U17 3alpha

WORKSHOP MANUAL
KUBOTA EXCAVATOR
U17-3
Code No.97899-61952
Record of Revisions
Symbol Date Main Revised Points & Corrective Measures Person-in-charge
Aug. 2008 Maintenance intervals EU - version revised. I. Okae
Oct. 2008 Correction of descriptions on: I. Okae

1. Engine model name for EU - version
2. Retractable track frame
U17-3α is the model name of EU - version

U17/U17-3 is the model name of KTC, KCL and KTA - version
CONTENTS
I. GENERAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-1
II. MACHINE BODY

• Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-1
• Service Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-1
III. ENGINE
• Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-1
• Service Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-1
IV. HYDRAULIC SYSTEM

• Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-1
• Service Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-1
V. ELECTRICAL SYSTEM
• Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-1
• Service Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-1
WSM U17-3α/U17-3/U17 I. GENERAL
I. GENERAL
A. BODY AND ENGINE IDENTIFICATION MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-3
B. SAFETY PRECAUTIONS FOR SERVICING, DISASSEMBLY AND REASSEMBLY . I-S-5
a. Safety Measures Before Starting Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5
b. Safety Measures During Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5
c. Preparation for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6
d. Precautions for Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6
C. IMPORTANT SAFETY PROCESS AND CRITICAL FUNCTIONAL PROCESS . . . . . I-S-7
D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING. . . . . . . . . . . . . . . . . . I-S-9
a. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-9
E. MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-15 1
a. EU-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-15 1
b. PP (KTC, KCL)-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-17

c. KTA-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-19
d. Hydraulic Oil Check for Machines with Hydraulic Breakers . . . . . . . . . . . . . . . . . . I-S-20
e. Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-21
f. Troubleshooting for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-23
g. Periodic Replacement of Important Component Parts . . . . . . . . . . . . . . . . . . . . . . I-S-24
h. Recommended Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-25
i. Lifting Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-26
F. PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-31
a. U17-3α Development Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-31
b. Why Minor Change? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-31
c. Quick Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-32
d. Major Sales Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-33
e. Specifications Comparison. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-34
I-S-1
I-S-2
A. BODY AND ENGINE IDENTIFICATION MARKS

If trouble occurs during use, or servicing is necessary,
contact your dealer. Pass on your machine model,
engine type and serial number to them.
Example: S/N 10001
No. Items Contents

1 MODEL U17-3α
2 SERIAL No. 10001
3 MASS 1650
4 MAX, DRAW BAR PULL 32.3
5 POWER 11.6
6 MAX,VERT,LOAD 2.7
7 PRODUCT IDENTIFICATION NUMBER >JKUU0173*01S10001<
8 MANUFACTURED YEAR 2008
EU-version
No. Items Contents

1 Machine model U17-3α
2 Serial No. 10001
3 Engine No.
4 PRODUCT IDENTIFICATION No. >JKUU0173*01S10001<
Name plate: Code No. RA018-57721
I-S-3
(1) Machine serial number
(1) Serial No.

(2) 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 fol-
lows.
e.g. D902-8L001
“8” indicates year of 2008 and “L” indicates June.
So, 8L indicates that the engine was manufactured
in June 2008.
(1) Engine serial No.
Year of manufacture Month of manufacture

Alphabet or Alphabet or Engine Serial Number
Year Year Month
Number Number
0001 ~ 9999 10000 ~
1 2001 F 2015 January A0001 ~ A9999 B10000 ~
2 2002 G 2016 February C0001 ~ C9999 D10000 ~
3 2003 H 2017 March E0001 ~ E9999 F10000 ~
4 2004 J 2018 April G0001 ~ G9999 H10000 ~
5 2005 K 2019 May J0001 ~ J9999 K10000 ~
6 2006 L 2020 June L0001 ~ L9999 M10000 ~
7 2007 M 2021 July N0001 ~ N9999 P10000 ~
8 2008 N 2022 August Q0001 ~ Q9999 R10000 ~
9 2009 P 2023 September S0001 ~ S9999 T10000 ~
A 2010 R 2024 October U0001 ~ U9999 V10000 ~
B 2011 S 2025 November W0001 ~ W9999 X10000 ~
C 2012 T 2026 December Y0001 ~ Y9999 Z10000 ~
D 2013 V 2027
E 2014
A: Engine Model Name and Serial Number
I-S-4
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 disassembled 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. Crane work must be carried out using pre-
must be mended.) determined 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 hydraulic units 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 removing bolts.
any problems before starting work.
2. Hammer heads (metal parts) must be firmly (4) Cranes
secured to their handles. 1. Basically, 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 personnel.
(3) Set 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. 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
thinner, oily articles, etc.) in appropriate to place wood pieces underneath.
containers at selected locations to prevent 2. When charging batteries, make sure there
fire hazards. are no open flames in the immediate vicin-
ity.
b. Safety Measures During Work 3. All electric tools must be grounded.
(1) Protectors 4. Before welding the machine, remove the
battery.
1. Wear goggles when using chisels for chip- • When removing the battery, be sure to
ping. disconnect negative (-) cord first.
2. Use appropriate protectors during welding. • When mounting the battery, be sure to
3. Wear a helmet when working with a crane connect the positive (+) cord first.
or at elevated locations.
I-S-5
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 coating.
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.
e. Maintenance
CAUTION
When adding oil and servicing:
1. Park the machine on a large, flat place.
2. Place the bucket and dozer on the ground.
3. Stop the engine
4. Move the attachment control lever and dozer lever to make sure the remaining pressure is relieved.
5. Draw out the starter key and check around the machine for safety.
Before starting the job, carefully read the Operational Manual in " ! Servicing Precautions" on the yellow
pages.
f. Waste Disposal
WARNING
Do not carelessly throw away and burn waste materials. Such actions may lead to environmental pollu-
tion and punishment by local laws.
When disposing of waste:
* Let out waste fluid from the machine into a container.
* Do not let waste fluid flow on the ground as well as into a river, lake, marsh, and sea.
* Contact your dealer or a qualified industrial waste handler to treat (dispose of or incinerate) harmful
waste materials. Those materials include waste oil, fuel, cooling water (anti-freeze), coolant, solvent,
filters, batteries, rubber and other toxic substances.
I-S-6
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.)
1. Essential Adhesives
Screw adhesive type:
• Unless otherwise specified, use Three-Bond 1324 adhesive (medium-duty type).
Keep the screw threads free of oil and water.
Instantaneous adhesive:
• Use Three-Bond 1733 or Three-Bond 1741E adhesive.
Keep the bond areas free of oil and water.
2. 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)
3. 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)
I-S-7
I-S-8
D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING

1. Operate the Machine and Check for Unusual Noise and Vibrations.
2. Make Sure the Safety Decals and Wireharness Clamps Are in Their Specified Positions.
3. With the Machine Front in a Specified Posture, Check the Amount of Hydraulic 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 hydraulic 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) Extend the track cylinder to Max. position.
4) 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.
Oil gauge (level)

Some space needed
Red circle
Specified Leftward
machine posture swinging
a. Piping
(1) General precautions
• Tighten 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.
* Excessively 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.
I-S-9
(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 torque.
• 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-10
(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-11
(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
10 Ø50 ~ 60 RC401-63190 50 ~ 60
11 Ø32 ~ 44 RD411-63820 3.61 ~ 4.35
12 Ø32 ~ 51 68311-72830
(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-12
(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-13
(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 the mating seal beforehand.
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)
(11) Adhesives
1. Thread adhesive
Loctite 271 or equivalent (heavy-duty)
ThreeBond 1305P or equivalent (heavy-duty)
Types of thread adhesive
ThreeBond TB1401B or equivalent (light-duty)
ThreeBond 1324 (medium-duty) unless otherwise specified
* No oil and water allowed on the threads.
Type of instant adhesive ThreeBond 1733 or 1741E
* No oil and water allowed on the threads.
2. Radiator hose sealant

Sealant ThreeBond #1208E or equivalent
I-S-14
E. MAINTENANCE INTERVALS
a. EU-version
[Operator servicing]
General maintenance Elapsed hours of operation

50 100 150 200 250 300 350 400 450 500 Interval
Checking the engine oil level daily
Check hydraulic oil level daily
Check fuel level daily
Check coolant level daily
Lubricate front-end
daily
attachments
Checking the radiator and oil
daily
cooler
Check electric cables and
daily
connections
Check water separator daily
Check V-belt daily
Drain water from the fuel
reservoir
500 h
Lubricate the swivel gear 50 h
Battery service 50 h
Tracks and chassis: clean,
weekly
visually inspect and check (50 h)
tension
Check nuts and bolts 100 h
Check, clean air filter 1.) 200 h
Grease the swivel bearing 200 h
1.) Under dusty conditions the air filter must be cleaned more frequently or replaced.
I-S-15 1
[Operator servicing]
General maintenance Elapsed hours of operation

550 600 650 700 750 800 850 900 950 1000 Interval
Checking the engine oil level daily
Check hydraulic oil level daily
Check fuel level daily
Check coolant level daily
Lubricate front-end
daily
attachments
Checking the radiator and oil
daily
cooler
daily
connections
Check water separator daily
Check V-belt daily
Drain water from the fuel
reservoir
500 h
Lubricate the swivel gear 50 h
Battery service 50 h
Tracks and chassis: clean,
weekly
visually inspect and check (50 h)
tension
Check nuts and bolts 100 h
Check, clean air filter 1.) 200 h
Grease the swivel bearing 200 h
I-S-16 1
[Servicing by skilled personnel or KUBOTA dealer]
Servicing Elapsed hours of operation *

50 100 150 200 250 300 350 400 450 500 Interval
Check/adjust V-belt tension 250 h

Check coolant hoses and
clamps
250 h
Grease pilot valve linkage 250 h

Change engine oil and oil
filter
500 h
Replace the fuel filter 4.) 500 h
Change return filter for the 500 h

hydraulic oil tank 3.) Please contact your KUBOTA dealer.
Replace the drive unit oil 500 h
Change hydraulic oil and
Please contact your KUBOTA dealer. 1000 h
suction filter 2.)
Replace the in-line filter Please contact your KUBOTA dealer. 1000 h
Replace the air filter elements
1000 h
1.)
Change running gear and
track roller oil
Check alternator and starter
motor
Please contact your KUBOTA dealer. Annually
connections
Safety inspection Annually
Replace the coolant and rinse every 2
the cooling system years
Replace coolant hoses and 250 h
clamps Please contact your KUBOTA dealer.
every 6
Change hydraulic hoses Please contact your KUBOTA dealer.
years
* The servicing identified with z must be carried out after the specified hours of operation after initial
operation have been reached.
2.) When using a hydraulic hammer over 20% → every 800 h.
When using a hydraulic hammer over 40% → every 400 h.
3.) When using a hydraulic hammer up to 50% → every 200 h.
Replace the return filter approximately 250 hours after the initial operation.
4.) Earlier if necessary.
I-S-16-1 1
[Servicing by skilled personnel or KUBOTA dealer]
Servicing Elapsed hours of operation

550 600 650 700 750 800 850 900 950 1000 Interval
Check/adjust V-belt tension 250 h

Check coolant hoses and
clamps
250 h
Grease pilot valve linkage 250 h

Change engine oil and oil
filter
500 h
Replace the fuel filter 4.) 500 h
Change return filter for the 500 h

hydraulic oil tank 3.) Please contact your KUBOTA dealer.
Replace the drive unit oil 500 h
Change hydraulic oil and
suction filter 2.)
Replace the in-line filter Please contact your KUBOTA dealer. 1000 h
Replace the air filter elements
1000 h
1.)
Change running gear and
track roller oil
Check alternator and starter
motor
Please contact your KUBOTA dealer. Annually
connections
Safety inspection Annually
Replace the coolant and rinse every 2
the cooling system years
Replace coolant hoses and 250 h
clamps Please contact your KUBOTA dealer.
every 6
Change hydraulic hoses Please contact your KUBOTA dealer.
years
2.) When using a hydraulic hammer over 20% → every 800 h.
3.) When using a hydraulic hammer up to 50% → every 200 h.
4.) Earlier if necessary.
I-S-16-2 1
b. PP (KTC, KCL)-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 500 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 500 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-17

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 500 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 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
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-18
c. KTA-version
Hour meter indicator Ref.
No. Checkpoints Intervals Consequently
50 100 150 200 250 300 350 400 450 500 550 600 1000 2000 page
1 Fuel check Daily check 49
check Daily check 50
2 Engine oil
change every 250 hrs 56
3 Hydraulic oil**
4 Coolant
change every 2 years 64
5 Lubrication points check Daily check 52
6 Radiator check Daily check 53
7 Battery condition check every 50 hrs 50,51
8 Electrical lines check Daily check, Annual servicing 64
Greasing of swing
9 every 50 hrs 54
bearing teeth
10 Drive unit oil change every 500 hrs 59
11 Fan belt tension adjust every 200 hrs 57
Radiator hoses check every 200 hrs 58
12
and clamps change every 2 years 64
clean every 200 hrs 55
13 Air filter element* @
Greasing of swing
14 every 200 hrs 56
ball bearings
Fuel pipes and check every 200 hrs
15
hoses change every 2 years 58
16 Engine oil filter change every 250 hrs 58
check every 50 hrs
17 Fuel filter
change every 500 hrs 59 @
Hydraulic return
18 change every 1000 hrs 60
filter element
Hydraulic suction
filter element
Front idler and
track roller oil
Dynamo and
21 starter motor check every 2000 hrs 63
22 Radiator system rinse every 2 years 64

Fuel injection nozzle
23 (Injection pressure) check every 1500 hrs 57 @
24 Injection pump check every 3000 hrs 57 @
IMPORTANT:
• * Clean the air filter more frequently if used in dusty conditions. With heavy soiling, replace the filter.
** 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 "REGULAR CHECKS AND MAINTENANCE WORK".
• The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the
U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of
the required maintenance on the engine according to the above instruction. Please see the Warranty
Statement in detail.
I-S-19
d. 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%
3. Kubota’s recommended breakers for U17-3α and

U17/U17-3.
(Japanese breakers)
Furukawa HB2G
Tokuu TNB-1E
Maruzen MHB-71
Nippon Pneumatic H-08X
I-S-20
e. Maintenance Items
(1) Drive unit Oil Change (First Oil Change of the 100 hours)
CAUTION
To avoid personal injury:
• Lower attachments on the ground, stop the engine and remove the key before undertaking the oil
change.
1) Rotate the crawler so that the drain plug of the

drive unit is in the bottom position.
2) Remove the drain plug to let the oil run out. Screw
in and tighten the drain plug again and fill with
gear oil through the oil check port.
3) Fill oil until it overflows out of the oil check port.

