mounting screw (6) so
that there be no gap between the engine stop lever and
the engine stop solenoid plunger (7).
A After reassembling the fan belt, be sure to adjust the fan
belt tension.
A Do not confuse the direction of the fan.
(1) Engine Stop Solenoid (6) Engine Stop Solenoid Mounting
(2) Cooling Fan Screw
(3) Fan Belt (7) Plunger
(4) Stopper
(5) Engine Stop Lever A: 0 mm (0 in.)
0000003304E
III-S-66
(3) Cylinder Head, Valves and Oil Pan

Cylinder Head Cover
1. Remove the head cover screws (1).
2. Remove the cylinder head cover (2).
(When reassembling)
A Check to see if the cylinder head cover gasket is not defective.
6.86 to 11.3
Cylinder head cover
Tightening torque 0.7 to 1.15
screw
5.1 to 8.3 ft-lbs
(1) Head Cover Screws [a] Z602-E

(2) Cylinder Head Cover [b] D902-E
0000003305E
Injection Pipes
1. Loosen the screws on the pipe clamp (1).
2. Detach the injection pipes (2).
(When reassembling)
A Sent compressed air into the pipes to blow out dust. Then,
reassemble the pipes in the reverse order.
24.5 to 34.3
Injection pipe retaining
nut
18.1 to 25.3 ft-lbs
(1) Pipe Clamp [a] Z602-E

(2) Injection Pipe [b] D902-E
0000003195E
III-S-67
Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe (1).
2. Remove the nozzle holder assemblies (2).
3. Remove the copper gasket (5) and the heat seal (6).
4. Remove the lead (3) from the glow plugs (4).
5. Remove the glow plugs (4).
(When reassembling)
A Replace the copper gasket and heat seal with new one.
19.6 to 24.5
Overflow pipe retaining
2.0 to 2.5
nut
14.5 to 18.1 ft-lbs
49.0 to 68.6
Tightening torque Nozzle holder assembly 5.0 to 7.0
36.2 to 50.6 ft-lbs
7.85 to 14.7
Glow plug 0.8 to 1.5
5.8 to 10.8 ft-lbs
(1) Overflow Pipe [a] Z602-E

(2) Nozzle Holder Assembly [b] D902-E
(3) Lead
(4) Glow Plug
(5) Copper Gasket
(6) Heat Seal
0000003196E
III-S-68
Rocker Arm and Push Rod

1. Remove the rocker arm bracket screws (1).
2. Detach the rocker arm assembly (2).
3. Remove the push rods (3).
(When reassembling)
A When putting the push rods (3) onto the tappets (4), check to
see if their ends are properly engaged with the dimples.
A After installing the rocker arm, be sure to adjust the valve

clearance.
9.8 to 11.3
Rocker arm bracket
screw
7.2 to 8.3 ft-lbs
(1) Rocker Arm Bracket screws [a] Z602-E

(2) Rocker Arm Assembly [b] D902-E
(3) Push Rod
(4) Tappet
0000003197E
III-S-69
Cylinder Head
1. Loosen the pipe clamps (1), and remove the water return pipe
(2).
2. Remove the cylinder head screw in the order of (n or j) to (a).
3. Lift up the cylinder head to detach.
4. Remove the cylinder head gasket and O-ring (3).
(When reassembling)
A Replace the cylinder head gasket with a new one.
A Securely fit the O-ring (3) to the pipe pin.
A Tighten the cylinder head screws after applying sufficient oil.
A Tighten the cylinder head screws in order of (a) to (n or j).
A Tighten them uniformly, or the head may deform in the long
run.
A Retighten the cylinder head screws after running the engine
for 30 minutes.
37.3 to 42.2
Tightening torque Cylinder head screw 3.8 to 4.3
27.5 to 31.1 ft-lbs
(1) Pipe Clamp A: Gear Case Side

(2) Water Return Pipe (n or j) to (a): To Loosen
(3) O-ring (a) to (n or j): To Tighten
[a] Z602-E
[b] D902-E
0000003198E
III-S-70
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
A Visually check the contact between tappets and cams for
proper rotation. If defect is found, replace tappets.
A Before installing the tappets, apply engine oil thinly around
them.
A Do not change the combination of tappet and tappet

guide.
(1) Tappet
0000001324E
Valves
1. Remove the valve caps (2).
2. Remove the valve spring collet (3), pushing the valve spring
retainer (4) by valve spring replacer (1).
3. Remove the valve spring retainer (4), valve spring (5) and
valve stem seal (6).
4. Remove the valve (7).
(When reassembling)
A Wash the valve stem seal and valve guide hole, and apply
engine oil sufficiently.
A After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
A Do not change the combination of valve and valve guide.

(1) Valve Spring Replacer (5) Valve Spring
(2) Valve Cap (6) Valve Stem Seal
(3) Valve Spring Collet (7) Valve
(4) Valve Spring Retainer
0000001325E
III-S-71
Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws (1).
2. Remove the oil pan (2) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil strainer (3).
(When reassembling)
A After cleaning the oil strainer, check to see that the filter mesh
in clean, and install it.
A Visually check the O-ring (4), apply engine oil, and install it.
A Securely fit the O-ring to the oil strainer.
A To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order from the center.
For Z602-E
A Using the hole (5) numbered "2", install the oil strainer by
mounting screw.
For D902-E
A Using the hole (6) numbered "3", install the oil strainer by
mounting screw.
A Scrape off the old adhesive completely. Wipe the sealing

surface clean. Now apply new adhesive 3 to 5 mm (0.12 to
0.20 in.) thick all over the contact surface. Apply the
adhesive also on the center of the flange as well as on the
inner wall of each screw hole.
A Cut the nozzle of the "liquid gasket" (Three Bond 1207D or
equivalent) container at its second notch. Apply "liquid
gasket" about 5 mm (0.20 in.) thick.
Within 20 minutes after the application of fluid sealant,
reassemble the components. Wait then for about 30
minutes, and pour oil in the crankcase.
(1) Oil Pan Mounting Screw [a] Z602-E
(2) Oil Pan [b] D902-E
(3) Oil Strainer
(4) O-ring
(5) Hole Numbered "2"
(6) Hole Numbered "3"
0000003199E
III-S-72
(4) Timing Gear, Camshaft and Fuel Camshaft

Injection Pump, Fuel Feed Pump and Speed Control Plate
1. Remove the socket head screws and nuts, and remove the
injection pump (1).
2. Remove the screws and separate the speed control plate (2),
taking care not to damage the governor spring (4).
3. Disconnect the governor spring (4) and remove the speed
control plate (2).
4. Remove the fuel feed pump (3).
(When reassembling)
A Hook the governor spring (4) to the governor lever (5) first and
install the speed control plate (2).
A Be sure to place the copper washers underneath two screws
(6). (Two screws (6) in the upper of the speed control plate
(2).)
A Position the slot (7) on the fork lever just under the slot (8) on
the crankcase.
A Insert the injection pump (1) so that the control rod (10) should
be pushed by the idling adjusting spring (9) at its end and the
pin (11) on the rod engages with the slot (7) on the fork lever
(as shown in the photo).
A The sealant is applied to both sides of the soft metal

gasket shim. The liquid gasket is not required for
assembling.
A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad
(0.5 )
A In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1) Injection Pump (7) Slot (Fork Lever Side)
(2) Speed Control Plate (8) Slot (Crankcase Side)
(3) Fuel Feed Pump (9) Idling Adjusting Spring
(4) Governor Spring (10) Control Rod
(5) Governor Lever (11) Pin
(6) Screw and Copper Washer
0000001327E
Fan Drive Pulley
1. Secure the flywheel to keep it from turning.
2. Remove the fan drive pulley screw.
3. Draw out the fan drive pulley with a puller.
(When reassembling)
A Install the pulley to the crankshaft, aligning the mark (1) on
them.
A Apply engine oil to the fan drive pulley retaining screws. And
tighten them.
98.1 to 107.9
Tightening torque Fan drive pulley screw 10.0 to 11.0
72.3 to 79.6 ft-lbs
(1) Alignment Mark
0000001328E
III-S-73
Gear Case
1. Disconnect the start spring (2) from the fork lever 1 (3).
2. Remove the screw (1) of inside the gear case and outside
screws.
3. Remove the gear case (4).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the gear case gasket.
A Be sure to set three O-rings inside the gear case.
(1) Screw (Inside) (3) Fork Lever 1
(2) Start Spring (4) Gear Case
0000001329E
Idle Gear
1. Remove the external snap ring (3), the collar (2) and the idle
gear (1).
2. Remove the idle gear shaft mounting screws (4).
3. Remove the idle gear shaft (5).
(When reassembling)
A Apply engine oil to the idle gear shaft mounting screw (4). And
tighten them.
A Install the idle gear, aligning the mark (6) on the gears referring
to the photo.
9.8 to 11.3
Idle gear shaft mounting
screw
7.2 to 8.3 ft-lbs
(1) Idle Gear (4) Idle Gear Shaft Mounting

(2) Idle Gear Collar Screw
(3) External Snap Ring (5) Idle Gear Shaft
(6) Alignment Mark
0000001330E
III-S-74
Camshaft
1. Remove the camshaft mounting screws (1) and draw out the
camshaft with gear (2) on it.
(When reassembling)
A When install the camshaft, apply engine oil to the camshaft
journals.
A Apply engine oil to the camshaft mounting screws. And
tighten them.
(1) Camshaft Mounting Screw (2) Camshaft Gear
0000001331E
Fuel Camshaft
1. Remove the retaining plate (1).
2. Remove the fork lever holder mounting screws (8), then draw
out the injection pump gear (3) and fuel camshaft (2) with the
governor fork assembly.
(When reassembling)
A Hook the governor spring (7) to the fork lever 2 (6) as shown
in the figure before installing the fork lever assembly to the
crankcase.
(1) Retaining Plate (5) Fork Lever 1
(2) Fuel Camshaft (6) Fork Lever 2
(3) Injection Pump Gear (7) Governor Spring
(4) Governor Sleeve (8) Fork Lever Holder Mounting
Screw
0000001332E
Oil Pump and Crankshaft Gear

1. Remove the oil pump gear (6).
2. Remove the oil pump (5).
3. Remove the collar (4), O-ring (3) and crankshaft oil slinger (2).
(When reassembling)
A Install the collar (4) after aligning the marks on the gear. (See
the photo at "Idle Gear".).
(1) Crankshaft Gear (4) Crankshaft Collar
(2) Crankshaft Oil Slinger (5) Oil Pump
(3) O-ring (6) Oil Pump Gear
0000001333E
III-S-75
(5) Piston and Connecting Rod

Connecting Rod
1. Remove the connecting rod caps (1) using a bihexagonal
8 mm socket.
(When reassembling)
A Align the marks (a) with each other. (Face the marks toward
the injection pump.)
A Apply engine oil to the connecting rod screws and lightly screw
it in by hand, then tighten it to the specified torque.
If the connecting rod screw won't be screwed in smoothly,
clean the threads.
If the connecting rod screw is still hard to screw in, replace it.
26.5 to 30.4
Tightening torque Connecting rod screw 2.7 to 3.1
19.5 to 22.4 ft-lbs
(1) Connecting Rod Cap (a) Mark
0000003200E
Piston
1. Turn the flywheel and bring the piston to top dead center.
2. Draw out the piston upward by lightly tapping it from the
bottom of the crankcase with the grip of a hammer.
3. Draw out the other piston in the same method as above.
(When reassembling)
A Before inserting the piston into the cylinder, apply enough
engine oil to the piston.
A When inserting the piston into the cylinder, face the mark on
the connecting rod to the injection pump.
A Do not change the combination of cylinder and piston.

Make sure of the position of each piston by marking. For
example, mark "1" on the No.1 piston.
A When installing the piston into the cylinder, place the
gaps of all the piston rings as shown in the figure.
A Carefully insert the piston using a piston ring compressor
(1). Otherwise, their chrome-plated section may be
scratched, causing trouble inside the cylinder.
(1) Piston Ring Compressor (a) 0.785 rad (45 )
(A) Top Ring Gap (b) 0.785 rad (45 )
(B) Second Ring Gap (c) 1.57 rad (90 )
(C) Oil Ring Gap
(D) Piston Pin Hole
0000001335E
III-S-76
Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool (Code No.
07909-32121).
2. Remove the piston pin (7), and separate the connecting rod
(6) from the piston (5).
(When reassembling)
A When installing the ring, assemble the rings so that the
manufacturer's mark (12) near the gap faces the top of the
piston.
A When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
A Apply engine oil to the piston pin.
A When installing the connecting rod to the piston, immerse the
piston in 80 (176 ) oil for 10 to 15 minutes and insert the
piston pin to the piston.
A When installing the connecting rod to the piston, align the
mark (8) on the connecting rod to the fan-shaped concave (9).
A Mark the same number on the connecting rod and the

piston so as not to change the combination.
(1) Top Ring (9) Fan-Shaped Concave
(2) Second Ring (10) Expander Joint
(3) Oil Ring (11) Oil Ring Gap
(4) Piston Pin Snap Ring (12) Manufacturer's Mark
(5) Piston
(6) Connecting Rod
(7) Piston Pin
(8) Mark
0000003201E
III-S-77
(6) Crankshaft
Flywheel
1. Secure the flywheel to keep it from turning using a flywheel
stopper. (See page III-S-63.)
2. Remove all flywheel screws (1) and then remove the flywheel
(2).
(When reassembling)
A Align the "1TC" mark (a) on the outer surface of the flywheel
horizontally with the alignment mark (b) on the rear end plate.
Now fit the flywheel in position.
A Apply engine oil to the threads and the undercut surface of the
flywheel screw and fit the screw.
53.9 to 58.8
Tightening torque Flywheel screw 5.5 to 6.0
39.8 to 43.4 ft-lbs
(1) Flywheel Screw (a) 1TC Mark

(2) Flywheel (b) Alignment Mark
0000003202E
Bearing Case Cover

1. Remove the bearing case cover mounting screws. First,
remove inside screws (1) and then outside screws (2).
2. Remove the bearing case cover (6).
(When reassembling)
A Fit the bearing case gasket (3) and the bearing case cover
gasket (4) with correct directions.
A Install the bearing case cover (6) to position the casting mark
"UP" (a) on it upward.
A Apply engine oil to the oil seal (5) lip and take care that it is not
rolled when installing.
A Tighten the bearing case cover mounting screws with even
force on the diagonal line.
9.8 to 11.3
Bearing case cover
mounting screw
7.2 to 8.3 ft-lbs
(1) Bearing Case Cover Mounting (5) Oil Seal

Screw (Inside) (6) Bearing Case Cover
(2) Bearing Case Cover Mounting
Screw (Outside) (a) Top Mark "UP"
(3) Bearing Case Gasket (b) Upside
(4) Bearing Case Cover Gasket
0000001337E
III-S-78
Crankshaft Assembly
For Z602-E
1. Remove the main bearing case screw 2 (1).
2. Turn the crankshaft to set the crankpin of the cylinder to the
horizontal directions (Right or Left). Then draw out all the
crankshaft, holding the crankpins to the horizontal directions.
For D902-E
1. Remove the main bearing case screw 2 (1).
2. Turn the crankshaft to set the crankpin of the third cylinder to
the bottom dead center. Then draw out the crankshaft until the
crankpin of the second cylinder comes to the center of the third
cylinder.
3. Turn the crankshaft by 2.09 rad (120 ) counterclockwise to set
the crankpin of the second cylinder to the bottom dead center.
Draw out the crankshaft until the crankpin of the first cylinder
comes to the center of the third cylinder.
4. Repeat the above steps to draw out all the crankshaft.
(When reassembling)
A Clean the oil passage of the crankshaft with compressed air.
A Install the crankshaft assembly, aligning the screw hole of
main bearing case screw 2 with the screw hole of crankcase.
A When tightening the main bearing case 2, apply oil to the main
bearing case screw 2 (1) and screw by hand before tightening
the specific torque. If not smooth to screw by hand, align the
screw holes between the crankcase and the main bearing
case.
26.5 to 30.4
Main bearing case
screw 2
19.5 to 22.4 ft-lbs
(1) Main Bearing Case Screw 2 A: Cut place for removing and
installing the crankshaft
[a] Z602-E
[b] D902-E
0000003203E
III-S-79
Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (9), and remove
the main bearing case assembly 1 (1), being careful with
crankshaft bearing 3 (4) (5).
2. Remove the main bearing case assembly 2 (2) and the main
bearing case assembly (3) as above. Keep in mind, however,
that the thrust bearing (8) is installed in the main bearing case
assembly (3).
(When reassembling)
A Clean the oil passage in the main bearing cases.
A Apply clean engine oil on the bearings.
A Install the main bearing case assemblies in original positions.
Since diameters of main bearing cases vary, install them in
order to marking (b) (1 for Z602-E and 1, 2 for D902-E) from
the gear case side. (Refer to the figure.)
A Be careful not to confuse the top and bottom of the crankshaft
bearing 3 (4) (5).
(Install the bearing with the oil groove (c) up.)
A Match the alignment numbers (a) on the main bearing case
assembly 1.
A Do the same for the main bearing case assembly 2 (2) and the
main bearing case assembly (3) too.
A When installing the main bearing case 1 and 2, face the mark
"FLYWHEEL" to the flywheel.
A Install the thrust bearing (8) with its oil groove facing outward.
A Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 to the specified
torque.
12.7 to 15.7
Main bearing case
screw 1
9.4 to 11.6 ft-lbs
(1) Main Bearing Case Assembly 1 (a) Alignment Number

(2) Main Bearing Case Assembly 2 (b) Marking (1 or 2)
(3) Main Bearing Case Assembly (c) Oil Groove
(4) Crankshaft Bearing 3
(Upper, with oil groove)
(5) Crankshaft Bearing 3 (Lower)
(6) Crankshaft Bearing 2
(Upper, with oil groove)
(7) Crankshaft Bearing 2 (Lower)
(8) Thrust Bearing
(9) Main Bearing Case Screw 1
0000003204E
III-S-80
[3] SERVICING
(1) Cylinder Head and Valves
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head's four sides and two
diagonals as shown in the figure.
3. Measure the clearance with a thickness gauge.
4. If the measurement exceeds the allowable limit, correct it with
a surface grinder.
A Do not place the straightedge on the combustion

chamber.
A Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.0020 in.
0000001342E
Cylinder Head Flaw

1. Prepare an air spray red check (Code No. 07909-31371).
2. Clean the surface of the cylinder head with the detergent (2).
3. Spray the cylinder head surface with the red permeative liquid
(1). Leave it five to ten minutes after spraying.
4. Wash away the red permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with the white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permetive Liquid (3) White Developer
(2) Detergent
0000000875E
III-S-81
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Insert the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement exceeds the allowable limit, replace the
valve.
5. If it still exceeds the allowable limit after replacing the valve,
correct the valve seat face of the cylinder head with a valve
seat cutter (Code No. 07909-33102) or valve seat grinder.
6. Then, correct the cylinder head surface with a surface grinder,
or replace the cylinder head.
0.10 (protrusion) to
0.10 (recessing) mm
Factory spec.
Valve recessing (Intake 0.0039 (protrusion) to
and Exhaust) 0.0039 (recessing) in.
0.30 (recessing) mm
Allowable limit
0.0118 (recessing) in.
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
0000001343E
Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an outside micrometer.
3. Measure the valve guide I.D. with a small hole gauge, and
calculate the clearance.
4. If the clearance exceeds the allowable limit, replace the
valves. If it still exceeds the allowable limit, replace the valve
guide.
0.030 to 0.057 mm
Clearance between Factory spec.
0.00118 to 0.00224 in.
valve stem and valve
guide 0.10 mm
Allowable limit
0.0039 in.
5.968 to 5.980 mm
Valve stem O.D. Factory spec.
0.23496 to 0.23543 in.
6.010 to 6.025 mm
Valve guide I.D. Factory spec.
0.23661 to 0.23720 in.
0000000877E
III-S-82
Replacing Valve Guide

(When removing)
1. Press out the used valve guide using a valve guide replacing
tool. (See page S-62.)
(When installing)
1. Clean a new valve guide and valve guide bore, and apply
engine oil to them.
2. Press in a new valve guide using a valve guide replacing tool.
3. Ream precisely the I.D. of the valve guide to the specified
dimension.
Valve guide I.D. (Intake 6.010 to 6.025 mm
Factory spec.
and Exhaust) 0.2366 to 0.2372 in.
A Do not hit the valve guide with a hammer during

replacement.
(A) When removing (B) When installing
0000003205E
Valve Seating
1. Coat the valve face lightly with prussian blue and put the valve
on its seat to check the contact.
2. If the valve does not seat all the way around the valve seat or
the valve contact is less than 70 %, correct the valve seating
as follows.
3. If the valve contact does not comply with the reference value,
replace the valve or correct the contact of valve seating.
2.12 mm
Valve seat width Factory spec.
0.0835 in.
(1) Correct (3) Incorrect

(2) Incorrect
0000000879E
III-S-83
Correcting Valve and Valve Seat
A Before correcting the valve and seat, check the valve

stem and the I.D. of valve guide section, and repair them
if necessary.
A After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
0.785 rad
Valve face angle Factory spec.
45
2) Correcting Valve Seat

1. Slightly correct the seat surface with a 0.785 rad (45 ) valve
seat cutter (Code No. 07909-33102).
2. Fitting the valve, check the contact position of the valve face
and seat surface with prussian blue. (Visual check) [ If the
valve has been used for a long period, the seat tends to come
in contact with the upper side of the valve face.]
3. Grind the upper surface of the seat with a 0.262 rad (15 )
valve seat cutter until the valve seat touches to the center of
the valve face (so that (a) equals (b) as shown in the figure)
4. Grind the seat with a 0.785 rad (45 ) valve seat cutter again,
and visually recheck the contact between the valve and seat.
5. Repeat steps 3 and 4 until the correct contact is achieved.
6. Continue lapping until the seated rate becomes more than 70
% of the total contact area.
0.785 rad
Valve seat angle Factory spec.
45
(1) Valve Seat Cutter (a) Identical Dimensions

(A) Check Contact (b) Valve Seat Width
(B) Correct Seat Width (c) 0.262 rad (15 )
(C) Correct Seat Surface (d) 0.785 rad (45 )
(D) Check Contact
0000003400E
Valve Lapping
1. Apply compound evenly to the valve lapping surface.
2. Insert the valve into the valve guide. Lap the valve onto its
seat with a valve flapper or screwdriver.
3. After lapping the valve, wash the compound away and apply
oil, then repeat valve lapping with oil.
4. Apply prussian blue to the contact surface to check the seated
rate. If it is less than 70 %, repeat valve lapping again.
A When valve lapping is performed, be sure to check the

valve recessing and adjust the valve clearance after
assembling the valve.
0000001345E
III-S-84
Free Length and Tilt of Valve Spring

1. Measure the free length (A) of valve spring with vernier
calipers. If the measurement is less than the allowable limit,
replace it.
2. Put the valve spring on a surface plate, place a square on the
side of the valve spring.
3. Check to see if the entire side is in contact with the square.
Rotate the valve spring and measure the maximum tilt (B).
If the measurement exceeds the allowable limit, replace it.
4. Check the entire surface of the valve spring for scratches.
If there is any defect, replace it.
31.3 to 31.8 mm
Factory spec.
1.232 to 1.252 in.
Free length (A)
28.4 mm
Allowable limit
1.118 in.
1.2 mm
Tilt (B) Allowable limit
0.047 in.
(A) Free Length (B) Tilt
0000003633E
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed in the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
64.7 N / 27.0 mm
Factory spec. 6.6 kgf / 27.0 mm
Setting load / Setting 14.6 lbs / 1.063 in.
length 54.9 N / 27.0 mm
Allowable limit 5.6 kgf / 27.0 mm
12.3 lbs / 1.063 in.
0000000883E
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm shaft O.D. with an outside
micrometer.
2. Measure the rocker arm I.D. with an inside micrometer, and
then calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit, replace the
rocker arm and measure the oil clearance again. If it still
exceeds the allowable limit, replace also the rocker arm shaft.
0.016 to 0.045 mm
Oil clearance between Factory spec.
0.00063 to 0.00177 in.
rocker arm and rocker
arm shaft 0.15 mm
Allowable limit
0.0059 in.
10.473 to 10.484 mm
Rocker arm shaft O.D. Factory spec.
0.41232 to 0.41276 in.
10.500 to 10.518 mm
Rocker arm I.D. Factory spec.
0.41339 to 0.41410 in.
0000000884E
III-S-85
Push Rod Alignment

1. Place the push rod on V blocks.
2. Measure the push rod alignment.
push rod.
0.25 mm
Push rod alignment Allowable limit
0.0098 in.
0000000885E
Oil Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet O.D. with an outside micrometer.
2. Measure the I.D. of the tappet guide bore with a cylinder
gauge, and calculate the oil clearance.
3. If the oil clearance exceeds the allowable limit or the tappet is
damaged, replace the tappet.
0.016 to 0.052 mm
0.00063 to 0.00205 in.
tappet and tappet guide
bore 0.10 mm
Allowable limit
0.0039 in.
17.966 to 17.984 mm
Tappet O.D. Factory spec.
0.70732 to 0.70803 in.
18.000 to 18.018 mm
Tappet guide bore I.D. Factory spec.
0.70866 to 0.70937 in.
0000001346E
III-S-86
(2) Timing Gear, Camshaft

Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating
gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shafts and the gear.
4. If the oil clearance isn't proper, replace the gear.
0.043 to 0.124 mm
Factory spec.
Backlash between idle 0.00169 to 0.00488 in.
gear and crank gear 0.15 mm
Allowable limit
0.0059 in.
0.047 to 0.123 mm
Factory spec.
Backlash between idle 0.00185 to 0.00484 in.
gear and cam gear 0.15 mm
Allowable limit
0.0059 in.
0.046 to 0.124 mm
Backlash between idle Factory spec.
0.00181 to 0.00488 in.
gear and injection pump
gear 0.15 mm
Allowable limit
0.0059 in.
0.041 to 0.123 mm
Backlash between oil Factory spec.
0.00161 to 0.00484 in.
pump drive gear and
crank gear 0.15 mm
Allowable limit
0.0059 in.
0000001347E
Idle Gear Side Clearance
1. Set a dial indicator with its tip on the idle gear.
2. Measure the side clearance by moving the idle gear to the
front and rear.
idle gear collar.
0.20 to 0.51 mm
Factory spec.
0.0079 to 0.0201 in.
Idle gear side clearance
0.80 mm
Allowable limit
0.0315 in.
0000001348E
Camshaft Side Clearance
1. Set a dial indicator with its tip on the camshaft.
2. Measure the side clearance by moving the cam gear to the
front and rear.
camshaft stopper.
0.15 to 0.31 mm
Factory spec.
Camshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
0000001349E
III-S-87
Camshaft Alignment
1. Support the camshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the camshaft alignment.
camshaft.
0.01 mm
Camshaft alignment Allowable limit
0.0004 in.
0000000891E
Cam Height
1. Measure the height of the cam at its highest point with an
outside micrometer.
2. If the measurement is less than the allowable limit, replace the
camshaft.
26.88 mm
Factory spec.
Cam height of intake 1.0583 in.
and exhaust 26.83 mm
Allowable limit
1.0563 in.
0000000892E
Oil Clearance of Camshaft Journal

1. Measure the camshaft journal O.D. with an outside
micrometer.
2. Measure the cylinder block bore I.D. for camshaft with a inside
micrometer, and calculate the oil clearance.
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.00197 to 0.00358 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.
32.934 to 32.950 mm
Camshaft journal O.D. Factory spec.
1.29661 to 1.29724 in.
Camshaft bearing I.D.

33.000 to 33.025 mm
(Cylinder block bore Factory spec.
1.29921 to 1.30020 in.
I.D.)
0000001350E
III-S-88
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an outside micrometer.
2. Measure the idle gear bushing I.D. with an inside micrometer,
and calculate the oil clearance.
bushing.
4. If it still exceeds the allowable limit, replace the idle gear shaft.
0.020 to 0.084 mm
0.00079 to 0.00331 in.
idle gear shaft and idle
gear bushing 0.10 mm
Allowable limit
0.0039 in.
19.967 to 19.980 mm
Idle gear shaft O.D. Factory spec.
0.78610 to 0.78661 in.
20.000 to 20.051 mm
Idle gear bushing I.D. Factory spec.
0.78740 to 0.78941 in.
0000001351E
Replacing Idle Gear Bushing

(When removing)
1. Press out the used idle gear bushing using an idle gear
bushing replacing tool. (See page III-S-62.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new bushing using an idle gear bushing replacing
tool, until it is flush with the end of the idle gear.
(A) When removing (B) When installing
0000003206E
(3) Piston and Connecting Rod

Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in both the horizontal and
vertical directions with a cylinder gauge.
piston.
20.000 to 20.013 mm
Factory spec.
0.78740 to 0.78791 in.
Piston pin bore I.D.
20.05 mm
Allowable limit
0.7894 in.
0000000897E
III-S-89
Oil Clearance between Piston Pin and Small End Bushing

1. Measure the piston pin O.D. where it contacts the bushing with
an outside micrometer.
2. Measure the small end bushing I.D. with an inside micrometer,
and calculate the oil clearance.
bushing. If it still exceeds the allowable limit, replace the
piston pin.
0.014 to 0.038 mm
0.00055 to 0.00150 in.
piston pin and small end
bushing 0.10 mm
Allowable limit
0.0039 in.
20.002 to 20.011 mm
Piston pin O.D. Factory spec.
0.78748 to 0.78783 in.
20.025 to 20.040 mm
Small end bushing I.D. Factory spec.
0.78839 to 0.78897 in.
0000000898E
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing
replacing tool. (See page III-S-62.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil
to them.
2. Insert a new bushing onto the tool and press-fit it with a press
so that the seam (1) of bushing positions as shown in the
figure, until it is flush with the connecting rod.
3. Drill a hole to the bushing with aligning the oil hole (2) of
connecting rod. (Refer to the figure.)
A Be sure to chamfer the oil hole circumference with an oil

stone.
0.015 to 0.075 mm
0.00059 to 0.00295 in.
piston pin and small end
bushing (Spare parts) 0.15 mm
Allowable limit
0.0059 in.
Small end bushing I.D. 20.026 to 20.077 mm

Factory spec.
(Spare parts) 0.78845 to 0.79043 in.
(1) Seam (A) When removing

(2) Oil Hole (B) When installing
(a) 0.785 rad (45 )
0000003207E
III-S-90
Piston Ring Gap

1. Insert the piston ring into the lower part of the cylinder (the
least worn out part) with piston.
2. Measure the ring gap with a thickness gauge.
piston ring.
Factory 0.20 to 0.35 mm
spec. 0.0079 to 0.0138 in.
Top ring
Allowable 1.25 mm
limit 0.0492 in.

Second spec. 0.0138 to 0.0197 in.
Piston ring gap
ring Allowable 1.25 mm
limit 0.0492 in.

spec. 0.0079 to 0.0138 in.
Oil ring
Allowable 1.25 mm
limit 0.0492 in.
0000000900E
Clearance between Piston Ring and Piston Ring Groove
1. Clean the rings and the ring grooves, and install each ring in
its groove.
2. Measure the clearance between the ring and the groove with
a thickness gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit with new ring,
replace the piston.
Second spec. 0.00354 to 0.00472 in.
ring Allowable 0.15 mm
Clearance between limit 0.0059 in.
piston ring and piston
ring groove Factory 0.04 to 0.08 mm
spec. 0.0016 to 0.0031 in.
Oil ring
Allowable 0.15 mm
limit 0.0059 in.
0000000901E
III-S-91
Connecting Rod Alignment

1. Remove the crankpin bearing, and install the connecting rod
cap.
2. Install the piston pin in the connecting rod.
3. Install the connecting rod on the connecting rod alignment tool
(Code No. 07909-31661).
4. Put a gauge over the piston pin, and move it against the face
plate.
5. If the gauge does not fit squarely against the face plate,
measure the space between the pin of the gauge and the face
plate.
connecting rod.
Space between gauge 0.05 mm
Allowable limit
pin face plate 0.0020 in.
0000001381E
III-S-92
(4) Crankshaft
Crankshaft Side Clearance
1. Set a dial indicator with its tip on the end of the crankshaft.
2. Measure the side clearance by moving the crankshaft to the
front and rear.
thrust bearings.
4. If the same size bearing is useless because of the crankshaft
journal wear, replace it with an oversize one referring to the
table and figure.
0.15 to 0.31 mm
Factory spec.
Crankshaft side 0.0059 to 0.0122 in.
clearance 0.50 mm
Allowable limit
0.0197 in.
(Reference)
A Oversize thrust bearing
Oversize Bearing Code Number Marking
0.2 mm Thrust bearing 1 02 15261-23950 020 OS

0.008 in. Thrust bearing 2 02 15261-23970 020 OS
0.4 mm Thrust bearing 1 04 15261-23960 040 OS

0.016 in. Thrust bearing 2 04 15261-23980 040 OS
A Oversize dimensions of crankshaft journal

0.2 mm 0.4 mm
Oversize
0.008 in. 0.016 in.
23.40 to 23.45 mm 23.80 to 23.85 mm

Dimension A
0.9134 to 0.9154 in. 0.9213 to 0.9232 in.
46.1 to 46.3 mm 46.3 to 46.5 mm

Dimension B
1.815 to 1.823 in. 1.823 to 1.831 in.
1.8 to 2.2 mm radius 1.8 to 2.2 mm radius

Dimension C
0.071 to 0.087 in. radius 0.071 to 0.087 in. radius
(0.8-S)
The crankshaft journal must be fine-finished to higher than
0000001353E
Crankshaft Alignment
1. Support the crankshaft with V blocks on the surface plate at
both end journals.
2. Set a dial indicator with its tip on the intermediate journal.
3. Measure the crankshaft alignment.
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.0008 in.
0000000905E
III-S-93
Oil Clearance between Crankpin and Crankpin Bearing

1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage (Code No.: 07909-30241) on the
center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
4. Measure the amount of the flattening with the scale, and get
the oil clearance.
crankpin bearing.
6. If the same size bearing is useless because of the crankpin
wear, replace it with an undersize one referring to the table
and figure.
A Never insert the plastigage into the crankpin oil hole.

A Be sure not to move the crankshaft while the connecting
rod screws are tightened.
0.020 to 0.051 mm
0.00079 to 0.00201 in.
crankpin and crankpin
bearing 0.15 mm
Allowable limit
0.0059 in.
33.959 to 33.975 mm
Crankpin O.D. Factory spec.
1.33697 to 1.33760 in.
33.995 to 34.010 mm
Crankpin bearing I.D. Factory spec.
1.33893 to 1.33898 in.
(Reference)
A Undersize crankpin bearing
Undersize Bearing Code Number Marking
0.2 mm
Crankpin bearing 02 15861-22970 020 US
0.008 in.
0.4 mm
Crankpin bearing 04 15861-22980 040 US
0.016 in.
A Undersize dimensions of crankpin

0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.

Dimension A
4 mm dia. 4 mm dia.
Dimension B
0.16 in. dia. 0.16 in. dia.
33.759 to 33.775 mm dia. 33.559 to 33.575 mm dia.

Dimension C
1.32910 to 1.32973 in. dia. 1.32112 to 1.32185 in. dia.
(0.8-S)
The crankpin must be fine-finished to higher than
0000000906E
III-S-94
Oil Clearance between Crankshaft Journal and Crankshaft

Bearing 1
1. Measure the O.D. of the crankshaft front journal with an
outside micrometer.
2. Measure the I.D. of the crankshaft bearing 1 with an inside
micrometer, and calculate the oil clearance.
crankshaft bearing 1.
journal wear, replace it with an undersize one referring to the
table and figure.
0.034 to 0.106 mm
0.00134 to 0.00417 in.
crankshaft journal and
crankshaft bearing 1 0.20 mm
Allowable limit
0.0079 in.
43.934 to 43.950 mm
Crankshaft journal O.D. Factory spec.
1.72968 to 1.73031 in.
Crankshaft bearing 1 43.984 to 44.040 mm

Factory spec.
I.D. 1.73165 to 1.73386 in.
(Reference)
A Undersize crankshaft bearing 1
0.2 mm
Crankshaft bearing 1 02 1G460-23910 020 US
0.008 in.
0.4 mm
Crankshaft bearing 1 04 1G460-23920 040 US
0.016 in.
A Undersize dimensions of crankshaft journal

0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.

Dimension A
4 mm dia. 4 mm dia.
Dimension B
0.16 in. dia. 0.16 in. dia.
43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.

Dimension C
1.72181 to 1.72244 in. dia. 1.71394 to 1.7147 in. dia.
(0.8-S)
0000001354E
III-S-95
Replacing Crankshaft Bearing 1

(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (See page III-S-63.)
(When installing)
1. Clean a new crankshaft bearing 1 and crankshaft journal bore,
and apply engine oil to them.
2. Using a crankshaft bearing 1 replacing tool, press in a new
bearing 1 (2) so that its seam (1) directs toward the exhaust
manifold side. (See figure.)
0.0 to 0.3 mm
Dimension (A) Factory spec.
0.0 to 0.0118 in.
(1) Seam (3) Cylinder Block

(2) Crankshaft Bearing 1 (a) 0.366 rad (21 )
0000003208E
Bearing 2 (Crankshaft Bearing 3)
1. Put a strip of plastigage (Code No. 07909-30241) on the
center of the journal.
2. Install the bearing case and tighten the bearing case screws 1
to the specified torque, and remove the bearing case again.
3. Measure the amount of the flattening with the scale, and get
the oil clearance.
crankshaft bearing 2 (crankshaft bearing 3).
journal wear, replace it with an undersize one referring to the
table and figure.
A Be sure not to move the crankshaft while the bearing case

screws are tightened.
Oil clearance between 0.028 to 0.059 mm
Factory spec.
crankshaft journal and 0.00110 to 0.00232 in.
crankshaft bearing 2 0.20 mm
(Crankshaft bearing 3) Allowable limit
0.0079 in.
Crankshaft journal O.D. 43.934 to 43.950 mm

Factory spec.
(Flywheel side) 1.72968 to 1.73031 in.

Factory spec.
I.D. 1.73142 to 1.73201 in.
Crankshaft journal O.D. 43.934 to 43.950 mm

Factory spec.
(Intermediate) 1.72968 to 1.73031 in.

Factory spec.
I.D. 1.73142 to 1.73201 in.
0000000909E
III-S-96

Bearing 2 (Crankshaft Bearing 3) (Continued)
(Reference)
A Undersize crankshaft bearing 2 and 3
Crankshaft bearing 2 02 15694-23930

020 US
0.2 mm Crankshaft bearing 2F 02 1G460-07530
0.008 in. Crankshaft bearing 3 02 1G460-07580
020 US
Crankshaft bearing 3F 02 1G460-07630
Crankshaft bearing 2 04 15694-23940

040 US
0.4 mm Crankshaft bearing 2F 04 1G460-07540
0.016 in. Crankshaft bearing 3 04 1G460-07590
040 US
Crankshaft bearing 3F 04 1G460-07640
A Undersize dimensions of crankshaft journal

0.2 mm 0.4 mm
Undersize
0.008 in. 0.016 in.

Dimension A
4 mm dia. 4 mm dia.
Dimension B
0.16 in. dia. 0.16 in. dia.
43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.

Dimension C
1.72181 to 1.72244 in. dia. 1.71394 to 1.7147 in. dia.
43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.