Gear oil volumes Approx. 0.25 L (0.07 USgal.)
Oil change
• first oil change after 100 hrs
• then every 500 hrs
• or at least once a year
(1) Oil check port (also serves as oil filling port)
4) Use prescribed gear oil SAE 90. (2) Drain plug
(2) Inspection and Cleaning of the Air Filter Element

Open the engine bonnet and remove the dust-cover. Take out only outer element, clean the element, case
interior and reassemble. During reassembly, take care to install the dust-cover so that its TOP mark (arrow)
faces up-wards. Do not remove the inner element.
IMPORTANT:
• Should the machine be used in extremely dusty areas, the air filter element must be inspected and
cleaned more frequently than in the specified maintenance periods.
• The air filter has a dry element, keep free from oil.
• Do not run the engine without the air filter.
(1) Outer element

(2) Inner element
(3) Dust-cover
(4) Clamps
I-S-21
CAUTION
To avoid personal injury:
• Wear eye protection.
Cleaning with compressed air

Pressure of compressed air must be under 205 kPa
(2.1 kgf/cm2, 30 psi) and the cartridge should be
blown clean from the inside to the outside until the
dust deposits are remarkably reduced.
IMPORTANT:
• If the air suction is still inadequate, or the color of
the exhaust gases is abnormal even after the
cleaning, the air filter element must be replaced.
(3) Cleaning the Track Frame Slide Pipes

When the slide pipes of the track frame are clogged or adhered with soil or sand, clean the slide pipes in the
following manner according to need.
WARNING
To avoid the personal injury or death:
• Place the machine on even ground when cleaning the track frame slide pipes.
1. First lift the machine off the ground using the

dozer blade and boom functions.
2. Switch the track width change / dozer select lever
to the “Track width change” position.
3. Push the control lever forward, and expand the
track width to 1240 mm (48.8 in.).
4. Remove soil and sand adhered to the slide pipes,
then put grease evenly around the pipes. Make
sure all 4 slide pipes are greased.
5. Retract and expand the track width repeatedly for
a few times by moving the control lever, so that
the grease is spread adequately.
6. Switch the track width change / dozer select lever
to the “Dozer” position.
7. Place the machine down on the ground carefully (1) Track frame slide pipes
by moving the dozer blade and the boom.
I-S-22
f. Troubleshooting for Operators

If the excavator does not show the desired performance, or when trouble arises, refer to the table below and
undertake appropriate measures.
Trouble Cause Countermeasure
* Check fuel tank and filter
Fuel is too viscous * Remove impurities and water
* If necessary, replace filter
* Remove water from the fuel tank
* Check fuel pipe joint bolts and nuts for looseness
Air or water in the fuel system * Purging of the fuel system (for fuel filter and injection pump,
Starting difficulties see "PURGING OF THE FUEL SYSTEM" in "OTHER
ADJUSTMENTS AND REPLACEMENTS".)
* Pour hot water over the radiator
Oil viscosity is too high that the
* Use oils of different viscosities depending on the ambient
engine runs sluggishly in winter
temperature. (Use SAE10W, SAE10W-30 or SAE10W-40)
Battery is almost dead; insufficient
* Recharge battery
compression
Insufficient engine Low fuel level * Check fuel and add if necessary
power Clogged air cleaner * Clean the air filter element
Engine suddenly * Check fuel and add if necessary
Low fuel level
stops * Purge the fuel system
Poor fuel * Use high quality fuel
Engine
Abnormal exhaust
gas color Too much engine oil * Drain engine oil to prescribed oil level
Defective seal of the water pump * Replace
Worn or torn fan belt * Adjust or replace
Thermostat is defect * Replace
Coolant level too low * Fill to prescribed level
Radiator grill or fins are clogged * Clean
Coolant is contaminated with rust
* Replace coolant fluid and add anti-rust
Water temperature from the cylinder head or crank case
too high (Overheat- Defective radiator cap (Evaporation) * Replace
ing) Corroded coolant pipes * Clean
Continuous operation under full load * Reduce load
Cylinder head gasket is damaged
* Replace
(Coolant loss)
Engine oil level too low * Fill to prescribed level
Maladjustment of fuel injection * Readjust ignition timing
Use of poor fuel * Use prescribed fuel
Boom, arm, bucket, Hydraulic oil level too low * Add oil
Hydraulic System
drive, swing and

dozer power is too Leakages of hoses and/or joints * Replace hose or joint
low
Non-function of
Swing lock pin is in lock position * Remove swing lock pin in unlock position
swing motor
Blocked through stones * Remove

Drive System
Deviation of drive
direction Crawler too loose or too tight * Adjust accordingly
I-S-23
g. Periodic Replacement of Important Component Parts

To ensure safety in operation, you are strongly requested to inspect and service the machine at regular inter-
vals. For added safety, ask your KUBOTA dealer to replace the following important component parts.
These parts are prone to degradation in material or subject to wear and tear with time. It is difficult to judge
how much they have been affected at regular inspection. It is therefore necessary to replace them with new
ones, whether wear is visible or not after a specified time of use.
If any of them is found worn even before the specified use, it must be repaired or replaced the same way as
other parts.
If any of the hose clamps is found deformed or cracked, the hose clamp must also be replaced.
For the hydraulic hoses other than the ones to be replaced periodically, inspect them for the following points.
If found unusual, tighten them up, replace them.
When replacing the hydraulic hoses, change their O rings and sealings with new ones.
For replacement of the important parts, contact your KUBOTA dealer.
• At the following periodic inspections, check the fuel hoses and hydraulic hoses as well.
Inspection Interval Check points
Daily Checks Oil leak at fuel and hydraulic hose connections and points
Every month Oil leak at fuel and hydraulic hose connections and points Damages at fuel and hydraulic hose
(cracks, chafing)
Every year Oil leak at fuel and hydraulic hose connections and points Interference, deformation, degrada-
tion, twist and other damages (cracks, chafing) of fuel and hydraulic hoses
List of important component parts

No. Component parts Q'ty Period
1 Fuel hose (Fuel tank-Fuel filter) 2
2 Fuel hose (Fuel filter-Fuel pump) 2
3 Fuel hose (Fuel pump-Fuel nozzle) 2
4 Fuel hose (Fuel nozzle-Fuel tank) 1
5 Fuel hose (Fuel tank-Fuel drain) 1
6 Hydraulic hose (Main pump suction) 1
7 Hydraulic hose (Main pump delivery) 4 Every 2 years or 4000 hours
8 Hydraulic hose (Boom cylinder) 2
9 Hydraulic hose (Arm cylinder) 2
10 Hydraulic hose (Bucket cylinder) 2
11 Hydraulic hose (Swing cylinder) 2
12 Hydraulic hose (Dozer cylinder) 2
13 Hydraulic hose (Service port) 4
To prevent serious damage to the hydraulic system, use only KUBOTA genuine hydraulic
hose.
I-S-24
h. Recommended Oils
IMPORTANT
1. ISO 46 viscosity grade is being used at the assembly line before delivery.
2. Use engine oil API service classification CD, CE or CF.
3. Use SAE 90 (API, CLA/GL5) as drive unit oil for all seasons.
Application Viscosity Shell Mobil Exxon MIL-Standard
SAE Shell Rotella T10W XD-3 10W

In winter or by Mobil Delvac 1310
10W Shell Rimula 10W XD-3 Extra 10W
low tempera-
tures SAE Shell Rotella T20W-2 XD-3 20W-20
Mobil Delvac 1320
20W Shell Rimula 20W-20 XD-3 Extra 20W-20
SAE Shell Rotella T30 XD-3 30

Mobil Delvac 1330
Engine oil
30 Shell Rimula 30 XD-3 Extra 30 MIL-L-2104C

In summer or by MIL-L-2104D
SAE Shell Rotella T40 XD-3 40
high ambient Mobil Delvac 1340
40 Shell Rimula 40 XD-3 Extra 40
temperatures
SAE
Shell Rimula 50 Mobil Delvac 1350
50
All-Season Multi-pur- XD-3 15W-40

Shell Rotella T15W
engine oil pose XD-3 Extra 15W-40
SAE Mobilube HD80W-90

In winter or by 75 Shell Oil S8643
low tempera- MIL-L-2105C
tures SAE Mobilube HD80W-90
80 Shell Spirax HD80W
Gear oil
SAE Mobilube 46 MIL-L-2105

In summer or by 90 Shell Spirax HD90 Mobilube HD80W-90 MIL-L-2105C
high ambient
temperatures SAE Mobilube HD85W-140 MIL-L-2105C
140 Shell Spirax HD140 Mobilube HD80W-140 MIL-L-2105C
All-weather Multi-pur- Shell Spirax HD80W

Mobilube HD80W-90 GX80W-90 MIL-L-2105C
gear oil pose Shell Spirax HD85W
ISO
In winter or by Shell Tellus T32 Mobil DTE-Oil 13 NUTO H32
32
low tempera-
Hydraulic oil
tures ISO
Shell Tellus T46 Mobil DTE-Oil 15 NUTO H46
46
In summer or by
ISO
high ambient Shell Tellus T68 Mobil DTE-Oil 16 NUTO H68
68
temperatures
Grease Shell Alvania EP2 Mobilux EP2 BEACON Q2
Fuel Light oil No. 2-D (ASTM D975)
Fuel under -5°C Light oil No. 1-D (ASTM D975)
I-S-25
i. Lifting Capacity
• 7KHOLIWLQJFDSDFLW\RIWKHH[FDYDWRULVEDVHGRQ,62DQGGRHVQRWH[FHHGRIWKHVWDWLFWLOWORDG
RURIWKHK\GUDXOLFOLIWLQJFDSDFLW\RIWKHPDFKLQH
• 7KH OLIWLQJ FDSDFLW\ LV PHDVXUHG DW WKH IURQW SLQ SDUW RI WKH DUP ZLWK WKH DUP IXOO\ H[WHQGHG 7KH ERRP
F\OLQGHULVWKHRSHUDWLQJF\OLQGHU
The excavator as delivered may only transport materials in the bucket. The lifting of loads with
the bucket or any other means of attachment is not allowed. The excavator can be retrofitted for
lifting loads.
• 7KHOLIWLQJFRQGLWLRQVDUH
1. Over front end, dozer down, standard arm

2. Over front end, dozer up, standard arm
3. Over side, standard arm
Do not lift loads which exceed the values indicated in the lifting capacity tables.
The values given in the tables apply only to level and hard grounds. When working on soft
ground, the machine can tip over easily, as the load is concentrated on one side only and the
track or the dozer can dig into the ground.
The values given in the tables apply only for loads without bucket. If a bucket is used, the weight
of the bucket must be subtracted from the values in the tables. The weight of mounted
accessories (e.g. hydraulic hammer) must be subtracted from the lifting capacity.
When lifting loads using the excavator with a lifting capacity (acc. to ISO 10567:1992) of
more than 1000 kg or a tilting moment 40,000 Nm, the excavator should be equipped
with additional devices as described in EN 474-5 / section 4.1.7.5.
I-S-26
(1) U17-3α
Lifting capacity over front end, dozer down
MODEL U17-3α SPECIFICATION CANOPY VERSION WITH RUBBER CRAWLER
KBM Standard arm
kN (t)
Load radius (mm)
Height
[mm] Mini- Maxi-
1500 2000 2500
mum mum
4500
4000
3500
3000
3.7
2500
(0.37)
3.1 3.6
2000
(0.32) (0.36)
5.2 4.5 4.0 3.6
1500
(0.53) (0.46) (0.41) (0.37)
6.2 4.6 3.8
1000
(0.63) (0.47) (0.38)
6.9 4.9 3.8
500
(0.70) (0.50) (0.39)
6.6 4.8 3.6
GL 0
(0.67) (0.49) (0.37)
7.3 8.1 5.8 4.3 3.2
-500
(0.75) (0.83) (0.60) (0.44) (0.33)
11.0 7.0 4.9 3.6
-1000
(1.12) (0.71) (0.50) (0.37)
5.3 3.7
-1500
(0.54) (0.37)
-2000
-2500
Lifting capacity over front end, dozer up

KBM Standard arm
kN (t)
Load radius (mm)
Height
[mm] Mini- Maxi-
1500 2000 2500
mum mum
4500
4000
3500
3000
2.9
2500
(0.30)
3.1 2.9
2000
(0.32) (0.30)
5.2 4.0 2.8 2.1
1500
(0.53) (0.41) (0.29) (0.22)
3.8 2.7 2.1
1000
(0.39) (0.28) (0.21)
3.6 2.6 2.0
500
(0.37) (0.27) (0.20)
3.5 2.6 2.0
GL 0
(0.36) (0.27) (0.20)
7.3 5.5 3.5 2.5 2.0
-500
(0.75) (0.56) (0.36) (0.26) (0.20)
11.0 5.6 3.5 2.5
-1000
(1.12) (0.57) (0.36) (0.26)
5.3 3.6
-1500
(0.54) (0.37)
-2000
-2500
I-S-27
Lifting capacity over side (track width 1240 mm)

KBM Standard arm
kN (t)
Load radius (mm)
Height
[mm] Mini- Maxi-
1500 2000 2500
mum mum
4500
4000
3500
3000
2.7
2500
(0.28)
3.1 2.7
2000
(0.32) (0.28)
5.2 3.7 2.7 2.0
1500
(0.53) (0.38) (0.28) (0.20)
3.5 2.6 2.0
1000
(0.36) (0.26) (0.20)
3.3 2.5 1.9
500
(0.34) (0.24) (0.17)
3.3 2.4 1.9
GL 0
(0.33) (0.24) (0.19)
7.3 5.0 3.2 2.4 1.8
-500
(0.75) (0.51) (0.33) (0.24) (0.19)
10.9 5.1 3.2 2.4
-1000
(1.11) (0.52) (0.33) (0.24)
5.2 3.3
-1500
(0.53) (0.34)
-2000
-2500
I-S-28
(2) U17-3, U17

ROPS CANOPY
RUBBER TRACK
LIFTING CAPACITY OVER-FRONT BLADE DOWN

Unit=1kN
LIFTING POINT LIFT POINT RADIUS (m)
HEIGHT (m) MIN 1.5 2.0 2.5 MAX
2.5 3.7
2.0 3.1 3.6
1.5 5.2 4.5 4.0 3.6
1.0 6.2 4.6 3.8
GL 0.5 6.9 4.9 3.8
0 6.6 4.8 3.6
-0.5 7.3 8.1 5.8 4.3 3.2
-1.0 11.0 7.0 4.9 3.6
-1.5 5.3 3.7
LIFTING CAPACITY OVER-FRONT BLADE UP

Unit=1kN
2.5 2.9
2.0 3.1 2.9
1.5 5.2 4.0 2.8 2.1
1.0 3.8 2.7 2.1
GL 0.5 3.6 2.6 2.0
0 3.5 2.6 2.0
-0.5 7.3 5.5 3.5 2.5 2.0
-1.0 11.0 5.6 3.5 2.5
-1.5 5.3 3.6
LIFTING CAPACITY OVER-SIDE TRACK WIDTH 1240mm

Unit=1kN
2.5 1.8
2.0 2.6 1.8
1.5 3.9 2.5 1.8 1.3
1.0 2.3 1.7 1.3
GL 0.5 2.1 1.6 1.2
0 2.1 1.5 1.2
-0.5 6.1 3.1 2.0 1.5 1.2
-1.0 6.1 3.1 2.1 1.5
-1.5 3.2 2.1
3 WARNING
To avoid personal injury or death:
Operate always in standard track width 1240mm(49.0 in), except to pass through
narrow space.
Do not operate in narrow track width 990mm(39.0 in), it makes risk of the excavator
tipping over.
LIFTING CAPACITY OVER-SIDE TRACK WIDTH 39.0 in LIFTING CAPACITY OVER-SIDE TRACK WIDTH 990mm
ONLY REFERENCE ONLY REFERENCE
Unit=1000 lbs. Unit=1kN
LIFT POINT LIFT POINT RADIUS (ft) LIFTING POINT LIFT POINT RADIUS (m)
HEIGHT (ft) MIN 6 8 MAX HEIGHT (m) MIN 1.5 2.0 2.5 MAX
8 0.43 2.5 1.8
6 0.67 0.43 2.0 2.6 1.8
4 0.62 0.40 0.28 1.5 3.9 2.5 1.8 1.3
GL 2 0.55 0.38 0.27 1.0 2.3 1.7 1.3
0 0.52 0.36 0.26 GL 0.5 2.1 1.6 1.2
-2 0.97 0.52 0.35 0 2.1 1.5 1.2
-4 0.98 0.53 0.36 -0.5 6.1 3.1 2.0 1.5 1.2
-1.0 6.1 3.1 2.1 1.5
-1.5 3.2 2.1
I-S-29
I-S-30
F. PRODUCT INFORMATION
a. U17-3α Development Concept

• The engine, D902 of KX41-3 for North America is substituted for D782 to face competitive machines with
larger engines.
• Traveling & turning performance are advanced and durability is also upgraded with a travel motor hose
inner-packed. Kubota original digital meter and anti-theft system are introduced as well.
• Additionally, outer flange track roller, short-pitched rubber track, digital meter, anti-theft system and work
light are upgraded.
• The model U15-3 is re-named U17-3α to compete with machines labeled 1.7~1.8t.
b. Why Minor Change?

Be more competitive through advanced “Performance“ & “Quality“!
1) New Engine
Higher output engine
D782 → D902
2) Enhancement of undercarriage
• Advanced traction force
• Increased travel motor torque
• Outer-flange track roller
• Short-pitched rubber track
• Travel motor hose protection
New model name - ”U17-3α” (EU-version)
I-S-31
c. Quick Chart
: additional sales feature
: enhancement of undercarriage
: other design change
* Power socket (12V)
1) Engine
D782-BH D902-BH
9) Steel track (OPT)

Track link height 2) Pump capacity
10mm(0.39”) lowered 7.2 7.5cc
(same as KX41-3)
4) Dozer arm 45mm
(1.79”) extended
3) Kubota original digital
meter
* Undercarriage 20mm
(0.79”) forward designed
5) Track roller Outer

flange type
6) Short-pitched rubber 7) Travel motor hose 8) Travel motor torque

track protected increased
I-S-32
d. Major Sales Feature

1) Engine
U15-3 U17-3α Difference
mode D782-EBH D902-E3BH -
output (sales catalog) kW(PS) 9.6(13) 11.8(16) 2.2(+3)
speed rpm 2300 2300 equivalent
number of cylinder/
/L 3 / 0.778 3 / 0.898 - / +0.12
displacement
2) Pump capacity
7.2 ⇒ 7.5cc (Same pump as KX41-3 )
3) Kubota Original Digital Meter

Newly equipped digital meter same as other KX-3/U-3 series, over 1.5t class. For EU market, an easier
key setting of Anti-theft system is introduced.
4) Dozer arm
45mm extended for easier cleaning with the dozer edge.
5) Outer-flange type track roller
6) Short-pitched rubber track

(less travel vibration)
7) Travel motor’s torque increased
U15-3 U17-3α Difference

Travel speed Low/high km/h 2.2 / 4.1 2.2 / 4.1 equivalent
Low/high
kN 10.7/5.3 14.7/7.7 +4.0 / +2.4
(measured)
Traction force
Low/high
kN 12.9 / 6.5 14.2/7.1 +1.3 / +0.6
(theoretical)
I-S-33
8) Protected travel motor hose

Travel motor hoses are covered for better look and durability.
9) Steel track (OPT)

Track link height is lowered by 10mm to prevent from being
stuck with soil.
e. Specifications Comparison
(Rubber track) Kubota Kubota Komatsu Yanmar
Item U15-3 U17-3α PC18MR-2 Universal Vio17

Weight rubber/steel kg 1600/1670 1650/1710 1640/1710 1620/1680
Model D782-EBH D902-BH-1 3D67E-1 3TNV70
Engine
Output kW (PS) 9.6 (13) 11.8 (16) 11.2 (15.2) 10.1 (13.7)
(Sales catalog value)
RPM rpm 2300 2300 2600 2200
Overall width mm 990-1240 990-1240 980-1300 950-1280
Bucket kN (kgf) 15.2 (1550) 15.2 (1550) 15.9 (1620) 15.2 (1550)
Max. digging force
Arm kN (kgf) 8.5 (865) 8.5 (865) 9.9 (1000) 8.5 (870)
Max. digging height mm 3540 3540 3615 3690
Max. dumping height mm 2440 2440 2610 2630
Max. digging depth mm 2310 2310 2160 2200
Max. vertical digging depth mm 1910 1910 1785 1850
Max. digging reach @ground level mm 3840 3840 3935 3710
Low/high (measured) kN 10.7/5.3 14.7/7.7 8.8/8.2
Traction force
Low/high (theoretical) kN 12.9/6.5 14.2/7.1
Digital panel No Yes No No
Anti-theft system (EU) No Yes No No
Track roller Inner Outer Inner Outer
Short pitched rubber track Long Yes Long Yes
Protected travel hoses No Yes No No
I-S-34
WSM U17-3α/U17-3/U17 Mechanism II. MACHINE BODY
II. MACHINE BODY
Mechanism Section
A. MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-3

a. Major Dimensions and Working Range (with Rubber Crawler) . . . . . . . . . . . . . . . II-M-3
b. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-5
c. Main Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-7
d. U17-3α vs U17/U17-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-8
B. MACHINE BODY STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-9
a. Overall Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-9
b. Under Carriage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-M-15
II-M-1
II-M-2
A. MACHINE SPECIFICATIONS
a. Major Dimensions and Working Range (with Rubber Crawler)
α
1. Specifications for the U17-3α: EU-version
KUBOTA Excavator
Model name U17-3α
Canopy
Type (rubber crawler)
Operating
(without driver) kg 1650
weight
Volume m³ 0,04
Bucket
Width mm 400
Type 3 cylinder diesel engine, water-cooled
Model name KUBOTA D902-BH-1
Displacement cm³ 898
Engine
Engine performance
kW 11,6
DIN 70020
Rated speed 1/min 2300
Swivel speed (swivel
1/min 9,1
frame)
fast
4,1
km/h
Vehicle speed
slow
2,1
Performance km/h
Ground pressure kPa
26 (0,26)
(without driver) (kgf/cm²)
Climbing performance % (degree) 58 (30)
Max. lateral sway % (degree) 27 (15)
Dozer (width x height) mm 990 x 260; 1240 x 260

Swing angle Left rad (degree) 1,13 (65)
of the boom Right rad (degree) 1,01 (58)
Max. volume
L/min 27
Service port (theoretical)
connector MPa 18,6
Max. pressure
(kgf/cm²) 190
Volume of the fuel reservoir L 19
Pulling capacity of the tow lug N 32300
Tongue load at the tow lug N 2700
LpA dB (A) 79
Noise level
LwA (2000/14/EC) dB (A) 92
Vibration at the drive lever m/s² < 3,0
Vibration at the control lever m/s² < 4,5
Vibration at the driver's seat m/s² < 0,5
Vibration at the bottom plate m/s² < 0,9
II-M-3
2. Specifications for the U17/U17-3: PP-version

KUBOTA EXCAVATOR
Model name U17/U17-3
Type Canopy
Operating weight lbs.(kg) 3704 (1680)
(including operator's)
Type Water cooled 4 cycle diesel engine with 3 cylinder
Model name KUBOTA D902
Total displacement 898 (54.8)
Engine cc (cu.in)
Engine power kW(Hp) 12.7 (17.0)
SAE gross
Rated speed rpm 2300
Unit swing speed rpm 9.1
Travel Fast mph (km/h) 1.4 (2.1)

speed Slow 2.6 (4.1)
mph (km/h)
Performance
Ground psi 3.7
pressure (kPa) 26
(With operator) [kgf/cm2] [0.26]
Climbing angle %(deg) 58 (30)
Dozer Width X Height in.(mm) 39.0/48.8 X 10.2 (990/1240 X 260)
Left deg (rad) 65 (1.13)
Boom swing angle
Right deg (rad) 58 (1.01)
Max. displacement
Pressure (Theoretical) 7.13 (27)
connection US gal (L)/min
for psi 2702
attachments Max. pressure
(MPa) (18.6)
[kgf/cm2] [190]
Fuel tank capacity US gal (L) 5.0 (19)
NOTE:
Above dimensions are based on the machine with rubber trucks and JPN bucket.
JPN = made in Japan
Speciﬁcations subject to change without notice.
∗ With unloaded digging bucket.
∗ Firm compacted soil.
∗ Operators must exercise extra caution and follow instructions in the operator's manual.
∗ Worse condition or heavier attachment to the above will decrease climbing angle.
II-M-4
b. Dimensions
α
1. U17-3α: EU-version
All dimensions in mm
A B C D E F G H I J K L M N O P Q R S T
990/ 990/
510 385 620 990 3540 2440 2310 1910 1440 2340 2630 280 190 2750 795 3545 3840 3900
1240 1240
II-M-5
2. U17/U17-3: PP-version
in. (mm)
A B C D E F G H I J K L M N O P Q R S
39/ 39/
20.08 15.2 48.8 24.4 39.0 48.8 139.0 96.1 90.9 75.2 56.7 92.1 11.0 7.5 108.3 31.3 139.6 151.2 153.5
(510) (385) 990/ (620) (990) 990/ (3540) (2440) (2310) (1910) (1440) (2340) (280) (190) (2750) (795) (3545) (3840) (3900)
( )
1240 ( )
1240
II-M-6
c. Main Specifications
model U17-3α U17/U17-3 Remarks
Brand KUBOTA KUBOTA
Type D902-BH-1 D902-E3-BH-2
Engine PS/rpm 16.7/2300 16.3/2300
Output
kW/rpm 12.3/2300 12.0/2300
Displacement 3
cm (in )3 898 (54.8) ←
Machine weight kg (lbs) 1650 (3638) ←
Standard bucket
capacity
heaped m3 (ft3) 0.04 (1.34) CECE
Maximum digging force, arm KN (kgf) lbf 8.8 (900) 1984.1 Teeth bottom
Maximum digging force, bucket KN (kgf) lbf 15.2 (1550) 3417.2 Teeth bottom
Cycle time sec/cycle
Digging performance m3/h (ft3/h)
Dozer capacity m3 (ft3) without extention blade
Hydraulic pump Relief pressure MPa (kg/cm2) psi 21.6 (220) 3129 ←
P1, P2 Pump discharge rate L/min (USGPM) 16.6 (4.39) ←
Relief pressure MPa (kg/cm2) psi 18.6 (190) 2702 ←
P3 Pump discharge rate L/min (USGPM) 10.4 (2.75) ←
Digging performance, cycle time conditions:

Dig 1 m depth with Standard bucket and dump soil on the ground after 45° swivel.
II-M-7
d. U17-3α vs U17/U17-3
1. Comparison between EU and PP-version
Items U17-3α (EU-version) U17/U17-3 (PP-version)
1. Variable track { {
2. Rops / Fops canopy { {
3. Cab X X
4. Boom cylinder in upper location { {
5. Anti-theft system { {
6. TPSS (Two pattern selection system) X {
7. Travel high speed switch on the dozer lever { {
8. Service port flow confluence, P2 + P3 { {
9. Wrist type pilot control lever { {
10. LCD meter { {
11. High lift half suspension seat and seat belt { {
12. Front hydraulic hoses shoe-in type { {
13. Travel alarm X { (Option), KTA (STD)
14. Accel lever Pull-type Push-type
15. Engine type D902-BH-1 D902-E3-BH-2
16. Fan petal 7 7
17. Accumulator { {
18. Service port, third line { {
19. Travel safety system (Main spool unload method) { {
II-M-8
B. MACHINE BODY STRUCTURE AND FUNCTION

a. Overall Arrangement
(7)
(1)
(8)
(16)
(9)
(2)
(10)
(11)
(12)
(3)
(4)
(13)
(5) (14)
(6)
(15)
Vertical Operation
(1) Service port pedal (9) Fuel tank

(2) Control valve (10) Swivel motor
(3) Oil cooler (11) Swivel joint
(4) Battery (12) Oil tank
(5) Radiator (13) Unloading valve
(6) Suction pipe (14) Pump
(7) Swing pedal (15) Engine
(8) Selector valve (16) Travel hi-low pedal (Japan)
Note: For the export model, the travel Hi-Low control switch is located on the dozer lever grip.
II-M-9
1. Arrangement of control levers
(1) Left control console

(2) Drive levers and control pedals
(3) Right control console
(4) Driver's seat
(11) Track width change/dozer select lever
II-M-10
(1) Right control lever (1) Warning light

(2) Horn switch (2) Display screen
(3) Arm rest (3) Display selector switch
(4) Travel speed button (4) Working light button
(5) Dozer control lever
(6) Throttle lever
(7) Starter switch
(8) Travel speed indicator
(9) Rotary beacon button
(10) Display
(6) Working light switch
Adoption of Meters
Hour meter, oil level gauge and Easy checker
(oil lamp, charge lamp, glow lamp and fuel level
alarm lamp) for various indications.
II-M-11
Direction of accel lever: EU-version PP-version

(Machine front)
(1) Throttle lever (1) Throttle lever (A) “FAST“

(B) “SLOW“
(1) (2)
(4)
(5)
(3)
(1) Hood Left (4) Oil cooler

(2) Hood Rear (5) Radiator
(3) Wing nut
The oil cooler and the radiator can be checked and cleaned by opening the left hood.
Engine oil can be refilled by opening the inspection

door after lifting up the seat.
(1)
(1) Oil filler port
II-M-12
(1) (2)
(3)
(1)
(3)
(4) (4)
(2)
(5) (6)
(1) Water separator

(2) Fuel filter
(3) Air cleaner
(4) Reserve tank
• Adoption of fuel level gauge makes it possible to check the remaining oil amount.
• A gauge is mounted at the side of the fuel filler port. When fuel is nearly filled up, the pointer of the gauge
starts moving and about 2 liters of fuel oil is filled up.
• A hydraulic oil filler port is provided also at the side of the fuel filler port.
(2)
(3)
(4)
(5)
(1) (6)
(7)
(1) Fuel filter cartridge

(2) Water separator
(3) Water separator handle
(4) Indication line
(5) Float (Red)
(6) Cup
(7) Retainer ring
Like in the models of KX91-3Sα and KX121-3Sα Series, the fuel filter has been separated from the water
separator.
II-M-13
2. Swing bracket
(7)
(11)
(12)
(8)
(9)
(10)
(1) Swing bracket

(2) ~ (6) Bushing
(7) After installing the bush, pin of φ34.9 (φ1.374) 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.
(1)
(4)
(1) Bushing end to be fitted to boss end

(2) Bush (506040)
(3) Bush (506040)
(4) Bushing end to be fitted to boss end
II-M-14
b. Under Carriage Components

1. Swivel bearing
( ) : in
(φ18.03)
(4) (P.C.D 17.24)
(φ15.75)
(1)
(0.197)
(2)
(1.378)
(1.18)
(0.0197)
(3) (φ12.58)
(P.C.D 12.93)
(φ13.46)
(P.C.D 14.25)
(φ15.75)
(1) Seal B
(2) S-mark
(3) Seal A
(4) Rp 1/8, for grease nipple Apply the nylon plug in position.
1) Number of teeth = 73 Details of the grease fitting Plug outer soft zone
2) Backlash = 0.05 ~ 0.35 mm
(0.002 ~ 0.014 inch)
3) P.C.D. = φ 328.5
4) Induction-harden the inner and outer ring
raceways as well as the tooth flank and
bottom.
Raceway surface hardness: 50 ~ 60 HRC
Tooth flank and bottom surface hardness:
52 ~ 60 HRC Machine front Inner soft zone S - mark
(See the Gear Specifications for gear
hardening details.)
5) Inner ring’s “S” marking and outer ring’s
stopper on the soft zone.
When installing the bearing, position the
soft zone where there is the least load.
6) Radial clearance (Measuring load) (0.03
~ 0.25)
Axial clearance (Measuring load) (0.03 ~
0.15)
II-M-15
2. Track frame (adjustment of play)

1 4 5
(1)
A B
2 3
A
B
(2)
(1) Stopper bolt 4

Apply screw adhesive to their threads.
4 locations in total
(2) Track frame, right and left, 4 locations in total
Apply grease over the hatched (///////) surfaces.
Magnified view of adjusting portion
(0.177)
or less
(0.748)
(0.354) (1.339)
(Set bolt)
No. Part Name Q'ty

(1) Set bolt (RA221-21161) 2
(2) Nut 1
Play adjusting procedure

1. Tighten the play adjusting setbolts until they reach the left and right sides of the frame.
2. Loosen the play adjusting setbolts by 1/4 turns when they have reached the frame.
3. Lock the adjusting setbolts by nuts.
II-M-16
3. Structure of track roller
(1)
(2)
(1) Make sure the plug's end face does not stretch out of the shaft. No. Part Name
(2) Make sure the shaft stretches more than 0.1 mm at both ends. 1 Track roller subassembly
2 Roller: A
3 Roller: B
4 Color: A
5 Color: B
6 Shaft
7 Ring stopper
8 Bushing
9 Seal: Group
10 O-ring
11 Hex socket plug
Notes:
1. Fill the bearing with oil (40 cm3 (2.44 in3)).
2. Use Engine genuine oil SAE30 class CD or equivalent.
3. Use care not to confuse the sides of the shaft circlip.
(Rolled-over side to be fitted in the groove is inner side, while the burred (sharp) side is the outer side)
4. The roller should be turned smoothly after it has been assembled completely.
5. Dimensions of assembling jigs for seal etc. and the assembling procedure are equivalent to those of
RA211-2170Δ.
II-M-17
4. Tension Device
1) Rubber track
2 3
No. Part No. Part Name Q'ty Remarks

1 RA231-2130Δ Idler assembly 2
2 RA231-2150Δ Cylinder assembly (left) 1 Track (left)
RA231-2160Δ Cylinder assembly (right) 1 Track (right)
3 RA231-2155Δ Grease fitting (grease cylinder) 2
In the case of rubber crawler, position it so that the joint marking ( ) comes at the top center (see below).
(4)
10 ~ 15 mm
(4) Joint 10 ~ 15 mm
(0.39 ~ 0.59 in.)
II-M-18
2) Iron track
(8)
1 2 3 4
No. Part No. Part Name Q'ty Remarks (8) Cast line provided on the side to
identify apart from the idler assem-
1 RA231-2340Δ Idler assembly 2 Specific for iron crawler bly (RB237-2130Δ).
2 RA231-2150Δ Cylinder assembly (left) 1 For track (left)
RA231-2160Δ Cylinder assembly (right) 1 For track (right)
3 RC101-2155Δ Grease fitting (grease cylinder) 2
4 RA231-2112Δ Frame, track (left) 1
RA231-2113Δ Frame, track (right) 1
In the case of iron crawler type, fit the guide plate and sliding plate in position.
5 6 7
(9)
No. Part No. Part Name Q'ty Remarks (9) Attention to the fitting posi-
tion of the sliding plate
5 RA231-2318Δ Guide 4 Specific for iron crawler, 2 pcs. each for left and right
6 01133-61030 Bolt 12
7 90545-11341 Plug 4
Adjusting the crawler tension
25 ~ 30 mm
25 ~ 30 mm
(0.98 ~ 1.18 in.)
II-M-19
5. Idler and tension spring, rubber track

Rubber track (17)
(18)
(19)
(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
(17) This angle indicates the tilt between the yoke K and spring retainer M.
(18) Spring's preset length
(19) Spring bottom not to stretch out of the line A
1) Pre-set length of spring: L=130 mm (5.12 inch)

2) Bolt(16) tightening torque: 77.5 ~ 90.2 N·m
(7.9 ~ 9.2 kgf·m)
(57.16 ~ 66.53 ft·lbf)
Apply screw lock agent. (Locktite 271).
OK NO 3) Lub oil: Engine oil SAE30 CD. 30cc (1.83 in3)
(Spring roll pin direction)
II-M-20
Iron track
(1)
(2)
(1) Spring's preset length: 137.5 mm (5.41 in.)