Dimension D
1.72181 to 1.72244 in. dia. 1.71394 to 1.7147 in. dia.
(0.8-S)
0000000910E
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the six positions (see figure)
with a cylinder gauge to find the maximum and minimum I.D.'s.
2. Get the difference (Maximum wear) between the maximum
and the minimum I.D.'s.
3. If the wear exceeds the allowable limit, bore and hone to the
oversize dimension. (Refer to "Correcting Cylinder".)
4. Visually check the cylinder wall for scratches. If deep
scratches are found, the cylinder should be bored. (Refer to
"Correcting Cylinder".)
72.000 to 72.019 mm
Factory spec.
2.83464 to 2.83539 in.
Cylinder I.D.
72.169 mm
Allowable limit
2.84129 in.
(A) Top (a) Right-angled to Piston Pin

(B) Middle (b) Piston Pin Direction
(C) Bottom (Skirt)
0000001355E
III-S-97
Correcting Cylinder
1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
72.500 to 72.519 mm
Factory spec.
Cylinder I.D. 2.85433 to 2.85507 in.
[Oversize] 72.669 mm
Allowable limit
2.86098 in.
Horn to 1.2 to 2.0 m Rmax.

Finishing
(0.000047 to 0.000079 in. Rmax.)
2. Replace the piston and piston rings with oversize ones.

Oversize Part Name Code Number Marking
0.25 mm Piston 1G460-21900 025

0.0098 in. Piston ring assembly 1G460-21090 025
A When the oversize cylinder is worn beyond the allowable

limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (2) Cylinder I.D. [Oversize]
[Before Correction]
0000000913E
III-S-98
3. LUBRICATING SYSTEM
[1] CHECKING
Engine Oil Pressure
1. Remove the engine oil pressure switch, and set an oil
pressure tester (Code No.: 07916-32032).
2. Start the engine. After warming up, measure the oil pressure
of both idling and rated speeds.
3. If the oil pressure is less than the allowable limit, check the
following.
A Engine oil insufficient
A Oil pump defective
A Oil strainer clogged
A Oil filter cartridge clogged
A Oil gallery clogged
A Excessive oil clearance
A Foreign matter in the relief valve
More than 49 kPa
At idle Factory
0.5
speed spec.
7 psi
196 to 441 kPa

Factory
Engine oil pressure 2.0 to 4.5
spec.
At rated 28 to 64 psi
speed 147 kPa
Allowable
1.5
limit
21 psi
(When reassembling)
A After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
14.7 to 19.6
Tightening torque Oil pressure switch 1.5 to 2.0
10.8 to 14.5 ft-lbs
0000001356E
[2] SERVICING
Rotor Lobe Clearance
1. Measure the clearance between lobes of the inner rotor and
the outer rotor with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the
oil pump rotor assembly.
0.03 to 0.14 mm
Rotor lobe clearance Factory spec.
0.0012 to 0.0055 in.
0000000915E
III-S-99
Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump
body with a thickness gauge.
Clearance between
0.07 to 0.15 mm
outer rotor and pump Factory spec.
0.0028 to 0.0059 in.
body
0000000916E
Clearance between Rotor and Cover

1. Put a strip of plastigage (Code No. 07909-30241) onto the
rotor face with grease.
2. Install the cover and tighten the screws.
3. Remove the cover carefully, and measure the amount of the
flattening with the scale and get the clearance.
Clearance between 0.075 to 0.135 mm
Factory spec.
rotor and cover 0.00295 to 0.00531 in.
0000000918E
III-S-100
4. COOLING SYSTEM
Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway
between the fan drive pulley and the alternator pulley at
specified force 98 N (10 kgf, 22 lbs).
loosen the alternator mounting screws and relocate the
alternator to adjust.
7.0 to 9.0 mm
Deflection (A) Factory spec.
0.28 to 0.35 in.
0000001384E
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.
(A) Good (B) Bad
0000000920E
Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with its end
inserted between the valve and seat.
2. Heating the water gradually, read the temperature when the
valve opens and leaves the string.
3. Continue heating and read the temperature when the valve
opens approx. 8 mm (0.315 in.).
replace the thermostat.
Thermostat's valve 69.5 to 72.5
Factory spec.
opening temperature 157.1 to 162.5
Temperature at which
85
thermostat completely Factory spec.
185
opens
0000001382E
III-S-101
A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled
down. Otherwise, hot water way gush out, scalding nearby people.
0000000922E
Radiator Cap Air Leakage
1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.:
RCT-2A-30S) on the radiator cap.
2. Apply the specified pressure (88 kPa, 0.9 , 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.6
, 9 psi).
3. If the measurement is less than the factory specification,
replace the radiator cap.
More than 10 seconds for
pressure fall from
Pressure falling time Factory spec. 88 to 59 kPa
(from 0.9 to 0.6
from 13 to 9 psi)
(1) Radiator Tester (2) Adaptor
0000000923E
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester (1) (Code No. 07909-31551) and an
adaptor (2) (BANZAI Code No.: RCT-2A-30S) and raise the
water pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, repair with the radiator
cement. When water leak is excessive, replace the radiator.
157 kPa
Radiator water leakage
Factory spec. 1.6
test pressure
23 psi
(1) Radiator Tester (2) Adaptor
0000001383E
III-S-102

Thermostat Assembly
1. Remove the thermostat cover mounting screws (1), and
remove the thermostat cover (2).
2. Remove the thermostat assembly (4).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) only at
the thermostat cover side of the gasket (3).
(1) Thermostat Cover Mounting (3) Thermostat Cover Gasket
Screw (4) Thermostat Assembly
(2) Thermostat Cover
0000001357E
Water Pump Assembly
1. Loosen the alternator mounting screws, and remove the fan
belt.
2. Remove the fan and fan pulley.
3. Remove the water pump assembly from the gear case cover.
4. Remove the water pump flange (1).
5. Press out the water pump shaft (2) with the impeller (6) on it.
6. Remove the impeller from the water pump shaft.
7. Remove the mechanical seal (5).
(When reassembling)
A Apply a liquid gasket (Three Bond 1215 or equivalent) to the
both sides of gasket (4).
A Replace the mechanical seal with new one.
(1) Water Pump Flange (4) Water Pump Gasket
(2) Water Pump Shaft (5) Mechanical Seal
(3) Water Pump Body (6) Impeller
0000001358E
III-S-103
5. FUEL SYSTEM
(1) Injection Pump
Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (facing the flywheel) until
fuel flows from the delivery valve holder.
4. Continue to turn the flywheel slowly, and stop it as soon as the
fuel level at the tip of the delivery valve holder begins to
increase.
5. Check to see if the timing angle lines on the flywheel is aligned
with the alignment mark (2).
6. If the injection timing is out of adjustment, readjust the timing
with shims.
0.30 to 0.33 rad (17 to 19 )
Injection timing Factory spec.
before T.D.C.
A The sealant is applied to both sides of the shim (soft metal

gasket shim). The liquid gasket is not required for
assembling.
A Shims are available in thickness of 0.20 mm (0.0079 in.),
0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine
these shims for adjustments.
A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays
or advances the injection timing by approx. 0.0087 rad
(0.5 ).
A In disassembling and replacing the injection pump, be
sure to use the same number of new shims with the same
thickness.
A Refer to figure below to check the thickness of the shims.
(1) Timing Line (4) Two-holes:
(2) Alignment Mark 0.20 mm (0.0079 in.)
(3) Shim (Soft Metal Gasket Shim) (5) One-hole:
0.25 mm (0.0098 in.)
(6) Without hole:
0.30 mm (0.0118 in.)
0000001359E
III-S-104
Fuel Tightness of Pump Element

2. Remove the injection pipes and glow plugs.
3. Install the injection pump pressure tester to the injection pump.
4. Install the injection nozzle (1) jetted with the proper injection
pressure to the injection pump pressure tester (2). (Refer to
the photo.)
5. Set the speed control lever to the maximum speed position.
6. Run the starter to increase the pressure.
7. If the pressure can not reach the allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
13.73 MPa
Fuel tightness of pump
Allowable limit 140
element
1991 psi
A Never try to disassemble the injection pump assembly.

For repairs, you are strongly requested to contact a
Kubota-authorized pump service shop.
(1) Injection Nozzle (3) Protection Cover for Jetted Fuel
(2) Injection Pump Pressure Tester
0000001360E
III-S-105
Fuel Tightness of Delivery Valve

2. Remove the injection pipes and glow plugs.
3. Set a pressure tester to the fuel injection pump.
4. Install the injection nozzle (1) jetted with the proper injection
pressure to the injection pump pressure tester (2).
5. Run the starter to increase the pressure.
6. Stop the starter when the fuel jets from the injection nozzle.
After that, turn the flywheel by the hand and raise the pressure
to approx. 13.73 MPa (140 , 1991 psi).
7. Now turn the flywheel back about half a turn (to keep the
plunger free). Maintain the flywheel at this position and clock
the time taken for the pressure to drop from 13.73 to 12.75
MPa (from 140 to 130 , from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73
to 12.75 MPa (from 140 to 130 , from 1991 to 1849
psi).
9. If the measurement is less than allowable limit, replace the
pump with new one or repair with a Kubota-authorized pump
service shop.
10 seconds
13.73 12.75 MPa
Factory spec.
140 130
Fuel tightness of 1991 1849 psi
delivery valve 5 seconds
13.73 12.75 MPa
Allowable limit
140 130
1991 1849 psi
A Never try to disassemble the injection pump assembly.

For repairs, you are strongly requested to contact a
Kubota-authorized pump service shop.
(1) Injection Nozzle (3) Protection Cover for Jetted Fuel
(2) Injection Pump Pressure Tester
0000001361E
III-S-106
(2) Injection Nozzle
A Check the injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood
poisoning may be caused.
0000000932E
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester (Code No. 07909-
31361), and check the nozzle spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a) Good (b) Bad
0000000933E
Fuel Injection Pressure

31361).
2. Slowly move the tester handle to measure the pressure at
which fuel begins jetting out from the nozzle.
replace the adjusting washer (1) in the nozzle holder to adjust
it.
13.73 to 14.71 MPa
Fuel injection pressure Factory spec. 140 to 150
1991 to 2134 psi
(Reference)
A Pressure variation with 0.01 mm (0.0004 in.) difference of
adjusting washer thickness.
Approx. 235 kPa (2.4 , 34 psi)
(1) Adjusting Washer
0000000934E
III-S-107
Valve Seat Tightness

31361).
2. Raise the fuel pressure, and keep at 12.75 MPa (130 ,
1849 psi) for 10 seconds.
3. If any fuel leak is found, replace the nozzle piece.
No fuel leak at
12.75 MPa
Valve seat tightness Factory spec.
130
1849 psi
0000000935E
Nozzle Holder
1. Secure the nozzle retaining nut (7) with a vise.
2. Remove the nozzle holder (1), and take out parts inside.
(When reassembling)
A Assemble the nozzle in clean fuel oil.
A Install the push rod (4), noting its direction.
A After assembling the nozzle, be sure to adjust the fuel injection
pressure.
34.3 to 39.2
Nozzle holder 3.5 to 4.0
25.3 to 28.9 ft-lbs
19.6 to 24.5
Tightening torque Overflow pipe nut 2.0 to 2.5
14.5 to 18.1 ft-lbs
49.0 to 68.6
Nozzle holder assembly 5.0 to 7.0
36.2 to 50.6 ft-lbs
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
0000000936E
III-S-108
6. ELECTRICAL SYSTEM
[1] CHECKING
(1) Starter
Motor Test
A Secure the starter to prevent it from jumping up and down

while testing the motor.
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable and the leads from the
starter.
3. Remove the starter from the engine.
4. Disconnect the connecting lead (2) from the starter C terminal
(1).
5. Connect a jumper lead from the connecting lead (2) to the
battery positive terminal post.
6. Connect a jumper lead momentarily between the starter motor
housing and the battery negative terminal post.
7. If the motor does not run, check the motor.
(1) C Terminal (2) Connecting Lead
0000001148E
Magnet Switch Test (Pull-in, Holding Coils)
A Preparate a 6 V battery for the test, and each test should

be carried out for 3 to 5 seconds.
1) Checking Pull-in Coil
1. Connect jumper lead from the battery's negative terminal post
to the C terminal.
2. The plunger should be attracted strongly when a jumper lead
is connected from the battery positive terminal to the S
terminal.
2) Checking Holding Coil
1. Connect jumper leads from the battery's negative terminal
post to the body and the battery's positive terminal post to the
S terminal.
2. Push the plunger in by hand and release it. Then, the plunger
should remain being attracted.
0000001149E
(2) Glow Plug

Glow Plug Continuity
1. Disconnect the lead from the glow plugs.
2. Measure the resistance with an ohmmeter between the glow
plug terminal and the chassis.
3. If 0 ohm is indicated, the screw at the tip of the glow plug and
the housing are short-circuited.
4. If the factory specification is not indicated, the glow plug is
faulty.
Glow plug resistance Factory spec. Approx. 0.9
0000001152E
III-S-109
(3) Engine Stop Solenoid

Engine Stop Solenoid Test
1. Disconnect the 1P connector from the engine stop solenoid.
2. Remove the engine stop solenoid from the engine.
3. Connect the jumper leads from the battery positive terminal to
the 1P connector, and from the battery negative terminal to the
engine stop solenoid body.
4. If the solenoid plunger is not attracted, the engine stop
solenoid is faulty.
(1) Battery (12 V)
0000001163E

(1) Starter
(1) Magnetic Switch

Mounting Nut
(2) Housing
(3) Magnetic Switch
(4) C Terminal Nut
(5) Shaft Assembly
(6) Drive Lever
(7) Overrunning Clutch
(8) Connecting Lead
(9) Mounting Screw
(10) Armature
(11) Yoke
(12) Brush Holder
(13) Rear End Frame
(14) Through Bolt
1. Unscrew the C terminal nut (4), and disconnect the connecting lead (8).
2. Unscrew the magnetic switch mounting nuts (1), and remove the magnetic switch (3) from the housing (2).
3. Unscrew the through bolts (14) and mounting screw (9), and remove the rear end frame (13).
4. Remove the brush from the brush holder while holding the spring up.
5. Remove the brush holder (12).
6. Draw out the armature (10) and yoke (11) from the housing.
7. Draw out the shaft assembly (5) with the drive lever (6) and overrunning clutch (7) from the housing.
(When reassembling)
5.9 to 11.8
Tightening torque C Terminal Nut 0.6 to 1.2
4.3 to 8.7 ft-lbs
0000001167E
III-S-110
(2) Alternator
Pulley
1. Secure the hexagonal end of the pulley shaft with a double-
ended ratchet wrench as shown in the figure, loosen the pulley
nut with a socket wrench and remove it.
(When reassembling)
58.3 to 78.9
Tightening torque Pulley nut 5.95 to 8.05
43.0 to 58.2 ft-lbs
0000001364E
Rear End Cover

1. Unscrew the three rear end cover screws and the B terminal
nut, and remove the rear end cover.
0000001365E
Brush Holder
1. Unscrew the two screws holding the brush holder, and remove
the brush holder (1).
(1) Brush Holder
0000001366E
IC Regulator
1. Unscrew the three screws holding the IC regulator, and
remove IC regulator (1).
(1) IC Regulator
0000001367E
III-S-111
Rectifier
1. Remove the four screws holding the rectifier and the stator
lead wires.
2. Remove the rectifier (1).
(1) Rectifier
0000001368E
Rear End Frame

1. Unscrew the two nuts and two screws holding the drive end
frame and the rear end frame.
2. Remove the rear end frame (1).
(1) Rear End Frame
0000001369E
Rotor
1. Press out the rotor (1) from drive end frame (3).
A Take special care not to drop the rotor and not to damage
the slip ring or fan, etc.
(1) Rotor (3) Drive End Frame
(2) Block
0000001370E
Retainer Plate
1. Unscrew the four screws holding the retainer plate, and
remove the retainer plate (1).
(1) Retainer Plate
0000001371E
III-S-112
Bearing on Drive End Side

1. Press out the bearing from drive end frame (3) with a press
and jig (1).
(1) Jig (3) Drive End Frame
(2) Block
0000001372E
Bearing at Slip Ring Side

1. Lightly secure the rotor (1) with a vise to prevent damage, and
remove the bearing (2) with a puller (3).
(1) Rotor (3) Puller
(2) Bearing
0000001373E
[3] SERVICING
(1) Starter
Overrunning Clutch
1. Inspect the pinion for wear or damage.
2. If there is any defect, replace the overrunning clutch assembly.
3. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking
direction.
4. If the pinion slips or does not rotate in the both directions,
replace the overrunning clutch assembly.
0000001168E
III-S-113
Commutator and Mica

1. Check the contact face of the commutator for wear, and grind
the commutator with emery paper if it is slightly worn.
2. Measure the commutator O.D. with an outside micrometer at
several points.
3. If the minimum O.D. is less than the allowable limit, replace the
armature.
4. If the difference of the O.D.'s exceeds the allowable limit,
correct the commutator on a lathe to the factory specification.
5. Measure the mica undercut.
6. If the undercut is less than the allowable limit, correct it with a
saw blade and chamfer the segment edges.
30.0 mm
Factory spec.
1.181 in.
Commutator O.D.
29.0 mm
Allowable limit
1.142 in.
Less than 0.02 mm

Factory spec.
0.0008 in.
Difference of O.D.'s
0.05 mm
Allowable limit
0.0020 in.
0.50 to 0.80 mm
Factory spec.
0.0197 to 0.0315 in.
Mica undercut
0.20 mm
Allowable limit
0.0079 in.
(1) Segment (a) Correct

(2) Undercut (b) incorrect
(3) Mica
0000001169E
Brush Wear
1. If the contact face of the brush is dirty or dusty, clean it with
emery paper.
2. Measure the brush length (A) with vernier calipers.
3. If the length is less than the allowable limit, replace the yoke
assembly and brush holder.
14.0 mm
Factory spec.
0.551 in.
Brush length (A)
9.0 mm
Allowable limit
0.354 in.
0000001170E
III-S-114
Brush Holder
1. Check the continuity across the brush holder and the holder
support with an ohmmeter.
2. If it conducts, replace the brush holder.
0000001171E
Armature Coil
1. Check the continuity across the commutator and armature coil
core with an ohmmeter.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator
with an ohmmeter.
4. If it does not conduct, replace the armature.
0000001172E
Field Coil
1. Check the continuity across the lead (1) and brush (2) with an
ohmmeter.
2. If it does not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with an
ohmmeter.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Brush
0000001173E
III-S-115
(2) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
0000001374E
Stator
1. Measure the resistance across each lead of the stator coil with
an ohmmeter.
2. If the measurement is not within factory specification, replace
it.
3. Check the continuity across each stator coil lead and core with
an ohmmeter.
4. If infinity is not indicated, replace it.
Stator resistance Factory spec. Less than 1
0000001375E
Rotor
1. Measure the resistance across the slip rings.
2. If the resistance is not the factory specification, replace it.
3. Check the continuity across the slip ring and core with an
ohmmeter.
4. If continuous, replace it.
Rotor resistance Factory spec. 2.9
0000001376E
Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an sand paper or on a lathe.
14.4 mm
Factory spec.
0.5669 in.
Slip ring O.D.
14 mm
Allowable limit
0.5512 in.
0000001377E
III-S-116
Brush Wear
1. Check the length of the brush, if the length is shorter than the
allowable limit, replace it.
2. Make sure that the brush moves smoothly.
3. If the brush is defective, replace it
10.0 mm
Factory spec.
0.3937 in.
Brush length
1.5 mm
Allowable limit
0.0591 in.
0000001378E
Rectifier
1. Check the continuity across each diode of rectifier with an
ohmmeter.
2. The rectifier is normal if the diode in the rectifier conducts in
one direction and does not conduct in the reverse direction.
0000001379E
IC Regulator
1. Check the continuity across the "B" terminal and the "F"
terminal of IC regulator with an ohmmeter.
2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
B: "B" Terminal F: "F" Terminal
0000001380E
III-S-117
III-S-118
C.Engine WSM : D782 -B
Fllowing pages cover Engine model D782 -B.
But only pages that contain different data and contents from engin WSM of D902 - E were selected.
Except the following pages, data and contents are identical to engin WSM of D902 - E.
III-S-119
III-S-120
III-S-121
III-S-122
III-S-123
III-S-124
III-S-125
III-S-126
III-S-127
III-S-128
III-S-129
III-S-130
III-S-131
III-S-132
III-S-133
III-S-134
III-S-135
III-S-136
III-S-137
III-S-138
III-S-139
III-S-140
III-S-141
III-S-142
III-S-143
III-S-144
III-S-145
III-S-146
III-S-147
III-S-148
III-S-149
III-S-150
III-S-151
III-S-152
III-S-153
III-S-154
IV.Hydraulic system
A.Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-3
a. Common circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-3
b. Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-6
c. Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-9
d. Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-10
e. Swivel performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-11
f. Traveling performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-13
g. Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-15
B.Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-19
a. Testing Instruments & special tools . . . . . . . . . . . . . . . . . . . . . . IV-S-19
b. Pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-21
c. Pressure measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-22
d. Drain measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-30
e. Measurement of block performance . . . . . . . . . . . . . . . . . . . . . . IV-S-32
f. Operating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-34
g. Straight travel performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-36
h. Cylinder natural fall amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-37
i. Control and Traveling lever operating force . . . . . . . . . . . . . . . . IV-S-37
j. Lever stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-37
C.Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-38
a. Pump specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-38
b. Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-40
c. Swivel performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-42
d. Traveling performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-42
e. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-44
g. Motor oil drain amount test sample . . . . . . . . . . . . . . . . . . . . . . . IV-S-46
h. Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-47
D.Disassembling and reassembling . . . . . . . . . . . . . . . . .IV-S-57
a. Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-57
b. Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-68
c. Pilot valve (PP version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-112
c. Pilot valve (EU version). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-135
d. Swivel motor (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-146
d. Swivel motor (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . . . IV-S-159
e. Rotary Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-161
f. Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-176
g. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-194
h. Unload valve (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-203
IV-S-1
h. Unload valve (KX36-3 EU, KX41-3 EU). . . . . . . . . . . . . . . . . . IV-S-206
i. Change valve (Dozer, Track)(KX41-3 PP). . . . . . . . . . . . . . . . IV-S-207
i. Change valve (Dozer, Track) (KX36-3 EU, KX41-3 EU) . . . . . IV-S-211
j. TPSS valve (TPSS = Two patern selection system) (PP Version)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-212
k. Oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-215
l. Delivery hose (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-216
m. Return hose (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-217
n. Table of hoses (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-218
O. Pilot Hose (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . . . . . IV-S-223
P. Delivery Travel, Swivel, Blade, Swing Hose (KX36-3 EU, KX41-3 EU)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-225
Q. Suction, Return Hose (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . IV-S-227
R. Table of Hoses (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . IV-S-230
IV-S-2
A.Troubleshooting
a. Common circuit
Engine System
Engine not starts Starter not rotates normally Check electrical components
Starter rotates but engine not starts Check engine components
Check electrical components
Engine starts but not

Engine not stops
normally
Irregular engine revolution
White or blue engine exhaust
Black or dark gray engine exhaust
Insufficient output Check engine components
Excessive oil consumption
Oil contaminated with fuel
Oil contaminated with water
Low oil pressure
High oil pressure
Overheating
Radical battery discharge (battery runs out)
Glow lamp not lit Check electrical components
Charge lamp not lit
Charge lamp not turned OFF
Engine revolution drops and engine stops with load imposed Check engine components
Check hydraulic components
IV-S-3
Hydraulic system
Engine starts but hydraulic

Whole hydraulic pressure system not operates Check hydraulic components
system not starts
Boom, arm, bucket, swing, or dozer cylinder not operates Check hydraulic components
Swivel not operates Check swivel components
Traveling not operates Check traveling components
Slow and weak hydraulic

Abnormal top speed engine revolution Check engine components
pressure equipment
Slow and weak total hydraulic pressure system Check hydraulic components
Slow and weak boom, arm, bucket, swing, or dozer cylinder Check hydraulic components
Slow and weak swivel speed Check swivel components
Slow and weak travel Check traveling components
Traveling speed range not change Check traveling components
Skewing Check traveling components
Excessive natural drop of Excessive boom, arm, bucket, or dozer cylinder

hydraulic system, hydraulic Check hydraulic components
natural drop
system not stop, excessive
oil flow
Swivel not stops or excessive flow occurs Check swivel components
Travelling motion not stops or runs away on slopes Check traveling components
Temperature of
Engine system error; cooling water, oil, or combustion system Check engine components
operating oil tank rises
Check heat insulator and

Improper attachment of heat insulator on engine bonnet cover mounting conditions
Give proper traveling control

Operator's traveling control is not normal instructions
Check specifications of
Attachment not satisfies recommended operating range attachment and machine
Use recommended oil

Oil not of recommended quality or in recommended quantity
Hydraulic pressure system error Check hydraulic components
IV-S-4
Abnormal sound while in Loosened mounting bolts or nuts for cover and Check cover and other
operation other parts around source of abnormal sound parts mounting conditions
Tube, hose, or other parts around source of Check tube or hose mounting
abnormal sound in contact with other parts conditions
Check pin or bushing wear

Generation of abnormal sound from pins or bushings or seizing
Generation of abnormal sound from hydraulic system Check hydraulic components
Generation of abnormal sound from engine system Check engine components
Check crawler, idler, or truck

Generation of abnormal sound from undercarriage roller mounting conditions
IV-S-5
b. Hydraulics
Reference
Failure Probable cause Remedy
page
Whole hydraulic pres- 1) The quantity of hydraulic oil in the tank is insuffi- Supply or replace the hydraulic
sure system not oper- cient or the hydraulic oil is of poor quality. oil.
ates 2) The suction line (suction filter) is clogged. Check the suction line or replace
Slow speed and weak the suction filter.
power.
3) The pump mounting coupling is in improper con- Repair or replace the pump cou-
dition. pling.
4) The pump drive shaft is broken. Replace the shaft.
5) The seizing of or damage to pump internal parts. Repair or replace the pump.
The boom, arm, bucket, 1) The hydraulic pressure pilot line filter is blocked. Clean or replace the pilot filter.
or swivel does not oper- 2) The change valve is in improper condition. Disassemble or replace the
ate. change valve.
Slow speed and weak
power. 3) The seizing of or damage to the internal parts of Replace the pilot pump.
the pilot pump.
The boom, bucket, or 1) The main relief valve (P1) is not at the specified Check and adjust the main relief
traveling LH does not pressure. valve (P1).
operate. 2) The seizing of or damage to the internal parts of Repair or replace the pump.
Slow speed and weak the P1 or P2 pump system if the arm, service
power. port, or traveling RH does not operate.
The arm, service port, 1) The main relief valve (P2) is not at the specified Check and adjust the main relief
or traveling RH does not pressure. valve (P2).
operate. 2) The seizing of or damage to the internal parts of Repair or replace the pump.
Slow speed and weak the P1 or P2 pump system if the boom, bucket,
power. or traveling LH does not operate.
The swing, dozer, or 1) The main relief valve (P3) is not at the specified Check and adjust the main relief
swivel does not oper- pressure. valve (P3).
ate. 2) The seizing of or damage to the internal parts of Repair or replace the pump.
Slow speed and weak the P3 pump system.
power.
The boom or arm does 1) The operation or adjustment of the TPSS link is Check and adjust the link.
not operate. improper.
Slow speed and weak 2) The TPSS valve is in improper operation. Disassemble the valve and
power. replace the seal.
Only the boom does not 1) The overload relief valve of the boom is not at Check and repair the overload
operate. the specified pressure. relief valve.
Slow speed and weak 2) The spools of the control valve boom section is Check and repair the spools.
power. in improper operation.
3) The pilot valve is in improper condition. Measure the secondary pressure
and check the pilot valve.
4) Damage to the packing of the boom cylinder rod. Disassemble the cylinder and
replace the seal.
Only the arm does not 1) The overload relief valve of the arm is not at the Check and repair the overload
operate. specified pressure. relief valve.
Slow speed and weak 2) The spools of the control valve arm section is in Check and repair the spools.
power. improper operation.
4) Damage to the packing of the arm cylinder rod. Disassemble the cylinder and
replace the seal.
IV-S-6
Reference
page
Only the bucket does 1) The overload relief valve of the bucket is not at Check and repair the overload
not operate. the specified pressure. relief valve.
Slow speed and weak 2) The spools of the control valve bucket section is Check and repair the spools.
4) Damage to the packing of the bucket cylinder Disassemble the cylinder and
rod. replace the seal.
Only the swing does not 1) Improper adjustments to the swing pedal and Check and adjust the pedal and
operate. link. link.
Slow speed and weak 2) The spools of the control valve swing section is Check and repair the spools.
3) The anti-void valve is in improper condition. Check and replace the anti-void
valve.
4) Damage to the swing cylinder rod. Disassemble the cylinder and
replace the seal.
Only the dozer or leg 1) Improper adjustments to the dozer lever and Check and adjust the lever and
expansion and contrac- cable. cable.
tion function does not 2) The spools of the control valve dozer section is Check and repair the spools.
operate. in improper operation.
Slow speed and weak
power. 3) Damage to the packing of the dozer cylinder or Disassemble the cylinder and
tracking cylinder rod. replace the seal.
4) The operation or adjustment of the link of the Check and adjust the link.
change valve (dozer and truck) is improper.
5) The change valve (dozer and truck) is in Disassemble the valve and
improper operation. replace the seal.
Only the service port 1) Improper adjustments to the service port pedal Check and adjust the pedal and
does not operate. and link. link.
Slow speed and weak 2) The spools of the control valve service port sec- Check and repair the spools.
power. tion is in improper operation.
The natural drop of the 1) The overload relief valve is not at the specified Check and repair the overload
boom, arm or bucket pressure. relief valve.
cylinder is excessive. 2) Damage to the spool or spring of the control Check and repair the spool or
valve. the spring.
3) Damage to the packing of the boom cylinder rod. Disassemble the cylinder and
replace the seal.
The swing cylinder 1) Improper adjustments to the link system of the Check and adjust the link.
returned to the neutral swing pedal.
position moves. 2) The anti-void valve is in improper condition. Check and replace the anti-void
valve.
3) Damage to the stick or spring of the spool of the Check and repair the spools.
control valve.
4) Damage to the swing cylinder rod. Disassemble the cylinder and
replace the seal.
Natural drop of the 1) Damage to the spool or spring of the control Check and repair the spools.
dozer cylinder is exces- valve.
sive. 2) The change valve (dozer and truck) is in Disassemble the valve and
improper operation. replace the seal.
3) Damage to the packing of the dozer cylinder rod. Disassemble the cylinder and
replace the seal.
IV-S-7
Reference
page
The temperature of the 1) Hot air overflows due to damage to the division Check around the oil cooler.
operating oil tank rises. plate around the oil cooler.
2) Clogging of the oil cooler. Cleaning of oil cooler.
3) Clogging of the return filter. Check and replace the return fil-
ter.
4) The low-pressure line is clogged with a foreign Check the low-pressure line.
matter.
IV-S-8
c. Pump
Problem Cause Correction
1) Engine rpm higher than specified. 1) Readjust as specified.
1. The engine gets overloaded. 2) Pressure higher than specified. 2) Readjust as specified.
3) Pump internal parts seized or damaged. 3) Repair or replace the pump.
2. The pump flowrate drops 1) Engine rpm too low. 1) Readjust the rpm.
extremely with too low 2) Pump coupling defective. 2) Repair or replace the pump coupling.
discharge pressure. 3) Pump internal parts seized or damaged. 3) Repair or replace the pump.
1) Air or water mixed in hydraulic oil. 1) Retighten the circuit connections, the
suction pipe in particular. Replace if
water is mixed in.
3. Unusual noise or unusual 2) Suction strainer clogged. 2) Clean or replace the suction strainer.
vibrations occur (cavitation 3) Suction pipe clogged or throttled. 3) Correct the suction pipe.
phenomenon). 4) Attached pump in trouble (if provided). 4) Repair or replace the attached pump.
5) Piston shoe poorly crimped. 5) Replace the piston assembly.
6) Pump loosely mounted. 6) Mount correctly.
7) Coupling defective. 7) Replace the coupling.
1) O-ring or sheet packing defective. 1) Replace the O-ring or sheet packing
4. There is oil leak. (install as specified).
2) Oil leak from oil seal edge. 2) Replace or repair the oil seal or shaft.
IV-S-9
d. Motor
Problem Cause Correction
No pressure rise or no oil flow. Check the entire hydraulic circuit including the valves and pumps.
Oil viscosity inappropriate. Ensure the specified viscosity ranges.
Motor failure
to run Dust, degraded hydraulic oil, cavitation, Run the motor alone and get it under a pressure of 30 kgf/cm2 (2.9
internal parts seized due to excessive radial MPa) or so. If it fails to run, then some internal parts might be seized
load, unusual contact, bearing damaged. or damaged. Disassemble the motor and replace damaged parts.
Check the pump discharge rate, the motor rpm, and the valves for oil
Incoming flowrate too low.
leak.
Rpm not as
Low viscosity and internal leak for oil
designed Ensure the specified viscosity ranges.
temperature or other reason.
Internal parts worn out. Replace worn-out parts.
Wrong Wrong pipe connections. Reverse the pipe connections.
turning Poor valve timing due to wrong
direction Disassemble and reassemble again for good valve timing.
disassembling/reassembling procedures.
Replace the oil seal. Repair or replace if the shaft seal contact surface
Oil seal scratched or worn.
is scratched or worn.
Loose bolt or plug, resulting in oil leak (at Tighten the bolt and plug to their specified torques. See also if the O-
joints) from O-ring. ring is damaged. Replace the O-ring as required.
Oil leak O-ring scratched or damaged. Replace the O-ring.
Check for hit marks, burr, etc. Correct the surface with #600 or so
Dust or dent on the O-ring contact face.
sandpaper. Replace the O-ring. Clean up and reassemble.
Cracked port, damaged screw. Replace the housing. Use an appropriate joint and tighten it to the
Inappropriate joint. specified torque.
Shaft poorly fitted. Center the shaft exactly.
Let out the air completely. Fill the motor with oil and keep it running
Air left in the circuit or motor.
Unusual under no load until there is no air bubbles in the tank.
noise Pump's cavitation. Unclog the suction filter.
Apply oil or grease to each connection and carefully listen to the noise
Air mixed in the suction pipe line.
there. If the noise is less, retighten the joint there.
Unusual Cooler in trouble. Repair the cooler.
temperature
rise Motor seized. Repair or replacement
As listed above, there are various problems and their possible causes. The majority of troubles are,
however, caused by the entry of dust. Be very attentive not to allow any dust into the system.
IV-S-10
e. Swivel performance
Check that only the swivel components are in improper condition.
Reference
page
1. The swivel does not 1) The spooling of the pilot valve is improper. Check the operation of the valve,
turn left or right. and disassemble and clean the
valve.
2) The spool stick of the control valve operates Check the operation of the valve,
improperly. and disassemble and clean the
valve.
3) The secondary pressure of the pilot is improper. Measure the pressure.
4) Relief valve pressure is improper. Measure the pressure, and dis-
assemble, clean, and adjust the
valve.
5) Excessive motor drain. Measure the drain.
6) Internal damage to the motor. Disassemble, clean, and replace
the motor.
7) Internal damage to the control valve. Disassemble, clean, and replace
the control valve.
2. One of the two sides 1) The spooling of the pilot valve is improper. Check the operation of the valve,
does not work. and disassemble and clean the
valve.
valve.
valve.
the motor.
the control valve.
3. The power is low. 1) The spooling of the pilot valve is improper. Check the operation of the valve,
The speed is low. and disassemble and clean the
valve.
valve.
valve.
the motor.
the control valve.
IV-S-11
Reference
page
4. The swivel does not 1) The spooling of the pilot valve is improper. Check the operation of the valve,
stop with the position and disassemble and clean the
set to neutral. valve.
An excessive flow. 2) The spool stick of the control valve operates Check the operation of the valve,
valve.
valve.
5. Excessive shock 1) The spooling of the pilot valve is improper. Check the operation of the valve,
with the swivel and disassemble and clean the
comes to a stop. valve.
No inching is possi- 2) The spool stick of the control valve operates Check the operation of the valve,
ble. improperly. and disassemble and clean the
valve.
valve.
6. The swivel wobbles 1) The spool of the control valve operates improp- Check the operation of the valve,
when the swivel is erly. and disassemble and clean the
pressed by hand. valve.
valve.
IV-S-12
f. Traveling performance
Check in advance that only the traveling components are in improper condition.
Reference
page
Machine does not run. 1. Sticking or dropping of the traveling lever of the Adjust and replace the link sys-
link system. tem.
2) Sticking of the spool of the control valve. Disassemble, clean, and replace
the control valve.
3) Internal leakage of the rotary joint. Disassemble the rotary joint and
replace the seal.
4) Sticking of the spool of the counter balance Disassemble, clean, and replace
valve. the counter balance valve.
5) Excessive motor drain. Measure the drain quantity, dis-
assemble, and replace the
motor.
6) Internal damage to the motor. Disassemble and replace the
motor.
Slow traveling speed. 1) The link system of the traveling lever is in Adjust the link system.
Low traveling power. improper operation.
2) The spooling of the control valve is improper. Disassemble, clean, and replace
the control valve.
3) Internal leakage of the rotary joint. Disassemble the rotary joint and
replace the seal.
4) The spooling of the counter balance valve is Disassemble, clean, and replace
improper. the counter balance valve.
5) Excessive motor drain. Measure the drain quantity, dis-
assemble, and replace the
motor.
6) Internal damage to the motor. Disassemble and replace the
motor.
7) Sticking of the spool of the communicating valve. Clean or replace the communi-
cating valve and clean the filter.
Skewing 1) The left and right traveling levers of the link sys- Adjust the link system.
(Only in traveling con- tem are not in uniformed operation.
trol) 2) The left and right control valves are not in uni- Disassemble, clean, and replace
formed spool operation. the control valve.
3) Internal leakage of the rotary joint on one side. Disassemble the rotary joint and
replace the seal.
4) Sticking of the spool of the counter balance Disassemble, clean, and replace
valve. the counter balance valve.
5) The difference between the left and right in Measure the drain quantity, dis-
motor drain quantity is great. assemble, and replace the
motor.
6) Internal damage to the motor on one side. Disassemble and replace the
motor.
If the traveling right and left pumps are different in flow rate or pressure or if the delivery hose on one
side malfunctions, the product will skew. In that case, other operational errors will occur as well.
Machine does not stop 1) Improper returning or sticking of the link system Adjust the link system.
running. of the traveling lever.
Machine runs away on 2) Improper returning or sticking of the spool of the Disassemble, clean, and replace
slopes. control valve. the control valve.
3) Improper returning or sticking of the spool of the Disassemble, clean, and replace
counter balance valve. the counter balance valve.
IV-S-13
Reference
page
The traveling speed 1) The spool of the change valve is in improper Disassemble, and clean or
range does not change. operation. replace the change valve.
2) The high/low speed change spool in the travel Disassemble, and clean or
motor is in improper operation. replace the high and low speed
change valve in the travel motor.
3) The limit switch is in improper operation. Check and replace the switch.
4) The wireharness of the solenoid or limit switch is Check and replace the har-
broken. nesses.
IV-S-14
g. Electrical components
(1) Engine components
Failure Probable cause Remedy Remarks
1. The starter does not 1) Check that the slow-blow fuse or fuse has not Check and replace the fuse.
rotate. burnt out.
2) Check that the battery terminals are not loos- Tighten the terminals.
ened.
3) Check that the minimum voltage between the Charge or replace the battery.
battery terminals (positive and negative) is 10.5
V at the start position.
4) Exchange the auto-release relay and light relay. Check and replace the fuse.
5) Check that the starter M terminal is not loos- Tighten the terminals.
ened.
6) Check that the starter 50 terminal is at 9 V or Repair or replace the terminal.
over at the start position.
7) Check whether the key switch is in normal condi- Check and replace the fuse.
tion.
2. The starter rotates 1) Check that the fuel overflows to the tank with the Visual check.
but the engine does key switch turned ON.
not start. 2) Touch the fuel pump by hand and check that the Replace.
pump operates with the key switch turned ON.
3) Check that the fuel pump fuse has not burnt out. Replace.
4) Check that voltage is applied to the fuel pump Repair or replace the terminal.
coupler 1 and fuel pump coupler 2.
5) Check that the engine starts with the stop sole- Repair or replace the terminal.
noid dismounted.
6) Check that voltage is applied to the engine stop Repair or replace the terminal.
solenoid coupler with the key turned ON.
3. The engine does not 1) Check that the battery voltage is normal. Charge or replace the battery.
start smoothly at low 2) Check that the glow relay fuse has not burnt out. Replace.
temperatures.
3) Touch the glow relay by hand and check that the Replace.
glow relay operates.
4) Check that the voltage is applied to the glow Repair or replace the terminal.
relay coupler.
5) Check that the voltage is applied to the glow Repair or replace the terminal.
plug.
6) Check that the glow plug is in normal condition. Replace.
7)Check the glow relay. Replace.
IV-S-15
(2) Panel components (with key switch turned ON)
Reference
page
1. The glow symbol 1) Touch the glow relay by hand and check that the Replace.
does not appear on glow relay operates.
the panel. 2) Check that the coupler on the panel side is not Repair or replace the terminal.
disconnected.
3) Check the voltage of the coupler on the panel Replace.
side.
4) Check that the lamp has not burnt out. Replace.
2. The charge symbol 1) Check that the fuse has not burnt out. Replace.
does not appear on 2) Check that the alternator coupler is not discon- Repair or replace the terminal.
the panel. nected.
3) Check that the coupler on the panel side is not Repair or replace the terminal.
disconnected.
4) Check that the lamp has not burnt out. Replace.
3. The oil symbol does 1) Check that the fuse has not burnt out. Replace.
not appear on the 2) Check that the oil switch coupler is not discon- Repair or replace the terminal
panel. nected.
3) Check that voltage is applied to the oil switch Repair or replace the terminal
coupler.
4) Check that the symbol appears when the har- Replace the terminal
ness terminal of the oil switch is removed and
grounded to the body.
5) Measure the pressure of the engine oil. Repair the terminal
4. The remaining fuel 1) Check that the fuse has not burnt out. Replace.
does not appear on 2) Check that the charge and oil symbols appear Repair or replace the terminal
the panel. on the panel.
Lit : Normal
Not lit : Abnormal
3) Ground the harness terminal of the fuel sensor Repair or replace the terminal
to the body.
Lit : Normal
Not lit : Harness wire disconnection
IV-S-16
(3) Panel components (with engine started)
Reference
page
1. The charge symbol 1) Check that the 60-A fuse has not burned out. Replace.
does not appear on 2) Check that the alternator B terminal or the cou- Repair or replace the terminal.
the panel. pler is not disconnected.
3) Check that the alternator is in normal condition. Repair or replace the terminal.
2. The oil symbol does 1) Check that the specified quantity of the oil is pro- Replenish.
not appear on the vided.
panel. 2) Check that the oil switch coupler is not discon- Repair or replace the terminal.
nected.
3) Check that voltage is applied to the oil switch Replace.
coupler.
4) Measure the pressure of the engine oil. Replace the terminal
3. The water tempera- 1) Check that the fuse has not burnt out. Replace.
ture symbol does not 2) Check that the water temperature sensor cou- Repair or replace the terminal.
appear on the panel. pler is not disconnected.
disconnected.
4) Check that voltage is applied to the water tem- Replace the terminal
perature coupler.
5) Check that the water temperature sensor is in Replace the terminal
normal condition.
4. The remaining fuel 1) Check that the quantity of fuel is sufficient.
does not appear on 2) Check that the fuel sensor is in normal condition. Replace.
the panel.
5. The remaining fuel 1) Check that the fuse has not burnt out. Replace.
display on the panel 2) Check that fuel sensor coupler is not discon- Repair or replace the terminal.
does not move. nected.
disconnected.
4) Check that voltage is applied to the fuel pump Replace the terminal
coupler .
5) Check that the fuel sensor is in normal condition.
In addition to the above, refer to the check points described in the "Explanation of New Panel".
IV-S-17
(4) Others
Reference
page
1. The front attach- 1) Check that the fuse has not burnt out. Replace.
ment does not oper- 2.)Check that the lever lock solenoid and switch Repair or replace the terminal.
ate with the lock coupler are not disconnected.
lever released.
3) Exchange the coupler with the solenoid coupler Repair or replace the terminal.
for the second gear.
4) Check that voltage is applied to the lever lock Repair or replace the terminal.
solenoid coupler and switch coupler.
5) Check the electromagnetic valve. Repair or replace the terminal.
6) Check that the lever lock switch is in normal con- Replace.
dition.
2. The traveling speed 1) Check that the fuse has not burnt out. Replace.
does not change 2) Check that the solenoid coupler for the high Replace.
with the high speed speed and switch coupler are not disconnected.
panel pressed.
3) Exchange the coupler with the lever lock sole- Repair or replace the terminal.
noid coupler.
4) Check that voltage is applied to the solenoid Replace.
valve coupler for the high speed and switch cou-
pler.
5) Check the electromagnetic valve in the change Replace.
valve.
6) Check that the high speed switch is in normal Replace.
condition.
3. The horn does not 1) Check that the fuse has not burnt out. Replace.
sound with the horn 2) Check that the harness from the grip (horn Repair or replace the terminal.
switch pressed. switch) is not disconnected.
3) Check that the horn coupler and grip (horn Repair or replace the terminal.
switch) coupler are not disconnected.
4) Check that voltage is applied to the horn termi- Replace.
nal.
5) Check that the horn switch is in normal condi- Replace.
tion.
6) Check that the horn is in normal condition. Replace.
4. The work light is not 1) Check that the fuse has not burnt out. Replace.
lit when the work 2) Check that the work light terminal and switch Repair or replace the terminal.
light switch pressed. coupler are not disconnected.
3) Check that voltage is applied to the work light Replace.
terminal.
4) Exchange the work light relay and break-off Replace.
relay.
5) Check that the lamp has not burnt out.
IV-S-18
B.Testing
a. Testing Instruments & special tools
1) Gauges and special tools for pressure testing
1. Pressure hose
2. Pressure gauge; 2.94 MPa, 30kgf/cm2, 427 psi
For Secondary pilot pressure test.
3. Pressure gauge; 5.88 MPa, 60kgf/cm2, 853psi
For primary pilot pressure test.
4. Pressure gauge; 64.3 MPa, 350kgf/cm2,
4978psi
For main relief pressure and overload relief
pressure test.
5. Pipe joint (S, F2 - F2)
code No.: 69181-63191
6. Pressure test plug; PT 1/8
7. Allen wrench; M5
8. Plug; PT 1/8 Code No.: 68311-13381
9. Wrench; Size 17 - 19 mm
IV-S-19
2) Flow meter and special tools for flow testing
(5) (4) (3) (2) (1) Flow meter; Flowtech Inc. make
(1) (2) Loading handle
(3) Male-female joint 1” × 1”
(4) joint 1” × 1/2”
(5) Hose 1/2”
(6) O-ring
(3)
(4)
(5)
Drawing of (3) Male - female joint 1” × 1”
Vacuum pump
FESTO VAD-1/4 9334
P R
IV-S-20
b. Pump flow
1) Measuring procedure
1. Connect the tester to the pump outlet. Be
careful not to confuse the tester’s pipe con-
nections.
2. Open the tester’s loading valve. Start the
engine.
3. Set the engine to the maximum rpm.
4. Gradually close the loading valve. Apply the
rated load pressure (test pressure) to the
pump.
5. Measure the discharge flowrate and pump
rpm (engine rpm).
(1) Hydraulic oil tank (2) Pump
(3) Tester (4) Control valve 6. Calculate the volumetric efficiency and judge
the performance.
Pump discharge side 2) Checking the pump performance
To inspect the pump performance, apply the
specified pressure to the pump discharge side.
Measure the discharge rate at the specified rpm
to check the volumetric efficiency.
Volumetric efficiency =
Discharge rate at rated load
× 100(%)
Theoretical discharge rate (calculated value)
Notes :
1. The pump’s volumetric efficiency is proportional
to the pump rpm and inversely proportional to
the load pressure. During the test, keep the
(1) (2) (3) (4) engine at its maximum rpm.
(1) To control valve (P2)
2. The volumetric efficiency is the ratio of the
(2) To control valve (P1) discharge rate per pump turn (cc/rev) to the
(3) To control valve (P3) theoretical discharge rate (calculated value).
(4) To pilot valve The main relief set pressure is used as the
rated load.
3. The discharge rate under rated load must be
converted to that per pump turn. This is
because the pump usually runs at lower rpm.
Discharge rate under rated load

Discharge rate at rated load (L/min) × 1000
(cc/rev) =
Pump rpm at rated load (rpm)
4. The volumetric efficiency must be satisfied to

accept the pump for its performance.
5. The hydraulic oil temperature must be 50±5°C.
IV-S-21
c. Pressure measurement
(1) Pilot pressure
1) Primary pressure
1. Vacuum the hydraulic system line to prevent oil
from leaking out.
Install the vacuum pump onto the tank cap.Set the
main key on and get the safety lever down.
2. Open rear bonnet.
3. Install the pressure gauge on pilot pump delivery
port.
4. Start the engine and run it at the maximum speed.
5. Leave the safety lever up or get lever down.
6. Take 2 or 3 measurements to have an exact read-
ing.
7. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F
KX36-3, KX41-3, KX41-3V

3.9 ± 0.5 MPa
Reference Value 40 ± 5 kgf / cm2
569 ± 71 psi
Note :
In case of engin idle speed, pressure value is
slightly lower than that engine max. speed by 2 ~ 5
kgf / cm2 (0.2 ~ 0.5 MPa, 28 ~ 71 psi).
IV-S-22
2) Secondary pressure
1. Remove step.
2. Connect a joint for measurement to the arrow -
marked point and set pressure gauge on it.
4. Get the safety lever down to activate the unload
valve.
5. Shift the control lever to be measured.
6. Take 2 or 3 measurement to have an exact reading.
8. Pilot valve is at its max. stroke and control valve
spool is being fully shifted.
KX36-3, KX41-3, KX41-3V

1.96 ± 0.2 MPa
Reference Value
at idle speed 20 ± 2 kgf / cm2
284 ± 28 psi
2.16 ± 0.3 MPa
Reference Value
at max.speed 22 ± 3 kgf / cm2
313 ± 43 psi
(Boom - up)
(Arm - crowd)
IV-S-23
(2) Main relief valve
1) Measurement method
1. Set pressure gauge to the coupler at the main pump
discharge side. Or remove the plug off the main
pump discharge side and set the pressure gauge
there.
valve.
4. Get the following main relief valves activated.
5. Take 2 or 3 measurements to have their respective
exact readings.
7. Recommended testing actuators.
P1 : Bucket dump
P2 : Travel R (Arm)
P3 : Dozer up
Read the circuit diagram and take the appropriate
actuators not to mix up the main relief pressure and
overload relief pressure.
8. Specifications : Refer to page IV-S-41.
(P2)
2) Location of the main relief valve

P1 P3
P2
IV-S-24
3) Adjustment of main relief valve.
1. Loosen the lock nut of the P1, P2 or P3 main relief
valve.
2. Using a hex wrench, turn the adjusting screw to
reach the specified setting.
3. Then tighten up the lock nut. Clockwise turn raises
the pressure, and counterclockwise turn lowers it.
Main relief valve pressure rises by approximately 30
kgf / cm2 (2.9 MPa, 427 psi) at 60 degree turns of
adjusting screw.
4. Run the engine at the maximum speed. Move the
levers and make sure the pressure setting.
valve.
(a1 relief valve)
(a2 relief valve) (a3 relief valve)
IV-S-25
(3) Overload relief valve
1. Set the pressure gauge to the coupler at P1, P2, P3
port on the pump. Or remove the plug of P1, P2, P3
port and set pressure gauge there.
2. Raise the pressure setting of the main relief valve
about o.98 MPa (10 Kgf / cm2, 142 psi) over than
that of the overload relief valve setting to be tested.
3. Run the engine at 1500rpm for b1, b2, b3, b4, b5.
valve
5. Move the levers to get the overload relief valve acti-
vated.
Measure the pressure setting.
6. Take 2 or 3 measurements to have exact readings.
(P1) 8. Specifications : Refer to page IV-S-41.
(Adjust a1 main relief valve) (Adjust boom-up over load relief valve)
b1 : Bucket bottom
b2 : Boom rod
b3: Boom bottom
b4 : Arm rod
b5 : Arm bottom
a1 : P1 main relief valve
a3 : P3 main relief valve
(b1) (b2) (a1) (b5) (a3)
IV-S-26
2) Location of overload relief valves
(1) (2) (4)
Arm
Combination
Swing Dozer
Bucket
Swing
SP
Travel Travel
Supply
Boom
(3) (5)
(1) Bucket, bottom
(2) Boom, rod
(3) Boom, bottom
(4) Arm, bottom
(5) Arm, rod
IV-S-27
3) Adjustment of overload relief valve.
1. Loosen the lock nut of the overload relief valve.
Using a hex wrench, turn the adjusting screw to
reach the specified setting.
Then tighten up the lock nut. Clockwise turn raises
the pressure, and counterclockwise turn lowers it.
2. Run the engine at the maximum speed.
valve.
4. Move the levers and make sure the pressure set-
ting.
(Test boom down overload pressure)
IV-S-28
(4) Swivel brake valve pressure
1. Set the pressure gauge to the coupler at the P3 port
on pump. Or remove the plug of P3 port and set
pressure gauge on it.
valve.
3. Bring the bucket or arm tip end in contact with a
solid block. Slowly move at toward the block.
4. With the engine at rated rpm, measure the relief
pressure.
(Swivel motor, relife valve.)
IV-S-29
d. Drain measurement
(1) Traveling motor
1. Vacuum the hydraulic system line to prevent oil
from leaking out.
2. Disconnect the drain hose from the travel motor and
connect another hose (the pressure gauge hose will
do) where the drain hose was disconnected.
3. Float the crawlers as shown as below.
4. Run the engine one minute at max. rpm with the
lever in the forward position and measure the
amount of hydraulic oil in the pan.
5. If the measurement exceeds the specification,
determine the cause and replace the assembly.
7. Reference value : Refer to page IV-S-46.
Never place your body under the crawler.

(1) (2)
(1) Drain port (Travel motor lock condition)

(2) 2nd speed pilot line (3)
(3) Main high pressure hoses
IV-S-30
(2) Swivel motor
1. Remove step.
2. Locate front attachment to traveling position. Bucket
should be located 1 m above from ground.
3. Remove drain hose of the swivel motor and recieve
drain oil in a suitable reservoir.
4. Swivel the machine one minute at max. engine rpm
and measure amount of hydraulic oil in the reser-
(1) voir.
Make sure nobody is around swivel radius area.
5. Reference value : Refer to page IV-S-46.
Vacuum the hydraulic system line to prevent

oil leakage while fitting hoses.
(1) Vacuum pump, compression air type

(2) Drain port
(3) Measuring cylinder
(2) (3)
(Swivel motor lock condition)
IV-S-31
e. Measurement of block performance
(1) Swivel
1. Locate the machine on the 20 deg. slope.
2. The front position is of arm dump and bucket
crowd. Keep the boom so that the boom end pin is
aligned with the bucket pin.
3. Mark the outer ring of swivel bearing and truck
frame.
4. Unlock the safety lock lever, and measure the one
minute shifting distance between them with engine
idling rpm and engin stop condition.
5. Load on the bucket should be as follows.
KX36-3: 63 kg (139 lbs)-exclude bucket weight
KX41-3: 72 kg (159lbs)-exclude bucket weight
Engine idle under 30 degrees / min
Reference Value
Engine stop
6. Hydraulic oil temp. : 50 ± 5°C, 122 ± 41°F.
IV-S-32
(2) Traveling
1. Park the machine on a 20deg. slope. Keep front at
traveling position.
2. Put marks on the truck frame and the crawler.
3. Measure 10 minutes slip-distance without engine run-
ning.
4. Hydraulic oil temp. : 50 ± 5°C, 122 ± 41°F.
KX36-3, KX41-3S, KX41-3V

300 mm/10 min
Reference Value
0.98 ft/10 min
IV-S-33
f. Operating speed
(1) Checking each operating speed.
[Important points]
1. Measure full stroke operating time with no load on the standard bucket.
2. Make several mesurement and use average time for judgement.
3. Two different measurements are expected for the forward and backward movements as well as the
right and left swivelings.
Obtain their respective measurements. Do not calculate for their average.
4. Before operation, make sure nobody is around the machine.
[Measurement conditions]
1. Engine rpm is max..
2. Hydraulic temperature is 50 ± 5°C, 122 ± 41°F.
3. Ground is flat.
4. Measure time after several pre-operation.
(2) Boom cylinder

1. Arm and bucket cylinder shouls be most shorted posi-
tion.
2. Measure the time from the bucket is on the ground to
the boom highest position, and from the boom highest
position to the ground.
Note:The cushioning time is not included.
[sec]
KX36-3 KX41-3S KX41-3V EU KX41-3V PP
Reference Up 2.3 ~ 2.9 2.0 ~ 2.6 m m
Value Down 2.8 ~ 3.4 2.7 ~ 3.3 m 2.3 ~ 2.9
(3) Arm cylinder

1. Position the boom and arm as showm at left.
2. Measure the arm cylinder full stroke operating time.
[sec]
Reference Crowd 3.1 ~ 3.7 m m m
Value Dump 1.9 ~ 2.5 2.1 ~ 2.7 m m
IV-S-34
(4) Bucket cylinder
1. Position the boom and arm as showm at left.
2. Measure the bucket cylinder full stroke operating time.
[sec]
Reference Crowd 2.1 ~ 2.7 2.5 ~ 3.1 m m
Value Dump 1.9 ~ 2.5 1.7 ~ 2.3 m m
(5) Swing cylinder

1. Position the boom, arm and bucket as showm at left.
(with the bottom of the bucket about 1 m (33 ft) above
from the ground.)
2. Measure the swing cylinder full stroke operating time.
(right to left and left to right)
[sec]
Reference Left 4.4 ~ 5.0 4.3 ~ 4.9 m m
Value Right 3.7 ~ 4.3 3.6 ~ 4.2 m m
(6) Dozer cylinder

1. Place the bucket on the ground. Position the machine
as shown at left for the dozer to make a full stroke.
2. Measure the dozer cylinder full stroke operating time.
[sec]
Reference Left 1.0 ~ 1.6 m m 1.3 ~ 1.9
Value Right 1.4 ~ 2.0 m m 1.7 ~ 2.3
IV-S-35
(7) Swivel speed
1. Position the boom, arm and bucket as showm at left.
2. Measure three times rotation time.
[sec/three turns]
Reference Value 2.4.6 ~ 30.0 m m m
(8) Traveling speed

1. Travel the machine untill getting max. speed.
2. After getting max. speed, measure the 10 mm (33 ft)
traveling time.
[sec]
Reference 1F 2.0 ~ 2.4 2.2 ~ 2.6 2.0 ~ 2.4 2.1 ~ 2.5
Value 2F - 3.9 ~ 4.7 3.6 ~ 4.4 3.7 ~ 4.5
g. Straight travel performance

1. Travel the machine untill getting max. speed.
2. Measure the vertical distance from the traveling line.
Under 600 mm/10 m

Reference Value
1.97 ft / 32.8 ft
IV-S-36
h. Cylinder natural fall amount
1. Locate the machine on the flat ground, and put the
load the bucket.
Load on the bucket should be as follows.
2. Arm cylinder must be fully retracted. Bucket cylinder
must be fully extended.
3. Locate the bottom of bracket about 1 m above from
the ground. Stop the engine.
4. Mark on the rod of each cylinder.
5. Measure the fall distance after 10 min.
Reference Value Refer to page IV-S-44
i. Control and Traveling lever operating force

1. Stop the engine.
2. Measure force of right and left control and traveling
levers.
3. Start the engine, operate the control lever or traveling
lever for a full stroke, and measure the max. operating
force.
4. Make three measurements and take their average.
5. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 9°F.
j. Lever stroke
1. Stop the engine.
2. Move each lever from neutral to full stroke end, and
measure each stroke with respect to the top center of
the each lever glip.
3. If any lever is loose at its neutral position, measure the
stroke from each loose end.
4. Make three measurements and take their average.
IV-S-37
C.Specifications
a. Pump specifications
No. Machine model KX36-3 KX41-3S/V EU KX41-3V PP Remarks
Unit STD value STD value STD Allowance
1 Manufacturer NACHI m m
2 Pump type PVD-00B-14P- PVD-00B-15P- m
5G3-4978A 5G3-4982A
3 Pump rated RPM 2300 m m
4 Theoretical dis- p1 cc/rev 7.2 7.5 m
charge amount cu.in./rev 0.44 0.46 m
capacity
p2 cc/rev 7.2 7.5 m
cu.in./rev 0.44 0.46 m
p3 cc/rev 4.5 m m
cu.in./rev 0.27 m m
p4 cc/rev 2.7 m m
cu.in./rev 0.16 m m
5 Theoretical p1 L/min 16.6 17.3 m
delivery amount USGPM 4.37 4.56 m
at rated rpm:
p2 L/min 16.6 17.3 m
USGPM 4.37 4.56 m
p3 L/min 10.4 m m
USGPM 2.73 m m
p4 L/min 6.2 m m
USGPM 1.64 m m
6 Actual delivery Load: cc/rev 7.30 0.40 -0.40 Recommeded limit :
amount : p1,p2 15kgf/cm2 KV =80%
(1.47MPa) cu.in./rev 0.45 0.02 -0.02 Service limit : KV =70%
(213psi)
Load: cc/rev 6.42 0.32 -0.32
2
50kgf/cm
(4.90MPa) cu.in./rev 0.39 0.02 -0.02
(711psi)
Load: cc/rev 5.30 0.27 -0.27
100kgf/cm2
(9.8MPa) cu.in./rev 0.32 0.02 -0.02
(1422psi)
Load: cc/rev 4.15 0.21 -0.21
150kgf/cm2
(14.7MPa) cu.in./rev 0.25 0.01 -0.01
(2130psi)
Load: cc/rev 2.64 0.13 -0.13
2
200kgf/cm
(19.6MPa) cu.in./rev 0.16 0.01 -0.01
(2845psi)
IV-S-38
No. Machine model KX36-3 KX41-3S/V EU KX41-3V PP Remarks
Unit STD value STD value STD Allowance
amount : p3 15kgf/cm 2 KV =85%
(213psi)
Load: cc/rev 3.83 0.20 -0.20
200kgf/cm2
(19.6MPa) cu.in./rev 0.23 0.01 -0.01
(2845psi)
amount : pp 40kgf/cm 2 KV =85%
(569psi)
IV-S-39
b. Relief Valve
(1) Bench set data
No. Type of valve Unit KX36-3 KX41-3S/V EU KX41-3V PP Remarks
STD Allowance STD Allowance STD Allowance
1 a1:Main relief MPa 20.6 0.5 0.0 21.6 0.5 0.0 21.6 0.3 -0.2 at 17.4l/min
valve of P1 2 210 5 0 220 5 0 220 3 -2 (4.6USGPM)
kgf/cm
Bar 206 5 0 216 5 0.0 216 3 -2.0
psi 2986 71 0 3128 71 0 3128 43 -28
valve of P2 210 5 0 220 5 0 220 3 -2 (4.6USGPM)
kgf/cm2
Bar 206 5 0.0 216 5 0.0 216 3 -2.0
psi 2986 71 0 3128 71 0 3128 43 -28
valve of P3 205 5 0 210 5 0 210 3 -2 (4.6USGPM)
kgf/cm2
Bar 201 5 0.0 206 5 0.0 206 3 -2.0
psi 2915 71 0 2986 71 0 2986 43 -28
4 ap:Primary pilot MPa 3.9 0.3 -0.2 3.9 0.3 -0.2 3.9 0.3 -0.2
system pressure 40 3 -2 40 3 -2 40 3 -2
kgf/cm2
Bar 39.2 2.9 -2.0 39.2 2.9 -2.0 39.2 2.9 -2.0
psi 569 43 -28 569 43 -28 569 43 -28
5 as:Secondary MPa 2.8 0.0 0.0 2.8 0.0 0.0 2.8 0.0 0.0
pilot system pres- 29 0 0 29 0 0 29 0 0
kgf/cm2
sure
Bar 28.3 0.3 -0.2 28.3 0.3 -0.2 28.3 0.3 -0.2
psi 410 4 -3 410 4 -3 410 4 -3
6 b1:Overload relief MPa 23.5 0.5 0.0 23.5 0.5 0.0 23.0 0.3 -0.2 at 5.0l/min
valve of bucket 240 5 0 240 5 0 235 3 -2 (1.3USGPM)
kgf/cm2
bottom
Bar 235 5 0.0 235 5 0.0 231 3 -2.0
psi 3413 71 0 3413 71 0 3342 43 -28
valve of boom rod 280 5 0 280 5 0 280 3 -2 (1.3USGPM)
kgf/cm2
Bar 275 5 0.0 275 5 0.0 275 3 -2.0
psi 3982 71 0 3982 71 0 3982 43 -28
valve of boom 174 5 0 174 5 0 180 3 -2 (1.3USGPM)
kgf/cm2
bottom
Bar 171 5 0.0 171 5 0.0 177 3 -2.0
psi 2474 71 0 2474 71 0 2560 43 -28
9 b4,b5:Overload MPa 23.5 0.5 0.0 23.5 0.5 0.0 23.0 0.3 -0.2 at 5.0l/min
relief valve of 240 5 0 240 5 0 235 3 -2 (1.3USGPM)
kgf/cm2
arm, rod and bot-
tom Bar 235 5 0.0 235 5 0.0 231 3 -2.0
psi 3413 71 0 3413 71 0 3342 43 -28
10 c1,:Overload MPa 23.5 0.5 0.0 23.5 0.5 0.0 23.0 0.3 -0.2 at 5.0l/min
relief valve of 240 5 0 240 5 0 235 3 -2 (1.3USGPM)
kgf/cm2
swivel motor R&L
Bar 235 5 0.0 235 5 0.0 231 3 -2.0
psi 3413 71 0 3413 71 0 3342 43 -28
IV-S-40
(2) Machine set data (at the pump gauge port)
No. Type of valve Actuator Unit KX36-3 KX41-3S/V EU KX41-3V US Remarks
STD Allowance STD Allowance STD Allowance
1 a1:Main relief Bucket dump MPa 20.6 1.0 -0.5 21.6 1.0 -0.5 21.6 1.0 -1.0 at Max. speed
valve of P1 210 10 -5 220 10 -5 220 10 -10
kgf/cm2
Bar 206 10 -5 216 10 -5 216 10 -10
psi 2987 145 -73 3132 145 -73 3128 142 -142
2 a2:Main relief Arm MPa 20.6 1.0 -0.5 21.6 1.0 -0.5 21.6 1.0 -1.0 at Max. speed
valve of P2 210 10 -5 220 10 -5 220 10 -10
kgf/cm2
Bar 206 10 -5 216 10 -5 216 10 -10
psi 2987 145 -73 3132 145 -73 3128 142 -142
3 a3:Main relief Blade up MPa 20.1 1.0 -0.5 20.6 1.0 -0.5 20.6 1.0 -1.0 at Max. speed
valve of P3 205 10 -5 210 10 -5 210 10 -10
kgf/cm2
Bar 201 10 -5 206 10 -5 206 10 -10
psi 2915 145 -73 2987 145 -73 2986 142 -142
4 ap:Primary Engine start MPa 3.9 0.2 0.0 3.9 0.2 0.0 4.9 0.5 -0.5 at Max. speed
pilot system Safety lever 40 2 0 40 2 0 50 5 -5
kgf/cm2
pressure up
Bar 39.0 2.0 0.0 39.0 2.0 0.0 49.0 4.9 -4.9
psi 566 29 0 566 29 0 711 71 -71
5 as:Second- Control lever MPa 2.7 0.2 -0.2 at Max. speed
ary pilot sys- shift end 28 2 -2
kgf/cm2
tem pressure (boom,arm,bu
cket,swivel) Bar 27.5 2.0 -2.0
psi 398 28 -28
6 b1:Overload Bucket crowd MPa 24.5 2.0 -2.0 at 1500rpm
relief valve of 250 20 -20
kgf/cm2
bucket bot-
tom Bar 245 20 -20
psi 3555 284 -284
7 b2:Overload Boom up MPa 27.5 2.0 -2.0 at 1500rpm
kgf/cm2
boom rod
Bar 275 20 -20
psi 3982 284 -284
8 b3:Overload Boom down MPa 19.6 2.0 -2.0 at 1500rpm
kgf/cm2
boom bottom
Bar 196 20 -20
psi 2844 284 -284
9 b4,b5:Over- Arm MPa 25.5 2.0 -2.0 at 1500rpm
load relief 2 260 20 -20
kgf/cm
valve of arm,
rod and bot- Bar 255 20 -20
tom psi 3697 284 -284
10 c1,:Overload Swivel MPa 18.1 1.0 -1.0 at Max. speed
kgf/cm2
swivel motor
R&L Bar 181 10 -10
psi 2631 142 -142
IV-S-41
c. Swivel performance
Machine model KX36-2 KX41-2S/V EU KX41-2V PP Remarks
Unit
Manufacturer SUMITOMO EATON
Model 2-200DOS-E3888
Displacement cc/rev 195 m m
Max.oil flow L/min 30 m m
Motor speed rpm 53.3 m m at 10.4L/min
Brake valve pressure MPa 13.2 m m
kgf/cm2 135 m m
Drain amount at lock L/min
Drain amount while rotating L/min
Swivel speed rpm 8.7 m m
3 times rotation swivel speed sec 6.9 m m
Swivel block performance deg. 30 m m 1min. 20 degree slope
Capable swivel rotation angle deg. 25 m m
Play at the tip of bucket mm 53 m m
inch 2.1 m m
Brake release pressure MPa 13.2 m m
kgf/cm2 135 m m
d. Traveling performance
No. Machine model KX36-3 KX41-3S EU KX41-3V EU KX41-3V PP
1 Motor Displacement Low speed 10.92cm 3/rev 12.46cm3/rev 11.36cm3/rev 0.693 cu.in
High speed - 6.88cm3/rev 6.21cm3/rev 0.379 cu.in
2 Gearbox ratio 1 : 37.22 1 : 31.8 1 : 34.2 1 : 36.96
3 Total displacement High speed - 396.23cm3/rev 396.23cm3/rev 419.87cm3/rev 25.62 cu.in
Low speed 406.44cm3/rev 218.78cm3/rev 235.30cm3/rev 229.52cm3/rev 14.01 cu.in
4 Max.pressure 206 bar 216 bar 21.6MPa 3129 psi
(220kgf/cm2)
5 Max.flow 16.6 l/min 17.3l/min m 4.57 USGPM
6 Max.drain pressure Continuous 1 bar m m 14.5 psi
Peak 5 bar m m 72.5 psi
7 Max.motor output High speed - 273 Nm 39.0 Nm 8.78 ft•lbs
torque (theoretical) at 216 bar at 216 bar at 3129 psi
Low speed 35.8Nm 428 Nm 21.3 Nm 4.79 ft•lbs
at 206 bar at 216 bar at 216 bar at 3129 psi
8 Max.motor output High speed - 2515 rpm 2786 rpm
speed (theoretical) Low speed 1520 rpm 1388 rpm 1523 rpm
9 Max.gearbox output High speed - 751 Nm 810 Nm 788.5 Nm 177.3 ft•lbs
torque (theoretical) Low speed 1333 Nm 1361 Nm 1467 Nm 1443 Nm 324.5 ft•lbs
10 Max.gearbox output High speed - 73.4 rpm 75.4 rpm
speed (theoretical) Low speed 40.8 rpm 40.6 rpm 41.2 rpm
IV-S-42
No. Machine model KX36-3 KX41-3S EU KX41-3V EU KX41-3V PP
11 Counter balance spool operating 3 bar 6-7 bar
pressure
12 Check valve cracking pressure less than 0.3 bar m
13 Hydraulic motor oil ISO VG46 m m
14 Gearbox oil type ISO VG150 E.P./ m SAE-30-CD
SAE 80W90 API
GL5/MIL-L-2105
15 Gearbox oil: quantity 1 l ± 10% 0.3 l ± 10% 330 cm3 20.13 cu.in
16 Oil temperature -20 °C/+100°C m m
17 Total weight 17kg ± 10% m m
18 Climbing ability 30° m m m
19 Max. traction force 1F 11.9 kN 12.2 kN 13.1 kN 12.7 kN 2855 lbw
2F - 6.7 kN 7.2 kN 7.1 kN 1596 lbw
20 Traveling block performance less than 300 mm m m m
21 Traveling Rubber/ 1F 2.2 km/h 2.4 km/h 2.2 km/h 2.3 km/h 1.43 mph
speed Steel crawler 2F - 4.3 km/h 4.0 km/h 4.1 km/h 2.55 mph
22 10m traveling time 1F 16.3 sec 15.0 sec 16.3 sec 15.7 sec
2F - 8.4 sec 9.0 sec 8.8 sec
23 Straight travel per- 1,2F less than 600 mm m m m less than 23.6 in
formance
24 Drain amount at lock 1F
2F -
25 Drain amount while 1F
rotating 2F -
26 Hi-speed change pressure -
1st o 2nd
27 Manufacturer TRASMITAL- m m NACHI

KAYABA
28 Motor type MAG10 MAG12V-TRB m PHV-120
29 Sprocket, PCD 277.18 mm m m m 10.91 in
30
IV-S-43
e. Cylinder
(1) Speed
(unit : sec.)
Unit KX36-3 KX41-3S EU KX41-3V EU KX41-3V PP Remarks
(A) (B) (A) (B) (A) (B) (A) (B)
Boom cylinder Up Canopy 2.3~2.9 3.5 2.0~2.6 3.1 2.0~2.6 3.1 2.0~2.6 3.1 GL to Max. height
Cabin 2.3~2.9 3.5 2.0~2.6 3.1 2.0~2.6 3.1 - - (exclude cushion time)
Boom cylinder Down Canopy 2.8~3.4 4.1 2.7~3.3 4.0 2.7~3.3 4.0 2.3~2.9 3.5 Max.height to GL
Cabin 2.8~3.4 4.1 2.7~3.3 4.0 2.7~3.3 4.0 - -
Boom cylinder cushion 0.4~1.3 1.6 0.4~1.3 1.6 0.4~1.3 1.6 0.4~1.3 1.6
Arm cylinder Crowd 3.1~3.7 4.4 3.1~3.7 4.4 3.1~3.7 4.4 3.1~3.7 4.4 Cylinder full stroke
Arm cylinder Dump 1.9~2.5 3.0 2.1~2.7 3.2 2.1~2.7 3.2 2.1~2.7 3.2
Bucket cylinder Crowd 2.1~2.7 3.2 2.5~3.1 3.7 2.5~3.1 3.7 2.5~3.1 3.7 Cylinder full stroke
Bucket cylinder Dump 1.6~2.2 2.6 1.7~2.3 2.8 1.7~2.3 2.8 1.7~2.3 2.8
Swing cylinder Left Canopy 4.4~5.0 6.0 4.3~4.9 5.9 4.3~4.9 5.9 4.3~4.9 5.9 Cylinder full stroke
Cabin 4.4~5.0 6.0 4.3~4.9 5.9 4.3~4.9 5.9 - -
Swing cylinder Right Canopy 3.7~4.3 5.2 3.6~4.2 5.0 3.6~4.2 5.0 3.6~4.2 5.0
Cabin 3.7~4.3 5.2 3.6~4.2 5.0 3.6~4.2 5.0 - -
Blade cylinder Up 1.0~1.6 1.9 1.0~1.6 1.9 1.0~1.6 1.9 1.3~1.9 2.3 Cylinder full stroke
Blade cylinder Down 1.4~2.0 2.4 1.4~2.0 2.4 1.4~2.0 2.4 1.7~2.3 2.8
Truck cylinder Extend - - - - Cylinder full stroke
Truck cylinder Retract - - - -
(A) New machine reference value

(B) Allowable limit
(2) Natural fall

Unit KX36-3 KX41-3S EU KX41-3V EU KX41-3V US Remarks
(A) (B) (A) (B) (A) (B) (A) (B)
Load weight kg(lbs) 63 (139) 72 (159) 72(159) 72(159) include bucket weight
Boom cylinder mm 15 75 15 75 15 75 15 75 Boom raise, Arm
inch 0.59 3.0 0.59 3.0 0.59 3.0 0.59 3.0 extend, Bucket crowd,
Bucket load: heaped
Arm cylinder mm 10 50 10 50 10 50 10 50 capacity 10
inch 0.39 1.97 0.39 1.97 0.39 1.97 0.39 1.97 min Engine stop
Bucket cylinder mm 4 20 4 20 4 20 4 20
inch 0.16 0.79 0.16 0.79 0.16 0.79 0.16 0.79
Dozer cylinder mm 13 65 13 65 13 65 13 65
inch 0.51 2.56 0.51 2.56 0.51 2.56 0.51 2.56
Oil temp. : 50 ± 5°C, 10 minutes (A) New machine reference value