(2) Spring bottom not to stretch out of the line A
Idler assy mounting bolt

M12 x 1.25, L = 45
Tightening torque:
77.5 ~ 90.2 N·m
(7.9 ~ 9.2 kgf·m)
57.2 ~ 66.5 ft·lbs
Apply screw lock agent (Locktite 271)
II-M-21
6. Rubber track
Rubber crawler's peripheral length: 48P x 70L = 3360 ± 10
Spec items U17-3α, U17/U17-3

Type 230 x 35 x 96
Lug height 18.0 mm (0.906 in)
Iron core pitch 48 mm (3.780 in)
Circunference 3360 ± 10 mm (132.283 in)
Number of steel cords 48 ± 4 (1.890 in)
Steel cords lap length 260 mm (10.236 in)
Steel cords strength 3.92 KN (400 kgf) or more (882 lbf)
Thickness of crawler main part 23.0 mm (0.906 in)
Ditto joint parts 26.5 mm (1.043 in)
Core metal FCD450 (Equiv.)
Number of core metal (Links) 35
Sprocket specifications
Reference pitch 90 -00.5
Reference number of teeth 9.5
P.C.D. (Pitch circle diameter) 277.18 -02.5
Sprocket pitch 45.62
Sprocket number of teeth 19
Outer diameter 286 -02.5
Roller diameter 22
II-M-22
7. Steel track shoe

RA231-2250-1 (230-37)
(0.87)
( ) : in
(Link)
(Bushing)
(0.63) (0.87)
(1.73)
(2.91)
(2.28)
(3.03)
(1.02)
(1.65)
(0.63)
(5.91)
(Bushing)
(Link)
(9.06)
Over 25(0.98)
(when assembled) (Pin)
(0.55)
(3.54) (3.54) (3.54)

(2.20)
(3.07)
(0.91)
(0.87)
(0.22)
(0.65)
(Inside) (Common for both ends)

(Outside)
Rubber pad
(3.54) (3.54) (3.54)

(2.20)
(3.86)
(0.91)
(1.44)
(1.56)
(0.22)
(Inside) (Common for both ends)

(Outside)
Tighten hex nuts to torque of 70 ~ 100 N·m (51.6 ~ 73.8 ft·lbf) 7.14 ~ 10.2 kgf·m.
II-M-23
II-M-24
WSM U17-3α/U17-3/U17 Service II. MACHINE BODY
II. MACHINE BODY
Service Section
A. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3
a. Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3
b. Main Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3
c. Lever Stroke and Operating Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-4
d. Dimensions of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-5
e. Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-14
B. FRONT ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-25
a. Pin, Bush and Shim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-25
b. Instruction to Press in the Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-29
c. Greasing Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-34
C. UPPER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-39
a. Swivel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-39
b. Travel Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-40
c. Accelerator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-43
d. Dozer Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-48
f. Swing Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-52
g. Service Port Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-54
h. Pilot Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-55
i. Limit Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-58
j. Seat and Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-59
k. Wrist Rest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-60
l. Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-61
m. Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-63
D. UNDERCARRIGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-65
a. Track Tension Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-65
b. Track Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-68
II-S-1
II-S-2
A. SPECIFICATIONS
a. Machine Weight
Iron crawler isn’t available for these models.
(1) KE, KDG, KUK-version
Unit U17-3α
STD arm / Rubber kg 1650
Canopy
STD arm / Iron kg 1720
(2) PP (KTC, KCL, KTA)-version

Unit U17/U17-3
Rubber track kgf (lbs) 1680 (3704)
4 post Rops
Iron track kgf (lbs) 1750 (3858)
Long arm is installed in standard version.
b. Main Specifications
model U17-3α (EU) U17/U17-3 (PP)
Brand KUBOTA KUBOTA
Type D902-BH-1 D902-E3-BH-2
Engine PS/rpm 16.7/2300 16.3/2300
Output
kW/rpm 12.3/2300 12.0/2300
3
Displacement cm (in3) 898 898 (47.5)
Machine weight Rubber track kg (lbs) 1650 (3638) 1680 (3704)
Bucket kN (kgf) lbf 15.2 (1550) 3147 ←
Excavating capacity
Arm kN (kgf) lbf 8.8 (900) 1978 ←
Hydraulic pump Relief pressure MPa (kg/cm2) psi 21.6 (220) 3129 ←
P1, P2 Pump discharge rate L/min (US GPM) 17.3 (4.57) ←
Relief pressure MPa (kg/cm2) psi 18.6 (190) 2702 ←
P3 Pump discharge rate L/min (US GPM) 10.4 (2.75) ←
II-S-3
c. Lever Stroke and Operating Force

Reference on new vehicle
Unit U17/U17-3, U17-3α Remarks
Stroke mm (in) 72 (2.83) Measured at the grip end
Boom lever Operating force N (kgf) lbf 13.7 (1.4) 3.1 Measured 20 mm below the grip end
Play mm (in) 2>
= (0.079 >
=)
Arm lever Operating force N (kgf) lbf 13.7 (1.4) 3.1 Measured 20 mm below the grip end
Play mm (in) 2>
= (0.079 >
=)
Bucket lever Operating force N (kgf) lbf 13.7 (1.4) 3.1 Measured 20 mm below the grip end
Play mm (in) 2>
= (0.079 >
=)
Swivel lever Operating force N (kgf) lbf 13.7 (1.4) 3.1 Measured 20 mm below the grip end
Play mm (in) 2>
= (0.079 >
=)
Operating force N (kgf) lbf 15.0 (1.5) 3.3 Measured 20 mm below the grip end
Clearance LH/RH lever
mm (in) 5 (0.197) Longitudinal direction
at neutral position.
Travel lever
Clearance LH/RH lever
at most forward and mm (in) 10 (0.394) Longitudinal direction
backward position.
Clearance LH/RH lever mm (in) 2 ~ 5 (0.079 ~ 0.197) Lateral direction
Acceleration lever Operating force N (kgf) lbf 33.3 (3.4) 7.5 Measured 30 mm below the grip top
Dozer lever
Operating force N (kgf) lbf 30.4 (3.1) 6.8 Measured 20 mm below the grip end
Lock lever, up Operating force N (kgf) lbf 19.6 (2.0) 4.4
Lock lever, down Operating force N (kgf) lbf 29.4 (3.0) 6.6
Swing pedal Operating force N (kgf) lbf 98.0 (10.0) 22.0 Measured at the grip end
Travel high SW Operating force N (kgf) lbf - Electric switch
II-S-4
d. Dimensions of Parts
(1) Front pins and bush
[Unit: mm (in)]
Location No. Pin diameter x length Bush inner dia. x outer dia. x length Remarks
(1) φ35 x 257 (φ1.38 x 10.12) φ35 x φ45 x 45 (φ1.38 x φ1.77 x1.77)
(2) φ35 x 160 (φ1.38 x 6.30) φ35 x φ45 x 35, 44 (φ1.38 x φ1.77 x1.38, 1.73)
(3) φ35 x 160 (φ1.38 x 6.30) φ35 x φ45 x 45 (φ1.38 x φ1.77 x1.77)
(4) φ30 x 112.5 (φ1.38 x 4.43) φ30 x φ40 x 35 (φ1.18 x φ1.57 x1.38)
(5) φ30 x 96 (φ1.38 x 3.78) φ30 x φ40 x 35 (φ1.18 x φ1.57 x1.38)
(6) φ50 x 109 (φ1.38 x 4.29) φ50 x φ60 x 37, 28, 40 (φ1.97 x φ2.36 x1.46, 1.10, 1.57)
(7) φ50 x 109 (φ1.38 x 4.29) φ50 x φ60 x 37, 28, 40 (φ1.97 x φ2.36 x1.46, 1.10, 1.57)
(8) φ30 x 160 (φ1.38 x 6.30) φ30 x φ40 x 35 (φ1.18 x φ1.57 x1.38)
(9) φ30 x 142 (φ1.38 x 5.59) φ30 x φ40 x 35 (φ1.18 x φ1.57 x1.38)
(10) φ30 x 191 (φ1.38 x 7.52) φ30 x φ38 x 35 (φ1.18 x φ1.50 x1.38)
(11) φ30 x 142 (φ1.38 x 5.59) φ30 x φ40 x 45 (φ1.18 x φ1.57 x1.77)
(12) φ30 x 192.5 (φ1.38 x 7.58) φ30 x φ40 x 35 (φ1.18 x φ1.57 x1.38)
(13) φ30 x 192.5 (φ1.38 x 7.58) φ30 x φ38 x 35 (φ1.18 x φ1.50 x1.38)
(14) φ30 x 182 (φ1.38 x 7.17) φ30 x φ38 x 35 (φ1.18 x φ1.50 x1.38)
(15) φ30 x 182 (φ1.38 x 7.17) φ30 x φ38 x 35 (φ1.18 x φ1.50 x1.38)
* The working limits of the pins are 1.0 shorter than the reference on new vehicle.
Outside
diameter
Length
Outside
diameter
Length
(New pin and bush tolerance)

[Unit: mm]
0.08 , φ30 -0.07 , φ35 -0.07 , φ50 -0.07
pin:φ25 --0.05 -0.05 -0.05 -0.05
bush:Inner dia.φ25 +0.100 , φ30 +0.100 , φ35 +0.130

+0.130 +0.130
+0.100 , φ50 +0.060
+0.090
Outer dia.φ38 +0.040 , φ40 +0.070 , φ45 +0.070 , φ60 +0.070

+0.070 +0.100 +0.100 +0.100
[Unit: in]
0.003 , φ1.18 -0.003 , φ1.38 -0.003 , φ1.97 -0.003
pin:φ0.98 --0.002 -0.002 -0.002 -0.002
bush:Inner dia.φ0.98 +0.004 , φ1.18 +0.004 , φ1.38 +0.005

+0.005 +0.005
+0.004 , φ1.97 +0.002
+0.004
Outer dia.φ1.50 +0.002 , φ1.57 +0.002 , φ1.77 +0.002 , φ2.36 +0.002

+0.003 +0.003 +0.003 +0.003
II-S-5
(2) Bucket fixture dimensions

Unit U17-3α, U17/U17-3 Remarks
A mm (in) 45.3 (1.78)
B mm (in) 2 x M12 x 1.25
C mm (in) 45.3 (1.78)
D mm (in) 45.3 (1.78)
E mm (in) 16.5 (0.65)
F mm (in) 3.95 (0.16)
G mm (in) 865 (34.06)
H mm (in) 2 (0.08)
I mm (in) 180 (7.09)
J mm (in) 167.5 (6.59)
K mm (in) 104.5 (4.11)
L mm (in) 735 (28.94)
M mm (in) 173 (6.81)
N mm (in) 175 (6.89)
O mm (in) 85 (3.35)
II-S-6
(3) Bucket link pin
[Unit: mm (in)]
Parts name Specifications
(1) Bucket link 1 φ30 x 95.5 (φ1.18 x 3.76)
(2) Bush A φ30 x φ38 x W35 (φ1.18 x φ1.50 x W1.38)
(3) Pin A dia φ30 x 192.5 (φ1.18 x 7.58)
(5) Bucket link 2, 3 φ30 - φ30 (φ1.18 - φ1.18)
(6) Arm boss φ55 x φ38 x L125.5 (φ2.17 x φ1.50 x L4.94)
(7) Bush B φ30 x φ38 x W35 (φ1.18 x φ1.50 x W1.38)
(8) Pin B dia φ30 x 192.5 (φ1.18 x 7.58)
(10) Bucket cylinder L/S (stroke) 529 / 802 (269) (20.83 / 31.57 (10.59))
II-S-7
(4) Track roller

(A) Reference on new vehicle
(B) Allowable limit
Unit U17/U17-3, U17-3α Remarks
(a) Guide diameter (A)/(B) mm φ73/69 (2.87/2.72)
(b) Outside diameter (A)/(B) mm φ117/113 (4.61/4.45)
(c) Roller outside width (A)/(B) mm 135 (5.31)
(d) Roller guide width (A)/(B) mm 66 (2.60)
(e) Slide plate (A)/(B) mm 9/4 (0.35/0.16)
(c)
Slide plate
(d)
(e)
(b)
(a)
II-S-8
(5) Idler and sprocket

(B) Allowable limit
Idler 202/196 (7.95/7.72) Rubber Crawler

(A)/(B) mm (in)
(a) Outside diameter 196/190 (7.72/7.48) Steel Crawler
(b) Guide width (A)/(B) mm (in) 27/23 (1.06/0.91)
(c) Idler width (A)/(B) mm (in) 60/55 (2.36/2.17)
Sprocket
(A)/(B) mm (in) 290/284 (11.42/11.18)
(d) Outside diameter
Sprocket
(A)/(B) mm (in) 23/18 (0.91/0.71)
(e) Wheel width
(c)
(e)
(a)
(d)
(b)
II-S-9
(6)Dozer
(1) Pin outside dia. - Length mm (in) φ30-102.5 (φ1.18-4.04)
(2) Outside diameter - Length mm (in) φ30-84.5 (φ1.18-3.33)
(3) Outside diameter - Length mm (in) φ30-84.5 (φ1.18-3.33)
(4) Outside diameter - Length mm (in) φ30-95 (φ1.18-3.74) Track cylinder mounting pin
(5) Outside diameter - Length mm (in) φ25-133 (φ0.98-5.24) Extension blade mounting pin
A Width mm (in) 1244/990 (48.98/38.98)
B Height mm (in) 261 (10.28)
C Length mm (in) 710 (27.95)
D Tip wear thickness mm (in) t 9 (t0.35)
E Distance between supports mm (in) 434 (17.09)
Movement above ground/below ground mm (in) 263/182 (10.35/7.17)
Dozer capacity 3 (ft3) 0.067 (2.25) w/o Extension blade
m
II-S-10
(7) Bucket dimensions

(1) mm (in) 400 (15.75) Lip outside width
(2) mm (in) 456 (17.95) Side cutter outside width
(3) mm (in) 60.5 x 6 (2.38) φxt
(4) mm (in) 139.5 (5.49)
(5) mm (in) 95.5 (3.76) Arm end width
(6) mm (in) 16 (0.63)
(7) mm (in) 22 (0.87)
(8) mm (in) 47.75 (1.88)
(9) mm (in) φ49 (1.93)
(10) mm (in) φ60 (2.63)
(11) mm (in) φ30 (1.18)
(12) mm (in) φ30 (1.18)
(13) mm (in) 457 (17.99)
(14) mm (in) 380.5 (14.98)
(15) mm (in) φ48.5 (1.91)
(16) mm (in) 126.5 (4.98)
(17) mm (in) 88.5 (3.48)
(18) mm (in) 16.5 (0.65)
II-S-11
(8) Parts weight

* The weights in the table below are approximate.
Machine weight kg (lbs) 1650 (3638), 1680 (3704) Rubber track
Body weight kg (lbs) 1340 (3527)
Maximum breaker weight kg (lbs) 90 (198)
Swing bracket and boom cylinder
Backhoe overall kg (lbs) 177 (390)
not included
Upper swivel structure kg (lbs) 816 (1799) Canopy/cabin
Lower travel structure kg (lbs) 577 (1272) Rubber crawler
Track frame kg (lbs) 61/83/61 (135/183/135) Left/center/right
Swivel frame kg (lbs) 150 (331)
Swing bracket kg (lbs) 28 (62)
Boom kg (lbs) 67 (148)
Arm kg (lbs) 30 (66)
Bucket kg (lbs) 29 (64), 40 (88) 450-400
Dozer kg (lbs) 67 (148)
Counterweight kg (lbs) 205 (452)
Iron crawler kg (lbs) 89 (196)
Rubber crawler kg (lbs) 56 (124)

Engine kg (lbs) 64 (141) Dry weight
Hydraulic tank kg (lbs) 13 (29) With filter
Fuel tank kg (lbs) 1.6 (3.5)
Swivel bearing kg (lbs) 17 (38)
Battery kg (lbs) 13 (29)
Track roller kg (lbs) 4 (8.8)
Upper track roller kg (lbs) -
Sprocket kg (lbs) 5 (11.0)
Idler kg (lbs) 18 (40) Sprocket included
Canopy roof kg (lbs) 9 (20)
Post (support) kg (lbs) 21 (46)
Pump assembly kg (lbs) 14 (31)
Wheel motor kg (lbs) 17 (38)
Swivel motor kg (lbs) 15,(33)
Control valve kg (lbs) 14 (31) Without joint
Boom cylinder kg (lbs) 15 (33)
Arm cylinder kg (lbs) 12 (27)
Bucket cylinder kg (lbs) 11 (24)
Swing cylinder kg (lbs) 9 (20) Offset
Dozer cylinder kg (lbs) 7 (15)
Rotary joint kg (lbs) 13 (29)
Radiator kg (lbs) 2 (4.4)
II-S-12
(9) Water and Oil Quantity

Radiator soft water L (US gal) 2.6 (0.713) Kubota LLC-N-50F
Reserve tank soft water L (US gal) 0.56 (0.159)
Crankcase engine oil Class CF/CF-4
L (US gal) 3.6 (0.295)
(at filter replacement) 10W30
Hydraulic tank oil L (US gal) 13 (3.434) ISO VG 46
Total hydraulic oil L (US gal) 21 (5.812) ISO VG 46
Wheel motor gear oil L (US gal) 0.25 (0.066) SAE 90 (API, GL-4)
Swivel reduction gear oil L (US gal) -
Track roller gear oil cc (cu-in) 40 (2.44) Engine Oil SAE 30 Class CD
Carrier roller
cc (cu-in) - (-) Grease EP2
(upper roller)
Front idler cc (cu-in) 30 (1.83) Engine Oil SAE 30 Class CD
Fuel tank light oil (full) L (US gal) 19 (4.755) Diesel fuel No. 3
II-S-13
e. Quality Specifications
(Installation: Rubber track, standard arm and bucket.)
No Specifications Items Unit U17-3α (EU) / U17/U17-3 (PP) Remarks
Q1 Main Speed JIS A8404
1 1 Machine size Total length (Transport) mm 3570 ± 52
inch 102.4 ± 2.05
2 Total width mm 1240 / 990 ± 12
inch 48.8 / 39.0 ± 0.5
3 Total height (Canopy) mm 2300 ± 23
inch 90.6 ± 0.9
4 Total height (Cabin) mm -
inch -
2 1 Weight Machine weight (Canopy) kg 1600 ± 32 Fuel tank full
lbs 3527.4 ± 70.5
2 Machine weight (Cabin) kg -
lbs -
3 Ground contact press. kPa 27.73
(Canopy) psi 4.02
kgf/cm2 0.28
4 Ground contact press. kPa -
(Cabin) psi -
kgf/cm2 -
3 1 Performance Swivel speed rpm 9.1 ± 0.9 Rated engine RPM, η = 100%
2 Travel speed F1 km/h 2.1 ± 0.2
mph 1.31 ± 0.12
3 F2 km/h 4.1 ± 0.4
mph 2.55 ± 0.25
4 R1 km/h 2.1 ± 0.2
mph 1.31 ± 0.12
5 R2 km/h 4.1 ± 0.4
mph 2.55 ± 0.25
6 Gradeability deg. 30 <
4 1 Rear end min. turning radius mm 620 ± 12
inch 24.4 ± 0.5
2 Swivel frame rear ground clearance mm 422 ± 8
inch 16.6 ± 0.3
3 Tumbler center distance mm 1230 ± 37
inch 48.4 ± 1.5
4 Crawler total length mm 1587 ± 48
inch 62.5 ± 1.9
5 Crawler total width mm 1240 / 990 ± 26
inch 48.8 / 39.0 ± 1.0
6 Crawler shoe width mm 230 ± 5
inch 9.1 ± 0.2
7 Min. ground clearance mm 150 ± 4
inch 5.9 ± 0.2
II-S-14

5 1 Engine Model name EU: D902-BH-1
PP: D902-E3-BH-2
2 Rated output kW 11.6 ± 0.2
ps 13.0 ± 0.3
3 Rated speed rpm 2300
4 Displacement L 0.898
cc 898
US gal 0.184
6 1 Hydraulic pump type Variable x2 + gear
2 Pump delivery P1,P2 L 17.3
US gal 4.38
P3 L 10.4
US gal 2.75
P4 L 6.2
US gal 1.64
4 Main relief pres- P1,P2 MPa 21.6 +1.0
-0.5
sure (Bench set) +10
kgf/cm2 220 -5
+9.8
bar 216 -4.9
+142
psi 3128 -71
P3 MPa 18.6 +1.0

-0.5
+10
kgf/cm2 190 -5
+9.8
bar 186 -4.9
+142
psi 2702 -71
5 Main relief pres- P4 MPa 3.9 +0.3

-0.2
sure (Bench set) +3
kgf/cm2 40 -2
+3
bar 39 -2
+43
psi 569 -28
7 1 Swivel motor type

8 1 Under carriage Travel motor type Piston motor Hi-Low type
2 Parking brake type -
3 Crawler shoe type Rubber
9 1 Front attachment Bucket CECE m3 0.04 ± 0.002
heaped yd3 0.05 ± 0.003
capacity
2 SAE, JIS m3 0.04 ± 0.002
yd3 0.05 ± 0.003
3 Bucket width mm 456 ± 10 Without side cutter
inch 18.0 ± 0.4
4 Swing angle L deg. 63 ± 2
5 R deg. 58 ± 2
6 Max. digging radius mm 3901 ± 59
inch 153.6 ± 2.3
7 Ground level Max. digging mm 3843 ± 58
radius inch 151.3 ± 2.3
8 Ground level Min. finish mm 1320 ± 26 Bucket bottom horizontal
radius inch 52.0 ± 1.0
9 Max. digging depth mm 2306 ± 46
inch 90.8 ± 1.8
II-S-15

9 10 Front attachment Max. vertical digging depth mm 1911 ± 38
inch 75.2 ± 1.5
11 Max. digging height mm 3536 ± 71
inch 139.2 ± 2.8
12 Max. dump height mm 2443 ± 49
inch 96.2 ± 1.9
13 Max. dump height mm -
(Arm vertical) inch -
14 Min. turning radius mm 1426 ± 43
inch 56.1 ± 1.7
15 Min. turning radius mm 1207 ± 36
(Left swing) inch 47.5 ± 1.4
16 Off-set L mm 510 ± 15
amount inch 20.1 ± 0.6
17 R mm 385 ± 12
inch 15.2 ± 0.5
18 Max. digging force kgf 1491, 1412<
kN 14.6, 13.8<
lbw 3280, 3106<
19 Optional JIS, SAE m3
bucket range yd3
10 1 Blade Width mm 1244 / 990 ± 5
inch 49.0 / 39.0 ± 0.2
2 Height mm 265 ± 5
inch 10.4 ± 0.2
3 Length mm -
inch -
4 Max. lift above GL mm 281 ± 13
inch 11.1 ± 0.5
5 Max. below GL mm 192 ± 9
inch 7.6 ± 0.4
6 Displacement capacity m3
yd3
11 1 Water & oil Radiator capacity L 3.6
US gal 0.95
2 Reserve tank capacity L 0.56
US gal 0.15
3 Engine crank case L 3.6 With oil filter
US gal 0.95
4 Hydraulic oil Full L 21
(all amount) US gal 5.55
5 Hydraulic oil Tank L 13
(tank gauge) US gal 3.43
6 Wheel motor L 0.25
US gal 0.07
7 Swivel reduction case L -
US gal -
8 Track roller L 0.04
US gal 0.01
9 Front idler L 0.03
US gal 0.01
II-S-16

11 10 Water & oil Fuel tank L 17.5 ± 0.9
US gal 4.62 ± 0.24
Q2 Main Specs JIS A8404
1 1 Bucket tooth sluggish mm 73 ± 93
inch 2.87 ± 3.66
2 Decline of front attachment mm 0 ± 10
inch 0.00 ± 0.39
3 Blade's declination mm 0 ± 10
inch 0.00 ± 0.39
2 1 Eccentric amount from swing center mm - From swivel center
inch -
2 Distance to swing center mm -
inch -
3 1 Distance to boom pin mm -
inch -
2 Boom pin height mm - Exclude grouser
inch -
3 Min. clearance of bucket teeth to boom cylinder mm 37 +34
-16
protector +1.34
inch 1.46 -0.63
4 Clearance of boom cylinder to shoe mm -

inch -
4 1 Approach angle deg. 29.4 ± 3.0
2 Distance to blade tip mm - From swivel center
inch -
3 Distance of crawler end to blade mm -
inch -
4 Clearance of blade to weight mm -
inch -
5 1 Crawler height mm 354 ± 7 Include grouser on the sprocket
inch 13.94 ± 0.28
2 Max. crawler height mm 354 ± 7
inch 13.94 ± 0.28
3 Clearance of swivel frame to crawler mm
inch
4 Distance to idler center mm From swivel center
inch
5 Distance to sprocket center mm
inch
6 Protrusion amount of upper L/R mm
frame to crawler outer end inch
6 1 Swivel frame height mm
inch
2 Height to step mm Include rubber mat
inch
3 Height to seat mm
inch
4 SIP (ISO) mm
inch
II-S-17

Q3 Engine performance
1 1 Max. engine SAE J 1995 Gross kgf·m 5.57 / 5.31
torque N·m 54.6 / 52.1
ft·lbs 40.3 / 38.4
2 Torque rise % 9.2 / 6.8
2 1 Max. engine rpm no load rpm 2600 >
2 1 pump relief rpm
3 2 pump relief rpm 2300 < Arm + bucket
4 3 pump relief sec. 2300 < Arm + bucket + dozer
3 1 Idling rpm rpm 1350 +150
0
4 1 Engine start time (Normal temp and grow) sec. Glow 5 sec
5 1 Cold start Cell start time sec. Temp. -17°C
2 Number of start
6 1 Charge starting engine rpm
2 Charging voltage alternation Battery spec 12V 40A
& ampere
Q4 Travelling performance
1 1 Travel motor block performance, L/R mm 300 > 20 deg, 10 min
inch 11.81 >
2 1 Max. Traction F1 kgf 1437 ± 126 η = 65%
force kN 14.08 ± 1.24
lbs 3161 ± 278
2 F2 kgf 720 ± 64
kN 7.06 ± 0.63
lbs 1584 ± 141
3 1 Travel straight- F1 mm 600 > 10 m distance
ness inch 23.62 >
2 R1 mm 600 >
inch 23.62 >
3 Blade F1 mm 600 > Blade up & down 10 m distance
inch 23.62 >
4 Blade R1 mm 600 >
inch 23.62 >
4 1 Track shoe sag Steel mm 25 to 30
distance inch 0.98 to 1.18
2 Rubber mm 10 to 15
inch 0.39 to 0.59
Q5 Work performance
1 1 Work amount 45 deg digging & side dump m3/h
yd3/h
2 Digging, 180 deg loading m3/h
yd3/h
2 1 Cycle time 45 deg digging & side dump sec.
2 Digging, 180 deg loading sec.
3 1 Fuel consumption Calculated L/h Load coefficiency = 60%

US gal/h
2 Actual L/h
US gal/h
II-S-18

4 1 Boom lifting capacity kgf - Front end, Arm extend bucket
kN - crowd, at tooth
lbw -
2 Arm digging force kgf 863, 824< Bucket tooth root
kN 8.46, 8.07<
lbw 1903, 1817<
3 Bucket digging force kgf 1491, 1412< Machine stance to JIS bucket tooth
kN 14.6, 13.85< root
lbw 3287, 3113<
4 Blade force up kgf Cutting edge down force at ground
kN level
lbw
down kgf
kN
lbw
5 1 Boom speed up sec. 2.1 ± 0.3 Oil temp. 50 ± 5°C
2 down sec. 2.5 ± 0.3 Max. height to ground
6 1 Arm speed crowd sec. 3.3 ± 0.3
2 extend sec. 2.4 ± 0.3
7 1 Bucket speed crowd sec. 2.7 ± 0.3
2 dump sec. 1.8 ± 0.3
8 1 Blade speed up sec. 1.7 ± 0.3 Max. down to max. up
2 down sec. 2.1 ± 0.3 Max. up to max. down
9 1 Swivel angle while boom raise deg. GL-Max. height, before cushioning
2 Inching performance mm - CV spool stroke
inch -
10 1 Arm cylinder cavitation - Oil temp. 50 ± 5°C
2 Arm cylinder shrink mm 5 > Oil temp. 95 ± 5°C, 1300 rpm,
inch 0.2 > bucket heaped, load
11 1 Blade cylinder cavitation
12 1 Bucket outer width without side mm
cutter inch
2 with side cutter mm
inch
13 1 Max. digging height radius mm 2015 ± 202
inch 79.33 ± 7.95
2 Max. dump height radius mm 2012 ± 121 at bucket pin
inch 79.21 ± 4.76
3 Distance max. digging depth mm From swivel center
inch
4 Bucket bottom height at arm vertical mm 1200 ± 36 Bucket horizontal
inch 47.24 ± 1.42
5 Bucket wrist angle deg. 180 ± 3
6 Bucket bottom angle deg. Boom up, arm extend bucket
crowd
7 Distance to bucket tooth tip min. mm From swivel center
inch
8 Distance to bucket tooth tip Bucket bottom mm
horizontal inch
9 Item 7 to sprocket center mm
inch
II-S-19

13 10 Item 7 to blade mm
inch
11 Item 8 to sprocket center mm
inch
12 Item 8 to blade mm
inch
Q6 Swivel, swing performance
1 1 Swivel torque L kgf·m 255, 217< Arm extend, slow/quick
kN·m 2.5, 2.1<
ft·lbs 1844, 1569<
2 R kgf·m 255, 217<
kN·m 2.5, 2.1<
ft·lbs 1844, 1569<
2 1 Swivel capable angle at slope deg. 18 < Bucket load = JIS heaped x 1.8
3 1 Swivel block performance L/R deg. 30 >
4 1 Swivel slippage (Flat ground, no L / R deg. 90 deg swivel
load) deg.
5 1 Swivel start-up speed sec. 2.1 ± 0.2 0 ~ 90 deg swivel
6 1 Swivel torque, max. Left / Right kgf·m 255
N·m 2.5
ft·lbs 1844
7 1 Swing speed Left sec. 4.6 ± 0.3
2 Right sec. 3.7 ± 0.3
8 1 Swing Lock Swivel R&L mm 6 > 90 deg-swivel, 100 times actual
inch 0.24 > digging cylinder dislocation
2 Reciprocating L/R Swing mm 90 deg-swivel, 100 times
motion inch
Q7 Hydraulic performance
1 1 Relief pressure setting P1, P2 kgf/cm2 At pump delivery port 50 ± 5°C
MPa
bar
psi
2 P3 kgf/cm2
MPa
bar
psi
3 P4 kgf/cm2
MPa
bar
psi
2 1 Swivel brake relief pressure kgf/cm2 At pump delivery port
MPa
bar
psi
3 1 Suction negative pressure kgf/cm2 At -10°C
MPa
bar
psi
4 1 Boom relief pressure kgf/cm2 At +50°C
MPa
bar
psi
II-S-20