(B) Allowable limit
IV-S-44
(3) Cylinder maintenance data
No. Unit Boom Arm Bucket Dozer Swing Track Remarks

mm 35 30 30 30 30 30
A I.D.
in. 1.38 1.18 1.18 1.18 1.18 1.18
mm 35 30 30 30 30 30
B I.D.
in. 1.38 1.18 1.18 1.18 1.18 1.18
mm 45 45 45 45 35 35
C
in. 1.77 1.77 1.77 1.77 1.38 1.38
mm 45 45 45 45 35 35
D
in. 1.77 1.77 1.77 1.77 1.38 1.38
mm 30 35 35 30 30 30
E Rod O.D.
in. 1.18 1.38 1.38 1.18 1.18 1.18
mm 60 60 60 60 55 55
F Tube I.D.
in. 2.36 2.36 2.36 2.36 2.17 2.17
mm 70 70 70 70 65 65
G Tube O.D.
in. 2.76 2.76 2.76 2.76 2.56 2.56
mm 35 32 32 32 32 27.5
H
in. 1.38 1.26 1.26 1.26 1.26 1.08
Max. retraction mm 765 585 529 358 610 507
I
length in. 30.11 23.03 20.83 14.09 24.02 19.96
mm 35 32 32 32 32 28
J
in. 1.38 1.26 1.26 1.26 1.26 1.10
mm 469 339.5 276.5 97 340 289
K Stroke
in. 18.46 13.37 10.89 3.82 13.39 11.37
mm
L Port screw size G1/4(PF1/4) G1/4(PF1/4) G1/4(PF1/4) G1/4(PF1/4) G1/4(PF1/4) R1/4(PT1/4)
in.
N·m 390 ~ 430 390 ~ 430 390 ~ 430 215.6 ~ 235.2 215.6 ~ 235.2 137.2 ~ 156.8
Cylinder head
M kgf·m 40 ~ 44 40 ~ 44 40 ~ 44 22 ~ 24 22 ~ 24 14 ~ 16
tighting torque
ft·lbf 288 ~ 317 288 ~ 317 288 ~ 317 159 ~ 174 159 ~ 174 102 ~ 116
N·m 410 ~ 450 510 ~ 550 510 ~ 550 343 ~ 392 343 ~ 392 343 ~ 392
Piston tightning
kgf·m 42 ~ 46 52 ~ 56 52 ~ 56 35 ~ 40 35 ~ 40 35 ~ 40
N torque
ft·lbf 302 ~ 332 376 ~ 406 376 ~ 406 253 ~ 289 253 ~ 289 253 ~ 289
Piston screw size - M24 x 1.5 M24 x 1.5 M22 x 1.5 M22 x 1.5 M22 x 1.5
Seal kit No.
IV-S-45
f. Service port flow amount
(Test sample data : KX41-3PP)
Pressure Qs=Q2+Q3 Engine RPM
kgf/cm2 psi L/min USGPM
No load 28.0 7.3968 2440
50 711.2 27.1 7.1591 2350
75 1066.7 26.5 7.0006 2330
100 1422.3 25.3 6.6836 2310
120 1706.8 23.4 6.1816 2300
140 1991.3 21.1 5.5741 2300
150 2133.5 20.0 5.2835 2290
160 2275.7 19.1 5.0457 2290
170 2418.0 17.7 4.6759 2290
180 2560.2 16.4 4.3324 2290
190 2702.4 15.2 4.0154 2290
200 2844.7 13.3 3.5135 2290
Note : Above data is just for your information, not the specifications.
g. Motor oil drain amount test sample

(Test sample data : KX41-3PP, Serial No. 20001)
(1) Travel motor

Right side Left side
cc/min cu.in./min cc/min cu.in./min
1st F 164 10 131 8
(40~50 kgf/cm2) R 262 16 164 10
2nd F 787 48 606 37
(60~80 kgf/cm2) R 803 49 737 45
Lock F 240 15 350 21
(270 kgf/cm2) R 385 23 310 19
(2) Swivel motor

Right Left
cc/min cu.in./min cc/min cu.in./min
Swiveling condition (70 kgf/cm 2) 63 4 80 5
Lock condition (185 kgf/cm2) 335 20 365 22
Note : Above data is just for your information, not the specifications.
IV-S-46
h. Quality Specifications
No Specificatios Items Unit KX36-3EU KX41-3S EU KX41-3V EU KX41-3V PP Remarks
Q1 Main Speed JIS A8404
1 1 Machine size Total length mm 3670 ± 73 3665 ± 73 m m
(Transport) inch 144.5 ± 2.9 144.3 ± 2.9 m m
2 Total width mm 990 ± 10 990 ± 10 1300/994 ± 13 m
inch 39.0 ± 0.4 39.0 ± 0.4 51.2/39.1 ± 0.5 m
3 Total height mm 2283 ± 23 m m m
(Canopy) inch 89.9 ± 0.9 m m m
4 Total height mm 2283 ± 23 m m m
(Cabin) inch 89.9 ± 0.9 m m m
2 1 Weight Machine weight kg 1440 ± 29 1450 ± 29 1595 ± 32 m Fuel tank
(Canopy) lbs 3174.6 ± 63.9 3197 ± 63.9 3516.337 ± 70.5 m
2 Machine weight kg 1540 ± 31 1550 ± 31 1705 ± 34
(Cabin) lbs 3395.1 ± 68.3 3417.13 ± 68.3 3759 ± 75.0
3 Ground contact kPa
press. (Canopy) psi
kgf/cm2
4 Ground contact kPa
press. (Cabin) psi
kgf/cm2
3 1 Performance Swivel speed rpm 8.7 ± 0.9 m m m Rated engine
RPM, K=100%
2 Travel F1 km/h 2.2 ± 0.2 2.4 ± 0.2 2.2 ± 0.2 2.3 ± 0.2
speed mph 1.37 ± 0.12 1.49 ± 0.12 1.37 ± 0.12 1.43 ± 0.12
3 F2 km/h 4.3 ± 0.4 4 ± 0.4 4.1 ± 0.4
mph 2.67 ± 0.25 2.49 ± 0.25 2.55 ± 0.25
4 R1 km/h 2.2 ± 0.2 2.4 ± 0.2 2.2 ± 0.2 2.3 ± 0.2
mph 1.37 ± 0.12 1.49 ± 0.12 1.37 ± 0.12 1.43 ± 0.12
5 R2 km/h 4.3 ± 0.4 4 ± 0.4 4.1 ± 0.4
mph 2.67 ± 0.25 2.49 ± 0.25 2.55 ± 0.25
6 Gradeability deg > 30 m m m
4 1 Rear end min. turning radius mm 1070 ± 21 m m m
inch 42.1 ± 0.8 m m m
2 Swivel frame rear ground clear- mm 423 ± 8 m m 426 ± 8
ance inch 16.7 ± 0.3 m m 16.8 ± 0.3
3 Tambler center distance mm 1090 ± 33 m 1230 ± 37 m
inch 42.9 ± 1.3 m 48.4 ± 1.5 m
4 Crawler total length mm 1445 ± 43 m 1587 ± 48 m
inch 56.9 ± 1.7 m 62.5 ± 1.9 m
5 Crawler total width mm 990 ± 20 m 1300/994 ± 26 m
inch 39.0 ± 0.8 m 51.2/39.1 ± 1.0 m
6 Crawler shoe width mm 230 ± 5 m m m
inch 9.1 ± 0.2 m m m
7 Min. ground clearance mm 167 ± 5 158 m m
inch 6.6 ± 0.2 6.2 m m
IV-S-47
5 1 Engine,SAE Model name D782-BH D902-BH D902-BH D902-EBH
2 J1349 Gross Rated output kw 9.00 ± 0.20 11.80 ± 0.30 m m
DIN 70020 ps 12.2 ± 0.3 16.0 ± 0.4 m m
3 Rated speed rpm 2300 m m m
4 Displacement L 0.778 0.898 m m
cc 778 898 m m
Usgal 0.21 0.24 m m
6 1 Hydraulic pump type
2 Pump delivery L 16.6 x 2 17.3 x 2 m m
10.4, 6.2 10.4, 6.2 m m
Usgal 4.39 x 2 4.57 x 2 m m
2.75, 1.72 2.75, 1.72 m m
3 Main relief pressure p1, p2 Mpa 20.6 -0.2 21.6 -0.2 m m Valve bench
(Bench set) 210 +3, -2 220 +3, -2 m m set
kgf/cm2
Bar 206 216 m m
psi 2986 3128 m m
p3 Mpa 20.1 20.6 m m
kgf/cm2 205 220 m m
Bar 201 216 m m
psi 2915 3128 m m
p4 Mpa 3.9 +0.3 m m m
kgf/cm2 40 m m m
Bar 39 m m m
psi 569 m m m
7 1 Swivel motor type
8 1 Under carrage Travel motor type
2 Parking brake type
3 Crawler shoe type
9 1 Front attach- Bucket CECE m3 0.035 ± 0.002 0.04 ± 0.002 m m
ment heaped yd3 0.046 ± 0.052 ± m m
capacity
2 SAE, m3 0.035 ± 0.002 0.04 ± 0.002 m m
JIS yd3 0.046 ± 0.052 ± m m
3 Bucket width mm 402 ± 10 450 ± 10 m m Without side
inch 15.8 ± 0.4 17.7 ± 0.4 m m cutter
4 Swing L deg 73 ± 2 73 ± 2 m m
5 angle R deg 50 ± 2 m m m
6 Max. digging mm 3782 ± 57 3910 ± 59 m m
radius inch 148.92.2 153.9 ± 2.3 m m
7 Ground level Max. mm 3723 ± 56 3855 ± 58 m m
digging radius inch 146.6 ± 2.2 151.8 ± 2.3 m m
8 Ground level Min. mm 1237 ± 25 1231 ± 25 m m Bucket bot-
finish radius inch 48.7 ± 1.0 48.5 ± 1.0 m m tom horizontal
9 Max. digging mm 2227 ± 45 2370 ± 47 m m

depth inch 87.7 ± 1.8 93.3 ± 1.9 m m
IV-S-48
9 10 Front attach- Max. vertical dig- mm 1742 ± 35 1835 ± 37 m m
ment ging depth inch 68.6 ± 1.4 72.2 ± 1.5 m m
11 Max. digging mm 3458 ± 69 3540 ± 71 m m
height inch 136.1 ± 2.7 139.4 ± 2.8 m m
12 Max. dump mm 2366 ± 47 2455 ± 49 m m
height inch 93.1 ± 1.9 96.7 ± 1.9 m m
13 Max. dump height mm
(Arm vertical) inch
14 Mini. turning mm 1439 ± 43 1550 ± 47 m m
radius inch 56.7 ± 1.7 61.0 ± 1.9 m m
15 Mini. turning radius mm 1147 ± 34 1245 ± 37 m m
(Left swing) inch 45.2 ± 1.3 49.0 ± 1.5 m m
16 Off-set L mm 512 ± 15 m m m
amount inch 20.2 ± 0.6 m m m
17 R mm 323 ± 10 m m m
inch 12.7 ± 0.4 m m m
18 Max. digging kgf
force N
lbw
19 Optional JIS, m3
bucket SAE yd3
range
10 1 Dozer Width mm 990 ± 5 m 1300/990 ± 5 m
inch 39.0 ± 0.2 m 51.2/39.0 ± 0.2 m
2 Height mm 230 ± 5 m 231 ± 5 m
inch 9.1 ± 0.2 m 9.1 ± 0.2 m
3 Length mm
inch
4 Max. lift above GL mm 180 ± 9 181 ± 9 201 ± 10 m
inch 7.1 ± 0.4 7.1 ± 0.4 7.9 ± 0.4 m
5 Max. below GL mm 193 ± 10 m 205 ± 11 m
inch 7.6 ± 0.4 m 8.1 ± 0.4 m
6 Displacement m3
capacity yd3
11 1 Water & oil Radiator capacity L
US gal
2 Reserve tank L
capacity US gal
3 Engine crank L
case US gal
4 Hydraulic oil Full L
(all amount) US gal
5 Hydraulic oil Tank L 14.5 ± 0.7 m m m
(tank amount) US gal 3.83 ± 0.18 m m m
IV-S-49
11 6 Water & oil Gear oil Wheel L
motor US gal
7 Swivel L
reduction US gal
case
8 Track L
roller US gal
9 Front L
idler US gal
10 Fuel tank L 21 ± 1.1 m m 20 ± 1
US gal 5.55 ± 0.29 m m 5.28 ± 0.26
Q2 Main Specs JIS A8404
1 1 Bucket tooth slaggish mm 53 < 73 m m m
inch 2.1 < 2.9 m m m
2 Declination of front excavator mm < 10 m m m
inch < 0.39 m m m
3 Dozer's declination mm < 10 m m m
inch < 0.39 m m m
2 1 Eccentric amount from swing mm
center inch
2 Distance to swing center mm
inch
3 1 Distance to boom pin mm
inch
2 Boom pin height mm exclude
inch grouser
3 Min. clearance of bucket teeth mm 62 -16/+34 167 -16/+34 m m

to boom cylinder protector inch 2.4 -0.6/+1.3 6.6 -0.6/+1.3 m m
4 Clearance of boom cylinder to mm
shoe inch
4 1 Approach angle deg 26.5 ± 2.7 m 25.5 ± 2.6 m
5 1 Crawler height mm 357 ± 7 m m m Include
inch 14.06 ± 0.28 m m m grouser on
the spocket
2 Max. crawler height mm 358 ± 7 m m m Include
inch 14.09 ± 0.28 m m m grouser on
the spocket
3 Clearance of swivel frame to mm
crawler inch
4 Distance to idler center mm From swivel
inch centerl
5 Distance to sprocket center mm

inch
IV-S-50
Q3 Engine performance
1 1 Max. engine torque kgf•m
N•m
ft•lbs
2 Torque rise %
2 1 Max. engine no load rpm < 2600 m m m
2 rpm 1 pump relief rpm
3 2 pump relief rpm > 2300 m m m
4 3 pump relief sec > 2300 m m m
3 1 Idler rpm 1200.0 +150 m m m
4 1 Engine start time (Normal temp sec Grow 5 sec
and grow)
5 1 Cold start Cell start time sec Temp. -17 °C
2 Number of start
6 1 Charge starting engine rpm
2 Charging a1 Engine spec
voltage & 12V 40A
ampare
Q4 Travelling performance
1 1 Travel motor block perfor- mm < 300 m m m 20 deg, 10
mance, L/R inch < 11.81 m m m min
2 1 Max. Trac- F1 kgf.m 1.21346 ± 0.12237 1.24405 ± 0.12237 1.335828 ± 0.13256 1.29504 ± 0.13256 K=65%
tion force kN.m 11.90 ± 1.20 12.20 ± 1.20 13.10 ± 1.30 12.70 ± 1.30
ft.lbs 9±1 9±1 10 ± 1 9±1
2 F2 kgf.m 0.68321 ± 0.07138 0.734196 ± 0.07138 0.724 ± 0.07138
kN.m 6.70 ± 0.70 7.20 ± 0.70 7.10 ± 0.70
ft.lbs 5±1 5±1 5±1
3 1 Travel F1 mm < 600 m m m 10m dis-
straightness inch < 23.62 m m m tance
2 F2 mm < 600 m m
inch < 23.62 m m
3 DozerrF1 mm < 600 m m m Dozer up &
inch < 23.62 m m m down 10m
distance
4 DozerrR1 mm < 600 m m m
inch < 23.62 m m m
4 1 Track shoe Iron mm
sag distance inch
2 Rubber mm 10 - 15 m m m
inch 0.39 - 0.59 m m m
IV-S-51
Q5 Work performance
1 1 Work amount 45 deg digging & m3/h
side dump
yd3/h
2 Digging, 180 deg m3/h
loading
yd3/h
2 1 Cycle time 45 deg digging & sec
side dump
2 Digging, 180 deg sec
loading
3 1 Fuel con- Calculated L/h Load coeffi-
sumption US gal/h ciency=60%
2 Actual L/h
US gal/h
4 1 Boom lifting capacity kgf Front end,
kN Arm extend
bucket
lbw crowd, at
tooth
2 Arm digging force kgf 0.7342 > 0.69341 0.79538 > 0.7138 m 0.75459 > 0.7138 Bucket tooth
kN 7.20 > 6.80 7.80 > 7.00 m 7.40 > 7.00 root
lbw 5>5 6>5 m 5>5
3 Bucket digging force kgf 1.32563 > 1.25425 1.59076 > 1.50918 m m Machine
kN 13.00 > 12.30 15.60 > 14.80 m m stance to JIS
bucket tooth
lbw 10 >9 12 > 11 m m root
4 Dozer force up kgf Cutting edge
kN down force
at ground
lbw level
down kgf
kN
lbw
5 1 Boom speed up 1st sec 2.6 ± 0.3 2.3 ± 0.3 m m Oil temp.
2 up 2nd sec 50 ± 5°C
Max. heiht to
3 down sec 3.1 ± 0.3 3 ± 0.3 m 2.6 ± 0.3 ground
6 1 Arm speed crowd sec 3.4 ± 0.3
2 dump sec 2.2 ± 0.3 2.4 ± 0.3 m m
7 1 Bucket speed crowd sec 2.4 ± 0.3 2.8 ± 0.3 m m
2 dump sec 1.9 ± 0.3 2 ± 0.3 m m
8 1 Dozer speed up sec 1.3 ± 3 m m 1.6 ± 0.3 Max. down
to max. up
2 down sec 1.7 ± 0.3 m m 2 ± 0.3 Max. up to
max. down
9 1 Swivel angle while boom raise degree GL-Max.
height, before
cushioning
2 Incling performance mm CV spool
inch stroke
IV-S-52
10 1 Arm cylinder cavitation Oil temp.
50 ± 5°C
2 Arm cylinder shrink
11 1 Dozer cylinder cavitation
12 1 Bucket outer w/o side cutter mm
width inch
2 with side cutter mm
inch
13 1 Max. digging height radius mm 1895 ± 190 2044 ± 204 m m
inch 74.61 ± 7.48 80.47 ± 8.03 m m
2 Max. dump height radius mm 1529 ± 92 2083 ± 125 m m at bucket pin
inch 60.20 ± 3.62 82.01 ± 4.92 m m
3 Distance max. digging depth mm From swivel
inch center
4 Bucket bottom height at arm mm 1052 ± 32 929 ± 28 m m Bucket hori-

vertical inch 41.42 ± 1.26 36.57 ± 1.10 m m zontal
5 Bucket wrist angle degree 185 ± 3 186 ± 3 m m

6 Bucket bottom angle degree Boom up,
arm extend
bucket crowd
Q6 Swivel, swing performance
1 1 Swivel torque L kgf•m 0.25493 > 0.21414 m m m Arm
kN.m 2.50 > 2.10 m m m extend,show
/Quick
ft•lbs 2>2 m m m
2 R kgf•m 0.25493 > 0.21414 m m m
kN.m 2.50 > 2.10 m m m
ft•lbs 2>2 m m m
2 1 Swivel angle deg > 25 m m m Bucket
load=JIS
heaped x 1.8
3 1 Swivel block perfor- L/R deg < 30 m m m
mance
4 1 Swivel slippage L/R deg 90 deg
(Flat ground, no load) deg swivel
5 1 Swivel start-up speed sec 2.1± 0.2 m m m 0~90 deg

swivel
6 1 Swing torque, max. Left kgf•m
(Right) kN.m
ft•lbs
7 1 Swing speed Left sec 4.7 ± 0.3 4.6 ± 0.3 m m
2 Right sec 4.0 ± 0.3 3.9 ± 0.3 m m
8 1 Swing Lock Swivel mm <6 m m m 90 deg-swivel,
R&L inch < 0.24 m m m 100 times actual
digging cylinder
dislocation
2 Reciprocat- L/R Swing mm 90 deg-
ing motion inch swivel, 100
times
IV-S-53
Q7 Hydraulic performance
1 1 Relief pressure setting P1 kgf/cm2 210 +10
-5 220 -+10
5
m m At pump
delivery
MPa 20.6 +1
-0.5 21.6 -+4.0
0.5
m m 50 ± 5°C
bar 206 -+10
5 216 -+10
5
m m
psi 2978 -+145
73 3132 -+145
73
m m
2 P2 kgf/cm2 210 +10
-5 220 -+10
5
m m
MPa 20.6 +1
-0.5 21.6 -+4.0
0.5
m m
bar 206 -+10
5 216 -+10
5
m m
psi 2978 -+145
73 3132 -+145
73
m m
3 P3 kgf/cm2 205 +10
-5 210 -+10
5
m m
MPa 20.1 +1.0
-0.5 20.6 -+1.0
0.5
m m
bar 201 -+10
5 206 -+10
5
m m
psi 2915 -+145
73 2987 -+145
73
m m
4 P4 kgf/cm2 40 -+20 m m 40 +5
-5
MPa 3.9 -+0.2

0
m m 3.9 +0.5
-0.5
bar 39 +2
-0
m m 39 +5
-5
psi 566 -+29

0
m m 566 +71
-71
2 1 Swivel brake relief pressure kgf/cm2 185 ± 10 At pump

delivery port
MPa - - - 18.1 ± 1.0
bar - - - 181 ± 10
psi - - - 2631 ± 142
3 1 Cylinder oil sealing Boom mm < 15 m m m Arm extend,
capacity inch < 0.59 m m m bucket
2 Arm mm < 10 m m m height 1m,

inch < 0.39 m m m 10 min.
3 Bucket mm <4 m m m Bucket

inch < 0.16 m m m load=JIS
heaped*1.8
4 Dozer mm < 13 m m m Hydrauric oil
inch < 0.51 m m m tempera-
ture:50 ± 5°C
4 1 Boom cushioning per- 30°C sec <3 m m m
2 formance 50°C sec 0.4 - 1.3 m m m
3 80°C sec > 0.3 m m m
5 1 Accumulator function sec
time
6 1 Service port flow No load/ L 27.0 27.7

load Usgal 11.89 11.89
IV-S-54
Q8 Lever operating force & stroke
1 1 Boom lever operating up 1st kgf•m 1.29504 ± 0.49966 m m 1.39701 ± 0.49966
force N.m 12.70 ± 4.90 m m 13.70 ± 4.90
ft•lbs 9±4 m m 10 ± 4
2 up 2nd kgf•m
N.m
ft•lbs
3 down kgf•m 1.29504 ± 0.49966 m m 1.39701 ± 0.49966
N.m 12.70 ± 4.90 m m 13.70 ± 4.90
ft•lbs 9±4 m m 10 ± 4
4 Arm lever kgf•m 1.29504 ± 0.49966 m m 1.39701 ± 0.49966
N.m 12.70 ± 4.90 m m 13.70 ± 4.90
ft•lbs 9±4 m m 10 ± 4
5 Bucket lever kgf•m 1.29504 ± 0.49966 m m 1.39701 ± 0.49966
N.m 12.70 ± 4.90 m m 13.70 ± 4.90
ft•lbs 9±4 m m 10 ± 4
6 Swivel (Swing) lever kgf•m 1.29504 ± 0.49966 m m 1.39701 ± 0.49966
N.m 12.70 ± 4.90 m m 13.70 ± 4.90
ft•lbs 9±4 m m 10 ± 4
7 Dozer lever up kgf•m 2.10062 ± 0.80558 m m m
N.m 20.60 ± 7.90 m m m
ft•lbs 15 ± 7 m m m
down kgf•m 1.89667 ± 1.00952 m m m
N.m 20.60 ± 8.90 m m m
ft•lbs 15 ± 7 m m m
8 Travel lever L/R kgf•m 1.89667 ± 1.00952 m m 1.49898 ± 0.49966
N.m 18.60 ± 9.90 m m 14.70 ± 4.90
ft•lbs 14 ± 7 m m 11 ± 4
9 Accelerator lever up kgf.m 4.99661 ± 0.99932 m m m
N.m 49.00 ± 9.80 m m m
ft.lbs 36 ± 7 m m m
down kgf.m 3.99729 ± 1.10129 m m m
N.m 39.20 ± 10.80 m m m
10 Swing pedal kgf.m 4.79267 ± 1.20327 m m 3.97689 ± 0.99932
N.m 47.00 ± 11.80 m m 39.00 ± 9.80
ft.lbs 35 ± 9 m m 29 ± 7
11 Safety lock L up kgf.m 1.20327 ± 0.30591 m m m Up & down
lever, L&R N.m 11.80 ± 3.00 m m m
ft.lbs 9±2 m m m
down kgf.m 3.39565 ± 0.30591 m m m
N.m 33.30 ± 3.00 m m m
IV-S-55
1 11 Safety lock R up kgf.m 0.49966 ± 0.20394 m m m
lever, L&R N.m 4.90 ± 2.00 m m m
ft.lbs 4±1 m m m
down kgf.m 0.49966 ± 0.20394 m m m
N.m 4.90 ± 2.00 m m m
ft.lbs 4±1 m m m
13 Service port pedal kgf.m 6.39362 ± 10.00 m m 4.99661 ± 1.01972 L / R
N.m 62.70 ± 10.00 m m 49.00 ± 10.00
ft.lbs 46 ± 7 m m 36 ± 7
14 Bonnet lifting force kgf.m
N.m
ft.lbs
15 Bonnet holding force kgf.m
N.m
ft.lbs
2 1 Boom lever stroke up mm 75 ± 10 m m 72 ± 10
inch 2.95 ± 0.39 m m 2.83 ± 0.39
2 down mm 75 ± 10 m m 72 ± 10
inch 2.95 ± 0.39 m m 2.83 ± 0.39
3 Arm lever stroke mm 75 ± 10 m m 74 ± 10
inch 2.95 ± 0.39 m m 2.91 ± 0.39
4 Bucket lever stroke mm 75 ± 10 m m 74 ± 10
inch 2.95 ± 0.39 m m 2.91 ± 0.39
5 Swivel, swing lever stroke mm 75 ± 10 m m 74 ± 10
inch 2.95 ± 0.39 m m 2.91 ± 0.39
6 Dozer lever up & down mm 70 ± 10 m m
inch 2.76 ± 0.39 m m
7 Travel lever, L & R, F & L mm 90 ± 10 m m 80 ± 10
R inch 3.54 ± 0.39 m m 3.15 ± 0.39
R mm 90 ± 10 m m 80 ± 10
inch 3.54 ± 0.39 m m 3.15 ± 0.39
8 Accelerator lever stroke mm
inch
9 Swing pedal stroke mm 25 ± 10 m m 23 ± 10
inch 0.98 ± 0.39 m m 0.91 ± 0.39
10 Service port pedal stroke mm 15 ± 10 m m m
inch 0.59 ± 0.39 m m m
Q10 Comfortability
1 1 Noise level At oper- Canopy db(A) < 78 m m < 77
2 ator's Cab db(A) < 78 m m Cab door
ear LPA closed
3 Noise db(A) < 92 m m m
source;
LWA
IV-S-56
D.Disassembling and reassembling
a. Pump
(1) Component of pump
Ref.No. Part Name Q’ty Ref.No. Part Name Q’ty

010 ASSY PUMP,PISTON 1 230 HOLDER,SPRING 1
020 SHAFT 1 240 GUIDE,SPRING 1
030 ASSY CYLINDER 1 250 PIN 1
040 ASSY PISTON 10 260 ROD 1
050 HOLDER 1 270 PIN 1
060 HOLDER 1 280 PIN 1
070 PIN 3 290 PIN 1
080 SPRING 1 300 BEARING,BALL 1
090 RETAINER 2 310 SPRING,PLATE 8
100 CIR CLIP,INTERNAL 1 320 CIR CLIP,INTERNAL 1
110 PLATE 1 330 BOLT,HEX-SOC-HD 4
120 PIN 2 340 PLUG 4
130 KIT SEAL 1 350 PLUG 1
140 GASKET 1 360 PIN,SPRING 1
150 SEAL,OIL 1 370 SCREW,SET 1
160 O RING 1 380 NUT,LOCK 1
170 O RING 2 390 ASSY PUMP,GEAR 1
180 WASHER,SEAL 1 400 COUPLING 1
190 O RING 1 410 COLLAR 1
200 O RING 1 420 BOLT 2
210 O RING 1 430 WASHER,PLAIN 2
220 SPRING 1
IV-S-57
1 Body - S 1 37 -
2 Body - H 1 38 -
3 Shaft 1 39 O ring 1
4 Cylinder barrel 1 40 O ring 2
5 Valve plate 1 41 -
6 Piston 10 42 -
7 Shoe 10 43 -
8 Shoe holder 1 44 Screw 4
9 Barrel holder 1 45 -
10 Swash plate 1 46 -
11 Needle 3 47 -
12 Ball 2 48 -
13 Packing 1 49 Plug 4
14 Spring C 1 50 -
15 Spring T 1 51 Plug 1
16 - 52 -
17 - 53 -
18 Spring holder 1 54 -
19 Spring guide 1 55 -
20 Pin 1 56 Spring pin 1
21 Rod G 1 57 -
22 - 58 -
23 - 59 -
24 Retainer 2 60 Screw 1
25 Stopper pin A 1 61 Nut 1
26 Stopper pin B 1 62 Seal washer 1
27 Pin 1 63 -
28 - 64 -
29 - 65 Gear pump kit 1
30 Bearing 1 66 Coupling 1
31 Needle bearing 1 67 Collar 1
32 Oil seal 1 68 Screw 2
33 Coned disk spring 8 69 O ring 1
34 Snap ring 1 70 Washer 2
35 Snap ring 1 71 O ring 1
36 - 72 O ring 1
IV-S-58
(2) Adaptor installation (KX36-3 EU, KX41-3 EU)

(14) To pilot valve
(13)
(11) (12) (14)
Ref.No. Part Name Q’ty Tightning torque Remarks

1 Pump 1
2 Body 4 P1, P2, P3, P4
3 Adaptor 4 P1, P2, P3, P4
4 T - joint 3 P1, P2, P4
5 T - joint 1 P3
6 Adaptor 1 P3
7 Flange (Suction) 1
8 Bolt 4 M10 x 1.5
9 O - ring 1
10 Bolt 2 77.5 ~ 90.2 N·m, 7.9 ~ 9.2 kgf·m M10 x 1.25
IV-S-59
(3) Adaptor installation

(14) To pilot valve
(11) (12) (13) (14)
Ref.No. Part Name Q’ty Tightning torque Remarks

1 Pump 1
2 Adaptor (L, G3/8-G3/8) 3
3 Plug 4 R1/8 (PT1/8)
4 Adaptor 1
5 Oring 4 04810-00140
6 Adaptor (L, G3/8-union) 1 3.72 ~ 42.1 N·m, 3.8 ~ 4.3 kgf·m, 27.4 ~ 31.1 ft ~ lbf
7 Suction flange 1
8 Bolt 4 M10 x 1.5 l = 20
9 Oring 1 04810-10350
10 Bolt 2 77.5 ~ 90.2 N·m, 7.9 ~ 9.2 kgf·m, 57.2 ~ 66.5 ft ~ lbf M12 x 1.25 l = 30
IV-S-60
(4) Disassembling and reassembling
Precautions before disassembly
• Remove all mud and dirt deposits off the pump surface. (Clean up the surface enough.)
• Let hydraulic oil out of the piston pump case and port hydraulic circuit.
• Choose a clean work spot. Be very careful not to allow any mud and dirt on the component parts.
• Handle the parts with enough care against dropping, hitting and scratching.
1) Disassembling
1. Remove the two bolts and the gear pump.
Tool : 13-mm closed wrench
(1)
(1) Bolt (2)

(2) Gear pump
2. Loosen the nut, and remove the nut and set-

screw. (Usually, however, do not loosen this nut
so as to keep the pressure balance constant.)
(1)
4-mm hexagonal wrench
(2)
(1) Nut
(2) Set screw
Before tightening the nut, record the protruding

margin (the dimension L as shown in the illus-
tration) of the setscrew for ease of pressure
adjustment after assembly.
IV-S-61
3. Remove the two bolts on the upper side out of
the four hexagon socket bolts. (1)
Tool : 8-mm hexagonal wrench
(1) Bolt
Tighten the two bolts (M10 x 65) for temporary (2)

securing for a screw length of approximately 10
mm.
(3)
Tool : 14-mm spanner (1)
(1) Bolt (M10 x 65)

(2) Body S
(3) Body H
After removing the remaining two hexagon

socket bolts, loosen the bolts for temporary
securing. Separate the body S and body H.
Tool : 8-mm hexagonal wrench

(2)
(1)
(1) Bolt
(2) Bolt (M10 x 65)
Rap the spring insertion part of the body H with

a resin mallet so that the body will be separated
with ease. (1)
(2)
(1) Body S
(2) Body H
IV-S-62
The body S and body H are separated.
(1) (2)
(1) Body S
(2) Body H
4. Remove the cylinder barrel kit.
(1)
(1) Cylinder barrel kit
5. Remove the swash plate and barrel holder.

(1)
(2)
(1) Swash plate

(2) Barrel holder
6. Remove the pivot pin, stopper pin, disc spring, (4) (2), (3)
and rod.
(1)
(1) Pivot pin

(2) Stopper pin
(3) Disc spring
(4) Rod
IV-S-63
7. Remove the snap ring.
(1)
Tool : Snap ring pliers
(1) Snap ring
8. Rap the shaft on the axis side with a resin mal-

let to extract the shaft.
9. Disassemble the cylinder barrel kit.

(5) (4) (3) (2) (2)
(6)
(1) Pinson, shoe, and show holder

(2) Spring
(3) cylinder barrel
(4) Retainer
(5) Snap spring
(6) Pin
IV-S-64
2) Reassembling
• Assemble the parts in the order reverse to that taken for disassembly. Clean the parts with wash oil,
and pay utmost attention to keep the parts free of dust sticking or contamination at the time of assem-
bly and protect each sliding part free of damage. The following section provides the important points of
assembly.
• Apply a little amount of grease to the circumference of the O-ring attached to the spigot section for the
prevention of damage.
1. Insert the oil seal to the body.

Apply a little grease to the rip and peripheral of
the oil seal, use the dedicated jig shown below,
and rap the oil seal with a hammer. (Take this
step only after the oil seal is replaced.)
(1)
(1) Body S
(2) Oil seal (2)
Oil seal insertion jig
2. Mount the valve plate. (4)

Carefully locate the valve plate by positioning it
with the spring pin on the body H. (3)
The side with the notch groove on the valve
plate is the face sliding on the cylinder barrel. (1)
Pay utmost attention not to locate the wrong
side.
(1) Valve plate

(2) Spring pin
(3) Hair groove
(4) Spring guide
(2)
IV-S-65
3. Attach a new packing to the positioning pin on
the body S.
(1)
(1) Gasket (2)

(2) Pin (2 - places)
4. Mount the two bolts (M10 x 65) for temporary (1)

securing to the two points on the upper side
and tighten the bolts slowly.
When the clearance between the body S and
body H becomes 5 to 10 mm, tighten the two
points on the lower side with the hexagon
socket bolts.
Then remove the bolts for temporary securing,
use the hexagon socket bolts in place of them,
and tighten the hexagon socket bolts. (1) Bolt (M10 x 65)
Tool : 14-mm spanner

8-mm hexagonal wrench
Tightning Torque : 53.9 ~ 63.7 N·m

5.5 ~ 6.5 kgf·m
39.8 ~ 46.9 kgf·m
5. Mount the gear pump
Tightning Torque : 19.6 ~ 21.6 N·m

2.0 ~ 2.4 kgf·m
14.5 ~ 15.9 ft·lbf
IV-S-66
3) Inspection and measurement
1. Piston Assembly and Cylinder Barrel (1) (2)
a) Visual Inspection
Check that the parts (sliding parts in partic-
ular) are free of damage, galling, or abnor-
mal wear.
b) Check that the clearance between the

external diameter of the piston and the
inner diameter of the cylinder barrel satisfy
the following condition: The clearance between piston assembly and cylinder barrel.
D - d = 0.05 mm.
>
(1) Piston assembly

(2) Cylinder Barrel
c) Check that the play of the piston and show (1) (2)
in the shaft direction satisfy the following
condition:
H = 0.2 mm
>
H
Play of Piston and Shoe
(1) Shoe
(2) pistonl
2. Shaft
Check that the wear of the oil seal mounting (1)
part is at a maximum of 0.025 mm.
Shaft Check
(1) Oil Seal Mounting Part
IV-S-67
b. Control valve
(1) Component of control valve

010 Assy valve, control 1 150 Plug 1
020 Assy valve, swing 1 160 Oring 1
030 Assy valve, blade 1 170 Plug 2
040 Assy valve, swivel 1 180 Assy valve, relief 1
050 Assy valve, travel st 1 190 Assy valve, relief 2
060 Assy valve, s/p 1 200 Assy valve 1
070 Assy valve, arm 1 210 Assy valve, relief 3
080 Assy valve, drive rh 1 220 Assy valve, relief 1
090 Assy valve, inlet 1 230 Assy valve, relief 1
100 Assy valve, drive lh 1 240 Oring 1
110 Assy valve, boom 1 250 Oring 2
120 Assy valve, bucket 1 260 Rod 3
130 Assy valve, outlet 1 270 Nut 6
140 Oring 1
IV-S-68
(2) Adaptor installation (KX36-3, KX41-3 EU)
No. Part Name Q’ty Remarks

A1, A2, A5, A7, A8, A9,
1 Adapter 12
B1, B2, B5, B7, B8, B9
P1, P2, P3
2 Adapter 9
A3, A45, A6, B3, B4, B6
3 Adapter 1 T1
4 Adapter 1 B6
5 Adapter 1
T2
6 Valve assy (Check) 1
IV-S-69
1 Adapter 4 Pa1, Pa2, Pa5, Pa7
Pb1, Pb2, Pb5, Pb7,
2 Adapter 6
Pp, Pp7
IV-S-70
(3) Adaptor installation (KX41-3 PP)
No. Part Name Q’ty Remarks No. Part Name

1 Tube joint (S, G1/8-G1/4) 4 A1, A5, B1, B5 11 Outlet
2 Tube joint (S, G1/8-G1/4) 4 A2, A3, B2, B3 12 Bucket
3 Elbow with seat 3 P1 ~ P3 13 Boom
4 Tube joint (L, G1/2-14) 1 T1 14 Travel, LH
5 Tube joint (L, G3/8-G3/8) 2 A4, B4 15 Inlet
6 Tube joint (S, G1/4-G3/8) 2 A6, B6 16 Travel, RH
7 Straight tube joint (G2-G3) 2 A7, B7 17 Arm
8 Straight tube joint 4 A8, A9, B8, B9 18 Service
9 Tube joint (S, G3/8-16) 2 T2, T3 19 Combination
10 Valve assembly (check) 1 T3 20 Swivel
Oring 12 1/4 use 1, 2, 7, 8 21 Dozer
Oring 6 3/8 use 3, 9, 10 22 Swing
IV-S-71
1 Tube joint (L, G1/8-G1/4) 4 Pa3, Pa5, Pa8’, Pb3
2 Tube joint (S, G1/8-G1/4) 2 Pa8, Pb8’
3 T-tube joint (F12) 2 Pa8, Pb8’
4 Tube joint (L, G1/8-G1/4) 1 Pa9
5 Tube joint (L, G1/8-G1/4) 3 Pp1, Pb5, Pb8
6 Tube joint (L, G1/8-8.4) 1 Pb9
Oring 6 1/8 use 1, 2
Oring 2 1/4 use 3
IV-S-72
Upper Side of Body
Lower Side of Body
Lower Side of Body

No. Part Name
1 Outlet
2 Bucket
3 Boom
4 Travel, LH
5 Inlet
6 Travel, RH
7 Arm
8 Service
9 Combination
10 Swivel
11 Dozer
12 Swing
Upper Side of Body
IV-S-73
(4) Inner parts of control valve
Swing
Dozer
Swivel
Combination
Service
Arm
Travel, RH
Inlet
Travel, LH
Boom
Bucket
Outlet
Tightning Torque
IV-S-74
1) Swing section
Tightning Torque
No. Part Name Q’ty Remarks No. Part Name Q’ty Remarks
1 Housing 1 6 Bolt 2
2a Spool 1 7 Check valve 1
2b Oring 1 Same as No.3 8 Spring 1
2c Back up ring 1 Same as No.4 9 Oring 1
2d Retainer 1 Same as No.5 10 Plug 1
2e Spring retainer 2 11 Cap 1
2f Spring 1 12 Bolt 2
2g Bolt 1 13 Oring 1
3 Oring 1 14 Plug 1
4 Back up ring 1 15 Anti- void valve 1
5 Retainer 1
IV-S-75
2) Dozer section
2g Bolt 1
3 Oring 1
4 Back up ring 1
5 Retainer 1
IV-S-76
3) Swivel section
1 Housing 1 8 Spring 1
2a Spool 1 9 Oring 1
2b Retainer 1 10 Plug 1
2c Spring 1
2d Spring retainer 1
2e Bolt 1
3 Oring 2
4 Cap A 1
5 Bolt 4
6 Cap, B 1
7 Check valve 1
IV-S-77
4) Service section
2g Bolt 1
3 Oring 1
4 Back up ring 1
5 Retainer 1
IV-S-78
5) Combination section
Set value Do not make

assembling
mistakes
Tightning Torque:
Do not make
assembling
mistakes
2b Retainer B 1 10 Plug 1
2c Spring 1 11 -
2d Retainer A 2 12 -
2e Bolt 1 13 Main Relief valve 1
3 Oring 2
4 Cap A 1
5 Bolt 4 Tightning torque : 5.88 ~ 6.86 N·m
0.6 0.7 kgf·m
6 Cap, B 1
7 Check valve 1
IV-S-79
6) Arm section
Do not make assembling mistakes