5 1 Cylinder oil sealing capacity Boom mm 25 > Arm extend, bucket
inch 0.98 >
2 Arm mm 15 > height 1 m, 10 min.
inch 0.59 >
3 Bucket mm 10 > Bucket load = JIS heaped*1.8
inch 0.39 >
4 Blade mm 25 >
inch 0.98 >
6 1 Boom cushioning performance 30°C sec. 3 >
2 50°C sec. 0.5 to 1.5
3 80°C sec. 0.3 <
7 1 Accumulator function time sec.
8 1 Service port flow No load L 27
US gal 8.14
2 Load L At 50 kgf/cm2
US gal
Q8 Lever operating force & stroke
1 1 Boom lever operating force up 1st kgf 1.4 ± 0.5 20 mm lower the lever top
N 13.7 ± 4.9
lbf 3.1 ± 1.1
2 up 2nd kgf
N
lbf
3 down kgf 1.4 ± 0.5
N 13.7 ± 4.9
lbf 3.1 ± 1.1
4 Arm lever Dump / crowd kgf 1.4 ± 0.5 Extend & crowd
N 13.7 ± 4.9 20 mm lower
lbf 10.1 ± 3.6
5 Bucket lever Dump / crowd kgf 1.4 ± 0.5 Dump & crowd
N 13.7 ± 4.9 20 mm lower
lbf 10.1 ± 3.6
6 Swivel lever L/R kgf 1.4 ± 0.5 Left & right
N 13.7 ± 4.9 20 mm lower
lbf 10.1 ± 3.6
7 Blade lever Up / down kgf 3.1 ± 0.5 Up & down
N 30.4 ± 4.9 20 mm lower
lbf 22.4 ± 3.6
8 Travel lever L/R kgf 1.5 ± 0.5 F&R
F/R N 14.7 ± 4.9 20 mm lower
lbf 10.8 ± 3.6
9 Accelerator lever kgf 3.4 ± 1.5 30 mm lower
N 33.3 ± 14.7
lbf 25 ± 10.8
10 Swing pedal kgf 7.0 ± 0.7
N 68.6 ± 6.9
lbf 15.4 ± 1.5
II-S-21

1 11 Safety lock lever, L&R up kgf 2.0 ± 1.0
N 19.6 ± 9.8
lbf 14.5 ± 7.2
down kgf 3.0 ± 1.0
N 29.4 ± 9.8
lbf 21.7 ± 7.2
12 Travel Hi-Lo change kgf - Electrical push-type switch on the
N - dozer lever
lbf -
13 Service port pedal L/R kgf 5.0 ± 1.0
N 49.0 ± 9.8
lbf 36.2 ± 7.2
14 Bonnet lifting force kgf
N
lbf
15 TPSS lever (PP-version) kgf 10.0 ± 1.0
N 98 ± 9.8
lbf 22 ± 2.2
2 1 Boom lever stroke up mm 72 ± 10 Tip of the grip
inch 2.83 ± 0.39
2 down mm 72 ± 10
inch 2.83 ± 0.39
3 Arm lever stroke mm 72 ± 10
inch 2.83 ± 0.39
4 Bucket lever stroke mm 74 ± 10
inch 2.91 ± 0.39
5 Swivel, swing lever stroke mm 74 ± 10
inch 2.91 ± 0.39
6 Blade lever up & down mm 80 ± 10
inch 3.15 ± 0.39
7 Travel lever, F & R L mm 75 ± 10
inch 2.95 ± 0.39
R mm 75 ± 10
inch 2.95 ± 0.39
8 Accelerator lever stroke mm 99
inch 3.9
9 Swing pedal stroke mm 6 ± 10 Pedal edge
inch 0.24 ± 0.39
10 Service port pedal stroke mm 12 ± 10
inch 0.47 ± 0.39
II-S-22

Q9 Stability
1 1 Tipping load/distance of load Front, Blade up kgf·m Arm extend, bucket crowd
point to tipping point N·m
ft·lbs
2 Front, Blade kgf·m
down N·m
ft·lbs
3 Rear, Blade up kgf·m
N·m
ft·lbs
4 Side kgf·m
(variable track) N·m
ft·lbs
2 1 Dynamic operation limit slope STD arm deg. Swivel angle = 0 deg. Blade up,
2 angle Long arm deg. side direction
3 Telescopic arm deg.
3 1 Bucket limited Extended Side kgf 188, 162< Front horizontal, bucket crowd arm
load, static N 1842, 1558< tip end load swing straight dozer
lbs 376, 357< up.
Bucket weight 37 kgf isn’t included.
2 Forward kgf 215, 175<
N 2107, 1715<
lbs 473, 386<
3 Retracted Side kgf 110, 95<
N 931<
lbs 209<
N 1078, 1715<
lbs 414, 386<
4 1 Bucket limited Extended Side kgf 138, 121< Arm extended, bucket crowd,
load, slow opera- N 1352, 1186< dozer up swing straight.
tion lbs 304, 267< Bucket weight 37 kgf isn’t included.
N 1490, 1274<
lbs 334, 287<
3 Retracted Side kgf 66, 63<
N 647, 619<
lbs 145, 139<
N 1490, 1274<
lbs 334, 287<
Q10 Comfortability
1 1 Noise level At opera- Canopy dB(A) 78> / 79>
2 tor's ear LPA Cab dB(A) - Cab door close
3 Noise source± LWA dB(A) 92 >
II-S-23
II-S-24
B. 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
RB2386645 2 Pin 10 φ 50 (φ 1.97in)
13
RB2386639 2 Bush 11 506037
35 34
RB2386638 2 Bush 12 506028
11
RB2384113 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
RB2386664 1 Pin 20 φ 35 (φ 1.38in)
RB2386659 1 Bush 21 354332 31 33 36
RB2386637 1 Bush 22 354348
0117361080 1 Bolt 23
Swing bracket - Swing cylinder
0257450100 1 Nut 24
Swing bracket - boom RA22166481 1 Pin 50 φ 30 (φ 1.18in)
0113361020 1 Bolt 52
6718166441 Spacer 54
RB2386656 1 Pin 30 φ 35 (φ 1.38in) 5358253561 1 Washer 55
RB2386646 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 RB2386664 1 Pin 60 φ 35 (φ 1.38in)
0661115010 1 Grease nipple 36 0117361080 2 Bolt 61
0257450100 1 Nut 62
Swing bracket - Swing cylinder
Boom - arm cylinder
RB2386746 1 Pin 40 φ 30 (φ 1.18in) Code No. Q’ty Part No. Remarks
0113361020 1 Bolt 41 RB2386654 1 Pin 70 φ 30 (φ 1.18in)
691816644 1 Spacer 42 0117361080 2 Bolt 71
535825356 1 Washer 43 0257450100 1 Nut 72
II-S-25
(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 RA22166761 1 Pin-EU 120 φ 30 (φ 1.18in)
RB2386663 1 Pin 80 φ 30 (φ 1.18in) RB2386676Δ 1 Pin-PP 120 φ 30 (φ 1.18in)
687216652Δ 2 Bush 81 303835 687216652Δ 2 Bush 121 303835
0117361080 1 Bolt 82 RA11167331 2 Dust seal 122
0257450100 1 Nut 83 0113361225 1 Bolt 123
0661115010 1 Grease nipple 84 0401560120 1 Plain washer 124
6874166921 1 Spacer 125
Arm - arm cylinder
0661115010 1 Grease nipple 126
RB2386665Δ 1 Pin 90 φ 30 (φ 1.18in) Bucket link1 - link2, 3
0117361065 1 Bolt 91
0257450100 1 Nut 92
RB23866771 1 Pin 130 φ 30 (φ 1.18in)
Arm - bucket cylinder RB23866781 2 Bush 131 303840
0117361080 1 Bolt 132
0211860100 2 Nut 133
RB2386665 1 Pin 100 φ 30 (φ 1.18in) 0661115010 1 Grease nipple 134
0117361065 1 Bolt 101
0257450100 1 Nut 102 Bucket link1 - bucket
Arm - bucket link2, 3 RA22166761 1 Pin-EU 140 φ 30 (φ 1.18in)
Code No. Q’ty Part No. Remarks RB2386676Δ 1 Pin-PP 120 φ 30 (φ 1.18in)
RB2386675 1 Pin 110 φ 30 (φ 1.18in) 6872166521 2 Bush 141 303835
687216652 2 Bush 111 303835 RA11167331 2 Dust seal 142
0117361080 1 Bolt 112 0113361225 1 Bolt 143
0211860100 2 Nut 113 0401560120 1 Plain washer 144
0661115010 1 Grease nipple 114 6874166921 1 Spacer 145
II-S-26
(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 Blade - blade cylinder

Code No. Q’ty Part No. Remarks Code No. Q’ty Part No. Remarks
RA21174441 2 Pin 150 φ 30 x 102.5L RB2387446 1 Pin 170 φ 30 x 84.5L
(φ 1.18 x L4.04 in) (φ 1.18 x L3.33 in)
0113361020 2 Bolt 151 0113361020 1 Bolt 171
6918166441 2 Collar 152 5358253661 1 Collar 172
5358253661 2 Washer 153 0661625010 1 Washer 173
Truck frame - truck cylinder
Truck frame - blade cylinder
RA21121441 2 Pin 180 φ 30 x 95L
RB2387446 1 Pin 160 φ 30 x 84.5L (φ 1.18 x L3.54 in)
(φ 1.18 x L3.33 in) 691912129 2 Bolt (Stopper) 181
0113361020 1 Bolt 161 0451260120 2 Washer 182
5358253661 1 Collar 162
0661625010 1 Washer 163 Blade - extension blade
RA21121441 2 Pin 190 φ 25 x 113L
(φ 0.98 x L4.45 in)
0552551000 2 Split pin 191
RG1088948 2 Pin 192
II-S-27
(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 (0.023 in) 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) RA211-6647 Shim (0.3, 70-36) SPCC
RB211-6762 Shim (0.5, 70-36) SPCC 2. Vertical clearance + 0.3 ~ +1.3 mm
68741-6688 Shim (1.0, 70-36) SPCC
68741-6689 Shim (1.6, 60-36) SPCC
} Selective use between swivel frame
and swing bracket.
(+ 0.012 ~ +0.051 in)
RA211-6649 Shim (2.0, 70-36) SPCC 3. Use the shim and

(3) RB238-6644 Thrust collar (2.3, 92-51) SK5M thrust collar selec-
tively with each part.
* Refer to the mounting method of thrust collar.
4. Installation of thrust Apply grease on both sur-
(4) RB238-6644 Thrust collar (2.3, 92-51) SK5M
RB238-6648 Thrust collar (2.0, 92-51) SK5M
RB238-6649 Thrust collar (2.5, 92-51) SK5M
} Selective use
collar face.
* Refer to the mounting method of thrust collar.

Apply grease
(5) RG401-6762 Shim (0.5, 70-36) SPCC
(6) 68721-6697 Shim (0.5, 60-31) SPCC
68051-6633 Shim (1.0, 60-31) SPCC } Selective use
} Selective use
(7) 68721-6697 Shim (0.5, 60-31) SPCC A clearance of 1-2 mm to be ensured
between lock-bolt tightened face and nut
68051-6633 Shim (1.6, 60-31) SPCC
(8) 68721-6697 Shim (0.5, 60-31) SPCC
(9) 68721-6697 Shim (0.5, 60-31) SPCC
Lock nut type Double nut type
II-S-28
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-29
(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 (0.09 in)
095: 2.3, 2.0, 2.5 selective
Shim
200: 0.5, 1.0, 1.6 selective
II-S-30
(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 2
(3)
(4)
1
(2) 1 Bush
2 Dust seal
3 Collar
(3)
Specifications, New pin and bushing

[Unit: mm (inch)]
Model KX008-3, U10-3 KX36-3, KX41-3S, V U17/U17-3, U17-3α U20-3, U25-3α Remarks
Pin outer dia. o 35 --0.05 -0.002
o 50 --0.05 -0.002
← o 60 --0.05 -0.002
0.08 ( o 1.38 -0.003 ) 0.08 ( o 1.97 -0.003 ) 0.08 ( o 2.36 -0.003 )
Pin material S45C-D, S43C-D ← ← ←

Bush inner dia. o 35 +0.07
( o 1.38
+0.011
+0.006 ) o 50 +0.07
( o 1.97
+0.011
+0.006 ) ← o 60 +0.07 +0.011
( o 2.36 +0.006 )
+0.04 +0.04 +0.04
Bush outer dia. o 43 +0.09 +0.004

o 60 +0.09 +0.004
← o 72 +0.09 +0.004
+0.06 ( o 1.69 +0.002 ) +0.06 ( o 2.36 +0.002 ) +0.06 ( o 2.83 +0.002 )
Bush material STKM16A

S43C ← ← ←
S45C
Thrust washer, shims Thrust collar Thrust collar
thickness : 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 ← ←
Test pin, to go through
- o 49.95 ( o 1.967) ← -
smoothly
pin: High frequency induction surface hardening/

Effective hardened depth: 2 ~ 4mm (0.08” ~ 0.16”)
Surface hardness: 52 ~ 59 HRC
Diameter value is for single part before installation.
II-S-31
(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 method is just for your reference.
Swing bracket looseness measuring procedure photos
II-S-32
(6) Service tip to ease customer complain

Front sluggishness caused by pin-bushing worn-out largely depends on the following factors.
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 storage: 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 operating condition, attachment weight, applica-
tion and maintenance level mentioned above.
6. Service limit: Allowable service limit to all pins and bushings is 1.0 mm (0.039 in) wear
from the new diameter size.
II-S-33
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°
(06616-25010)
C-type: 90°
(06616-35010)
(1)
(2) (3) (4) Turn the swivel bearing every 90 degrees
and lubricate the balls and tooth faces (8
locations in total). If already disassembled,
the balls and tooth faces may be lubri-
cated before being reassembled.
(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-34
(5)
(5) A - type (Boss - greasing)
(7) B - type (Boss - greasing)
(7)
(7) (7)
1 4 5
(6)
A B
(7)
Q’ty
(1) Frame (Truck, center) 1
(2) Frame (Truck, L) 1
(3) Frame (Truck, R) 1
A B
(4) Bolt, stopper 4
(5) Spring washer 4
(6) Stopper bolt (4)
Apply screw adhesive.
4 locations in total
(7) Track frame right and left, 4 locations in total
Apply grease all around the hatched surfaces.
II-S-35
A B
(1) A B
(1) Stopper bolt
(1) (1)
Model Code No. Bolt Tightening torque Tip dia φ
(mm)
K008-3 69191-2129-3 M12 x 1.25 77.5 ~ 90.2 N·m 10 17
U10-3 (7T) (7.90 ~ 9.20
U15, U15-3 kgf·m)
KX41-3V 57.1 ~ 66.5 ft·lbf
U17-3α RA231-21292 M20 x 1.5 367.7 ~ 431.5 N·m 17 27

(37.5 ~ 44.0
kgf·m)
271.2 ~ 318.2 ft·lbf
II-S-36 2
(2) (1)
(1) View from below the track frame
(center)
(2) Track cylinder
(3) Tighten up the plastic clamp here.
(Ensure a clearance of over 10 mm
with the telescopic cylinder rod. See
(6)
the -marked point.)
(4) Adjust the adapter angle to produce
a clearance of 1-10 mm between the
plate (Part C) and the hose.
(5) To cylinder bottom
(6) To cylinder rod
(5)
B C
(4)
(4)
Q’ty
040
010 Frame, track center 1 030 050
020 Frame, track LH 1
030 Frame, track RH 1 110
040 Cover, motor 2 080 120
050
050 Bolt, flange 6 060 070 040
060 Pin 2
070 Bolt, stopper 2
080 Washer, spring 2
090 Cover, bottom 1 070
080
100 Bolt 4 060
010
110 Bolt, stopper 4
120 Washer, spring 4
020
090
100 140
130
II-S-37 2
II-S-38
C. UPPER STRUCTURE
a. Swivel Bearing
(1)
B
Pass between the hoses (2)
(selector valve - SJ).
A Selector
valve
(5)
Ｓ
Swing Tooth Horizontal Front
cylinder face Ball
(6)
Direction of the swing
cylinder's grease adaptor
Machine front
(4)
(3)
(1) Machine rear