Set Set
value value
Tightning Tightning
Torque Torque
Tightning
Torque
Strict observation
Apply LockTight #242 to prevent loosening
2b Spring Retainer B 1 10 Plug 1
2c Spring 1
2d Spring Retainer A 1
2e Bolt 1
3 Oring 2
4 Cap A 1
5 Bolt 4
6 Cap, B 1
7 Check valve 1
IV-S-80
7) Boom section
Set Set
value value
Tightning Tightning
Torque Torque
Tightning
Torque
Strict observation
2c Spring 1
2d Spring Retainer A 1
2e Bolt 1
3 Oring 2
4 Cap A 1
5 Bolt 4
6 Cap, B 1
7 Check valve 1
IV-S-81
8) Bucket section
Set
value
Tightning
Torque
Tightning
Torque
Strict observation
2c Spring 1 11 Oring 1
2d Spring Retainer A 1 12 Plug (PF3/8) 1
2e Bolt 1 13 Check valve 1
3 Oring 2 14 Spring 1
4 Cap A 1
5 Bolt 4
6 Cap, B 1
7 Check valve 1
IV-S-82
9) Travelling section (LH & RH)
Tightning Torque
Strict observation
1 Housing 1 6 Bolt 2 M5 x 10
2b Oring 1 Same as No.3 8 Plug (PF1/4) 1
2c Back up ring 1 Same as No.4 9 Cap 1
2d Retainer 1 Same as No.5 10 Bolt 2 M5 x 45
2e Spring retainer 2
2f Spring 1
2g Bolt 1
3 Oring 1
4 Back up ring 1
5 Retainer 1
IV-S-83
10)Inlet section
Do not make
assembling
Set mistakes
value Do not make assembling mistakes Set
value
Tightning
Torque
Tightning
Torque
Do not make
assembling
mistakes
Tightning
Torque Strict observation
1 Housing 1 8 Oring 1
2b Spring retainer B 1 10 Spring 1
2c Spring 1
2d Spring retainer A 1
2e Bolt 1
3 Oring 2
4 Cap A 1
5 Bolt 4 M5 x 20
6 Cap, B 1
7 Plug (PF1/8) 1
IV-S-84
11) Outlet section

1 Housing 1
2 Oring 1
3 Plug (PF1/4) 1
4 Oring 1
5 Plug (PF3/8) 1
IV-S-85
1) Disassembling
Precautions (Observe for Safety)
• Disassembly Precautions
The product is disassembled and assembled in the manufacturer's factory, in principle. If the user is
under the necessity of disassembling or assembling the product, strictly observe the following precau-
tions in a factory that has sufficient hydraulic equipment technology.
1. All the hydraulic equipment is highly precisely processed with a minute clearance between adjacent
blocks. Select an especially clean place and carefully disassemble or assemble the equipment so
that the equipment will be free of dust, earth, or sand.
2. Before the disassembly, prepare a valve structure drawing and fully familiarize yourself with the
structure.
3. At the time of removing the control valve from the equipment, provide a dustproof cap to each port.
Before disassembling the equipment, recheck that the port is covered with the cap. Then wash the
exterior of the control valve assembly.
Work on an appropriate workbench, putting a clean sheet of paper or rubber mat thereon.
4. If the equipment is left disassembled, be sure to apply antirust oil and seal the equipment so as to
prevent the equipment from corrosion.
5. Handle the control valve with care while carrying or moving it, and do not hold the exposed part of
the lever spool or relief.
6. Never rap the equipment if the equipment does not move smoothly.
7. After disassembling and assembling the equipment, it is desirable to conduct a variety of tests
including relief setting, leak, and flow resistance tests. Hydraulic pressure test equipment is required
for the tests.
Do not disassemble the following parts but replace the whole assemblies though it is possible to take
them apart technically, because it is difficult to test and adjust them.
• Main relief valve

• Overload relief valve (Overload valve)
• Anti-cavitation valve
IV-S-86
• Tools Required for Disassembly
Prepare the following tools before disassembling the control valve.
The following tools are necessary to the disassembly of the control valve. These tools do not include
ones to disassemble the port joint or link joint.
Tools Q'ty Size
Hexagon spanner One each 4mm, 6mm, 8mm
spanner One each 13mm, 19mm, 22mm
Socket wrench One each 13mm, 19mm, 22mm
Torque wrench 1 1.96 ~ 19.6 N·m {0.2 kgf·m ~ 2.0 kgf·m}
Torque wrench 1 19.6 ~ 98.1 N·m {2.0 kgf·m ~ 10 kgf·m}
Tweezers 1
Magnet 1
Pliers 1
Phillips-head screwdriver (Large and medium) One each
In addition to the above, prepare clean wash oil, grease, LockTight #242, tags, and permanent marker.
IV-S-87
• Procedure for Disassembly of Each Part
• Disassemble the parts on a clean workbench after fully removing the residual oil in the valve and locat-
ing the valve port upward.
Inlet section
1. Removal of Relief Valve

Loosen and remove the relief valve (8) from the inlet section (1) with a 22-mm socket wrench (or a
spanner).
Note:
Do not remove the relief valve by using
the 19-mm sides of the hexagonal part.
2. Removal of Plug (PF1/4)

Loosen and remove the plug (2) from the inlet section (1) with a 6-mm hexagon spanner.

Loosen and remove the plug (4) from the inlet section (1) with a 8-mm hexagon spanner.
The figure shows the P1 inlet sec-

tion. Take the same procedure to
disassemble the P2 pressure gov-
ernor.
The P2 inlet section is, however,
not mounted with the plug shown in
Item 3).
IV-S-88
• Disassembling of swivel, dozer, service section
Swivel, dozer and service sections are similar in structure and shape. Therefore, the following section
explains the swivel section as a typical example.
1. Return Spring Cap

Loosen and remove the two M5 bolts (12) with a 4-mm hexagon spanner.
Remove the return spring cover (11) and extract the spool assembly from the body (1).
Note:
Remove the spool assembly
slowly in the horizontal direction.
Carefully remove the spool
assembly, or otherwise the spool
seal (with the O-ring and backup
Spool assembly ring) will be shifted to the edge of
the spool and damaged by the
edge. Record the direction of the
spool and the main component
into which the spool is inserted so
as not to make mistakes at the
time of assembly.
2. Link Mounting Block

• Loosen the two M5 small Phillips-head screws (6) with a Phillips-head screwdriver.
• Remove the O-ring retainer (5), and remove the backup ring (4) and O-ring (3) from the body (1)
carefully so that the backup ring and O-ring will not be damaged.
IV-S-89
3. Load Check Valve
Use a 6-mm hexagon spanner and loosen the check valve support (10).
Take out the check valve spring (8) and check valve (7) from the main part (1).
IV-S-90
• Disassembling of arm, boom, bucket section
Arm, boom and bucket sections are similar in structure and shape. Therefore, the following section
explains the arm section as a typical example.
1. Disconnection of Overload Valve

Use a 22-mm socket wrench (or spanner) and loosen and remove the overload valve (17) from the
main part (1).
Note:
Do not use the 19-mm sides for
removal. Keep in mind the mount-
ing location of the overload valve
on the main part before dismount-
ing the overload valve.

Use an 8-mm hexagon spanner, and loosen and remove the plug (14) from the main part (1).

Note:
Spool assembly seal (with the O-ring and backup
ring) will be shifted to the edge of
time of assembly.
IV-S-91
5. Load Check Valve

IV-S-92
• Disassembling of travel section (LH, RH)

Note:
seal (with the O-ring and backup
Spool assembly ring) will be shifted to the edge of
time of assembly.

IV-S-93
3. Removal of Check Valve Support
IV-S-94
• Disassembling of swing section
1. Removal of Anti-cavitation Valve

Use a 22-mm socket wrench (or spanner), and loosen and remove the anti-cavitation valve (17) from
the main part (1).
Note:
Do not use the 8-mm hexagon
hole for removal.

Use an 8-mm hexagon spanner, and loosen and remove the plug (14) from the main part (1).

Note:
Remove the spool assembly slowly in the hori-
zontal direction. Carefully remove the spool
assembly, or otherwise the spool seal (with the
O-ring and backup ring) will be shifted to the
Spool assembly edge of the spool and damaged by the edge.
Record the direction of the spool and the main
component into which the spool is inserted so as
not to make mistakes at the time of assembly.
IV-S-95
5. Load Check Valve

IV-S-96
2) Reassembling
Precautions (Observe for Safety)
• Assembly Precautions
• Uneven tightening torque or internal dust contamination at the time of assembly may result in malfunc-
tions.
• Check the number of parts and compare the parts with the valve structure drawing at the time of
assembly so as to prevent mistakes in assembly or missing parts.
• Carefully clean the assembly parts with wash oil and dry them, and soak the parts in operating oil
before assembling them.
• Before applying LockTight, clean and degrease the applicable area, i.e., two screw threads. Do not
apply LockTight excessively or otherwise it will run off the edge and may result in operational failures.
• Precautions for Assembling Seal Parts
• In principle, do not reuse the O-rings or backup rings. Replace them with new ones.
• When assembling the O-rings, apply operating oil or grease to the O-rings and mounting parts to
ensure smooth lubrication.
Do not apply operating oil or grease to the O-rings mounted between any of the mating sides of adja-
cent main parts (supply, swivel, arm, travel, dozer, breaker, swing, boom, and bucket parts).
Carefully handle the O-rings at the time of assembly so that the O-rings will not break or receive dam-
age.
• Required Assembly Tools
• Use the necessary tools specified on pages IV-S-68 at the time of assembly.
IV-S-97
• Assembly Procedure for Each Part
1. Main Part
a) Lay out each main part in assembly order with the mating sides facing upward.
Mount the O-rings between the mating sides of the adjacent main parts. Do not apply operating
oil or grease to the O-rings at that time, or otherwise the operating oil or grease will run off the
edges and it will be misconceived as oil leakage.
The assembly order and the O-rings to be used are shown in the next page.
The sizes of the O-rings to be used are specified in the respective structure drawings as well.
b) Prepare an object with a flat surface, such as a level block, locate each main part in the order
shown in a) on the surface with the actuator port facing downward.
Make sure that each mating side is free of dust and that the O-rings are mounted securely.
c) Insert the three M8 mounting bolts from the side and lightly secure the bolts with the M8 nuts. At
that time, use an appropriate tool, such as a plastic hammer, and lightly hit each main part so that
the ports of the respective main parts will be aligned. Then tighten each nut while applying a 13-
mm spanner to the other side so as to prevent the other side from turning.
Do not apply the specified torque at a time. Tighten the nuts little by little in turn so that the three
nuts will be tightened evenly. Unless the specified torque is applied, the main parts may deform
or oil leakage may result.
• M8 nut tightening torque

13.7 to 14.7 N·m (1.4 to 1.5 kgf·m)
Hit lightly with an appropriate tool, such as a plastic hammer.
An object with a flat surface,

such as a level block.
Tighten the three Mount the main parts so that the port of each main
nuts evenly in turn. part will be closely in contact with each other.
IV-S-98
• Inlet section
The illustration shows the P1 governor. Take the following procedure to assemble the P2 inlet
section as well.
1. Assembling Plug (PF3/8)

Mount the O-ring (5) to the plug (4).
Lightly screw the plug (4) into the governor (1) and tighten the plug with an 8-mm hexagon spanner.
• Plug (4) tightening torque

39.2 to 49.0 N·m (4.0 to 5.0 kgf·m)
O-ring used
5: O-ring 1BP14

Lightly screw the plug (2) into the governor (1) and tighten the plug with an 6-mm hexagon spanner.

24.5 to 29.4 N·m (2.5 to 3.0 kgf·m)
O-ring used
3: O-ring 1BP11
IV-S-99
3. Mounting Relief Valve
Mount the O-rings (8a and 8b) to the relief valve (8).
Lightly screw the relief valve (8) into the inlet section (1) and tighten the relief valve with a 22-mm
socket wrench (or spanner).
Do not tighten the relief valve by using the 19-mm sides of the hexagon head.
If the relief valve has a failure, replace the assembly.
• Relief valve (8) tightening torque

39.2 N·m (4.0 kgf·m)
O-ring used
8a: O-ring 1BP10
8b: O-ring 1BP14
IV-S-100
• Swivel, Dozer, and Breaker Switching Valve
Swivel, dozer and service sections are similar in structure and shape. Therefore, the following section
explains the swivel section as a typical example.
1. Assembling Check Valve

a) Insert the check valve (7) straight, with the skirt facing downward, into the main part (1).
Insert the check valve spring (8) into the body of the check valve (7) next.
b) Restore the slant of the check valve (7) and mount the check valve support (10). Straighten the
check valve at that time, or otherwise the check valve (7) cannot be inserted into the hole of the
check valve support (10).
c) Mount the O-ring (9) to the check valve support (10), lightly screw the check valve support, and
tighten the check valve support with a 6-mm hexagon spanner.
• Check valve support (7) tightening torque

24.5 to 29.4 N·m (2.5 to 3.0 kgf·m)
Straighten the check valve at that time, or

otherwise the check valve cannot be inserted
into the hole of the check valve support.
Stop screwing the check valve support if the
check valve support is not screwed smoothly.
O-ring used
8: O-ring 1BP11

a) Mount the O-ring (3) first. Then mount the backup ring (4) to the O-ring mounting hole of the main
part (1).
b) Temporarily secure the O-ring presser (5) with the M5 cross-slot screws (6). Use a Philips screw-
driver.
Temporary
securing
After mounting the return spring

cover (11) on the opposite side,
temporarily secure the O-ring O-ring used, Backup ring
pressure so as to check that the 3: O-ring 1AP10A
spool will rotate lightly. 4: Backup ring T3P10A
IV-S-101
Slowly insert the spool assembly from the return spring cover (11) side into the spool hole of the main
part (1) in the horizontal direction.
Check that the direction of the main part and spool remains unchanged from the direction before the
parts are disassembled.
If there is a defect in the spool or its configuration parts, replace the assembly.
Put the return spring cover (11) next, and insert the two M5 bolts (12). Press the return spring cover
(11), press the O-ring presser (2d) until the O-ring presser comes in close contact with the main part
(1), and tighten the parts with the two M5 bolts (12) evenly.
At that time, check that the spool protruding on the spool link side will lightly rotate.
If the spool does not turn lightly, loosen the cross-slot screws once, make readjustments, and tighten
the parts.
Tighten the two M5 cross-slot screws (6) that are temporarily secured on the spool link side.
• M5 hexagon socket bolt (12) tightening torque

5.88 to 6.86 N·m (0.6 to 0.7 kgf·m)
• M5 cross slot screws (6) tightening torque
1.96 to 2.94 N·m (0.2 to 0.3 kgf·m)
Check that the spool

turns lightly.
IV-S-102
• Arm, Boom, and Bucket Switching Valve
Arm, boom and bucket sections are similar in structure and shape. Therefore, the following section
explains the arm section as a typical example.


24.5 to 29.4 N·m (2.5 to 3.0 kgf·m)

O-ring used
9: O-ring 1BP11

part (1).
driver.
Temporary
securing

IV-S-103
Check that the main part is the disassembled one and that the direction of the spool is the same.
the parts.

5.88 to 6.86 N·m (0.6 to 0.7 kgf·m)
1.96 to 2.94 N·m (0.2 to 0.3 kgf·m)

turns lightly.

Lightly screw the plug (14) into the main part (1) and tighten the plug with an 8-mm hexagon spanner.

39.2 to 49.0 N·m (4.0 to 5.0 kgf·m)
O-ring used
13: O-ring 1BP14
IV-S-104
5. Mounting Overload Valve
Mount the O-ring (17a) to the overload valve (17). Then lightly crew the overload valve (17) into the
main part (1), and use a 22-mm socket wrench (or spanner) and tighten the overload valve.
Do not use the 19-mm sides to tighten the overload valve.
If the overload valve has a failure, replace the assembly.
• Overload valve (8) tightening torque

39.2 N·m (4.0 kgf·m)
O-ring used
17a: O-ring 1BP14
IV-S-105
• Left and Right Travel Switching Valve
1. Mounting Check Valve Support

Mount the O-ring (7) to the check valve support (8), lightly screw the check valve support (8) into the
main part (1), and tighten the check valve support with a 6-mm hexagon spanner.

24.5 to 29.4 N·m (2.5 to 3.0 kgf·m)
O-ring used
7: O-ring 1BP11

part (1).
driver.
Temporary
securing

IV-S-106
Check that the direction of the main part and spool remains unchanged from the direction before the
parts are disassembled.
the parts.

5.88 to 6.86 N·m (0.6 to 0.7 kgf·m)
1.96 to 2.94 N·m (0.2 to 0.3 kgf·m)

turns lightly.
IV-S-107
• Swing section


24.5 to 29.4 N·m (2.5 to 3.0 kgf·m)

O-ring used
9: O-ring 1BP11

part (1).
driver.
Temporary
securing
spool will rotate lightly.
4: Backup ring T3P10A
IV-S-108
Check that the main part is the disassembled one and that the direction of the spool is the same.
the parts.

5.88 to 6.86 N·m (0.6 to 0.7 kgf·m)
1.96 to 2.94 N·m (0.2 to 0.3 kgf·m)

turns lightly.

Lightly screw the plug (14) into the main part (1) and tighten the plug with an 8-mm hexagon spanner.

39.2 to 49.0 N·m (4.0 to 5.0 kgf·m)
O-ring used
13: O-ring 1BP14
IV-S-109
5. Mounting Anti-cavitation Valve
Mount the O-ring (17a) to the anti-cavitation valve (17).
Then lightly screw the anti-cavitation valve (17) into the main part (1), and use a 22-mm socket
wrench (or spanner) and tighten the anti-cavitation valve.
Do not use the 8-mm sides of the anti-cavitation valve edge to tighten the anti-cavitation valve.
If the anti-cavitation valve has a failure, replace the assembly.
• anti-cavitation valve (8) tightening torque

39.2 N·m (4.0 kgf·m)
O-ring used
17a: O-ring 1BP14
IV-S-110
3) Maintenance Standards
The following section provides the replacement intervals of parts required and replacement methods in
cases other than overhauls due to machine trouble.
1. Spool Seal (O-ring and Backup Ring)

a) It is recommended to replace the parts with new ones once a year. The parts can be used longer
than usual according to the operating conditions (e.g., the amount of dust on the spool) and operat-
ing frequency.
b) If the parts are stored for a long time (e.g., six months or more) before the parts are mounted to the
valve in actual use, the spool seal may deform or adhere to the spool. In that case, it is recom-
mended to replace the spool seal with a new one.
2. Spool
a) The spool need not be replaced unless one of the following occurs: The sliding part is damaged by
foreign substances contained in the operating oil; the spool is bent due to unexpected force applied
to the link mounting part; the spool is broken.
3. Load Check Valve

a) If the seat should have flaw damage or defects because the seat bites foreign substances contained
in the operating oil, the body seat made of cast metal needs to be replaced.
The check valve needs to be replaced if it has flaw damage."
b) It is recommended to replace the O-ring on the plug with a new one when the plug is once disassem-
bled.
4. Relief Valve
a) If the set value drops or an abnormal pressure occurs while the relief valve is in used, the relief valve
needs a resetting. If the value does not return to normal, replace the cartridge.
5. Overload Valve
If the seat on the overload valve has flaw damage, the cartridge needs to be replaced.
6. Anti-cavitation Valve
If the seat on the anti-cavity valve has flaw damage, the cartridge needs to be replaced.
7. O-ring Replacement
a) When assembling the parts (e.g., the relief valve, overload valve, anti-cavity valve, and a variety of
plugs) once disassembled, it is recommended to replace the existing O-rings with new ones.
b) Replace the O-rings for the mating sides of the respective parts disassembled with new ones.
IV-S-111
c. Pilot valve (PP version)
(1) Components of pilot valve
No. Part Name Q’ty

010 assy valve,pilot lh 1
020 plate 1
030 plug 4
040 push rod 4
050 seal 4
060 o ring 4
070 seat,spring 4
080 washer 4
090 spring 4
100 spring 4
110 joint 1
120 nut 1
130 nut,adjusting 1
140 nut,lock 1
150 lever 1
160 knob 1
170 pin,spring 1
180 boot 1
IV-S-112
Horn switch
Right P / V Left P / V
2 1
Yellow paint (Front side)
32 T 32 T
P 4 3 P
About 250
About 250
4
Clamp (Hose) Clamp (Hose)
View from machine front

Front Front
2 2
T T
3 3
P 1 P 1
4 4
Rear Rear
1. Pilot valve LH
2. Pilot valve RH
3. Filter
4. Adaptor
• Filter is installed on P port of each side of pilot valve.
• Adaptor tightning torque : 24.5 ~ 29.4 N·m
2.5 ~ 3.0 kgf·m
18.1 ~21.7 ft·lbf
IV-S-113
(3) Pilot hose connection
7 5
8
REAR REAR
1 2
FRONT FRONT 6
3 4 1. Pilot valve LH
2. Pilot valve RH
3. Control valve
4. TPSS valve
5. Unload valve
6. Pump
7. to Rotary joint G port
8. Hydraulic oil tank
Thick line : Hoses whitch are connected to the LH and RH pilot valve.
No. Connecting point Application Part No. Part Name Q’ty Dimension Tape color
Reference (mm)
1 Pump (P4) ~ Unload V (P) P4 RB238-63242 Hydraulic hose (3/8) 1 690
2 PV (Left P) ~ T-tube joint PV (Left P) RB238-63331 Hydraulic hose (1/4) 1 940 White x 2
3 PV (Right P) ~ T-tube joint PV (Right P) RB238-63341 Hydraulic hose (1/4) 1 880 White x 4
(Two on both ends)
4 PV (Left T) ~ Oil tank PV left drain RB238-63351 Hydraulic hose (1/4) 1 1060 Orange x 2
5 PV (Right T) ~ Oil tank PV Right drain RB238-63361 Hydraulic hose (1/4) 1 980 Orange x 4
(Two on both ends)
6 Unload V (B) ~ SJ (G) 2nd gear signal RB238-63271 Hydraulic hose (1/4) 1 350
7 Unload V (A) ~ CV (Pp1) Travel lock RB238-63281 Hydraulic hose (1/4) 1 850
8 PV (Right 4) ~ TPSS (B2) Boom ascending RB238-63431 Hydraulic hose (1/4) 1 870 Gray x 2
9 PV (Right 2) ~ TPSS (B4) Boom descending RB238-63441 Hydraulic hose (1/4) 1 870 Light Blue x 2
10 PV (Left 2) ~ TPSS (B3) Arm dump RB238-63411 Hydraulic hose (1/4) 1 790 Blue x 2
11 PV (Left 4) ~ TPSS (B1) Arm scraper RB238-63421 Hydraulic hose (1/4) 1 770 Green x 2
12 PV (Left 1) ~ CV (Pb3) Swivel left RB238-63451 Hydraulic hose (1/4) 1 1690 Red x 2
13 PV (Left 3) ~ CV (Pa3) Swivel right RB238-63461 Hydraulic hose (1/4) 1 1980 Yellow x 2
14 PV (Right 3) ~ CV (Pb9) Bucket dump RB238-63471 Hydraulic hose (1/4) 1 1710 Brown x 2
15 PV (Right 1) ~ CV (Pa9) Bucket scraper RB238-63481 Hydraulic hose (1/4) 1 2020 Pink x 2
16 CV (Pa8) ~ CV (Pa8’) Boom ascending merge RB238-63371 Hydraulic hose (1/4) 1 175
17 CV (Pb8) ~ CV (Pb8’) Boom descending merge RB238-63381 Hydraulic hose (1/4) 1 170
18 TPSS (A3) ~ CV (Pb5) Arm dump RB238-62911 Hydraulic hose (1/4) 1 1460 Yellow x 2
19 TPSS (A1) ~ CV (Pa5) Arm scraper RB238-62921 Hydraulic hose (1/4) 1 1700 Green x 2
20 TPSS (A2) ~ CV (Pa8) Boom ascending RB238-62931 Hydraulic hose (1/4) 1 1770 Gray x 2
21 TPSS (A4) ~ CV (Pb8) Boom descending RB238-62941 Hydraulic hose (1/4) 1 1450 Light Blue x 2
IV-S-114
1) Pilot hose LH
(2)
(11)
(18)
(19)
(13)
(12)
(10)
(19)
(18) (11)
(10)
(1) (4) (6) (8) (11)(12)

(7) (9) (10)
(2)(3) (5)
No. Part Name Q’ty Tape color (1) Outlet

(2) Bucket
(2) Hydraulic hose (1/4) 1 White
(3) Boom
(10) Hydraulic hose (1/4) 1 Blue
(4) Travel, LH
(11) Hydraulic hose (1/4) 1 Green
(5) Inlet
(12) Hydraulic hose (1/4) 1 Red
(6) Travel, RH
(13) Hydraulic hose (1/4) 1 Yellow
(7) Arm
(18) Hydraulic hose (1/4) 1 Blue
(8) Service
(19) Hydraulic hose (1/4) 1 Green
(9) Combination
(10) Swivel
(11) Dozer
(12) Swing
IV-S-115
2) Pilot hose RH
(16)
(8) (3)
(14) (15)
(3) (9)
(20)
(15) (9)
(21)
(20)
(15)
(8)
(21)
(17) (14)
No. Part Name Q’ty Tape color

(3) Hydraulic hose (1/4) 1 White
(8) Hydraulic hose (1/4) 1 Gray
(9) Hydraulic hose (1/4) 1 Light blue
(14) Hydraulic hose (1/4) 1 Brown
(15) Hydraulic hose (1/4) 1 Pink
(16) Hydraulic hose (1/4) 1 -
(17) Hydraulic hose (1/4) 1 -
(20) Hydraulic hose (1/4) 1 Gray
(21) Hydraulic hose (1/4) 1 Light blue
IV-S-116
3) Pilot hose (Pilot valve T port)

(4) Hydraulic hose (1/4) 1 Orange
(5) Hydraulic hose (1/4) 1 Orange
(5)
(4)
4) Pilot hose (Pump to Anload valve)

(1)
(1) Hydraulic hose (3/8) 1
5) Pilot hose (Anload valve to R /J and C / V)
(6)
(7)
IV-S-117
(5) Disassembling and assembling
The structure of the pilot valve shown below may slightly differ between models, but the basic structure
remains the same. Disassemble and assemble the pilot valve according to the following procedure.
Ports 2 & 4 Ports 1 & 3
IV-S-118
1) Tools and tightening torque
Tightening torque
N·m
Tool Size (mm) Part No. Part name Screw size
kgf·m
ft·lbf
20.6 ± 1.5
Hex wrench 6 125 Hex socket bolt M8 2.1 ± 0.15
15.2 ± 1.1
22 312 Adjusting nut M14 68.6 ± 4.9
Spanner 7.0 ± 0.5
32 302 Disc M14 50.6 ± 3.6
47.1 ± 2.9
Special tool (Draw-
24 301 Joint M14 4.8 ± 0.3
ing on page 17)
34.7 ± 2.1
Others
• Vapor phase inhibitor
• Kerosene
• Heat-resistant grease
• Sandpaper (#1000, #2000)
• Oilstone
• Vise
2) Maintenance standard
Checkpoints Criteria Remarks

Replace the pilot valve assembly with Conditions:
new one if the oil leak exceeds 1000 cc/ Primary pressure: 2.95 MPa
Leak amount
min with the steering wheel at neutral or
2000 cc/min while in operation. Oil viscosity: 23 mm2/s
If the sliding face is worn over 10 P more This amount of wear corresponds to the
Spool than the non-sliding one, replace the above leak amount. The same condi-
pilot valve assembly with new one. tions as above are expected.
Push rod If the tip is worn 1 mm or more, replace the push rod with new one.
If the disc (302) or joint (301) is worn out
If the shakiness is caused by a loose fix-
Loose control elements and loose 2 mm or more, replace it with
ture, tighten it up.
new one.
If unusual noise, hunting, primary pres-
sure drop, etc, occurs and it cannot be
Stable operation corrected according to "Troubleshoot-
ing", replace the pilot valve assembly
with new one.
Note 1: It is advisable to replace the O-rings and other sealing elements at every disassembly. They may
be reused when they are found not damaged.
Note 2: When the hex socket bolt (125) has been loosened, be sure to replace the sealing washer (121).
IV-S-119
3) Disassembling
1. Preparations
(1) Prepare a workbench that is spacious enough for the parts handled and strong and stable
enough to keep the parts in place.
(2) Also have the tools and jigs, at hand.
2. General precautions
(1) The parts are precision-machined. Handle them with enough care not to hit them against each
other or drop them.
(2) Even if any part is hard to remove, do not strike it out or pry out forcibly. Such handling may
cause burrs or damages, which may invite oil leak or poor performance later. Try to do the job
with patience.
(3) Do not leave the taken-out or exposed parts unprotected. Moisture or dust may get stuck on
them, causing rust. If unavoidably the job is interrupted halfway, be careful to protect such parts
against rust and dust.
3. Disassembling procedure
IV-S-120
Photo 7-1
• Clean up the pilot valve with kerosene.
• Fix the pilot valve on a vise using copper (or lead)
sheets.
• Remove the bellows (501). [Photo 7-1]
• Be careful not to break the bellows (501)
Photo 7-2
• Apply a wrench across the adjusting nut (312) and
disc (302). Loosen and remove the adjusting nut and
disc. [Photos 7-2, 7-3 and 7-4]
(1)
If the jig shown on the Photo 7-5 is not available:
• Slightly tighten the adjusting nut (312) and disc (302)
shown in Photograph 7-2 instead of loosening them.
(2)
(1)Adjusting nut
(2)Disc
Photo 7-3
• As shown below, if the disc is loosened with a snap-

per, the joint (301) will be loosened together.
(1)
(2)
Photo 7-4
(1)Adjusting nut
(2)Disc
IV-S-121
Photo 7-5
• With the specified jig, turn the joint (301) counterclock-
wise to get it loose. [Photos 7-5 and 7-6]
• Photo 7-5 shows the jig in its specified position.
• Drawings of jig is shown in next page.
CAUTION:
When the return spring (221) is strong in force, take care in
loosening and drawing out the joint (301). The plate (151),
plug (211) and push rod (212) may pop out together when
taking out the joint.
Photo 7-6
Photo 7-7
• Remove the plate (151).
(When the return spring (221) is strong in force) [Photo
7-7]
(When the return spring (221) is weak in force) [Photo
7-8]
Photo 7-8
IV-S-122
Drawing of Jig
The jig consists of a main part and two bushings.
1. Drawing of Main Part
(Chromium-molybdenum steel)
(Hi - Carbon Steel)
2. Drawing of Bushing 3. Usage of Jig
(Chromium-molybdenum steel)
IV-S-123
Photo 7-9
• When the return spring (221) is weak in force, the slid-
ing resistance of the O-ring holds the plug (211) inside
the casing (101). Using a bladed screwdriver, draw out
the plug. [Photo 7-9]
• Using its outer groove, draw out the plug (211) with
care not to get it damaged by an unbalanced load.
CAUTION:
Keep in mind that when the plug (211) may pop out by the
force of the return spring (221).
Photo 7-10
• Pull the push rod (212), plug (211), reducing valve
assembly, and return spring (221) out of the casing
(101). [Photo 7-10]
• Keep record of the positional relation with the casing
hole.
Photo 7-11
• Fix the pilot valve, with its port plate (111) upward, in
the vise.
• Using the specified hex wrench, loosen and remove
the hex socket bolt (125). [Photo 7-11]
IV-S-124
Photo 7-12
Detach the port plate (111) and O-ring (122) from the cas-
ing (101). [Photos 7-12 and 7-13]
Draw the bushing (131) out of the casing (101).
Photo 7-13
Photo 7-14
To disassemble the reducing valve, do the following.
Press in the spring seat (216) to get the secondary-pres-
sure spring (241) warped. Then slide this spring seat side-
ways and pass it through the larger hole and out of the
spool (201). [Photo 7-14]
Be careful not to scratch the surface of the spool (201).

Do not allow the spring seat (216) 6 mm or lower than
specified.
Handle this group of parts as an assembly.
Photo 7-15
Next separate the following parts: spool (201), spring seat
(216), secondary-pressure spring (241) and washer 2
(217). [Photo 7-15]
IV-S-125
Photo 7-16
Remove the folding-purpose spring (246) and spring seat
(218) from the push rod (212). [Photo 7-16]
Photo 7-17
Draw the push rod (212) out of the plug (211). [Photo 7-17]
Photo 7-18
Remove the O-ring (214) and seal (213) from the plug
(211). Use a small bladed screwdriver or the like to take
out the seal (213). [Photos 7-18 and 7-19]
Photo 7-19
IV-S-126
Clean up the parts.
1) Put the parts one by one in a rough-washing container
with kerosene. (Rough washing)
2) Put the parts one by one in a finish-washing container
with kerosene. Slowly turn them and wipe them clean
thoroughly inside and out. (Finish washing)
Using clean waste cloth, wipe kerosene away from the
parts.
Keep the parts against rust.

Apply rust-preventive to the specified parts.
Note :
• Do not wipe dirty parts in kerosene from the beginning
because otherwise they might get scratched. Keep
them dipped until dirt, fat and grease become loose
enough off the parts.
• Be attentive to keep the kerosene clean enough. Oth-
erwise the parts may get scratched, leading to poor
performance when reassembled.
• Do not dry up the parts with compressed air. Dust and
moisture in the air may damage the parts or get them
rusty later.
• Do not leave the parts without rust-preventive. Rust
may build up, causing malfunction later.
IV-S-127
4) Assembling
1. Preparations
(1) As in the case of reassembling, prepare the specified workbench, tools and materials.
2. General precautions
(1) Take the same general precautions as in disassembling.
(2) Before reassembling, remove metal chippings and foreign matters from all the parts. Make sure
the parts are free of burrs, hit marks and other problems. If a burr or hit mark is found, get rid of it
with an oilstone.
(3) In principle, replace the O-rings and backup rings with new ones.
(4) When fitting the O-rings and backup rings, handle them with care not to damage it. (Apply a small
amount of grease for smooth fitting.)
(5) When fitting the parts in place, preferably use grease to avoid accidental drop.
(6) Tighten the bolts and the like to the their specified torques listed in each reassembling procedure.
Measure the tightening torques with a torque wrench.
(7) Finally apply blind plugs to all the open ports to avoid entry of dust.
3. Reassembling procedure
Photo 7-20
Fit the bushing (131) and O-ring (122) to the casing (101).
[Photo 7-20]
Photo 7-21
Install the port plate (111), with the hex socket bolt (125)
and seal washer (121) in between, on the casing (101).
[Photos 7-21 and 7-22]
• Carefully position the spring pin (126) in the casing

hole.
• Replace the seal washer (121) with new one.
Photo 7-22
IV-S-128
Photo 7-23
Tighten the hex socket bolt (125) to the specified torque.
[Photo 7-23]
• Alternately tighten the two bolts.

[Hex socket bolt (125)]
Screw size : M8
Tightning torque : 20.6 ± 1.5 N·m
210 ± 15 kgf·m
15.2 ± 1.1ft·lbf
Photo 7-24
Install the washer 2 (217), secondary-pressure spring
(241) and spring seat (216) in this order on the spool
(201). [Photo 7-24]
• Do not allow the spring seat (216) 6 mm or lower than

specified.
Photo 7-25 Then press in the spring seat (216) to get the secondary-
pressure spring (241) warped. Now slide this spring seat
sideways and pass it through the larger hole and onto the
spool (201). [Photo 7-25]
Photo 7-26 Fit the return spring (221) in the casing (101). Also fit the
reducing valve assembly to the casing (101). [Photo 7-26]
• Place these parts back in their original positions.
IV-S-129
Photo 7-27
Fit the O-ring (214) to the plug (221). [Photo 7-27]
• Alternately tighten the two bolts.

[Hex socket bolt (125)]
Screw size : M8
210 ± 15 kgf·m
15.2 ± 1.1ft·lbf
Photo 7-28 Fit the seal (213) to the plug (211). [Photo 7-28]
• Place the seal (213) with its lip positioned as shown

below.
Seal Plug
Push rod
Apply hydraulic oil.
Photo 7-29
Fit the push rod (212) into the plug (211). [Photo 7-29]
• Apply hydraulic oil over the surface of the push rod.
Photo 7-30
Fit the folding-purpose spring (246) and spring seat (218)
into the push rod (212). [Photo 7-30]
IV-S-130
Photo 7-31
Fit the plug assembly to the casing (101).
When the return spring (221) is weak in force, this assem-
bly is kept in place by the sliding resistance of the O-ring.
[Photo 7-31]
• Be careful not to pry the spool (201) too hard. Other-

wise the casing hole (101) may get damaged.
In case of the jig shown in page xxx is not available,

Photo 7-32 Please see page xxx.
When the return spring (221) is strong in force, fit all the
four plugs at once using the plate (151). Apply and tempo-
rarily tighten the joint (301). [Photo 7-32]
CAUTION:
Keep in mind that the plug assembly and plate (151) may
pop out.
Photo 7-33
Place the plate (151) in position.
Using the specified jig, tighten the joint (301) to the casing
(101) by the specified torque. [Photos 7-33 and 7-34]
• Photo 7-33 shows the jig in its specified position.

[Joint (301)]
Screw size : M14
480 ± 30 kgf·m
34.7 ± 2.1 ft·lbf
Photo 7-34
IV-S-131
• In case the jig shown in page xxx is not available. (From photo 7-31)
• Jit the disc (302) to the joint (301).
• Mount the adjusting nut (312) next. Apply a spanner to

the adjusting nut (312) and disc (302), and tighten
them to the specified torque.

700 ± 50 kgf·m
50.6 ± 3.6 ft·lbf
(Use torque wrench.)

• Screw in the disc unit it comes into even contact with
the four push rod (212).
WARNING:
Carefully adjust the final position of the disc (302). If it is
screwed in too much, the secondary pressure with the
lever at neutral may be wrongly applied, causing the
machine to malfunction.
• Apply a spanner to the disc (302), and tighten the disc

unit to the specified torque and secure the disc unit on
the casing (101).

480 ± 30 kgf·m
34.7 ± 2.1 ft·lbf
Go back to photo 7-37

IV-S-132
Photo 7-35
Fit the disc (302) to the joint (301). [Photo 7-35]
• Screw in the disc until it comes into even contact with

the four push rods (212).
WARNING:
Carefully adjust the final position of the disc (302). If it is
screwed in too much, the secondary pressure with the
lever at neutral may be wrongly applied, causing the
machine to malfunction.
Photo 7-36
Apply the adjusting nut (312) and fix it by applying the
specified wrench across the disc (302). Tighten the adjust-
ing nut to the specified torque. [Photo 7-36]
• In tightening the nut, keep the disc (302) in position.

[Adjusting nut (312)]
Screw size : M14
700 ± 50 kgf·m
50.6 ± 3.6 ft·lbf
Photo 7-37 Apply grease to the turning portion of the joint (301) and
the top of the push rod (212). [Photo 7-37]
Photo 7-38
Fit the bellows back into position. [Photo 7-38]
Pour vapor phase inhibitor from the ports and apply the
blind plugs.
• Be careful not to break the bellows (501).
IV-S-133
5) Trouble shooting
It is not easy to pinpoint trouble spots. The table below lists some typical problems, their possible causes
and corrections. Before starting repair jobs, refer to the table below.
A machine trouble is not necessarily caused by just one part, but by come different parts combined. It
should be noted that the corrections listed below might not be enough and additional measures might be
needed.
This chart does not cover all possible causes and corrections. Whenever necessary, it is therefore
essential for the repair supervisor to look further into the problem and cause in question.
Problem Causes Corrections

Secondary pressure failure to rise (1) Primary pressure too low. (1) Ensure the specified primary pres-
(2) Secondary-pressure spring (241) sure.
broken or worn out. (2) Replace the spring with new one.
(3) Too large a gap between the spool (3) Replace the remotely operated
(201) and casing (101). valve with new one.
Secondary pressure unstable (1) Sliding parts stuck. (1) Correct the stuck spot.
(2) Tank line pressure fluctuating too (2) Return the oil direct to the oil tank.
much. (3) Operate the machine to let out the
(3) Air sucked in the piping. air.
Secondary pressure too high (1) Tank line pressure too high. (1) Correct the stuck spot.
(2) Sliding parts stuck. (2) Return the oil direct to the oil tank.
IV-S-134
c. Pilot valve (EU version)
IV-S-135
IV-S-136
IV-S-137
IV-S-138
IV-S-139
IV-S-140
IV-S-141
IV-S-142
IV-S-143
IV-S-144
IV-S-145
d. Swivel motor (KX41-3 PP)
(1) Component of swivel motor
No. Part Name Q'ty Remarks

010 Assy motor,swivel 1 Include A ~ R and 020 ~ 220
020 Assy gear 1 Include A ~ D and 030 ~ 060
030 Bearing,ball 1
040 Bearing,ball 1
050 Plug 1
060 Retainer 1
070 Plate 1
080 Plate,valve 1
090 Valve 1
100 Plate 1
110 Spring 2
120 Pin 2
130 Drive 1
140 Gear,roller 1
150 Valve,drive 1
160 Assy valve 1 Include k, 170, 180, 190, 200
170 Ball 2
180 Plug 2
190 Spring 2
200 Plug 3
210 Bolt 4
220 Kit seal 1 Include C ~ Q
230 Bolt 4
IV-S-146
(2) Cross-sectional View of Swivel Motor
No. Part Name Q'ty Remarks No. Part Name Q'ty Remarks
1 Bearing housing 1 26 Relief cartridge (2) Include 32 ~ 44
2 Pinion gear 1 27 Steel ball (2)
3 Ball bearing 1 6308 LLU 28 Plug (2)
4 Ball bearing 1 6207 { 29 O-ring (2) 1BP14
5 Piug 1 R1/8 30 Spring (2)
{6 X-ring 1 31 Prug (3) R1/8
7 Retaining ring 1 32 Cartridge (2)
{8 O-ring 1 AS568-041 33 Screw guide (2)
{9 Shaft face seal 1 34 O-ring (2) 1BP16
10 Wear plate 1 35 Needle valve (2)
{11 O-ring 2 AS568-041 36 Spring washer (2)
12 Valve plate 1 37 Spring presser (2)
{13 O-ring 1 AS568-038 38 Orifice plate (2)
14 Valve 1 39 Spring (2)
15 Balancing plate 1 { 40 O-ring (2) 1BP18
16 Spring 2 { 41 O-ring (2) 1BP5
{17 Inner face seal 1 42 Hexagon socket setscrew (2)
18 Pin 2 43 Hexagon nut (2)
19 Outer face seal 1 { 44 O-ring (2) 1BP12
20 2K drive 1 45 Nameplate 1
21 Gear roller 1 46 Rivet 2
22 Valve drive 3 47 Hexagon bolt 4
23 O-ring 1 AS568-011
24 Valve housing assembly 1 Include 25 ~ 44 Pinion gear assembly Include 1 ~ 8
25 Valve housing (1) { Seal kit Include { items
IV-S-147
(3) Adaptor Installation

1 Motor assembly (swivel) 1 (613)
2 Adapter 2 A, B
O-ring 2 3/8 use A, B
3 Elbow with seat 1 B
4 Tube joint 1 A
5 Elbow joint 1 T
O-ring 2 1/4 use A, B
6 Bolt 4 M14 x 1.5 7T
IV-S-148
1) Tools
Tools Remarks
Torque wrench Capacity: 9.8 to 98 N·m
Socket 9/16” (or 14 mm)
Hexagonal socket 5 mm
8 mm
Snap ring pliers
Flat-blade screwdriver
Resin mallet
Press
2) Disassembling
At the time of disassembly, clean the work site and prepare a plastic box for parts.
Before disassembling the motor, clean up and around the port, and remove the paint coating of each joint
with a wire brush.
Caution :
Do not disassemble the parts unless it is necessary.
Pinion gear assembly, Valve housing assembly
Locate the valve housing part and secure the flange with a vise.
IV-S-149
Remove the four hexagon bolts (47). Do not remove the check plug (28) unless it is nec-
essary.
Remove the valve housing assembly (24). Pay Remove the balancing ring (15) and valve (14).
utmost attention not to lose spring (16) and pin
(18).
Do not remove the relief cartridge (26) unless it is

necessary.
IV-S-150
Remove the valve plate (12) and valve drive (22).
Remove the valve housing assembly (24). Pay Remove the wear plate (10).
utmost attention not to lose spring (16) and pin
(18).
Remove the gear roller (21) and driver (20).
IV-S-151
Remove the retaining ring (7)
Do not remove the pinion gear assembly unless it
is necessary.
Use a pressing machine (2) and remove the pinion (6) Remove the X-ring
gear shaft.
Remove the ball bearings (3) and (4).
IV-S-152
3) Assembly Procedure
Check the mating side of each part.
Flaw damage and burrs may result in leakage.
Clean each part with clear wash oil, and dry them with natural ventilation or an air blower.
Do not remove the part with cloths or paper towels, or otherwise the nap will stick to the part, which may
result in trouble.
Caution :
Replace the seals with new ones. Apply grease to the new ones before use.
Mount the X-ring (6) to the bearing housing (1).
IV-S-153
Mount the bearings (3) and (4) to the bearing hous- Mount the retaining ring (7).
ing (1).
Mount the shaft face seal (9) to the wear plate (10).
Use a pressing machine and mount the pinion gear Shaft face seal (9)
shaft (2) to the bearing housing (1).
Wear plate (10)
IV-S-154
Mount the O-ring (8) to the bearing housing (1). Mount the O-ring (8) to the valve plate (12).
Mount the drive (20). Mount the valve plate (12).
Mount the valve plate so that the drain hole of the valve
plate will coincide with the drain hole of the gear roller.
Mount the O-rings (8) and (23) to the wear plate (10).
Valve timing
Mount the valve drive and valve as shown in the
Mount the gear roller (21). Mount the gear roller so photograph.
that the drain hole of the waist plate will coincide Mount the valve (14).
with the drain hole of the gear roller.
When the spline tooth edge of the valve drive coin-

cide with the outer teeth of the gear roller star as
Mount the valve drive (22). shown in the illustration below, mark the tooth edge
of the valve drive with a felt pen.
Mount the parts so that the position of the marked
spline tooth of the side hole TP valve drive will be
shifted 15 degrees to the right (i.e., turn the valve
15 degrees counterclockwise).
Caution :
There will be a high risk if the valve timing is wrong
because the motor will rotate in the reverse direction.
Valve drive
Valve
Gear roller star
IV-S-155
Mount the inner face seal (17) and outer face seal Mount the relief cartridge (26) to the valve housing
(19) to the balancing ring (15). (25).
Inner face seal Outer face seal
Balancing ring
Mount the two springs (16) to the two points inside

the valve housing (25).
Mount the two pins (18) to the same hole.
Mount the steel ball (27), check plug (28), and

spring (30) to the valve housing (25).
IV-S-156
Make the positions of the two pins on the valve Mount the hexagon bolt (47).
housing and balancing pin grove coincide together. Mount the four bolts evenly to a tightening torque of
Then mount the balancing ring (15) to the valve 53 N·m.
housing (25).
Valve housing (25)
Pin (18)
Spring (16)
Balancing ring (15)
Mount the O-rings (23) and (13) to the valve hous-

ing assembly (24).
Mount the valve housing assembly.
Insert an appropriate tool, such as a screwdriver,
into a porthole to press the balancing plate when
mounting so that the balancing ring will not be dis-
connected.
IV-S-157
4) Trouble shooting
Trouble Cause Countermeasure
No motor rotation Insufficient oil in the tank Supply the tank with oil to an appropriate level.
Pump damage Replace the pump.
Improper operation of relief valve or set pressure Disassemble and clean the relief valve and set
the pressure to an appropriate level.
Slow response Low oil viscosity Use oil with appropriate viscosity.
Pump wear Repair or replace the pump.
Extremely low oil temperature Increase the tank size or oil cooler.
Low relief set pressure Set the relief valve to an appropriate pressure.
Unstable rotation Low relief set pressure Set the relief valve to an appropriate pressure.
Air contamination into suction side of pump Close the pipe on the pump suction side.
Reverse rotation Reversed piping Reverse the pipe connections.
Reversed motor valve timing Change the valve timing.

Oil leakage Bolt or plug loosening Tighten the bolt and plug to correct torque.
O-ring flaw damage or abrasion Replace the O-ring.
X-ring flaw damage or abrasion Replace the X-ring.

Drop the drain pressure to the permissible range.
Abnormal noise Residual air in circuit and motor Completely purge the air.
Pump cavitation Clean the clogged suction filter. Increase the suc-
tion pipe diameter of the pump.
Increase the boost pressure of the pump.
Caution :
The life of the motor is considered to have expired in the following cases.
The torque and revolutions are reduced.
The noise increases.
In the above cases, it is recommended to repair or replace the motor. Contact your Kubota representative for
motor repairs.
IV-S-158
d. Swivel motor (KX36-3 EU, KX41-3 EU)
(1) Component of swivel motor

010 Assy motor (swing) 1
020 Assy gear 1
030 Bearing,ball 1
040 Bearing,ball 1
050 Plug 1
060 Retainer 1
070 Plate 1
080 Plate,valve 1
090 Valve 1
100 Plate 1
110 Spring 1
120 Pin 1
130 Drive 1
140 Gear,roller 1
150 Valve,drive 1
160 Assy valve 1
170 Ball 1
180 Plug 1
190 Spring 1
200 Plug 1
210 Bolt 1
220 Kit seal 1
230 Bolt 4
IV-S-159

1 Motor assy (swingl) 1
2 Adapter 2
3 Adapter 2
4 Bolt 4
IV-S-160
e. Rotary Joint
(1) Components of Rotary Joint (KX41-3 PP)
No. Part Name Q’ty No. Part Name Q’ty

010 Housing 1 090 Collar 1
020 Shaft 1 100 External cir clip 1
030 Back up ring 18 110 O ring 1
040 D ring 9 120 Plug 4
050 Back up ring 2 130 Base 1
060 O ring 2 140 Bolt 4
070 Collar 1 150 Bolt 4
080 Plug 2
IV-S-161
(2) Components of Rotary Joint (KX36-3 EU, KX41-3 EU)
• KX36-3 EU

010 Assy joint, swivel 1 090 Coller 1
020 Shaft, swivel joint 1 100 Cir clip 1
030 Ring back up 14 110 Ring 2
040 Ring (D) 7 120 Base (Swivel joint) 1
050 Ring back up 2 130 Bolt 4
060 O - ring 2 140 Bolt 4
070 Coller 1
080 Body, swivel joint 1
IV-S-162
• KX41-3 EU (Fixed Track)

060 O - ring 2 140 Bolt 4
070 Coller 1
IV-S-163
• KX41-3 EU (Extendable Track)

060 O - ring 2 140 Bolt 4
070 Coller 1
IV-S-164
• KX36-3 EU
Front
Front
Front
No. Part Name Q'ty Remarks No. Part Name

1 Assy, swivel joint6 1 (623) (b) Blade cy1 (rod)
2 Bolt 4 M12 x 1.25 7T (c) Blade cy1 (bottom)
3 Adapter (L, G1/8-G1/4) 4 E, F, H, I (d) Running drain
4 Adapter 2 B, C (e) Running (right) lower side port
5 Adapter (G1/4-13) 1 D (f) Running (right) upper side port
6 Body 4 e, f, h, i (h) Running (left) lower side port
7 Joint 2 b, c (i) Running (left) upper side port
8 Adapter 2 d
IV-S-165
• KX41-3 EU (Fixed Track)
Front
Front
Front

5 Adapter 1 G (f) Running (right) upper side port
6 Elbow, pope 1 G (g) Speed increase signal
7 Adapter (G1/4-13) 1 D (h) Running (left) lower side port
8 Body 4 e, f, h, i (i) Running (left) upper side port
9 Joint 4 b, c, g
10 Adapter 2 d
IV-S-166
• KX41-3 EU (Extendable Track)
Front
Front
Front

5 Adapter 2 A, J (f) Running (right) upper side port
6 Adapter 1 G (g) Speed increase signal
7 Elbow, pope 1 G (h) Running (left) lower side port
8 Adapter (G1/4-13) 1 D (i) Running (left) upper side port
9 Body 4 e, f, h, i
10 Joint 4 b, c, g
11 Adapter 2 d
IV-S-167
(2) Adaptor installation (KX41-3V PP)
Machine front
Machine front Machine front
(1) Rotary joint assy (6) Adaptor (L, G1/4 - 13)

(2) Bolt (7) Adaptor (L, G3/8 - G3/8)
(3) Adaptor (L, G1/8 - G1/4) (8) Adaptor (L, G1/4 - G1/4)
(4) Adaptor (S, G1/8 - G1/4) (9) Adaptor (S, G3/8 - G3/8)
(5) Adaptor (S, G1/4 - G1/4) (10) Adaptor (L, G1/4 - G1/4)
IV-S-168
(3) Hose connection
1) Hose connection to the rotary joint body
(1) Dozer cylinder (3) Travel motor LH

(2) Track cylinder (4) Travel motor RH
IV-S-169
No. Mounting position Part No. Reference Part Name Q’ty Dimension (mm) Tape color on hose
5 R/J (l) ~ Travel M left A RB238-63911 Hydraulic hose (3/8) 1 790
6 R/J (n) ~ Travel M left B RB238-63911 Hydraulic hose (3/8) 1 790
7 R/J (f) ~ Travel M right B RB238-63911 Hydraulic hose (3/8) 1 790
8 R/J (e) ~ Travel M right A RB238-63911 Hydraulic hose (3/8) 1 790
9 R/J (g) ~ Travel M left PP RB238-63922 Hydraulic hose (1/4) 1 810 White x 1
10 R/J (g) ~ Travel M right PP RB238-63922 Hydraulic hose (1/4) 1 810 White x 1
11 R/J (d) ~ Travel M left DR RB238-63931 Hydraulic hose (1/4) 1 740
12 R/J (d) ~ Travel M right DR RB238-63931 Hydraulic hose (1/4) 1 740
13 R/J (b) ~ Intermediate joint RB238-64811 Hydraulic hose (1/4) 1 310
14 R/J (c) ~ Intermediate joint RB238-64831 Hydraulic hose (1/4) 1 310
15 Intermediate joint RB238-64821 Hydraulic hose (1/4) 310
~ Dozer cylinder rod
16 Intermediate joint RB238-64821 Hydraulic hose (1/4) 310
~ Dozer cylinder bottom
17 R/J (j) RB238-64851 Hydraulic hose (1/4) 950
~ Track cylinder bottom
18 R/J (a) RB238-64861 Hydraulic hose (1/4) 710
~ Track cylinder rod
IV-S-170
2) Hose connection to the rotary joint shaft
(1) Control valve (3) Hydroulic oil tank

(2) Change valve (4) Unload valve
IV-S-171
Part No. Dimension Tape color
No. Connecting point Application Part Name Q’ty
Reference (mm) on hose
5 CV(A7) ~ RJ(I) Travel left forward RB238-64411 Hydraulic hose (3/8) 1 620 Blue x 1
6 CV(B7) ~ RJ(H) Travel left backward RB238-64421 Hydraulic hose (3/8) 1 580 Red x 1
7 CV(A6) ~ RJ(F) Travel right forward RB238-64431 Hydraulic hose (3/8) 1 390 Green x 1
8 CV(B6) ~ RJ(E) Travel right backward RB238-64441 Hydraulic hose (3/8) 1 460 Yellow x 1
9 Variable leg V A1 Dozer up (rod) RB238-64731 Hydraulic hose (1/4) 1 420
~ RJ (B)
10 Variable leg V A2 Dozer down (bottom) RB238-64741 Hydraulic hose (1/4) 1 560
~ RJ (C)
11 Variable leg V B2 Track extend (bottom) RB238-64752 Hydraulic hose (1/4) 1 570 White x 1
~ RJ (J)
12 Variable leg V B1 Track retract (rod) RB238-64762 Hydraulic hose (1/4) 1 430 White x 2
~ RJ (A)
13 RJ(D) ~ Oil tank Traveling drain RB238-63761 Hose (drain 3) 1 330
14 RJ(G) ~ Unload valve 2nd signal RB238-63271 Hydraulic hose (1/4) 1 350
High speed signal
IV-S-172
(4) Assembling of the rotary joint
12
4 8
5 14
2 13
10 9 11
(1) Shaft (8) Plug

(2) Back up ring (9) Collar
(3) D - ring (10) External circlip
(4) Back up ring (11) O - ring
(5) O - ring (12) Plug
(6) Collar (13) Base
(7) Housing (14) Bolt
1. Apply grease over the inner and outer surface of the D - ring (3) before hand.
2. Apply grease over the inner and outer surface of the D - ring (5), (11) before hand.
3. Apply screw adhesive (Loctite 271) on the Botl (14).
Tightning torque: 48.1 ~ 55.9 N·m
4.9 ~ 5.7 kgf·m
35.5 ~ 41.2 ft·lbf
IV-S-173
(5) Disassembling of the Rotary Joint from machine
1. Jack up the equipment and support the equipment with a
sturdy harness.
Danger
The service member must not go under the equipment
with the front and dozer jacked up. The equipment may
fall, thus resulting in death.
2. Take off cover fromm center track frame.

(1) Center track frame
(2) Cover
(3) Bolt
(1)
(2)
(3)
3. Remove track cylinder hoses from track
cylinder.
Remove track cylinder from track frames.
(1) Hose connecting portion
(2) Track cylinder
(3) Track frame (1)
(3)
(2)
(3)
IV-S-174
4. Disconnect hoses on housing of rotary joint. (2)
Disconnect hoses on shaft of rotary joint.
(1) Housing
(2) Shaft
(1)
5. Remove bolts.
Take off base plate with
rotary joint assy.
(1) Bolt
(2) Base plate
(3) Rotary joint assy
(3)
(2)
(1)
IV-S-175
f. Travel motor
(1) Componet of travel motor
Ref.No. Part No. Reference Part Name Q’ty Ref.No. Part No. Reference Part Name Q’ty
040 RB238-6129-2 Assy motor,wheel 2 290 04810-00180 O ring 4
050 RB238-7812-0 Cover 2 300 08101-06201 Bearing,ball 2
060 RB238-7802-0 Assy gear 2 310 05411-00512 Pin,spring 2
070 04612-00260 Cir clip,external 2 320 RB238-7805-0 Assy body,motor 2
080 05411-00312 Pin,spring 6 330 RB238-7806-0 Assy shaft 2
090 RB238-7826-0 Cir clip,external 6 340 08101-06004 Bearing,ball 2
100 RB238-7813-0 Gear 8 350 RB238-7807-0 Assy cylinder 2
110 RB238-7814-0 Ring,seal 2 360 04611-00280 Cir clip,internal 2
120 RB238-7815-0 Ring,snap 2 370 RB238-7808-0 Kit seal 2
130 RB238-7816-0 Plate 2 380 04810-51050 O ring 2
140 RB238-7817-0 Ring,slide 2 390 04810-00060 O ring 2
150 RB238-7818-0 Needle 120 400 RB238-7829-0 Seal,oil 2
160 RB238-7819-0 Seal 2 410 04810-00140 O ring 4
170 RB238-7821-0 Bearing 4 420 04810-00180 O ring 4
190 RB238-7803-0 Kit seal 2 430 RB238-7831-0 Swash plate 2
200 04811-51300 O ring 2 440 07715-03215 Ball 4
210 RB238-7828-0 O ring 2 450 RB411-7824-0 Screw 14
220 04810-00110 O ring 4 460 RB411-7825-0 Pin 2
230 04810-00140 O ring 4 470 RB238-7824-0 Washer,plain 8
240 RB411-7813-0 Plug 4 480 RB238-7825-0 Plug 4
250 RB238-7801-2 Assy motor 2 490 RB238-7826-0 Cir clip,external 8
260 RB238-7804-2 Assy body,motor 2 500 RB238-7827-0 O ring 8
270 04811-00100 O ring 4 510 01311-11030 Bolt,hex-soc-hd 16
280 04810-00140 O ring 4 520 04512-60100 Washer,spring 16
IV-S-176
460
120 210 060-2 080 130 060-3 440 430 200 110 160-1 160-2 320-1 350-4 450 350-1 350-3 310 480 260-13 260-23
060-5 350-2 220
060-6 360 260-2
050 300 260-3
060-4 270
060-1 290
070 260-1 260-16 260-4
140 260-15 260-7
260-8
320-3 330-1 420
320-2 350-8 260-14
500 350-9
240 260-20
230 380
320-4
350-5 350-6 350-7 390 260-15 260-21 260-6 260-12 280 410 260-5 260-22 260-9
090 340 150 100 470 170
Ref.No. Part Name Q’ty Ref.No. Part Name Q’ty Ref.No. Part Name Q’ty
050 Cover 1 260-16 Plug 2 360 Snap ring 1
060-1 Carrier 2 1 270 O ring 2 200 O ring 1
060-2 B2 gear 3 280 O ring 2 500 O ring 1
060-3 S1 gear 1 290 O ring 2 220 O ring 2
060-4 B2 pin 3 260-20 Choke 1 230 O ring 2
060-5 Needle 39 260-21 Needle 2 380 O ring 1
060-6 Thrust washer 6 260-22 Metal plug 6 390 O ring 1
070 Snap ring 1 260-23 Choke 2 100 B1 gear 4
080 Spring pin 3 300 Bearing 1 110 Seal ring 1
090 Snap ring 3 310 Spring pin 1 120 O snap ring 1
260-1 Body 1 1 320-1 Body 2 1 130 Thrust plate 1
260-2 Spool 1 320-2 Control piston 1 140 Slide ring 1
260-3 Check valve 2 320-3 Oil seal 1 150 Needle 60
260-4 Spring guide 2 320-4 Metal plug 1 160-1 Floating seat 1set
260-5 Spool 1 330-1 Shaft 1 160-2 O ring
260-6 Shuttle spool 1 340 Bearing 1 170 Bearing 2
260-7 Spring V1 2 350-1 Cylinder barrel 1 240 Plug 2
260-8 Spring V2 2 350-2 Valve plate 1 470 Thrust washer 4
260-9 Spring V3 1 350-3 Piston 7 480 Plug 2
420 Plug 2 350-4 Shoe 7 430 Swash plate 1
411 Plug 2 350-5 Shoe holder 1 440 Ball 2
260-12 Plug 2 350-6 Barrel holder 1 450 Screw 7
260-13 Choke 2 350-7 Pin 3 460 Pin 1
260-14 Ring 2 350-8 Spring c 1
260-15 Plug 4 350-9 Retainer 2
IV-S-177
5 6 1
8 7 2 3
10 9 PP DR
PHV- 120- 37- 9- 8 158A

A
12 11
B
14 13
Travel motor LH
4
7 8
DR
11 12
PHV- 120- 37- 9- 8 158A

B
A
13 14
PP
9 10
Travel motor RH
Ref.No. Part Name Q’ty Remarks

1 Drive sprocket 2
2 Bolt 18 Tightning torque 60.8 ~ 70.6 N·m, 6.2 ~ 7.2 kgf·m, 44.8 ~ 52.1 ft·lbf
Apply loctite #271
3 Spring washer 18
4 Motor assembly (wheel) 2
5 Bolt 16
6 Spring washer 16
7 Straight joint 2
8 O - ring 2
9 Straight joint 2
10 O - ring 2
11 Straight joint 2
12 O - ring 2
13 Straight joint 2
14 O - ring 2
IV-S-178
(3) Hose connection
Dozer Hoses indicated with thick lines are
travel-related hoses.
Left track Right track
Extend track Part No. Dimension Tape color

Mounting position Part Name Q’ty
Reference (mm) on hose
R/J (l) ~ Travel M left A RB238-63911 Hydraulic hose (3/8) 1 790
R/J (n) ~ Travel M left B RB238-63911 Hydraulic hose (3/8) 1 790
R/J (f) ~ Travel M right B RB238-63911 Hydraulic hose (3/8) 1 790
R/J (e) ~ Travel M right A RB238-63911 Hydraulic hose (3/8) 1 790
R/J (g) ~ Travel M left PP RB238-63922 Hydraulic hose (1/4) 1 810 White x 1
R/J (g) ~ Travel M right PP RB238-63922 Hydraulic hose (1/4) 1 810 White x 1
S/J side Traveling motor, cylinder side R/J (d) ~ Travel M left DR RB238-63931 Hydraulic hose (1/4) 1 740
a. Extend track (retracted) Cylinder, rod side R/J (d) ~ Travel M right DR RB238-63931 Hydraulic hose (1/4) 1 740
b. Dozer up Cylinder, rod side R/J (b) ~ Intermediate joint RB238-64811 Hydraulic hose (1/4) 1 310
c. Dozer down Cylinder, bottom side R/J (c) ~ Intermediate joint RB238-64831 Hydraulic hose (1/4) 1 310
d. Drain Left and right drain port Intermediate joint RB238-64821 Hydraulic hose (1/4) 1 310
~ Dozer cylinder rod
e. Right reverse travel Right A (lower side)
Intermediate joint RB238-64821 Hydraulic hose (1/4) 1 310
f. Right forward travel Right B (upper side)
~ Dozer cylinder bottom
g. 2nd speed pilot Left and right travel in 2nd speed
R/J (j) RB238-64851 Hydraulic hose (1/4) 1 950
h. Left reverse travel Left B (lower side) ~ Track cylinder bottom
i. Left forward travel Left A (upper side) R/J (a) RB238-64861 Hydraulic hose (1/4) 1 710
j. Extend track (retracted) Cylinder, bottom side ~ Track cylinder rod
Procedure for Wheel Motor Hose Mounting (Recommended)

Motor (Left)
Motor (Right)
IV-S-179
(4) Disassembly and reassembly
1) General Precautions for Disassembly and Assembly
Pay attention to the following items when assembling or disassembling the equipment.
1. Work in a clean place. Pay attention to keep the equipment free of dust, paint film fragments, or
water. Prepare a clean container to keep the disassembled parts.
2. Before disassembling the equipment, remove the dirt on the exterior of the traveling motor, and
remove the paint on each joint with a wire brush.
3. Before disassembling each part, mark the part so that the part will be assembled to the original posi-
tion.
4. Carefully handle the disassembled parts so as not to damage them.
5. Clean the disassembled parts with wash oil.
6. Check whether the disassembled parts have any abnormal wear or seizing. Eliminate all burs.
7. Replace the seals and snap rings with new ones.
8. Fundamentally, press-fit parts (e.g., bearings and pins) described in the text cannot be disassem-
bled.
2) Assembly Procedure
The assembly procedure for the traveling motor is explained below. Take the procedure in reverse order
to disassemble the traveling motor.
Important points for disassembly is described in the following assembly procedure.
Hydraulic valve
Decelerator Hydraulic motor
Counter balance valve
Fig. 1 Block Diagram
IV-S-180
• Hydraulic Motor
1. The explanation begins with the state of the (1) (2)

motor with the bearing, spring pin, and O-ring
mounted to body 1.
(1) Body 1 (3) (4)
(2) Bearing
(3) Spring pin
(4) O - ring
2. Mount the counter balance valve and spool. (4) (3) (2) (1)
The configuration of the parts is shown in the
photograph.
Q’ty
(1) Spool 1
(2) Ring 2
(3) Spring 2
(4) Plug 2 (5)
(5) O - ring 2
3. Insert the spool and rings (for both sides) into (2) (1)
body 1.
(1) Spool
(2) Ring
4. Insert the springs (for both sides) into body 1.

(1) Spring
(1)
IV-S-181
5. Tighten the plugs each with an O-ring.
Tightening torque : 127 ~ 167 N·m
13 ~ 17kgf·m
93.7 ~ 123.2 ft·lbf
Hexagon double-face width : 27 mm
6. Mount the second gear change spool. (3) (1) (2)

photograph.
Q’ty
(1) Spool 1
(2) Spring 1
(3) Plug 2
(4) O - ring 2 (4)
7. Insert the second gear spool into body 1.

Set the insertion direction of the spool as
shown in the photograph.
(1) Spool
(1)
8. Insert the springs into body 1.

Set the insertion direction of the spring as
shown in the photograph.
(1) Spring (1)
IV-S-182
9. Tighten the plugs each with an O-ring (for both
sides).
4.7 ~ 5.3 kgf·m
33.9 ~ 37.6 ft·lbf
Hexagon socket double-face width : 8 mm
10. Mount the shuttle spool assembly.

(1)
photograph.
Q’ty
(1) Shuttle spool 1 (2)
(2) Needle 2
(3) Plug 2 (3)
11. Insert the shuttle spool into body 1.

(1) Shuttle spool (1)
12. Insert the needles (for both sides) into body 1.

(1) Needle (1)
IV-S-183
13. Tighten the plugs (for both sides).
Cover the plug with sealing tape turned around.
Tightening torque : 5.9 N·m
0.6 kgf·m
4.4 ft·lbf
Use a torque wrench to tighten the plugs.
14. Press-fit the oil seal to body 2.

(1)
• Apply grease between the oil seal lips.
• Insert the oil seal in the direction shown.
(2)
• Press-fit the parallel pin.
(1) Body 2
(2) Oil seal
(3) Pin
(3)
(2)
(1)
15. Press-fit the bearing to the shaft. (1)

(1) Shaft
(2) Bearing
(2)
16. Insert the control piston into body 2.

(1) Control piston (1)
(2)
(3)
IV-S-184
17. Mount the shaft to body 2.
Pay attention not to damage the oil seal with
the shaft.
(1) Shaft
(1)
18. Mount the two balls and swash plate to body 2.

Apply operating oil to the sliding face of the
swash plate.
If the swash plate drops at the time of assem-
bly, apply grease to the back of the swash
plate.
(1) Ball
(2) Swash plate
(1)
(2)
19. Mount the retainer, followed by the spring and (1) (2) (3) (4)
retainer to the cylinder barrel and secure with
the snap ring.
Q’ty
(1) Cylinder barrel 1
(2) Retainer 2
(3) Spring 3
(4) Snap ring 1
(4)
(2)
(3)
(2)
(1)
IV-S-185
20. Mount the piston and shoe assembly to the
shoe holder to make a shoe holder assembly.
(1) Shoe holder (2)
(2) Shoe, piston
(1)
21. Insert three pins to the cylinder barrel. Apply

operating oil to seven holes of the cylinder bar- (1)
rel.
(1) Cylinder barrel
(2) Pin (2)
22. Locate the barrel holder.

(1) Barrel holder (1)
23. Mount the shoe holder assembly to the cylinder

barrel.
24. Insert the cylinder barrel assembly into body 2

so that the shoe will come into contact with the
swash plate. (1)
Put approximately 100 cc of operating oil into
body 2.
(1) Cylinder barrel assy
(2) Body 2
(2)
IV-S-186
25. Mount the O-ring and valve plate to body 1, and
combine body 1 with body 2. (2)
• Mount the valve plate so that the copper face
of the valve plate will be on the upper side (1)
(i.e., cylinder barrel side).
• Apply the operating oil to the sliding face
(copper face) of the valve plate.
• Apply grease to the backside of the valve
plate (steel face) for the prevention of it from (3)
falling off.
(1) Body 1
(2) O - ring
(3) Valve plate (4) (1)
(4) Body 2
26. Tighten the assembly with the hexagon socket.

Tightening torque : 28.4 ~ 30.4 N·m
2.8 ~ 3.1 kgf·m
20.9 ~ 22.4 ft·lbf
Use a torque wrench to tighten the plugs.
When securing the motor with a vice, protect

the body with an appropriate material, such as
a copper plate.
IV-S-187
• Decelerator
1. Mount the floating seal and O-ring to the (2)

hydraulic motor.
The O-ring can be mounted with ease if grease
is applied.
Apply grease to the four pins.
(1) Floating seal
(2) O - ring
(1)
2. Mount a bearing inner ring first, followed by the (2)

steel ball provided with a retainer, to the
hydraulic motor.
• Do not make a mistake in the mounting direc-
tion of the bearing inner ring and retainer
when mounting them.
• The steel ball can be disconnected from the
retainer. Pay utmost attention not to lose the
steel ball.
(1) Bearing inner ring
(2) Steel ball with retainer
(1)
(2)
(1)
IV-S-188
3. Insert the seal ring with the O-ring set into the (1)
main component.
• Apply grease to the O-ring.
• Insert with the sealing side facing upward.
• See the following illustration for the insertion
direction.
(1) Seal ring
(2) O - ring
Larger chamfer (2)
Insertion side Sealing side
4. Mount the hydraulic motor to the main compo-

nent.
Tighten the decelerator flange and hydraulic
motor flange with a C clamp or hydraulic press.
5. Mount the steel ball with a retainer, followed by

the bearing inner ring, to the hydraulic motor.
(1) (2)
Do not make a mistake in the mounting direc-
tion of the bearing inner ring and retainer when
mounting them.
(1) Bearing inner ring
(2) Steel ball with retainer
(1) (2)
IV-S-189
6. Secure the bearing with the snap ring.
7. Mount the ring, followed by the thrust washer

gear, and needle, to the pin part of the hydraulic
motor.
Q’ty
(1) Ring 4
(2) Thust washer 4 (1) (2)
(3) B1 gear 4
(4) Needle 60
(4) (3)
Thrust plate side Washer side
8. Mount the thrust plate and fix with the snap (1)
ring.
• When mounting the thrust plate, check that
the protruding face of the inner diameter side
is upward.
• The snap ring has two sides. Mount the snap
ring so that the edge will face upward (cover
side).
• Do not widen the snap ring in excess, or oth- (1)Thrust plate
erwise the tension will be lost when the snap
ring is mounted. If the tension is lost, replace
the snap ring with a new one. (2)
(2)Snap ring
IV-S-190
9. Insert S1 gear into carrier 2 and secure the S2
gear with the snap ring.
ring so that the edge will face upward (cover (3)
side).
• Do not widen the snap ring in excess, or oth- (2)
the snap ring with a new one. (1)
(1) Carrier 2
(2) Gear S1
(3) Snap ring
Edge side
(3)
(1)
(2)
10. Mount the three thrust washers, followed by the

three B2 gears, needle, and three thrust wash- (3)
ers, to carrier 2 and secure them with the three
snap rings.
ring so that the edge will face upward (cover
side).
(1) (2) (1) (4)
• Do not widen the snap ring in excess, or oth-
the snap ring with a new one.
Q’ty
(1) Thust washer 6
(2) Gear B2 3
(3) Needle 39
(4) Snap ring 3
Edge side
(2) (3) (1)
(4)
(1)
IV-S-191
11. Mount the carrier 2 assembly to the main com-
ponent.
12. Mount the O-ring to the main component.

(1)
Apply grease to the O-ring.
(1) O - ring
13. Insert the slide ring into the cover. (1)

Apply grease to secure the slide ring.
(2)
(1) Cover
(2) Slide ring
14. Supply gear oil and mount the cover.

• Pay attention not to damage the O-ring. (1)
• Mount the cover so that the characters
"DRAIN" will be at the crena on the main
component.
(1) Cover (marked with "DRAIN")
(2) Cover crena
(2)
[Disassembly]
The cover can be removed with ease by lifting
the cover with a crane with a hoisting hook
applied to the drain plug screw.
IV-S-192
15. Mount the snap ring and secure the cover.
Apply a flat-blade screwdriver to the edge of
the snap ring and hammer the screwdriver in
the direction of the circumference.
(The above can be performed with ease if
implemented at the crena.)
[Disassembly]
The snap ring can be removed with ease if the
edge of the snap ring is moved to the crena of
the main component with a screwdriver and
hammer.
(1) Snap ring edge
(1)
16. Tighten the hexagon socket plug.

Tighten the plug on the side marked with
‘DRAIN’ first.
(Use the brim of the plug to stop the cover from
turning.)

4.7 ~ 5.2 kgf·m
33.9 ~ 37.6 ft·lbf
IV-S-193
g. Cylinder
(1) Components and specifications (KX41-3 EU)
1) Boom
010 Assy cylinder,boom 110 Ring,back up

020 Kit cylinder tube 120 O ring
030 Bush 130 Bush
040 Kit piston-rod 140 Piston
050 Bush 150 Seal,piston
060 Cylinder head 160 Wearing
070 Gasket 170 Screw,set
080 Ring,back up 180 Ball
090 Scraper 190 Spring
100 O ring 200 Nipple,grease
IV-S-194
2) Arm
010 Assy cylinder,arm 110 Ring,back up

030 Bush 130 Bush
070 Gasket 170 Nut, center lock
080 Ring,back up 180 Nipple,grease
090 Scraper
100 O ring
IV-S-195
3) Bucket
010 Assy cylinder,bucket 110 Ring,back up

030 Bush 130 Bush
070 Gasket 170 Nut, center lock
090 Scraper
100 O ring
IV-S-196
4) Dozer
010 Assy cylinder,blade 110 Ring,back up

030 Bush 130 Bush
070 Gasket 170 Nut, lock
090 Scraper
100 O ring
IV-S-197
5) Swing
010 Assy cylinder,swing 110 Ring,back up

030 Bush, pin 130 Bush
050 Bush, pin 150 Seal,piston
060 End 160 Wearing
070 Gasket 170 Nut, lock
090 Scraper
100 O ring
IV-S-198
6) Track
010 Assy cylinder,track 110 Ring,back up

030 Bush 130 Piston
040 Kit piston-rod 140 Seal,piston
050 Bush 150 Wearing
060 End 160 Nut, lock
070 Gasket 170 Bush
080 Ring,back up
090 Scraper
100 O ring
IV-S-199
1) Disassembling
1. Place the cylinder on a vise and place support.

2. Let hydraulic oil out of the cylinder.
Vice
Support
3. Undo the lock washer.

Hammer
Chisel
Lock washer
4. Loosen the cylinder head screw and detach the

cylinder head.
Pipe
Hook wrench
5. Draw out the piston rod together with the cylinder

head.
* If the pipe ports are open, place an oil pan below
the port at the retracting-side cylinder head.
6. Remove set screw.