1
(2) Marked “S“ (Soft zone of inside gear)

(3) Machine front
2
(4) Grease supply port (Must be faced to the

swivel frame hole)
3
(5) The ball inlet (Soft zone of outer race)

(6) Grease supply to teeth
1. Inner ring 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 side.
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-39
b. Travel Lever
To-and-fro differences of the right and left travel
levers
Lever position To-and-fro difference ( ) Travel lever adjustment 1. Adjustments of Mount the levers as Improper position
lever to neutral shown in the illus- ↓
Forward and Top view Front view position tration. Improper control
Within 10 mm (0.39 in.) each Mounting direc-
backward ends Link (MB)
RA221-6561Δ tion and angle
Neutral Within 5 mm (0.21 in.)
2. Travel lever rota- The levers must Improper return
tion return to the neu- ↓
tral position Improper action
promptly after oper-
Set up with the end ation.
Parallel
groove vertical.
3. Travel lever Levers not aligned
adjustments ↓
1) Forward/ → 5 mm (max.) Contact between
Backward (0.2 in) levers
tolerance of Improper action
left and right
levers
2) Clearance of → 5 ~ 25 mm (EU)
left and right (0.2 ~ 0.98 in)
levers 5 ~ 14 mm (KTC)
(0.2 ~ 0.55 in)
4. Grip mounting Mount the grips Improper assembly
Grip-to-grip clearance 2 5 Mounting direc- securely. ↓
tion and angle The grips must be Grips rotate
in backward/for-
ward directions.
5. Check items The valve spool Improper action
after mounting must operate full ↓
stroke. Increase in required
Grip The valve spool
must operate
operational power
smoothly.
67156-1833
(34.5)
Lever (travel, left)

RA221-6531
Lever (travel, right)

RA221-6532
Stopper bolt details

(7) (9.5)
Front
II-S-40
(1)
(4)
(9)
(6)
(5)
(7) (8)
(3)
(2)
Q’ty Remarks Item Points to remember

1 Lever (travel, left 1) 1 Greasing of bearing and Make sure the No greasing
2 Lever (travel, left 2) 1 DU part rotating shaft runs ↓
smoothly. Greater rotating resistance
3 Spring pin 2 Too much greasing
4 Lever assembly (travel, right) 1 ↓
Poor appearance
Lever (travel, right 1) 1
Tightening torque of bolt 77.2 ~ 90.2 N·m
Needle bearing 2 (7.9 ~ 9.2 kgf·m)
(56.9 ~ 66.5 ft·lbf)
5 Ball 4 M8 7T
6 Nut 4 M8 4T
7 Shaft (travel) 1
8 Bearing (mini-flange) 1
9 Bolt 4 M8 7T
II-S-41
(8) Component parts
No. Part code Part name Q'ty

010 RA221-6531-0 Lever (travel, left 1) 1
020 RA221-6533-2 Lever (travel, left 2) 1
030 05411-00630 Spring pin 2
040 67156-1833-0 Grip 1
050 68161-6516-2 Bellows rubber 2 1
060 - Blank -
070 - Blank -
080 RA011-6519-0 Headed pin 1
090 RA011-6517-0 Snap pin 1
100 RA221-6534-0 Link (plate 1) 1
7777772#
No. Part code Part name Q'ty

010 RA221-6530-0 Lever assembly 1
(travel, right)
020 11420-1639-0 Needle bearing 2
030 RA221-6536-0 Shaft (travel) 1
040 67156-1833-0 Grip 1
050 68161-6516-2 Bellows rubber 2 1
060 01155-60830 Bolt 4
070 02114-60080 Nut 4
080 RA011-6519-0 Headed pin 1
090 RA011-6517-0 Snap pin 1
100 RA221-6561-0 Link (M8) 1
110 RA221-6562-0 Pin (10-M8) 1
120 02114-60080 Nut 1 7777772#
II-S-42
c. Accelerator Lever
1. Idle speed: 1350 ± 50 rpm 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”)
4. Accel lever operating force: 20 ~ 30 N (2 ~ 3 kgf) (4.5 ~ 6.7 lbf)
No. Part name Q'ty Remarks

1 Bracket (operation, R) 1
2 Lever assembly (accelerator) 1
Lever (accelerator) 1
Bushing 2
3 Lever grip 2 1
4 Plain washer 1
5 Plain washer 2
6 Pan-shaped washer 2
7 Nut 2
8 Seal (lever, blade) 1
9 Bolt 2
10 Nut 2
11 Cable (accelerator) 1
12 Headed pin 1
13 Snap pin 6 1
14 Plain washer 1
15 Support (accelerator) 1
16 Bolt 2 M8 7T
(EU-version)
Shift up to the end before fitting in.
• Adjusting the engine rpm

First of all, move the engine-side and accelerator-side adjusting nuts to the forward end.
• Adjusting the idling speed
Using the adjusting bolt (9) for the accelerator lever side, adjust the speed adjusting lever so that the
entire plate serves the idling speed. Tighten up the nut (10).
• Adjusting the maximum speed
Make sure the lever is in contact with the maximum position. Apply the maximum adjusting bolt (9) in
slight contact with the lever. Tighten up the nut (10).
II-S-43
No. Parts Name Q'ty

010 Cable (accelerator) 1
020 Plain washer 1
030 Split pin 1
040 Support (accelerator) 1
050 Bolt 2
060 Headed pin 1
070 Snap pin 6 1
080 Plain washer 1
090 Lever assembly (accelerator) 1
100 Bushing 2
110 Lever grip 2 1
120 Plain washer 1
130 Plain washer 1
140 Pan-shaped washer 2
150 Plain washer 1
160 Nut 1
165 Nut 1
170 Bolt 2
180 Nut 2
II-S-44
(PP-version)
4
7
3
1 8 2
(15)
(15)
(12)
10 9 11
No. Parts Name Q'ty Remarks

1 Bracket (control, R) 1
2 Lever assembly (acceleration) 1
Lever (acceleration) 1
Bushing 2
3 Lever grip 2 1
4 Plain washer 1
5 Plain washer 2
6 Disc spring 2
7 Nut 2
9 Bolt 2
10 Nut 2
11 Cable (acceleration) 1
12 Move this part in advance to the forward end.
• Adjusting the engine rpm

First of all, move the engine-side and accelerator-side adjusting nuts to the forward end.
• Adjusting the idling speed
Using the adjusting bolt (9) for the accelerator lever side, adjust the speed adjusting lever so that the
entire plate serves the idling speed. Tighten up the nut (10).
• Adjusting the maximum speed
Make sure the lever is in contact with the maximum position. Apply the maximum adjusting bolt (9) in
slight contact with the lever. Tighten up the nut (10).
II-S-45
2 3
A
B C
(11)
5 10 4
8 9 7 6
A B C
8 9
(12)

1 Support (acceleration) 1
2 Cable (acceleration) 1
3 Lever assembly (acceleration, inverted) 1
Lever (acceleration, inverted) 1
Bushing 1
4 Rod (acceleration) 1
5 Spring 1
6 Plain washer 1
7 Snap pin 12 1 Anti-fall type
8 Plain washer 3
9 Snap pin 6 3 Anti-fall type
10 Bolt 2
11 Move this part in advance to the forward end.
12 How to hook the spring
II-S-46
(1)
(2)
(1) Cable accel

RA221-3515Δ
(2) Make sure there is no contact with the other parts.
II-S-47
d. Dozer Lever
(140) 1. Outer part of the cable shouldn’t be bent.
4 2 Straight length: 200 mm (7.78”) or more.
2. Allowable cable beading radius:
1 R = 150 mm (5.91”) or more.
3. Cable shouldn’t be twisted when fixing
4. Check points after installation
Control valve spool should shift smoothly
at full stroke.
5 3
1 Lever assembly (blade) 1
Lever (blade) 1
Bushing 2
2 Grip 1
4 Cable (blade) 1
8) Plain washer 1
(14
Snap pin 1
5 Bracket (cable, blade) 1
No. Parts Name Q'ty

010 Lever assembly (blade) 1
020 Bushing 2
030 Plain washer 1
040 Snap pin 1
060 Grip 1
070 Link assembly (blade) 1
080 Bushing 2
090 Shaft (blade) 1
100 Bolt 1
110 Headed pin 1
120 Snap pin 1
130 Link (blade) 1
140 Cable (blade) 1
150 Bracket (cable, blade) 1
160 Bolt 2
170 Plain washer 2
180 Snap pin 2
II-S-48
Blade cable (route)
Pass behind the weld zone of the bracket (muffler).
Pass behind the weld zone of the swivel frame.
Pass through the 2 openings in the rear left rib of the swivel
frame.
II-S-49
e. Control Link
Item Points to remember
Installation of control valve (8) Tightening torque Poor tightness
23.5 ~ 27.5 N·m ↓
(2.4 ~ 2.8 kgf·m) Loose bolt
(17.4 ~ 20.3 ft·lbs) ↓
(Apply thread adhesive.) Come-off, damage
Installation of rods and control valve Fit them as illustrated. Poor setup
↓
Operation failure
Installation of snap pin (05525-51000) and plain Fit them as illustrated. Poor setup
washer (04011-50100) on right-travel link only ↓
Operation failure
Installation of spring pin Drive the spring pin with its groove in Loose
the turning direction. ↓
Spring pin come-off
Installed on SP-spec. machine
Service Swing
Travel, right
Travel, left Dozer
No. Part Code Part Name Q’ty Remarks

1 RA221-6534Δ Link (plate 1) 2 Travel (left), dozer
2 RA221-6561Δ Link (MB) 1
3 RA221-6562Δ Pin (10-MB) 1 Travel (right)
4 02114-60086 Nut 1
5 RA121-6531Δ Link (operation) 1 Swing
6 RA011-6517Δ Snap pin 4
7 RA011-6519Δ Headed pin 4
8 01123-60816 Bolt 4
5 RA121-6531Δ Link (operation) 1 Service (SP)

6 RA011-6517Δ Snap pin 1
7 RA011-6519Δ Headed pin 1
II-S-50
RA221-6531Δ RA221-6533Δ
Lever (travel, left 1) Lever (travel, left 2)
Precautions in installing the spring pin

When driving the spring pin in position (marked * in the above figure), make sure its groove faces the turning direction.
Groove
Turning direction
II-S-51
f. Swing 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 neutral position smoothly.
(273.5) reference
3 2 1
(5) (6) (4)

(8) No. Part Code Part Name Q’ty
(67) reference
Lever assembly
1 RA221-6503Δ 1
(swing)
RA221-6543Δ Lever (swing) 1
(7) 08511-01410 Bushing 2
2 04011-5014 Plain washer 1
3 05525-51400 Snap pin 1
4 RA221-6546Δ Rod (swing) 1
Rod end, right-
66021-4337Δ 1
hand threaded
02114-60080 Nut 2
04512-60080 Spring washer 1
04011-50100 Plain washer 1
05525-61000 Snap pin 1
Move the pedal to the neutral position
5
and make sure its top is on a level.
6 RB238-6543Δ Pedal 1
RB238-6595Δ Bolt 1
02572-50100 Anti-rotation nut 1
Lever assembly
7 RB238-6506Δ 1
(swing pedal)
Lever (swing
RA221-6547Δ 1
pedal)
08511-01410 Bushing 2
8 04011-60140 Plain washer 1
05525-51400 Snap pin 1
II-S-52
No. Parts Name Q'ty No. Parts Name Q'ty

010 Lever assembly (swing 1) 1 170 Plain washer 1
020 Bushing 2 180 Snap pin 2
030 Lever assembly (swing 2) 1 190 Rod (swing) 1
040 Bushing 1 200 Rod end right-threaded screw 1
050 Plain washer 2 210 Nut 2
060 Snap pin 1 220 Spring washer 1
070 Rod end right-threaded screw (male) 1 230 Plain washer 1
080 Rod end right-threaded screw 2 240 Snap pin 2
090 Bolt (M8) 1 250 Pedal 1
100 Spring washer 1 260 Sheet (pedal) 1
110 Nut 1 270 Bolt 1
120 Headed pin 1 280 Plain washer 1
130 Snap pin 1 290 Anti-rotation nut 1
140 Link (operation) 1 300 Bracket (stopper) 1
150 Lever assembly (swing 3) 1 310 Trim (75.T4.5.U rubber) 1
160 Bushing 2 320 Bolt 2
II-S-53
g. Service Port Pedal

SP type only
No. Part Code Part Name Q’ty

Lever assembly
1 RB238-6508Δ 1
(SP pedal)
(1) (2) (4) RA221-6552Δ Lever (SP pedal) 1
08511-01410 Bushing 2
2 RB238-6543Δ Pedal 1
RB238-6595Δ Bolt 1
(101) reference

02572-50100 Anti-rotation nut 1
3 RA2221-6546Δ Rod (SP) 1
Rod end, right-
66021-4337 1
hand threaded
02114-60080 Nut 2
(3) 04512-60080 Spring washer 1
05525-61000 Snap pin 1
Move the pedal to the neutral position
4
and make sure its top is on a level.
(1)
(1) Shaft
II-S-54
h. Pilot Control Valve

(2) (1) (3)
(4)
(5)
(1) Lever directions

(6) (2) PV, right
(3) PV, left
(4) Front
(5) Nut
(6) Do not turn this part.

Fitting directions of grips Have the grip's projection forward. Different lever position
Left (RB101-6561Δ) ↓
Right (RC411-6562Δ) Control failure
Setup dimensions of operation See left. Malpositioned
lever (Reference value) ↓
Control failure
Lever move-up position See left. Malpositioned
Do not pull the hose by force. ↓
Kinky hose
↓
Damaged hose, oil leak
Tightening torque of lever lock For both sides Turning lever
nut (02052-60140) 39.0 ~ 43.0 N·m (4.0 ~ 4.4 kgf·m) (28.77 ~ 31.72 ft·lbf) ↓
Do not turn the hex PV nut. Control failure
Loose lever Within 2 mm Too loose
↓
Unspecified stroke
↓
Interference with nearby parts
Left (RB101-6561Δ) ↓
Fitting direction of grip lock nut Have the stepped (processed) side toward the grip. Wrong direction
(RC301-6524Δ) ↓
Tube not fixed properly
Tightening torque Poor tightness
25.0 ~ 27.0 N·m (2.5 ~ 2.8 kgf·m) (18.44 ~ 19.92 ft·lbf) ↓
Loose
↓
Control failure
Horn harness routing Pass the harness through the opening of the pilot valve. Contact
Install the vinyl tube (RB101-5339Δ) down into the opening of ↓
the lever. Apply tape to the other end. With the lever movement Cover peel-off
in mind, give the harness length some allowance. ↓
Short-circuit
II-S-55
570 mm (7) (8)

(22.4 in)
(9) (10)
(0.39 in)
10 mm
(11)
(12)
(13)
(14)
(15)
(16)
(21)
(17) (20)
(18)
(22)
(19)
(7) Reference value

(8) Grip to face forward
(9) Lever to face inward
(10) Lever lock position
(11) Within 2 mm out of position
(12) Plain washer
(13) Nut
(14) Bellows
(15) Position the stepped side opposite to the grip. Fit the bellows' rubber projection tightly to the step.
(16) Insert the protective tube down into the opening.
(17) Tube (vinyl)
(18) Apply tape to the end.
(19) Connector
(20) Design value: 160 mm (6.3 in.)
(21) Nut
II-S-56
(7)
(8)
No. Part Name Q’ty Remarks

1 Cover (PV) 1 Both sides
2 Plate (PV cover) 1 Both sides
3 Plug 1 Both sides
4 Tape (sealing) 1 Right only
(7) Cover (right, EU)

(8) Bracket (operation, R)
II-S-57
i. 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 outward B
(6) Lock lever, (R)
II-S-58
j. Seat and Seat Belt
(20)
(21)
(10)(11) (12)(13)(14) (1) (2) (15)

(19)
(22)
(16)(17)(18)
(23)
(3)(4)
(6) (5) (7)(8)(9)

(24)