(Boom cylinder only)
Shim
IV-S-200
7. Apply a wrench to the hex nut of the piston.
Loosen the nut.
8. Draw out the piston and remove the shim
9. Draw out the cylinder head.

10.Release the piston rod from the vise.
11.Remove plug, spring and ball from cylinder tube.

(Boom cylinder only --- cusion)
Tube
Ball
Spring
Plug
IV-S-201
2) Inspection
1.Piston rod warp
1. Mount the piston rod on a V-block.
2. Set a dial indicator at the center of the rod.
3. Rotate the piston rod and read the indicator. Warp
is one-half of the difference between the maxi-
mum and the minimum readings.
4. If the valve exceeds the allowable limit, replace
the piston rod.
• Reference value .. warp within 0.05 mm, 0.002in.
• Allowable value ... warp within 0.5 mm, 0.0197in.
2.Clearance between piston rod and bushing

1. Measure the piston rod O.D. and cylinder head
bushing I.D. and determin the clearance.
Rod size Clearance
Reference I25 to I40 mm less than 0.25 mm

value I45 to I75 mm less than 0.30 mm
Allowable I25 to I40 mm 0.4 mm
limit I45 to I75 mm 0.5 mm
Reference I0.9843 to 1.5748 in less than 0.010 in
value I1.7717 to 2.9528 in less than 0.012 in
Allowable I0.9843 to 1.5748 in 0.0158 in
limit I1.7717 to 2.9528 in 0.0197 in
3.Clearance between cylinder tube I.D. and Pis-

ton ring O.D.
1. Measure the cylinder tube I.D.
2. Calculate the piston ring thickness plus piston ring
groove O.D. determin the clearance.
Rod size Clearance

less than I60 mm 0.05 to 0.30 mm
Reference
I65 to I115 mm 0.05 to 0.35 mm
value
more than I120 mm 0.05 to 0.40 mm
less than I60 mm 0.60 mm
Allowable
I65 to I115 mm 0.70 mm
limit
more than I120 mm 0.80 mm
I2.3622 in less 0.0020 to 0.0118 in
Reference
I2.5590 to 4.5276 in 0.0020 to 0.0138 in
value
I4.7244 in more 0.0020 to 0.0157 in
I0.9843 to 1.5748 in 0.0236 in
Allowable
I1.7717 to 2.9528 in 0.0276 in
limit
I4.7244 in more 0.0315 in
IV-S-202
h. Unload valve (KX41-3 PP)
(1) Location of unload valve
(4)
(3) (2) (1)
(1) Unlode valve

(2) Rotary Joint
(3) Control valve
(4) Change valve (Dozer, track)
IV-S-203
(2) adaptor installation
Ref.No. Part Name Q’ty

010 Unload valve 1
020 Adaptor (L, G3/8 - G3/8) 1
030 O - ring 1
040 Adaptor (Class, G1/4) 1
050 O - ring 1
060 Adaptor (L, G1/4 - G1/4) 1
070 O - ring 1
080 Adaptor (G3/8 - 13) 1
090 O - ring 1
100 Bracket 1
110 Bolt 1
120 Bolt 1
110
Tightning torque 100 120
17.7 ~ 20.6 N·m
1.8 ~ 2.1 kgf·m
13.1 ~ 15.2 ft·lbfm
010 080 060 040 020

090 070 050 030
Tightning torque tightning torque tightning torque Tightning torque
49.0 ~ 53.9 N·m 24.5 ~ 29.4 N·m 24.5 ~ 29.4 N·m 49.0 ~ 53.9 N·m
5.0 ~ 5.5 kgf·m 2.5 ~ 3.0 kgf·m 2.5 ~ 3.0 kgf·m 5.0 ~ 5.5 kgf·m
36.1 ~ 39.8 ft·lbfm 18.1 ~ 21.7 ft·lbfm 18.1 ~ 21.7 ft·lbfm 36.1 ~ 39.8 ft·lbfm
IV-S-204
(3) Hose connection
5
7
8
REAR REAR
1 2
FRONT FRONT 6
3 4 1. Pilot valve LH
2. Pilot valve RH
3. Control valve
4. TPSS valve
5. Unload valve
6. Pump
(1)
(4)
Tape color
No. Connecting point Part No. Part Name Q’ty
on hose
1 Pump (P4) RB238-63242 Hydraulic hose (3/8) 1
~ Unload valve(P)
2 Unload valve (A) RB238-63331 Hydraulic hose (1/4) 1 White x 1
~ Pilot valve LH (P)
3 Unload valve (A) RB238-63341 Hydraulic hose (1/4) 1 White x 2
(2) ~ Pilot valve RH (P)
(3)
4
5 Unload valve (T) RB238-63761 Drain hose 1
~ Return Filter
(1) Unlode valve
6 Unload valve (B) RB238-63271 Hydraulic hose (1/4) 1
(2) Hydraulic Tank
~ Rotary joint (G)
(3) Return filter
7 Unload valve (A) RB238-63281 Hydraulic hose (1/4) 1
(4) Return hose ~ Control valve (Pp1)
IV-S-205
h. Unload valve (KX36-3 EU, KX41-3 EU)
Ref.No. Part Number Part Name Q’ty Part Name

1 RG138-6260 Valve, assy (Unload) 1
RG038-6260 Valve, assy (Unload) 1 Only for KX36-3
2 RG208-8623 Adaptor 1 Tightning torque of Adapter :
3 RG208-8640 Adaptor (M18 - M18 - M18) 1 Only for KX41-3 • G1/4
24.5 ~ 29.4 N·m
4 RG208-6383 Adaptor 1 (2.5 ~ 3.0 kgf·m)
• G3/8
5 RG208-6318 Adaptor 1 49.0 ~ 53.9 N·m
6 RG208-8625 Adaptor 1 (5.0 ~ 5.5 kgf·m)
7 RG238-6395 Adaptor 1
8 RG208-8616 Adaptor 1 Only for KX41-3
Tightning torque :
9 01315-11075E Bolt 2 M10 x 1.5 17.7 ~ 20.6 N·m
(1.8 ~ 2.1 kgf·m)
IV-S-206
i. Change valve (Dozer, Track)(KX41-3 PP)
(1) Location of change valve
(1)
(1) Change valve (Dozer, Track)
IV-S-207
(2) Components of change valve

010 Pin,joint 1
020 Washer,plain 2
030 Pin,snap 2
040 Lever,tpss 1
050 Grip,lever 2
060 Washer,plain 2
070 Pin,snap 4
IV-S-208

010 Change valve assy 1
020 Bracket 1
030 Bolt 2 M8 x 16
040 Bolt 2 M10 x 20
050 Adaptor (S, G1/4 - G1/4) 2
060 O - ring 6
070 Adaptor (L, G1/4 - G1/4) 1 Include 060
080 Adaptor (L, G1/4 - G1/4) 1
090 Adaptor (S, G1/4 - G1/4) 2
Tightning torque (Adaptor : 050, 070, 080, 090)
IV-S-209
(4) Hose connection
(5) (6)
(2)
(4) (1)
(3)
(6)
(3)
(4)
(5) (1)
(2)
No. Connecting point Part Name Q’ty Tape color on hose

1 Change valve (P1) ~ Change valve (A2), Dozer up Hydraulic hose (1/4) 1 pink
2 Change valve (P2) ~ Change valve (B2), Dozer down Hydraulic hose (1/4) 1 Brown
3 Change valve (A1) ~ Rotary joint (B), Dozer up Hydraulic hose (1/4) 1
4 Change valve (A2) ~ Rotary joint (C), Dozer down Hydraulic hose (1/4) 1
5 Change valve (B2) ~ Rotary joint (J), Track extend Hydraulic hose (1/4) 1 White
6 Change valve (B1) ~ Rotary joint (A), Track retract Hydraulic hose (1/4) 1 White x 2
IV-S-210
i. Change valve (Dozer, Track) (KX36-3 EU, KX41-3 EU)
Ref.No. Part Number Part Name Q’ty Part Name

1 RG138-6150 Assy valve, change 1 (625)
2 RG138-6153 Bracket (Valve) 1
3 01123-60816E Bolt 2 M8 7T
4 01135-61020E Bolt 2 M10 x 1.25 7T
5 RG138-6154 Lever (Elastic) 1
6 RG208-8616 Adaptor 6
IV-S-211
j. TPSS valve (TPSS = Two patern selection system) (PP Version)
(1) Components of TPSS valve

010 Assy valve,tpss 1
020 Blank -
030 Spool 1
040 O ring 1
050 O ring 3
060 Ring,back up 2
070 Plate 2
080 Rod 1
090 Bolt 4
100 Plug 1
110 O ring 2
IV-S-212
Tightning torque
23.5 ~ 27.5 N·m
2.4 ~ 2.8 kgf·m
17.3 ~ 20.3 ft·lbf

010 TPSS valve assy 1
020 Bolt 2
030 Adaptor (L, G1/8 - G1/4) 2 Include 040
040 O - ring 2
050 Adaptor (L, G1/8 - G1/4) 2
060 Adaptor (S, G1/8 - G1/4) 2
070 Adaptor (S, G1/8 - G1/4) 2
080 O - ring 6
Tightning torque (Adaptor : 050, 070, 080, 090)

15.0 ~ 16.5 N·m
1.5 ~ 1.7 kgf·m
11.0 ~ 12.2 ft·lbf
IV-S-213
(4) Hose connection
5
7
8
REAR REAR
1 2
FRONT 6
FRONT
1. Pilot valve LH
3 4 2. Pilot valve RH
3. Control valve
4. TPSS valve
5. Unload valve
6. Pump
Part No. Tape color

No. Connecting point Application Q’ty
Reference on hose
8 PV (Right 4) ~ TPSS (B2) Boom ascending RB238-63431 1 Gray
9 PV (Right 2) ~ TPSS (B4) Boom descending RB238-63441 1 Light Blue
10 PV (Left 2) ~ TPSS (B3) Arm dump RB238-63411 1 Blue
11 PV (Right 4) ~ TPSS (B1) Arm scraper RB238-63421 1 Green
16 CV (Pa8) ~ CV (Pa8’) Boom ascending merge RB238-63371 1
17 CV (Pb8) ~ CV (Pb8’) Boom descending merge RB238-63381 1
18 TPSS (A3) ~ CV (Pb5) Arm dump RB238-62911 1 Blue
19 TPSS (A1) ~ CV (Pa5) Arm scraper RB238-62921 1 Green
20 TPSS (A2) ~ CV (Pa8) Boom ascending RB238-62931 1 Gray
21 TPSS (A4) ~ CV (Pb8’) Boom descending RB238-62941 1 Light Blue
IV-S-214
k. Oil tank

1 Tank 1 M10 x20
Bolt 4 Tightning torque : 48.1 ~ 55.9 N·m
4.9 ~ 5.7 kgf·m
35.5 ~ 41.2 ft·lbf
Apply locktite #271
2 Oil gauge 1 Tightning torque : 9.8 ~ 11.3 N·m
1.00 ~ 1.15 kgf·m
7.2 ~ 8.3 ft·lbf
3 Adaptor (G1/4 - G1/4 - G1/4) 1
O - ring 1
4 Filter (Return) 1
5 Bolt 2
6 Adaptor (L, G1-219 1
7 Return hose 1 1
8 Hose clump (26 - 38) 2
9 Adaptor (G1 -14, 16) 1
10 Filter (Suction) 1
11 Plug 1 Tightning torque : 26.0 ~ 31.0 N·m
O - ring 1 2.7 ~ 3.2 kgf·m
19.2 ~ 22.9 ft·lbf
12 Plug 1
O - ring 1
13 Plug 1
O - ring 1
IV-S-215
l. Delivery hose (KX41-3 PP)
Ref.No. Part Name Q’ty Tape color on hose

010 Joint, pipe
020 Plug
030 Adaptor
040 O - ring
050 Joint, pipe
060 Hydraulic hose (3/8) 1 Red
070 Hydraulic hose (3/8) 1 White
080 Hydraulic hose (3/8) 1 Yellow
090 Hydraulic hose (3/8 1 Blue
IV-S-216
m.Return hose (KX41-3 PP)
110
150
090 130 170 180
(125)
(135)
Tape color Tape color

on hose on hose
010 Joint, elbow 1 110 Drain hose 1 1
020 O - ring 1 120 Clamp, hose 1
030 Elbow joint 1 130 Drain hose 2 1
040 O - ring 1 140 Clamp, hose 1
050 Hydraulic hose (1/4) 1 Orange 150 Drain hose 3 1 Orange
060 Hydraulic hose (1/4) 1 Orange x 2 160 Clamp, hose 1 Orange x 2
070 Return hose 1 1 170 Oil coolre hose 1 1
080 Clamp, hose 1 180 Oil coolre hose 2 2
090 Return hose 2 1
100 Clamp, hose 1
IV-S-217
High-pressure hose List (Pilot)
Part No. Dimension
No. Connecting point Application Part Name Q’ty Tape color Hose shape Remarks
Reference (mm)
1 Pump (P4) ~ Unload V (P) P4 RB238-63242 Hydraulic hose (3/8) 1 690 G3/8 PF0706 G3/8
2 PV (Left P) ~ T-tube joint PV (Left P) RB238-63331 Hydraulic hose (1/4) 1 940 White x 2 Quick PLT04 G1/4
White x 4
3 PV (Right P)~ T-tube joint PV (Right P) RB238-63341 Hydraulic hose (1/4) 1 880 (Two on both ends) Quick PLT04 G1/4
4 PV (Left T) ~ Oil tank PV left drain RB238-63351 Hydraulic hose (1/4) 1 1060 Orange x 2 Quick PLT04 G1/4
Orange x 4
5 PV (Right T) ~ Oil tank PV Right drain RB238-63361 Hydraulic hose (1/4) 1 980 (Two on both ends) Quick PLT04 G1/4
6 Unload V (B)~ SJ (G) 2nd speed signal RB238-63271 Hydraulic hose (1/4) 1 350 G1/4 PLT04 G1/4
7 Unload V (A)~ CV (Pp1) Travel lock RB238-63281 Hydraulic hose (1/4) 1 850 G1/4 PLT04 G1/4
8 PV (Right 4) ~ TPSS (B2) Boom up RB238-63431 Hydraulic hose (1/4) 1 870 Gray x 2 Quick PLT04 G1/4
9 PV (Right 2) ~ TPSS (B4) Boom down RB238-63441 Hydraulic hose (1/4) 1 870 Light Blue x 2 Quick PLT04 G1/4
10 PV (Left 2) ~ TPSS (B3) Arm crowd RB238-63411 Hydraulic hose (1/4) 1 790 Blue x 2 Quick PLT04 G1/4
11 PV (Left 4) ~ TPSS (B1) Arm scraper RB238-63421 Hydraulic hose (1/4) 1 770 Green x 2 Quick PLT04 G1/4
n. Table of hoses (KX41-3 PP)
12 PV (Left 1) ~ CV (Pb3) Swivel left RB238-63451 Hydraulic hose (1/4) 1 1690 Red x 2 Quick PLT04 G1/4
13 PV (Left 3) ~ CV (Pa3) Swivel right RB238-63461 Hydraulic hose (1/4) 1 1980 Yellow x 2 Quick PLT04 G1/4
14 PV (Right 3) ~ CV (Pb9) Bucket dump RB238-63471 Hydraulic hose (1/4) 1 1710 Brown x 2 Quick PLT04 Quick
15 PV (Right 1) ~ CV (Pa9) Bucket crowd RB238-63481 Hydraulic hose (1/4) 1 2020 Pink x 2 Quick PLT04 G1/4
16 CV (Pa8) ~ CV (Pa8’) Boom down merge RB238-63371 Hydraulic hose (1/4) 1 175 G1/4 PLT04 G1/4
IV-S-218
17 CV (Pb8) ~ CV (Pb8’) Boom descending RB238-63381 Hydraulic hose (1/4) 1 170 G1/4 PLT04 G1/4
merge
18 TPSS (A3) ~ CV (Pb5) Arm crowd RB238-62911 Hydraulic hose (1/4) 1 1460 Blue x 2 G1/4 PLT04 G1/4
Mounting
19 TPSS (A1) ~ CV (Pa5) Arm scraper RB238-62921 Hydraulic hose (1/4) 1 1700 Green x 2 G1/4 PLT04 G1/4 angle 45
degrees
20 TPSS (A2) ~ CV (Pa8) Boom up RB238-62931 Hydraulic hose (1/4) 1 1770 Gray x 2 G1/4 PLT04 G1/4
21 TPSS (A4) ~ CV (Pb8) Boom down RB238-62941 Hydraulic hose (1/4) 1 1450 Light Blue x 2 G1/4 PLT04 G1/4
High-pressure hose List (Upper Side)
Part No. Dimension
Reference (mm)
1 Pump (P1) ~ CV (P1) P1 RB238-63211 Hydraulic hose (3/8) 1 1945 Red x 3 G3/8 PF2106 G3/8
2 Pump (P2) ~ CV (P2) P2 RB238-63221 Hydraulic hose (3/8) 1 1925 White x 3 G3/8 PF2106 G3/8
3 Pump (P3) ~ CV (P3) P3 RB238-63231 Hydraulic hose (3/8) 1 2040 Yellow x 3 G3/8 PF2106 G3/8
4 CV (A7) ~ SJ (I) Travel left forward RB238-64411 Hydraulic hose (3/8) 1 620 Blue x 1 G3/8 PF2106 G3/8
5 CV (B7) ~ SJ (H) Travel left backward RB238-64421 Hydraulic hose (3/8) 1 580 Red x 1 G3/8 PF2106 G3/8
6 CV (A6) ~ SJ (F) Travel right forward RB238-64431 Hydraulic hose (3/8) 1 390 Green x 1 G3/8 PF2106 G3/8
7 CV (B6) ~ SJ (E) Travel right backward RB238-64441 Hydraulic hose (3/8) 1 460 Yellow x 1 G3/8 PF2106 G3/8
8 CV (B3) ~ Swivel motor (B) Swivel left RB238-64511 Hydraulic hose (1/4) 1 590 Gray x 2 G1/4 PF1704 G1/4
9 CV (A3) ~ Swivel motor (A) Swivel right RB238-64521 Hydraulic hose (1/4) 1 610 Light Blue x 2 G1/4 PF1704 G1/4
10 CV (A1) ~ Swing CYL Swing left RB238-64612 Hydraulic hose (1/4) 1 1300 Yellow Green x 2 G1/4 PF2104 G1/4
bottom
11 CV (B1) ~ Swing CYL rod Swing right RB238-64622 Hydraulic hose (1/4) 1 950 Orange x 2 G1/4 PF2104 G1/4
12 CV (A2) ~ Variable leg V P1 CV dozer up RB238-64711 Hydraulic hose (1/4) 1 640 Pink x 2 G1/4 PF2104 G1/4
13 CV (B2) ~ Variable leg V P2 CV dozer down RB238-64721 Hydraulic hose (1/4) 1 620 Brown x 2 G1/4 PF2104 G1/4
14 Extend track A1 ~ SJ (B) Dozer up (rod) RB238-64731 Hydraulic hose (1/4) 1 420 G1/4 PF2104 G1/4
15 Extend track A2 ~ SJ (C) Dozer down (bottom) RB238-64741 Hydraulic hose (1/4) 1 560 G1/4 PF2104 G1/4
Track extended
IV-S-219
16 Extend track B2 ~ SJ (J) (bottom) RB238-64752 Hydraulic hose (1/4) 1 570 White x 1 G1/4 PF1704 G1/4
17 Extend track B1 ~ SJ (A) Track retracted (rod) RB238-64762 Hydraulic hose (1/4) 1 430 White x 2 G1/4 PF1704 G1/4
High-pressure hose List (Front)
Part No. Dimension
Reference (mm)
1 CV (A8) ~ Boom CYL rod Boom up (rod) RB238-64162 Hydraulic hose (1/4) 1 3150 Yellow x 2 G1/4 PF2104 G1/4
2 CV (B8) ~ Boom CYL bot- Boom down (bottom) RB238-64172 Hydraulic hose (1/4) 1 2940 Green x 2 G1/4 PF2104 G1/4
tom
3 CV (B5) ~ Intermediate joint Arm dump (rod) RB238-64182 Hydraulic hose (1/4) 1 550 Black x 2 G1/4 PF2104 G1/4
4 CV (A5) ~ Intermediate joint Arm crowd (bottom) RB238-64192 Hydraulic hose (1/4) 1 600 Blue x 2 G1/4 PF2104 G1/4
5 CV (B9) ~ Bucket CYL rod Bucket dump (rod) RB238-64211 Hydraulic hose (1/4) 1 4060 Red x 3 G1/4 PF2104 G1/4
CV (A9) ~ Bucket CYL bot-
6 Bucket crowd (bottom) RB238-64221 Hydraulic hose (1/4) 1 3800 White x 3 G1/4 PF2104 G1/4
tom
Intermediate joint
7 ~ Arm CYL rod Arm dump RB238-64201 Hydraulic hose (1/4) 1 2260 Black x 2 G1/4 PF2104 G1/4
8 Intermediate joint Arm crowd RB238-64291 Hydraulic hose (1/4) 1 2040 Blue x 2 G1/4 PF2104 G1/4
~ Arm CYL bottom
9 CV (B4) ~ Intermediate joint SP RB238-64912 Hydraulic hose (3/8) 1 430 Pink x 2 G3/8 PF2106 G3/8
10 CV (A4) ~ Intermediate joint SP RB238-64922 Hydraulic hose (3/8) 1 480 Brown x 2 G3/8 PF2106 G3/8
Intermediate joint
11 SP RB238-64932 Hydraulic hose (3/8) 1 2770 Pink x 3 G3/8 PF2106 G3/8
~ Arm left side
Intermediate joint
12 ~ Arm right side SP RB238-64942 Hydraulic hose (3/8) 1 2770 Brown x 3 G3/8 PF2106 G3/8
IV-S-220
High-pressure hose List (Lower Side)
Part No. Dimension
Reference (mm)
1 SJ (i) ~ Traveling motor left A Travel left forward RB238-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
2 SJ (h)~ Traveling motor left B Travel left backward RB238-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
3 SJ (f) ~ Traveling motor right B Travel right forward RB238-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
4 SJ (e)~ Traveling motor right A Travel right backward RB238-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
5 SJ (g)~ Traveling motor left Pb Travel left 2nd speed RB238-63921 Hydraulic hose (1/4) 1 810 G1/4 PLT04 G1/4
signal
Travel right 2nd speed
6 SJ (g)~ Traveling motor right Pb RB238-63922 Hydraulic hose (1/4) 1 810 White x 1 G1/4 PLT04 G1/4
signal
7 SJ (d)~ Traveling motor left T1 Travel drain left RB238-63932 Hydraulic hose (1/4) 1 740 White x 1 G1/4 PLT04 G1/4
8 SJ (d)~ Traveling motor right T2 Travel drain right RB238-63931 Hydraulic hose (1/4) 1 740 G1/4 PLT04 G1/4
9 SJ (b)~ Intermediate joint Dozer up (rod) RB238-64811 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
10 SJ (c) ~ Intermediate joint Dozer down (bottom) RB238-64831 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
11 Intermediate joint Dozer up (rod) RB238-64821 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
~ Dozer CYL rod
Intermediate joint
12 Dozer down (bottom) RB238-64821 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
~ Dozer CYL bottom
13 SJ (c) ~ Truck CYL bottom Track extended (bottom) RB238-64851 Hydraulic hose (1/4) 1 950 G1/4 PF1704 G1/4
14 SJ (a)~ Truck CYL rod Track retracted (rod) RB238-64861 Hydraulic hose (1/4) 1 710 G1/4 PF1704 G1/4
IV-S-221
Suction hose List
Dimension(mm) Hose clamp used
Part No.
No. Mounting position Application Part Name Q’ty Remarks
Reference Inner Outer Part No. Part
Length
diameter diameter Reference Name
Tank side 39 51 Fabricated

1 Hydraulic tank ~ Pump Suction RB238-63111 Hose (Suction) 1 608
Pump side 32 44 hose
Low-pressure hose List

Part No.
Length
1 CV (T2) bottom ~ Oil cooler and later stage Oil cooler IN RB238-63612 Hose (Cooler 1) 1 1250 15.9 23.5 PA0310
2 Before oil cooler ~ Return filter IN Oil cooler OUT RB238-63622 Hose (Cooler 2) 1 680 15.9 23.5 PA0310
3 CV (T3) top ~ Return filter IN Oil cooler bypass RB238-63521 Hose (Return 2) 1 270 15.9 23.5 OKE12
4 Return filter OUT~ Oil tank Return RB238-63511 Hose (Return 2) 1 150 20 30 Fabricated
hose
5 Swivel motor (T) ~ CV (T1) Swivel motor drain RB238-63731 Hose (Drain 1) 1 860 13 19.8 OKE12
6 Unload V (T) ~ Return filter IN Unload V return RB238-63751 Hose (Drain 2) 1 533 12.7 20.7 Fabricated
hose
Fabricated
7 SJ (D) ~ Oil tank Traveling drain RB238-63761 Hose (Drain 3) 1 330 12.7 20.7
hose
IV-S-222
O.Pilot Hose (KX36-3 EU, KX41-3 EU)
No. Connecting point Part Name Part No. Q’ty

1 Pump (P4) ~ Unload valve(P) KX41 P4 RG138-6324 1
1 Pump (P4) ~ Unload valve(P) KX36 P4 RG038-6324 1
2 Unload valve (A2) ~ S/J (G) hi - speed singnal RG138-6327 1
3 Unload valve (A1) ~ CV (Pp1G) travel lock RG138-6328 1
4 PV (P, LH) ~ Unload valve (A1) pilot P, LH RG138-6333 1
5 PV (P, RH) ~ Unload valve (A1) pilot P, RH RG138-6334 1
6 PV (T, LH) ~ Oil tank (T) pilot T, LH RG138-6335 1
7 PV (T, LH) ~ Oil tank (T) pilot T, RH RG138-6336 1
8 PV (1, RH) [Rear] ~ CV (Pa2) Gray boom rod (up) RG138-6343 1
9 PV (3, RH) [Front] ~ CV (Pb2) Light blue boom bottom (down) RG138-6344 1
10 PV (3, LH) [Front] ~ CV (Pb5) BlueGray arm rod (dump) RG138-6341 1
11 PV (1, LH) [Rear] ~ CV (Pa5) Green arm bottom (crud) RG138-6342 1
12 PV (2, LH) [Left] ~ CV (Pb7) Red swivel LH RG138-6345 1
13 PV (4, LH) [Right] ~ CV (Pa7) Yellow swivel RH RG138-6346 1
14 PV (4, RH) [Right] ~ CV (Pb1) Brown bucket rod (dump) RG138-6347 1
15 PV (2, RH) [Left] ~ CV (Pa1) Pink bucket bottom (crud) RG138-6348 1
16 Unload valve (A) ~ CV (Pp) travel straight RG138-6329 1
IV-S-223
Swingframe side
Part No. Dimension
Reference (mm)
1 Pump (P4) ~ Unload valve (P) P4 RG138-6324 Hydraulic hose (3/8) 1 1120 G3/8 PF0706 G3/8
2 Unload valve (A2) ~SJ (G) Hi - speed signal RG138-6327 Hydraulic hose (1/4) 1 770 G1/4 PLT04 G1/4
3 Unload valve (A1) ~CV (Pp1) Travel lock RG138-6328 Hydraulic hose (1/4) 1 1200 G1/4 PLT04 G1/4
4 Pilot valve (P, LH) ~Unload valve (A1) Pilot P, LH RG138-6333 Hydraulic hose (1/4) 1 1560 G1/4 PLT04 G1/4 Pwf fitting
to fitting
5 Pilot valve (P, RH) ~Unload valve (A1) Pilot P, RH RG138-6334 Hydraulic hose (1/4) 1 1410 G1/4 PLT04 G1/4
6 Pilot valve (T, LH) ~Oil tank T Pilot T, LH RG138-6335 Hydraulic hose (1/4) 1 1090 G1/4 PLT04 G1/4
7 Pilot valve (T, RH) ~Oil tank T Pilot T, RH RG138-6336 Hydraulic hose (1/4) 1 1025 G1/4 PLT04 G1/4
8 Pilot valve (4, RH) ~CV (Pa2) Boom rod (up) RG138-6343 Hydraulic hose (1/4) 1 2010 Gray G1/4 PLT04 G1/4
9 Pilot valve (2, RH) ~CV (Pb2) Boom bottom (down) RG138-6344 Hydraulic hose (1/4) 1 1710 Light Blue G1/4 PLT04 G1/4
10 Pilot valve (2, LH) ~CV (Pb5) Arm rod (dump) RG138-6341 Hydraulic hose (1/4) 1 1765 Blue G1/4 PLT04 G1/4
11 Pilot valve (4, LH) ~CV (Pa5) Arm bottom (crud) RG138-6342 Hydraulic hose (1/4) 1 2115 Green G1/4 PLT04 G1/4
12 Pilot valve (1, LH) ~CV (Pb7) Swivel LH RG138-6345 Hydraulic hose (1/4) 1 1800 Red G1/4 PLT04 G1/4
13 Pilot valve (1, LH) ~CV (Pa7) Swivel RH RG138-6346 Hydraulic hose (1/4) 1 2055 Yellow G1/4 PLT04 G1/4
14 Pilot valve (3, LH) ~CV (Pb1) Bucket rod (dump) RG138-6347 Hydraulic hose (1/4) 1 1720 Brown G1/4 PLT04 G1/4
15 Pilot valve (1, RH) ~CV (Pa1) Bucket bottom (crud) RG138-6348 Hydraulic hose (1/4) 1 2030 Pink G1/4 PLT04 G1/4
16 Unload valve P ~CV (Pp) Travel straight RG138-6329 Hydraulic hose (3/16) 1 1120 G1/4 PLT04 G3/16
(2) Table of Hoses (KX36-3 EU, KX41-3 EU)
IV-S-224
KX36-3
Pwf fitting
1 Pump (P4) ~ Unload valve (P) P4 RG038-6324 Hydraulic hose (3/8) 1 1180 G3/8 PF0706 G3/8
to fitting
P. Delivery Travel, Swivel, Blade, Swing Hose (KX36-3 EU, KX41-3 EU)
• KX36-3 EU, KX41-3 EU Fixed Track

1 Pump (P4) ~ CV (P1) P1 RG138-6332 1
2 Pump (P4) ~ CV (P2) P2 RG138-6333 1
3 Pump (P4) ~ CV (P3) P3 RG138-6323 1
4 CV (A3) ~ SJ (I) Blue travel left front RG138-6443 1
5 CV (B3) ~ SJ (H) Red travel left rear RG138-6444 1
6 CV (A4) ~ SJ (F) Green travel right front RG138-6441 1
7 CV (B4) ~ SJ (E) Yellow travel right rear RG138-6442 1
8 CV (B7) ~ Swivel motor (B) Gray swivel left RG138-6451 1
9 CV (A7) ~ Swivel motor (A) Light Blue swivel right RG138-6452 1
10 CV (A9) ~ Swing cyl bottom Green swing left RG138-6461 1
11 CV (B9) ~ Swing cyl rod Yellow swing right RG138-6462 1
12 CV (B8) ~ SJ (C) Red cv dozer down RG038-6471 1
13 CV (A8) ~ SJ (B) Brown cv dozer up RG138-6472 1
IV-S-225
• KX41-3 EU Extendable Track

1 Pump (P4) ~ CV (P1) P1 RG138-6321 1
2 Pump (P4) ~ CV (P2) P2 RG138-6322 1
3 Pump (P4) ~ CV (P3) P3 RG138-6323 1
4 CV (A3) ~ SJ (I) Blue travel left front RG138-6443 1
5 CV (B3) ~ SJ (H) Red travel left rear RG138-6444 1
6 CV (A4) ~ SJ (F) Green travel right front RG138-6441 1
7 CV (B4) ~ SJ (E) Yellow travel right rear RG138-6442 1
8 CV (B7) ~ Swivel motor (B) Gray swivel left RG138-6451 1
9 CV (A7) ~ Swivel motor (A) Light Blue swivel right RG138-6452 1
10 CV (A9) ~ Swing cyl bottom Green swing left RG138-6461 1
11 CV (B9) ~ Swing cyl rod Yellow swing right RG138-6462 1
12 CV (B8) ~ SJ (C) Red cv dozer down RG038-6471 1
13 CV (A8) ~ SJ (B) Brown cv dozer up RG138-6472 1
14 Changeable V (A1)~ SJ (A) track cyl (rod) RG138-6473 1
15 Changeable V (A2)~ SJ (J) track cyl (bottom) RG138-6474 1
16 Changeable V (B1)~ SJ (B) dozer up (rod) RG138-6475 1
17 Changeable V (B2)~ SJ (C) dozer down (bottom) RG138-6476 1
IV-S-226
Q.Suction, Return Hose (KX36-3 EU, KX41-3 EU)
(1) Suction Hose
No. Part Name Part No. Q’ty Remarks

1 Hose (suction) RG138-6311 1 (631)
2 Hose clamp (34-44) 69741-7282 1
3 Hose clamp (50-65) 69481-1518 1
4 Grommet (1, swivel F) RG237-4125 1
IV-S-227
(2) Return Hose
No. Part Name Part No. Q’ty Remarks

1 Hose (return, 2) RG138-6352 1 L=315 C/V T2 oOil tank in T joint
2 Hose (cooler, 1) RG138-6361 1 L=690 Third line valve T joint oOil cooler front
3 Hose (cooler, 2) RG138-6362 1 L=740 Oil cooler rear oOil tank in T joint
4 Hose (drain, 1) RG138-6373 1 L=1100 Swivel motor T oThird line valve T joint
5 Hose (drain, 2) RG138-6375 1 L=400 Unload valve (T) oOil tank in T joint
6 Hose (drain, 3) RG138-6376 1 L=550 SJ (D) oOil tank
7 Hose (return, 1) RG138-6351 1 L=430 C/V (T1) oThird line valve T joint
8 Hose (third line) RG138-6351 1 L=400 C/V (B6) T joint (SP low) oThird line valve
IV-S-228
Low-pressure hose (Suction, Return, Drain, Third line)
Part No.
Length
39 51 69741-7283 Clamo, hose Molding, hose
1 Oil tank ~ Pump Suction RB238-6311 Hose (Suction) 1
32 44
(3) Table of Hoses
2 CV (T1) ~ Third line valve T joint Oil cooler IN RG138-6351 Hose (Return 1) 1 430 15.9 23.5 69741-7281 Clamo, hose PWR: 370
3 Third line valve T joint~ Oil cooler front Oil cooler IN RG138-6361 Hose (Cooler 1) 1 690 15.9 23.5 69741-7281 PWR: 630
4 Oil cooler rear ~ Oil tank in T joint Oil cooler OUT RG138-6362 Hose (Cooler 2) 1 740 15.9 23.5 69741-7281 PWR: 680
5 CV (T2) ~ Oil tank in T joint Oil cooler by pass RG138-6352 Hose (Return 2) 1 315 45 0 H.P hose DN12 OKE12
6 CV (B6) T joint (SP low)~ Third line valve T joint Third line RG138-6377 Hose (Third line) 1 400 90 L=45mm 0 H.P hose DN10 PWR:
fitting to fitting
PWR:
7 Swivel motor T ~ Third line valve T joint Swivel motor drain RG138-6373 Hose (Drain 1) 1 1100 0 H.P hose DN10
fitting to fitting
PWR:
8 Unload Valve (T) ~ Oil tank in T joint Unload Valve return RG138-6375 Hose (Drain 2) 1 400 90 H.P hose DN12 fitting to fitting
9 SJ (D) ~ Oil tank Travel motor drain RG138-6376 Hose (Drain 3) 1 550 20.7 69741-7281 Clamo, hose PWR: 490
IV-S-229
High pressure hose (In swing frame)
Part No. Dimension
Reference (mm)
1 Pump (P1) ~ CV (P1) P1 RG138-63211 Hydraulic hose (3/8) 1 1880 G3/8 PF2106 G3/8
4 CV (A3) ~ SJ (I) Travel left front RG138-64431 Hydraulic hose (3/8) 1 640 Blue G3/8 PF2106 G3/8
5 CV (B3) ~ SJ (H) Travel left rear RG138-64441 Hydraulic hose (3/8) 1 620 Red G3/8 PF2106 G3/8
6 CV (A4) ~ SJ (F) Travel right front RG138-64411 Hydraulic hose (3/8) 1 480 Green G3/8 PF2106 G3/8
7 CV (B4) ~ SJ (E) Travel right rear RG138-64421 Hydraulic hose (3/8) 1 550 Yellow G3/8 PF2106 G3/8
8 CV (B7) ~ Swivel motor (B) Swivel left RG138-64511 Hydraulic hose (1/4) 1 730 Gray G1/4 PF1704 G1/4
PWR:
9 CV (A7) ~ Swivel motor (A) Swivel right RG138-64521 Hydraulic hose (1/4) 1 850 Light Blue G1/4 PF1704 G1/4 fitting to
fitting
10 CV (A9) ~ Swing cyl bottom Swing left RG138-64611 Hydraulic hose (1/4) 1 1200 Green G1/4 PF2104 G1/4
11 CV (B9) ~ Swing cyl rod Swing right RG138-64621 Hydraulic hose (1/4) 1 1200 Yellow G1/4 PF2104 G1/4
12 CV (B8) ~ Changeable V (P2) CV Dozer down RG138-64711 Hydraulic hose (1/4) 1 820 Red G1/4 PF2104 G1/4
13 CV (A8) ~ Changeable V (P1) CV Dozer up RG138-64721 Hydraulic hose (1/4) 1 800 Brown G1/4 PF2104 G1/4
14 Changeable V (B1) ~SJ (B) Dozer up (rDozerod) RG138-64731 Hydraulic hose (1/4) 1 410 G1/4 PF2104 G1/4
15 Changeable V (B2) ~SJ (C) Dozer down (bottom) RG138-64741 Hydraulic hose (1/4) 1 480 G1/4 PF2104 G1/4
16 Changeable V (A2) ~SJ (J) Track cyl (bottom) RG138-64751 Hydraulic hose (1/4) 1 430 G1/4 PF1704 G1/4
17 Changeable V (A1) ~SJ (A) Track cyl (rod) RG138-64761 Hydraulic hose (1/4) 1 600 G1/4 PF1704 G1/4
IV-S-230
R. Table of Hoses (KX36-3 EU, KX41-3 EU)
KX41-3S and KX36-3

12 CV (B8) ~ SJ (C) CV Dozer down RG038-64711 Hydraulic hose (1/4) 1 1320 Red G1/4 PF2104 G1/4 PWR:
fitting to
13 CV (A8) ~ SJ (B) CV Dozer up RG038-64721 Hydraulic hose (1/4) 1 1100 Brown G1/4 PF2104 G1/4 fitting
For KX36-3 and KX41-3
High pressure hose (Front, Control valve port, Cylinder port)
Part No. Dimension
Reference (mm)
1 CV (A2) ~ Boom cyl rod Boom Up RG138-64161 Hydraulic hose (1/4) 1 1230 Green G1/4 PF2104 G1/4
2 CV (B2) ~ Boom cyl bottom Boom down RG138-64171 Hydraulic hose (1/4) 1 1250 Yellow G1/4 PF2104 G1/4
3 CV (B5) ~ Arm cyl rod Arm dump RG138-64181 Hydraulic hose (1/4) 1 1080 Gray G1/4 PF2104 G1/4
4 CV (A5) ~ Arm cyl bottom Arm close RG138-64191 Hydraulic hose (1/4) 1 1040 Blue G1/4 PF2104 G1/4 PWR:
fitting to
5 CV (B1) ~ Bucket cyl rod Bucket dump RG138-64211 Hydraulic hose (1/4) 1 1290 Pink G1/4 PF2104 G1/4 fitting
6 CV (A1) ~ Bucket cyl bottom Bucket close RG138-64221 Hydraulic hose (1/4) 1 1280 White G1/4 PF2104 G1/4
7 CV (A6) ~ SP arm left SP (High at left press) RG138-64911 Hydraulic hose (3/8) 1 1040 Brown G3/8 PF2106 G3/8
8 CV (B6) ~ SP arm right SP (Low at left press) RG138-64921 Hydraulic hose (3/8) 1 1070 White G3/8 PF2106 G3/8
9 CV (A2, B) ~ Boom cyl rod Boom Up RG138-64361 Hydraulic hose (1/4) 1 1770 Green G1/4 PF2104 G1/4
10 CV (B2, B) ~ Boom cyl bottom Boom down RG138-64371 Hydraulic hose (1/4) 1 1500 Yellow G1/4 PF2104 G1/4 PWR:
fitting to
11 CV (B5, B) ~ Arm cyl rod Arm dump RG138-64381 Hydraulic hose (1/4) 1 1550 Gray G1/4 PF2104 G1/4 fitting
12 CV (A5, B) ~ Arm cyl rod Arm close RG138-64391 Hydraulic hose (1/4) 1 1320 Blue G1/4 PF2104 G1/4
Only for KX41-3
IV-S-231
High pressure hose (Front, Cylinder port)
Part No. Dimension
No. Connecting point Application Reference Part Name Q’ty (mm) Tape color Hose shape Remarks
13 CV (B1, B) ~ Bucket cyl rod Bucket dump RG138-64311 Hydraulic hose (1/4) 1 2520 Pink G1/4 PF2104 G1/4
14 CV (A1, B) ~ Bucket cyl bottom Bucket close RG138-64321 Hydraulic hose (1/4) 1 2320 White G1/4 PF2104 G1/4 PWR:
fitting to
15 CV (A6, B) ~ SP arm left SP (High at left press) RG138-64931 Hydraulic hose (3/8) 1 2090 Brown G3/8 PF2106 G3/8 fitting
16 CV (B6, B) ~ SP arm right SP (Low at left press) RG138-64941 Hydraulic hose (3/8) 1 2090 White G3/8 PF2106 G3/8
Only for KX36-3

High pressure hose (Front, Cylinder port)
No. Connecting point Application Part No. Part Name Q’ty Dimension Tape color Hose shape Remarks
Reference (mm)
13 CV (B1, B) ~ Bucket cyl rod Bucket dump RG138-64311 Hydraulic hose (1/4) 1 2400 Pink G1/4 PF2104 G1/4
14 CV (A1, B) ~ Bucket cyl bottom Bucket close RG138-64321 Hydraulic hose (1/4) 1 2200 White G1/4 PF2104 G1/4 PWR:
fitting to
15 CV (A6, B) ~ SP arm left SP (High at left press) RG138-64931 Hydraulic hose (3/8) 1 2000 Brown G3/8 PF2106 G3/8 fitting
16 CV (B6, B) ~ SP arm right SP (Low at left press) RG138-64941 Hydraulic hose (3/8) 1 2000 White G3/8 PF2106 G3/8
For Valiable track (KX41-3V)
High pressure hose (Under carriage)
Part No. Dimension
Reference (mm)
1 SJ (i) ~ Travel motor L (P1) Travel left front RG138-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
2 SJ (h) ~ Travel motor L (P2) Travel left rear RG138-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
3 SJ (f) ~ Travel motor R (P2) Travel right front RG138-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
4 SJ (e) ~ Travel motor R (P1) Travel right rear RG138-63911 Hydraulic hose (3/8) 1 790 G3/8 PF2106 G3/8
PWR:fitting to fitting
5 SJ (g) ~ Travel motor L (Ps) Travel left 2speed RG138-63921 Hydraulic hose (1/4) 1 920 G1/4 PLT04 G1/4
6 SJ (g) ~ Travel motor R (Ps) Travel right 2speed RG138-63921 Hydraulic hose (1/4) 1 920 G1/4 PLT04 G1/4
7 SJ (d) ~ Travel motor L (T1) Drain RG138-63931 Hydraulic hose (1/4) 1 750 G1/4 PLT04 G1/4
9 SJ (b) ~ RG138-64821 Dozer up RG138-64811 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
10 RG138-64811 ~ Dozer cyl rod Dozer up RG138-64821 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4 Spring:fitting to fitting
11 SJ (c) ~ RG138-64821 Dozer down RG138-64811 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
12 RG138-64811 ~ Dozer cyl bottom Dozer down RG138-64821 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4 Spring:fitting to fitting
13 SJ (j) ~ Track cyl bottom Track wide RG138-64851 Hydraulic hose (1/4) 1 960 G1/4 PF1704 G1/4
14 SJ (a) ~ Track cyl rod Track narrow RG138-64861 Hydraulic hose (1/4) 1 720 G1/4 PF1704 G1/4
For Standard track (KX41-3, KX36-3)

High pressure hose (Under carriage)
IV-S-232
No. Connecting point Application Part No. Part Name Q’ty Dimension Tape color Hose shape Remarks
Reference (mm)
1 SJ (i) ~ Travel motor L (P1) Travel left front RG138-63951 Hydraulic hose (3/8) 1 600 G3/8 PF2106 G3/8
2 SJ (h) ~ Travel motor L (P2) Travel left rear RG138-63951 Hydraulic hose (3/8) 1 600 G3/8 PF2106 G3/8
3 SJ (f) ~ Travel motor R (P2) Travel right front RG138-63951 Hydraulic hose (3/8) 1 600 G3/8 PF2106 G3/8
4 SJ (e) ~ Travel motor R (P1) Travel right rear RG138-63951 Hydraulic hose (3/8) 1 600 G3/8 PF2106 G3/8
5* SJ (g) ~ Travel motor L (Ps) Travel left 2speed RG138-63921 Hydraulic hose (1/4) 1 650 G1/4 PLT04 G1/4 PWR:fitting to fitting
6* SJ (g) ~ Travel motor R (Ps) Travel right 2speed RG138-63921 Hydraulic hose (1/4) 1 650 G1/4 PLT04 G1/4
9 SJ (b) ~ RG138-64821 Dozer up RG138-64811 Hydraulic hose (1/4) 1 270 G1/4 PF2106 G1/4
10 RG138-64811 ~ Dozer cyl rod Dozer up RG138-64821 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4 Spring:fitting to fitting
11 SJ (c) ~ RG138-64821 Dozer down RG138-64811 Hydraulic hose (1/4) 1 270 G1/4 PF2106 G1/4 PWR:fitting to fitting
12 RG138-64811 ~ Dozer cyl bottom Dozer down RG138-64821 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4 Spring:fitting to fitting
* only use KX41-3S
V.Electrical System
A.Troubleshoothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-3
a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-3
b. Failure display and diagnosis criteria on the meter panel . . . . . . . V-S-4
c. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-5
d. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-6
B.Kubota Intelligent Control System. . . . . . . . . . . . . . . . . . V-S-7
a. Navigation list of messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-7
b. Meter display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-9
c. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-13
C.Wire harness installation . . . . . . . . . . . . . . . . . . . . . . . . V-S-15
a. Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-15
b. Engine earth, starter switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-16
c. Main harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-17
D.Others, for your reference . . . . . . . . . . . . . . . . . . . . . . . V-S-23
a. Photo samples taken from Hirakata assembly line . . . . . . . . . . . V-S-23
b. Photo samples taken from KBM assembly line : EU - version . . V-S-30
V-S-1
V-S-2
A.Troubleshoothing
a. General
(1) How to diagnose
The most important point in troubleshooting is to determine "Probable Causes". Once the probable causes
are determined, parts to be checked can be limited to those associated with such probable causes. There-
fore, unnecessary checks can be eliminated. The determination of the probable causes must be based on a
theory and be supported by facts and must not be based on intuition only.
TROUBLESHOOTING STEPS
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the prob-
lem symptoms could become more complicated, resulting in failure to determine the causes correctly and
making incorrect repairs.The four steps below should be followed in troubleshooting.
Observation of Problem
1 Symptoms Observe the symptom carefully. Check if there are also
other problems.
Determination of Probable In determining the probable causes, it is necessary to

2 Causes check the wiring diagram to understand the circuit as a sys-
tem. Knowledge of switches, relays and other parts is nec-
essany for accurate determination. The causes of similar
problems in the past must be taken into account.
Checking of Parts Associated Troubleshooting is carried out by making step by step

3 with Probable Causes and checks until the true cause is found. Always go through the
Determination of Faulty Parts. procedures considering what check is to be made where
for the best results.
Repair and Confirmation After the problems are corrected, be sure to check that the
4 system operates correctly. Also check that new problems
have not been caused by the repair.
FOUR BASIC CHECKING ITEMS FOR ELECTRICAL DIAGNOSIS

This manual contains the cable diagrams as well as the individual circuit drawings, operational explanations,
and troubleshooting hints for each component required to facilitate the task of troubleshooting. The informa-
tion is compiled in the following manner:
1. “Power source”
Is the supply voltage as specified? (Battery voltage at 12 V or microcomputer output at 5 V)
Æ If not specified, the system fails to work.
2. “Continuity”
Is there continuity along the specified lines and wire harnesses? Are the system’s resistance values as
specified?
Æ If not specified, no current flows.
3. “Earth”
Is the system completely grounded?
Æ If not grounded as specified, the electrical circuitry fails to function well.
4. “Insulation”
Are the system’s insulation resistances as specified?
Æ If an electric leak occurs, the current gets out of spec and the electrical devices malfunction.
V-S-3
b. Failure display and diagnosis criteria on the meter panel
The following table 1 shows data on failure diagnosis, for operating mode and service mode.
Note:
• Display items of the system in service mode can be checked with the fail record.
• In the case of a warning for fuel scarcity, the buzzer will be turned ON for a moment at five-minute inter-
vals.
Table 1. Failure diagnosis

Display Function
Buzzer Lamp Remedy
Operating mode service mode stop point
1 Fuel - 5-minute Yellow --- Replenish fuel.

intervals
2 Engine oil 2 Engine oil Continually Red --- Replenish oil.
Check pressure switch or speed
sensor.
3 Charge 3 Charge Momentarily Red --- Check battery, alternator or
speed sensor.
4 High voltage 4 High voltage Continually Red AI AUX Check power source.
5 Overheat 5 Overheat Continually Red AI AUX Check engine cooling system.
31 Lift up unload lever - Momentarily Yellow Engine does Lift up the safety lever.
not start Check safety switch.
32 Service hour - Momentarily Yellow --- The specified hour meter is set.
- 51 Coolant sensor Momentarily Red --- Check coolant temp or sensor.
- 52 Fuel sensor Momentarily Red --- Replenish fuel or check sensor.
55 Meter controller - Momentarily Red AI AUX Renew meter panel.
error
V-S-4
c. Engine
Trouble Check item Remedy
1. The starter does not run. (1) Check the slow-blow fuse (50A) and fuse (10A) for blowouts. Check or replace.
(2) Check the battery terminal for looseness. Retighten.
(3) Hold the starter switch in the starting position and check if a voltage of 10.5 Charge or replace.
V or more appears between the both ends (+, –) of the battery.
(4) Hold the starter switch in the starting position and check if a voltage of 9V Repair or replace.
or more is applied to the starter 50 terminal.
(5) Check if the key switch is normal. Check or replace.
(6) Check the starter M terminal for looseness. Retighten.
2. The starter runs but the (1) Turn On the key switch and check if fuel overflows into the tank. Check visually.
engine does not start. (2) Turn On the key switch and check by hand if the fuel pump is running. Replace.
(3) Check the fuel pump fuse for blowouts. Replace.
(4) Check if a voltage is applied to the Fuel pump coupler 1 and 2. Repair or replace.
(5) Disconnect the stop solenoid and check if the engine starts. Repair or replace.
(6) Turn On the key switch and check if a voltage is applied to the engine stop Repair or replace.
solenoid coupler.
3. The cold-temperature (1) Check if the battery voltage is normal. Charge or replace.
starting property is poor. (2) Check the glow relay fuse for blowouts. Replace.
(3) Check by hand if the glow relay is running. Replace.
(4) Check if a voltage is applied to the glow relay coupler. Repair or replace.
(5) Check if a voltage is applied to the glow plug. Repair or replace.
(6) Check if the glow plug is normal. Replace.
(7) Check the glow relay. Replace.
V-S-5
d. Others
Trouble Check item Remedy
1. The machine does not (1) Check the fuse (5A) for blowouts. Replace
run in spite of the (2) Check the lever lock solenoid coupler and switch coupler for disconnection. Repair or replace
machine lock lever being
(3) Interchange the lever lock solenoid coupler and 2nd-speed solenoid Repair or replace
released.
coupler.
(4) Check if a voltage is applied to the lever lock solenoid coupler and switch Repair or replace
coupler.
(5) Check the solenoid valve. Repair or replace
(6) Check if the lever lock switch is normal. Replace
2. The travel speed does (1) Check the fuse for blowouts. Replace
not change in spite of the (2) Check the 2nd-speed solenoid coupler and switch coupler for Replace
two-speed pedal being disconnection.
pressed.
(3) Interchange the 2nd-speed solenoid coupler and lever lock solenoid Repair or replace
coupler.
(4) Check if a voltage is applied to the 2nd-speed solenoid coupler and switch Replace
coupler.
(5) Check the solenoid valve. Replace
(6) Check if the 2nd switch is normal. Replace
3. The horn does not sound (1) Check the fuse for blowouts. Replace
in spite of the horn switch (2) Check the harness from the grip (horn switch) for breaking. Repair or replace
being pressed.
(3) Check the horn coupler and grip (horn switch) coupler for disconnection. Repair or replace
(4) Check if a voltage is applied to the horn terminal. Replace
(5) Check if the horn switch is normal. Replace
(6) Check if the horn is normal. Replace
4. The working light does (1) Check the fuse for blowouts. Replace
not go on in spite of the (2) Check the working light terminal and switch coupler for disconnection. Repair or replace
working light switch
(3) Check if a voltage is applied to the working light terminal. Replace
being pressed.
(4) Check the lamp for blowouts.
V-S-6
B.Kubota Intelligent Control If an error occurs with the machine, one of the fol-
lowing messages appears in the LCD display.
System In case of a trouble, immediately contact your local
dealer for inspection and repair.
a. Navigation list of messages
Warning Problem or failure Machine behavior
Message Correction
lamp Color (what happened) (provisional measure)
yellow Fuel running out. - Add fuel.
The engine may

be seized, failing
Engine hydraulic circuit to restart the
Immediately stop the
red error (clogged) or engine.
engine.
engine oil shortage. Immediately
contact your local
dealer for repair.
Check the fan belt.
(When the belt is in
Immediately
Charging line in trouble. good condition, keep
red contact your local
Charging failure. running until the
dealer for repair.
battery becomes
dead.)
If the message
does not
[Do not start the
reappear, no
engine on 24V line.
24V line engine startup repair is needed.
red Get it restarted to see
alternator defective. If the message
if there is the
stays on, contact
message again.]
your local dealer
for repair.
The engine has been Pull up the lever

The engine fails to
yellow started with the lever lock and start the
start.
lock down. engine.
The hour meter has

Carry out the
reached the specified
yellow - specified
count-up. Carry out the
maintenance job.
maintenance job.
Immediately
No message Sensor power line short The work light lights
red contact your local
(warning lamp flashing) circuited. up.
dealer for repair.
i Service hour meter
V-S-7
When the hour meter has counted up to the hours
circled in the maintenance list below, the message
appears. The message shows up as follows.
50 100 250 300 500 550 750 800 1000
1 Engine oil every 250 hrs
change
2 Hydraulic oil every 1000 hrs
Air filter Outer element every 1000 hrs

3 replace
element Inner element every 1000 hrs
5 Engine oil filter every 250 hrs
Hydraulic return filter
6 every 500 hrs
element replace
Hydraulic suction filter
7 every 1000 hrs
element
The message appears. The message shows up as

follows.
(The message reappears on the hour meter desig-

nated next.)
NOTE :
• The maintenance message disappears auto-
matically in about 10 seconds.
• When the key is turned from OFF to RUN, the
maintenance message reappears and disap-
pears again automatically in about 10 seconds.
• When the key is turned from OFF to RUN
repeatedly 10 times, the message disappears.
i In case the service hour meter replaced due to

any trouble with it, the meter is set to "0". Con-
tact your KUBOTA dealer for details.
V-S-8
b. Meter display
Display Selector Switch Charge Lamp
Press the display selector switch. The electronic This warning lamp lights up if the charging system
meter's LCD display will change from one indication gets in trouble with the engine running. When the
mode to the other. starter switch is turned "ON" with the engine off, the
Change the two-mode display according to your lamp lights up, and when the engine gets started,
jobs. the lamp goes out.
NOTE :
• If there is disconnection or breakage in the
charging system when the key is turned to
"RUN", the following message will appear.
Oil Lamp
This engine oil pressure warning lamp lights up if the
lubricating system gets in trouble with the engine
running. When the starter switch is turned "ON" with
the engine off, this lamp lights up, and when the
(1) Display selector switch engine gets started, the lamp goes out. If the lamp
(2) LCD display stays on with the engine running, stop the engine
and check the engine oil level.
NOTE :
• If there is disconnection or breakage in the oil
system when the key is turned to "RUN", the
following message will appear.
Glow Lamp
With the starter key at the "RUN" position, the
engine's preheat status is indicated.
(1) Fuel gauge (A) "INDICATION MODE 1"
(2) Water temperature gauge
(3) Oil lamp
NOTE :
(4) Hour meter • When the starter switch is turned to the "RUN"
(5) Charge lamp position, the engine will be preheated for a
(6) Glow lamp given period of time and the lamp will turn on.
• The above indication appears momentarily
NOTE : when the engine is started, but it does not mean
• With the starter key at the "STOP" position, any trouble. (This is because the oil charge sen-
press the electronic meter's display selector sor output becomes unstable when the engine
switch or the working light switch, and the LCD is started.)
display shows the hour meter, fuel gauge and
• The symbol appears momentarily when the
water temperature gauge for 10 seconds.
engine gets started. This is not an error.
V-S-9
LCD Display for Usual Operation
Fuel gauge CAUTION
To avoid personal injury:
CAUTION • If the fuel is poured too fast, the buzzer may
To avoid personal injury: sound not according to the fill-up progress.
• Before adding fuel, be sure to stop the • The moment when the buzzer starts beeping
engine. means that the fuel tank gets nearly full.
• Be sure to keep open flame away from the • Look into the oil filler port when pouring the
machine. Otherwise a fire may be caused. fuel. Listen to the buzzer sound for rough-
checking the fill-up progress.
With the starter key at the "RUN" position, the fuel
remaining in the fuel tank is indicated in the block. Water Temperature Gauge
CAUTION
• Do not open the radiator cap during and just
after operation. Hot water may gush out and
get you scalded. Wait until the radiator cools
down enough before opening the cap.
With the starter key at the "RUN" position, the

cooling water temperature is indicated. If the water
temperature indicator is near "H", take the steps
below.
1. Discontinue the job.
2. Set the engine to the idling speed and keep it
(1) Fuel gauge (A) "Empty" running for 5 minutes.
(B) "Full"
3. Stop the engine and check the following points
IMPORTANT : (1)-(3).
• If the fuel gauge indicator is near the "E" or the (1) Cooling water shortage or leak
"FUEL" message appears, add fuel as soon as (2) Fan belt tension
possible. If the indicator is near "E" and the (3) Mud or dust deposits on radiator
machine runs on a slope, the engine may run
out of fuel and get interrupted.
Fuel supply
The following functions are helpful in adding the fuel.
The fill-up progress can be roughly checked by
buzzer sound.
Procedure
1. Press the work light switch or the display selec-
tor switch on the meter with the key being at
OFF. (Keep the key at OFF.)
(1) Water temperature gauge (A) "WATER TEMP LOW"

(B) "WATER TEMP HIGH"
2. The message as shown above appears.

3. Add fuel.
4. The buzzer sound interval changes according
to the fill-up progress. As the fuel amount
becomes close to full, the buzzer sound
changes to continuous beeping.
V-S-10
Hour-meter
Indicates the total operating hours of the machine.
How the indication goes

• The meter advances one hour after an hour of operation regardless of the engine rpm.
Engine tachometer
Indicates the current rpm of the engine.
NOTE :
• The LCD display may be illegible when viewed from a certain angle. This is not a display failure.
LCD Display for Warning

Remaining fuel warning
If the fuel level become less, the lamp (yellow) starts flashing and the following message appears in the
display.
Battery charge warning

If the battery line gets in trouble, the lamp (red) starts flashing and the following message appears in the
display.
V-S-11
Engine oil pressure low warning
If the lube oil line gets in trouble, the lamp (red) starts flashing and the following message appears in the
meter.
Immediately stop the engine and check the engine oil level.
Warning Lamp
• The warning lamp is used to indicate broken wire, short-circuit, fuel shortage and other problems.
NOTE :
• Warnings and errors are displayed and also the alarm buzzer beeps.
• The warning lamp starts flashing in red if any trouble occurs. If the system gets in warning state, the
warning lamp starts flashing in yellow.
(1) Warning lamp (red, yellow)

(2) LCD display
IMPORTANT :
• Not just look at the meter, but also carry out the inspection and correction accordingly.
NOTE :
• Let your KUBOTA dealer inform you in detail concerning care and maintenance.
• The message can be displayed in 11 languages (English,French,German,Spanish,Italian,Portuguese,
Dutch,Danish,Swedish,Finnish,Norwegian).
Contact your KUBATA dealer to your language selection.
V-S-12
c. Fuses
CAUTION
• When changing fuse, stop the engine and turn the key in position "STOP"
Replacing Fuses
1. Remove the cover of the fuse box.
2. Replace the burnt out fuse with a fuse having the same capacity.
Fuse Capacities and Circuits
5A Glow
10A High speed
10A Main (with AI)
5A ROOM LIGHT 15A AUXILIARY
20A WORK LAMP 10A WIPER/WASHER
Spare
15A P.SOURCE/
5A METER SUB
BEACON
5A
10A
10A ALTERNATOR 5A HI SPEED

5A LEVER LOCK 5A WORK LAMP
10A HORN 10A METER MAIN
(1) Fuse box

(2) Auxiliary electric
Auxiliary Electric
Max power is less than 120 W including the "Beacon" (Auxiliary electric).
Slow Blow Fuse

Slow blow fuse is provided to protect the electrical circuits. If the fusible link is blown, check the electrical
circuits for trouble and then replace with a new compatible slow blow fuse.
V-S-13
(1) Slow blow fuse (50 A)
(2) Auxiliary electric
NOTE :
• If the machine keeps idling on the reserve power, the battery gets discharged. Raise the engine rpm.
V-S-14
C.Wire harness installation
a. Precautions
S (1) No contact with the peripheral parts along the route.

Unprotected members should not to be in contact.
S (2) Checking the routes.
1. Fuel hose should not to be clamped together.
2. Couplers, terminals, etc. are to be connected tight enough to withstand
usual pulling force.
3. Clamps are to be surely folded.
S (3) Clamping the harness at the specified points.
1. White-colored tapings to be clamped.
2. Clamps to be surely folded.
3. Harness-fixed clamps.
4. Anchor-shaped clamps should to be inserted deep to the stoppers.
5. Threaded clamps should to be inserted deep enough.
(1)
(1) Harness
(2) (2) Clamp
1) The harness tapings indicate the clamping positions. Clamp at these specified points.
2) Clamp the harness tight enough not to come off nor get loose.
3) Insert the handgrip-equipped harness deep into their mating holes.
4) Do not allow the harness to come out of the corrugated slit.
5) Catch the cord clamp at the corrugated winding.
V-S-15
b. Engine earth, starter switch
(1) (2)
S (1) Tightening torque of the cable fixing nut to the
stater-motor terminal
Tightening torque 5.9 ~ 11.8 N·m (0.6 ~ 1.2 kgf·m) (4)
S (2) Installation of starter switch (RC411-5346U)

1. Starter switch groove to be fitted to the projection of
the cover (top right)
(3)
2. Nut tightening torque 4.0 ~ 5.0 N·m (0.4 ~ 51 kgf·m)
S (3) Checking the automatic starter release function
Start the engine, place the key switch back to the start
position and make sure the starter is not activated. (1) Projection (Back side)
(2) Cover (R, upper)
RC417-4476U
(3) Groove
(4) Starter switch
(RC411-5346U)
(1)
(2) (4) (1) Battery cord (+)

(2) Grommet
(3) Grommet
(3) (4) Battery cord (+)
(5) Clamp
(7) (6) Flange nut
(7) Clamp to engin side
(6)
(5)
V-S-16
c. Main harness
Machine Rear (Engine room)
(1)
(2)
(8)
(3)
(4)
(5)
(6)
(7)
(1) Show blow fuse

(2) Glow
(3) Clamp
(4) Water temp sensor
(5) Altrenator
(6) Oil switch
(7) Stator
(8) Fuel pump
V-S-17
Machine Front (Engine room)
(1) (2)
(3)
(1)
(4)
(2)
(1) Clamp (1) Grommet

(2) Glow plug (2) Engin speed sensor
(3) Engin stop
(4) Grommet
Machine Front (Engine room)
(1)
(1)
(2)
(1) Clamp to fuel pipet (2)
(2) E - stop solenoid
(3) (1)
(1) Glow
(2) Clamp
(3) Engin speed sensor
(3)
(2)
(1) Clamp
(2) E - stop solenoid
(3) Fuel pump
V-S-18
Machine Rear (Engine room)
(5) Tighten the terminal at 30 degree

(6 Terminal & clamp
(7) Alternator
(1)
(5)
(2)
(6)
(7)
(3)
(4) (8) (9)
(10)
(1) Slow blow fuse (8) Clamp

(2) Clamp (9) Startor
(3) Water temp sensor (10) Battery (+)
(4) Oil switch
V-S-19
Battery cord (-) gose through seat support.
(2) (1)
(1) Battery cord (-)
(2) Grommet
(2) (1)
(1) Battery cord (+)

(2) Battery cord (-)
V-S-20
(2)
(1)
(3)
(11)
(4)
(5)
(6)
(9)
(10)
(7)
(8)
(1) To control panel

(2) Grommet
(3) Trance Hi (Y)
(4) Lever lock (Gr)
(5) Clamp
(6) Earth
(7) Work lamp harness
(8) Horn
(9) Clamp
(10) Fuel sensor
(11) Clamp
V-S-21
(1)
(2)
(3) (2)
(6)
(4)
(1)
(5)
(3)
(4)
(1) Hi - speed lamp (1) Clamp

(2) Horn switch (2) TPSS pilot hose
(3) Hi speed switch (3) Pilot hose
(4) Key switch (4) Relays, 4 pcs
(5) Clamp
(6) Power outlet
(5) (1)
(1)
(4)
(7) (2)
(6)
(5)
(2)
(4) (3)
(4) (3)
(1) View A (1) Fuse box

(2) To meter (2) Glow relay
(3) Clamp (3) Clamp
(4) Unload SW, R (4) Connect to battery cord
(5) Horn switch (5) Slow blow fuse
(6) Hi - speed lamp
(7) Key switch
V-S-22
D.Others, for your reference
a. Photo samples taken from Hirakata assembly line
1) Track frame, hose tightening.
3) Track cylinder, hose tighten.
V-S-23
4) Track cylinder installation.
(1)
(6)
(1) Pass the hoses through under of Track cYL.
(2)
(2) Clamp here.(Kabel binder)
(3) S/J (A) to Tr.cyl Bottom
(7) (3) (4) Keep space 10mm bitween Trackframe and hose when
hose fixing .
(4) (5) S/J (J) to Tr.cyl Rod
(5) (1) (6) Machine Left
(7) Dozer side
(8) Machine Right
(8)
6) Travel hose fixing.

Aim at center of hole of Track frame.
7) Clamp travel hoses.
V-S-24
8) Clamp travel hoses.
9) Track cyl hose [C/V (B2) to S/J(J)].
10) Hose assembling of swing frame.

(Not same as KBM Machine.)
11) Connecting front hoses.
V-S-25
12) <Easy assemble for water hose>
(1) Fix water hose and radiator.
(1)
13) Then , fix water hose and engine.
14) Engine speed sensor.

Clamp here.
15) Hose direction inside of Swing frame.
V-S-26
16) Fuel hose(return) assembling is later thanbon-
net assemble.
Reason: Partition plate is already fixed Bonnet.
17) Reserve tank hose direction.
18) Clamping of wireharness (front).
Pass wireharness through back of rod.

and fix by Kabel binder.
Fix point : front of number label.
19)
(1) Clamping of wireharness (front).

Not use this clamp holder.
Reason:Wireharness is sticking out from Swingframe
when swing Cyl moved.
(1) (2) Wireharness direction is out of hose gate.
(2)
V-S-27
20) Sub assy of operating stand.
21) Sub assy of operating stand.

See right.
22) Fuel filter
23) Factory uses magnet sheet for easy inserting

hoses.
Hose insert order (HIRAKATA)

(1) SP
(2) Bucket
(3) Boom
(4) Arm
V-S-28
24) Drain hose of reserve tank.
Insert hose end to weight's hole.
25)
(1) Fix wireharness and injection pipe by heat resistance type

Kabel binder.
(1)
(2) Connector Position.
(2)
26) Glow cable and stop solenoid connector.
V-S-29
b. Photo samples taken from KBM assembly line : EU - version
1) Alternater terminal fixing degree: 30°
2) KabelBinder include wireharness.
(1) Pull out the KabelBinder.
(1)
(2) Fix terminal and wireharness at white tape position by this

KabelBinder.
(3) Cut the remainder.
(3)
(2)
3) Starter motor
Clamp position.
(1) Clamp : Battery plus cable

(2) Clamp : wireharness
(1)
(2)
V-S-30
4) Clamp position.
(1) Heater hose's hoseband fixing is upward.

(1) (2) Clamp
(2)
5) Clamp
(1) Clamp position.
(1)
(1) Clamp position.

(1)
6) Wireharness direction
(1)
(1) Clamp position.
(2) Stop solenoid
(3) Stop relay
(4) Fuel pump
(4)
(2)
(3)
V-S-31
7) Electric components
(1) Fuelpump's coupler connecting is Upward fuelpump.
(2) Stop relay
(3) Fuel pump
(2) (1)
(3)
8) Clamp position.
[Arch , Frontside]
Add clamping plate.
(1) Insert clamp from this side.

(1) (For keeping space wireharness and accel lever.)
(1) 2speed harness route.

(2) Clamp hole Add 7mm hole.
(1)
9) 2speed harness route.

[Looking inside]
(1) (1) Clamp
V-S-32
10) Meter Panel (KX41-3)
(1) (2)
Main line work is only connecting.
(3) (7) (8) (Cover is already fixed in sub line.)
(4)
Easy way to connecting order.
(1) Lever lock

(5) (2) 2speed switch (dozer)
(6) (3) Horn
(4) Key switch
(5) Beacon switch
(6) 2speed light
(7) Heater switch
(8) Meter panel
(1) Key coupler hook up forward holder.
(1)
11) Meter Panel (KX41-3)

(1) Rubber boot
This side is front.
(2) Install rubber boot and plastic guide.

(2) (Plastic guide cannot fit if rubber boot is not installed.)
(1)
Cram wireharness into forword when meter assem-

ble.
V-S-33
12) Unload Valve
(1) (2)
(1) Wireharness of unload valve is branch out gromet position
of engine side.
(2) Clamp
(3) <Pre1 production>

Wireharness is branch into under seat support.
(3)
Pre1is blue line direction.
13) Wireharness earth terminal
Tighten like this photo.
To aviod contact with rod of changeable valve
14) Seat support
(1) (4) KX41-3

(2) (3)
(1) Slow blow fuse (incl. W/H)
(2) Relay:PL503-6859U
(3) Relay:T1060-3371U
(4) Relay: 4Pcs T1060-3372U
15) KX41-3
(1) CABIN model with Heater relay

(1) (2) Clamp
(2)
V-S-34
16) KX41-3
(1) CABIN model with Heater relay

(1) (2) Clamp
(2)
17) KX36-3
(1) (2)
(3) Seat support
(1) Relay: 1Pcs RB419-5371U

(2) Relay: 4Pcs T1060-3372U
(3) Auto release controler
(4) Auto glow unit
(4)
18) KX36-3
(1)
Seat support
[Pre1]
see inside
(1) Relay: 4Pcs T1060-3372U
V-S-35
(2)
(1)
(3)
19) KX41-3 Relay arrangement plan
(1) Main line : hook relay.

Sub line : assemble with Wire harness
(2) Main line : connect coupler.
Sub line : assemble with Seat support.
(3) Main line : insert clamp
(Fuse included Wire harness)
20) Seat support

[Series production plan]
(1) see inside
(1) Auto release controler
V-S-36
(2) (3)
(1)
(4)
21) KX36-3 Relay arrangement plan
(1) Main line : connect coupler.

Sub line : assemble with Seat support.
(2) Main line : hook relay.
Sub line : assemble with Wire harness
(3) Main line : insert clamp
(Fuse included Wire harness)
(4) Change position
[Series production]
22) KX36-3 couplers
Coupler for check bulb
(1) Glow
Orange coupler
• Black
• Black/Red
(2) Charge
Blue coupler
• Black/White
• Yellow/Red
(3) Engine oil
Orange coupler
• Blue
• Yellow/Red
(4) Fuel
Black coupler
V-S-37
23) KX36-3
Meter panel light
(1) Beacon
(6) (2) Fuel
(1) (2) (3) Glow
(4) Engine oil
(5) Battery
(6) Light
(3) (4) (5)
24) KX36-3
Meter panel connecting couplers.
25) Couplers for cabin
(1) Take couplers out of panel.

(Only Pre1.)
(1) Series production plan is going to change divergence
point.
(2) (2) Series production
Divergence point
26) Battery terminal

(1)
(1) Fix 60 degree
V-S-38
27)
(1) Clamp
(1)
28) Control Panel (KX36-3)

Clamp the harness to the bracket sheet and
connect the coupler on the back.
29) Relays under bracket sheet.

Mount the relays and fuse.
30) In the case of the cab type, no idling adjust-

ments or dozer stop bolt adjustments are possi-
ble unless the side plate is removed.
V-S-39
31) Engine speed cable : KX36-3
Idling setting use.
The digital panel is used if the model is the
KX41-3.
32) Third line
The line selector cock is on the operating tank.
The third unload T hose and pilot T hose are

mounted to the sub assembly.
33) Pilot T hose
34) Fuel Tank
The KX41-3 and KX36-3 are different in fuel

sensor.
V-S-40
35) Control panel KX36-3
36) Secure the parts with the steel plate clamp at

the point 10 mm of the corrugated edge.
(1)
(1) First position of white tape

Secure the front and back of this position with the speed
clamp.
(2) Secure the part with the speed clamp.
(2)
37) Slow blow fuse under the sheet board

Between slow blow and clamp
V-S-41
38)Clamp position
(1) Clamp
(1)
(2) Clamp
(2)
(3) Wiper moter
(3)
39) Hose fixing of unload unit.
(1) Aim at center of red marked points when this hose fixing.
(2) Aim at corner of Unload unit.(3 hoses)
(1)
(2)
V-S-42
40) Mount the track cylinder.
41) Travel hose (securing leg)
(1) The hose has been changed so that the hose can be
turned smoothly.
45-degree long neck to 90-degree long neck
(1)
42) Drain hose connections to swivel motor and

swivel joint
V-S-43
43) Grease tube connections to swivel bearing
44) Radiator
45) View from rear.
V-S-44
KUBOTA Corporation
CONSTRUCTION MACHINERY DIVISION
EDITOR:
CONSTRUCTION MACHINERY MANUFACTURING DEPT.
SERVICE SECTION
HIRAKATA PLANT
PHONE :+81-72-840-1195
FAX :+81-72-890-2886
KUBOTA Corporation Printed in Japan 0405.CMC.e.10 Code No.97899-60860

Kubota V Manual KX36 KX41 3V

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Kubota V Manual KX36 KX41 3V

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W ORKSHOP MANUAL

EU - version machine models : KX36-3, KX41-3S, KX41-3V

III Electrical system

Workability Bucket digging force improvement

b. Difference between KX36-3 and KX41-3

Differentiation KX36-3 KX41-3 Remark

Short stroke operating Digital panel High speed travel switch

Boom cylinder is installed

2) Flow characteristic simulation for operability improvement

Parent 100% compatible high compatible low compatible Original design

KX36-3 KX41-3(EU) KX41-3V

Machine weight kg 1440 ± 29 1450 ± 29 1595 ± 32 ←

Rear end min. turning mm 1070 ± 21 ← ← ←

Swivel frame rear mm 423 ± 8 ← ← 426 ± 8

kgf/cm2 210 +3, -2 220+3, -2 ← ←

6 psi 2986 3128 ← ←

Main relief pressure kgf/cm2 205 220 ← ←

Mpa 3.9 +0.3 ← ← ←

m3 0.035 ± 0.002 0.04 ± 0.002 ← ←

Ground level Max. mm 3723 ± 56 3855 ± 58 ← ←

Ground level Min. mm 1237 ± 25 1231 ± 25 ← ← Bucket bottom

Max. vertical digging mm 1742 ± 35 1835 ± 37 ← ←

Max. dump height mm

Mini. turning radius mm 1147 ± 34 1245 ± 37 ← ←

9 Front attachment mm 512 ± 15 ← ← ←

Hydraulic oil L 21 ± 1.1 ← ← 20 ± 1

Hydraulic oil L 14.5 ± 0.7 ← ← ←

Eccentric amount from mm From swivel

4 Distance of crawler end mm

(1) Packing, NBR

(1) Support 1 (5) Floating seal (9) Wire (13) Retainer

Pre-set length of spring : L

4-2 North America & Oceania - version : KX41-3V

Spec items KX36-3 KX41-3S, V EU KX41-3V US

(1) Swing bracket

Parts name Parts No. Specifications

2. Features of New Meter

Key switch ON (Only the glowing moment)

Normal screen (with the tachometer selected)

Normal screen (with the hourmeter selected)

KICS;Kubota Intelligent Control System,

Yes (delete Yes (delete

Yes (sample, date

4 AI(Auto idle) function No No

5 Engine overheat warning Yes No

6 Starter motor auto release function Yes Yes

7 Glowplug auto glow function Yes Yes

8 Travel high-low switch at lever grip Yes Yes

9 Fuel feed assist sound Yes Yes

10 Heater Yes (cab version) No

Harness and switch

name English meaning and explanation

data023 Indicates the model name.

data024 Indicates the model name.

data025 Indicates the model name.

data026 Indicates the model name.

data027 Indicates the model name.

data028 Indicates the model name.

data029 Indicates the model name.

data030 Indicates the model name.

data031 Indicates the model name.

data032 Indicates the model name.

Overheat warning Adjustable in 10C

water [V] temp [C]