Applying the Tightening torque (9T) Poor tightness
1 Seat assembly (canopy) 1
seat belt 60.8 ~ 70.6 N·m ↓
(6.2 ~ 7.2 kgf·m) Slack or looseness 2 Flange nut 4 4T
(44.8 ~ 52.1 ft·lbs) ↓ 3 Stopper (seat) 1
Come-off 4 Bolt 1 7T
Fitting the Apply grease to the Failure to apply grease
5 Bracket (seat) 1
sliding seat sliding rails. ↓
Earlier wear-out, rusty rails 6 Pin (seat lock) 1
to get the seat stuck 7 Tension spring 1
8 Plain washer 1
Finally move the seat Poor fitting
9 Snap ring 1
to make sure it slides ↓
smoothly. Impossible to slide along 10 Bracket (2, seat) 1
11 Bolt 2 7T
Seat belt
19 12 Pin (seat) 1
For both right and left, To be applied before setting up the canopy (ROPS, EU)
20 Canopy (ROPS, EU) 13 Plain washer 1
21 Seat belt (for both right and left) 14 Snap pin 1
22 E (left front) 15 Seat belt assembly 1
23 Mount in position with the hole forward. 16 Bolt 2 9T
24 Using a jig, place the part in parallel with the rail and tighten up the bolt. 17 Plain washer 2
18 Plain washer 2
II-S-59
k. Wrist Rest
(6)
(7) (8)
Item Points to remember No. Part Name Q’ty Remarks

Positioning Secure the rests at Wrong positioning 1 Bracket (wrist rest, L) 1
the wrist their bottom. ↓
rests Poor appearance 2 Bracket (wrist rest, R) 1
3 Wrist rest 2 Same for right and left
4 Bolt 4
5 Nut 4
6 Note the positions of the bolts.
7 (Operation box, left)
8 (Operation box, right)
(Installation of Arm rest for KTA)
(1) Fitting of the armrest (for both sides) (For both sides)
Fit the armrests as shown at left.
Insufficient tightening
↓
Loose bolt
↓
Come-off
(2) Bolt tightening torque

M8
23.5-27.5 N·m (2.4-2.8 kgf-m)
17.4-20.3 ft·lbs
Insufficient tightening
↓ (3)
Loose bolt (1) (2) (1) Stand support collar
↓ 63611-52322
(2) Plain washer
Come-off 04013-50080
(3) Bolt
01153-50822
II-S-60
l. Canopy
(1)
(10)(11) (2)(3)(4)
(5)(6)(7)(8)(9) (5)(6)(7)(8)
(12)
(13)

Applying the studs Tightening torque (4T) Looseness
(RA228-4535Δ) 107.9 ~ 125.5 N·m ↓
(11.0 ~ 12.8 kgf·m) Come-off
(79.6 ~ 92.6 ft·lbs) No. Part Name Q’ty Remarks
(Apply screw adhesive.) 1 Canopy (ROPS, EU) 1
Setting up the can- Tightening torque Poor tightness
2 Bolt 2 9T
opy (ROPS, EU) ↓
(RA228-4531Δ) Slack or looseness 3 Spring washer 2
↓ 4 Plain washer 2
Bolt (9T) Bolt damaged or broken
5 Stud 2 9T
(01176-61435) 166.7 ~ 196.1 N·m
(17.0 ~ 20.0 kgf·m) 6 Plain washer 2
(123.0 ~ 144.7 ft·lbs)
7 Spring washer 2
Nut (M14)
(7T) 8 Nut (M14) 2
(RA228-4536Δ)
123.6 ~ 147.1 N·m
(12.6 ~ 15.0 kgf·m) 9 Collar (M5) 1
(91.1 ~ 108.5 ft·lbs) 10 Tool box 1
11 Bolt 2 7T
12 Cushion (hood, cabin)) 2
13 Tool box (with the cover open)
II-S-61
(Stud bolt)
II-S-62
m.Weight
Installation of counterweight Stud Loose
A (RA211-4821Δ) (01517-51460) ↓
Tightening torque Come-off
107.9 ~ 125.5 N·m
(11.0 ~ 12.8 kgf·m)
(79.6 ~ 92.6 ft·lbf)
(Apply thread adhesive.)
Nut Loose
(02174-60140) ↓
Tightening torque Come-off
107.9 ~ 125.5 N·m
(11.0 ~ 12.8 kgf·m)
(79.6 ~ 92.6 ft·lbf)
(Apply thread adhesive.)

1 RA221-4821Δ Counterweight 1 205kg
2 01517-51460 Stud 2 7T M14 x 60L
3 04011-60140 Plain washer 2
4 04512-60140 Spring washer 2
5 02174-60140 Nut 2 4T
6 90585-1199Δ Plug 2 M16 x 2 (medium pitch)

1 RA221-4821-4 Counterweight 1
2 01517-51460 Stud bolt 2
3 04013-60140 Plain washer 2
4 04512-60140 Spring washer 2
5 02174-60140 Nut 2
6 90585-1190-0 Plug 2
II-S-63
II-S-64
D. 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
1
(4)
(5)
10 ~ 15 mm
(0.39 ~ 0.59 inch)
10 ~ 15 mm
(0.39 ~ 0.59 inch)

1 RA231-2130Δ Idler assembly 2
2 RA231-2150Δ Cylinder assembly (left) 1 Track (left)
RA231-2160Δ Cylinder assembly (right) 1
3 RC101-2155Δ Grease fitting (grease cylinder) 2 Track (Right)
(4) Joint
(5) For the rubber crawler, make such adjustment that the joint marking ( ) comes at the top center (see below).
II-S-65
(8)
1 2 3 4
No. Part Code Part Name Q’ty Remarks (8) Identifiable cast line provided on the
1 RA231-2340Δ Assy idler 2 Specific for iron crawler side to fit the RB237-2130Δ (idler
assembly)
2 RA231-2150Δ Assy cylinder, left 1 Track (left)
RA231-2160Δ Assy cylinder, right 1 Track (right)
3 RC101-2155Δ Nipple, grease cylinder 2
4 RA231-2112Δ Frame, track (left) 1
RA231-2113Δ Frame, track (right) 1
(9) 5 6 7
(10)
No. Part Code Part Name Q’ty Remarks (9) Attaching the guide plate and sliding
plate on the iron crawler type
Specific for iron crawler, 2 pcs. (10) Pay attention to the sliding plate
5 RA231-2318Δ Guide 4
each for left and right location.
6 01133-61030 Bolt 12
7 90545-11341 Plug 4
(11)
25 ~ 30 mm
(11) Adjusting the crawler tension
II-S-66
(2) Grease cylinder installation

3 4 5 1. Apply grease on dust seal, O-ring
(7) and backup ring.
2. Mating surface of backup ring
should be in side direction.
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
1 2 6 (8) 6. Apply grease and adjust the rubber
track sag distance.
7. Rubber track sag distance:
(9) (4) 10 ~ 15 mm
(0.39 ~ 0.59 inch)
8. Precaution:
Rotate track for 5 to 6 times and
measure the distance with “∞“ mark
at top position.
90° 90°
(7) A - part
(10) (8) Before fitting the grease fitting assembly
(6), insert the cylinder proper in position in
the track frame.
(9) Backup ring mating face
(10) Position the backup ring mating face within
the 90° range as shown above.
II-S-67
b. Track Roller
(3)
2
1 1 RA231-2170Δ Assy roller, truck 6 6

2 RC601-21851 Bolt 12 12 M12 x 1.25 x L30
(4) (3) Plate (sliding plate)

(4) Ensure a final clearance of below 1.5 mm.
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 screw lock (loctite 271) on the female 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.)
5. Slide plate: Tightening torque 48.1 ~ 155.9 N·m (4.9 ~ 5.7 kgf·m)(35.4 ~ 41.2 ft·lbf)
Apply screw lock agent (Loctite 271)
Notes:
1. Apply oil in the bearings. (40 cc (2.44 cn.in.))
2. Use Kubota Genuine Oil M80B or equivalent.
3. Be careful not to confuse the front and back of the
shaft circlip.
(Position the circlip so that its dull side to fit in the
groove should be inward and its sharp side out-
ward.)
4. Finally check for smooth rotation.
5. The setup dimensions and procedures for the seal
and other parts are the same as RA211-2170Δ.
II-S-68
WSM U17-3α/U17-3/U17 Mechanism III. ENGINE
III. ENGINE
Mechanism Section
A. ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-3

B. NEW EMISSIONS CONTROL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-7
a. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-7
b. Engine List for Minor Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-8 2
III-M-1
III-M-2
A. ENGINE SPECIFICATIONS
1. Main specifications
Machine model U17-3α U17/U17-3
Engine Model D902-BH-1 D902-E3-BH-2

No. of cylinder 3
mm 72 x 73.6
Bore x Stroke
in 2.83 x 2.90
cc 898
Displacement
in3 54.8
SAE kW/rpm 12.3/2300 12.0/2300
Max. output/rpm J1995 PS/rpm 16.7/2300 16.3/2300
Gross HP/rpm 16.5/2300 16.1/2300
Compression ratio 24
>
SAE N·m 54.6 = 52.1
>
Max. torque J1995 kgf·m 5.57 = 5.31
Gross ft·lbf 38.4
>
40.3 =
mm 473 x 402 x 546
Dimensions: L x W x H
in. 18.6 x 15.8 x 21.5
kg 72
Dry weight
lbs 159
mm 0.145-0.185
Valve clearance
in. 0.0057-0.0073
Firing sequence 1-2-3
Combustion chamber E-TVCS
Mpa 2.84-3.24
Compression pressure
(A)/(B) kgf/cm2 29-33
psi 412-469
Fan belt RPF2325
g/kWh 265
Fuel consumption ratio g/Psh 195
lbs/Hph 0.435
l/h 3.7
Fuel consumption
gal/h 0.98
Max. speed without load rpm 2670 >
=
>
Speed with 2 pumps relief rpm 2300 =
Speed with idling rpm 1200--1300
kPa 196-441
Engine oil pressure
with rated engine rpm kgf/cm2 2.0-4.5
psi 28.4-64.0
MPa 13.7
Injection pressure kgf/cm2 140
psi 1991
Cooling system Pressurized radiator (0.088 MPa, 0.9 kgf/cm2), water pump
g/kWh 0.95
Engine oil consumption ratio g/Psh 0.7
lbs/Hph 0.0016
III-M-3
2. Engine electric components

Machine model U17-3α U17/U17-3
Engine Model D902-BH-1 D902-E3-BH-2

Fuel injection pump type Bosch MDtype mini-pump
Nozzle type DN4PD62 mini-nozzle
Mpa 13.7
Injection pressure kgf/cm2 140
psi 1991
Dynomo 12V 480W
Manufacturer P/N 100211-1670
Regulator adjusting voltage V 14.2-14.8
Battery type YUASA
Nominal capacity of 5hrs rating Ah 36
Specific gravity of electrolite 1.28
Starter motor 12V 1.4KW
Manufacturer P/N 228000-0991
Glow plug Ω 1.5
3. Engine model and type code No.

Engine mode Type code No. Market
D902-BH-1 1G709-00000 EU
D902-E3-BH1 1G709-01000 Japan
D902-E3-BH2 1G709-02000 KTC, KTA
III-M-4 2
4. Machine model: U17-3α

Engine model: D902-BH-1
III-M-5
5. Machine model: U17/U17-3

Engine model: D902-E3-BH-2
III-M-6
B. NEW EMISSIONS CONTROL ENGINES

a. Outline
Tier 4 and Interim Tier 4 Engines for North American Market and Stage III A Engines for EU requirements
have been launched and mounted on Kubota Construction Machinery.
FEATURES and BENEFITS
Emissions
• Kubota Super Mini Series, the most compact multi-cylinder liquid cooled industrial diesel engines, com-
plies with EPA Tier 4 emissions regulations. These are the most stringent emissions regulations in the
world in this class.
• The 03-M Series engine complies with EPA Interim Tier 4 emissions regulations that are effective
through the end of 2012. This engine also complies with EU Stage III A requirements that are effective
through 2012 and beyond in the European market.
Durable Power
• The Kubota Super Mini Series has been chosen as a power source for a variety of applications since it
was first launched 25 years ago. It has become the benchmark in the compact diesel engine market.
• The D722 engine offers a seamless transition from Tier 2 to Tier 4 by totally maintaining the same perfor-
mance and physical characteristics of the previous Tier 2 engines.
• The Kubota 03-M Series is well recognized for industrial applications. With numerous features such as a
built-in solenoid, low fan position, and single side serviceability, this engine offers excellent performance
characteristics and application flexibility.
• The cooling water passages between the cylinder bores, using Kubota's original casting technology as a
countermeasure against heat load of high power density, provides both superior endurance and reliable
engine characteristics.
• The 03-M engine offers a seamless transition from Tier 2 to Interim Tier 4 by maintaining the same foot-
print and hard mounting points with only slight performance changes from the Tier 2 engine.
Clean and Quiet Power

• Kubota's original E-TVCS (Three Vortex Combustion System) has been improved. The airflow, combus-
tion chamber and piston recess were optimized to provide a 50% lower particulate matter (PM) level, the
same stringent level as above the 37kW class (EPA Interim Tier 4 Option 1).
• The half-float valve cover and MoS2 coated pistons lower noise levels by 1.0-2.0 dBA over conventional
diesel engines and provide reduced transmitted vibration from the valve area for better noise character-
istics.
III-M-7
b. Engine List for Minor Change

Fuel
Rated output Rated Torque consumption
Machine
No. Market Engine type Code No. SAE1349 NET SAE1349 NET ratio Remarks
Model
(kW/rpm) (N·m) SAE 1349 NET
g/kWh
1 K008-3 PP D722-E3-BH-3 1G408-01000 7.5/2050 39.1 255 Tier 4
2 U15 PP D782-E3-BH-4 1G409-00000 9.3/2300 43.3 270
3 U17/U17-3 PP D902-E3-BH-2 1G709-02000 11.3/2300 50.1 265
4 U17-3α EU D902-BH-1 16791-01000 11.6/2300 52.6 265 -
5 KX41-3 PP D902-E3-BH 1G709-00000 11.3/2300 50.1 265 Tier 4
6 U25S PP D1105-E3-BH-14 1G873-20000 14.8/2400 69.2 269
7 KX71-3S PP V1505-E3-BH-10 1G090-30000 19.0/2300 90.9 267
Interim Tier 4
8 KX91-3S2 PP D1703-M-E3-BH-US2 1G652-10000 20.1/2250 99.6 259
9 U35S2 PP D1703-M-E3-BH-US1 1G652-00000 20.1/2250 99.6 259
10 KX91-3α EU D1503-M-EBH-3-EC-N 1G723-50000 - Stage III A
KX101-3α EU D1503-M-EBH-4-EC-N 1G724-60000
11
U35-3α EU D1503-M-EBH-4-EC-N 1G724-60000
V2203-M-EBH-2-N 1G788-10000
12 KX121-3α EU V2203-M-EBH-3-N
1G797-10000 27.1/2250 140.7/1600 248
(AC)
V2203-M-EBH-2-N 1G788-10000
13 KX161-3α EU V2203-M-EBH-3-N
1G797-10000 27.1/2250 140.7/1600 248
(AC)
V2203-M-EBH-2-N 1G788-10000
14 U45-3α EU V2203-M-EBH-3-N
1G797-10000 27.1/2250 140.7/1600 248
(AC)
V2203-M-E3-BH-US1 1G655-00000 27.7/2250 137.0/1600 250 Interim Tier 4
15 KX121-3S PP V2203-M-E3-BH-US2 1G655-10000
27.4/2250 136.4/1600 253
(AC) (AC)
V2203-M-E3-BH-US1 1G655-00000 27.7/2250 137.0/1600 250
16 U45S PP V2203-M-E3-BH-US3 1G655-20000
26.9/2250 135.4/1600 257
(AC) (AC)
17 V2403-M-E3-BH-US1 1G604-00000 31.1/2300 151.4/1600 256
KX161-3S PP V2403-M-E3-BH-US2 1G604-10000
18 30.6/2300 150.4/1600 260
(AC) (AC)
19 R310α EU V1305-E2-RP-2 1G078-20000 -
20 R320S PP V1305-E3-RP 1G078-30000 17.3/2600 75.6/1900 274 Tier 4
21 R420S PP D1503-M-TE3-WL-US1 1G497-00000 27.7/2600 122.2/1600 268 Interim Tier 4
22 R420α EU D1503-M-T-E2RP-1 1G734-00000 Stage III A
23 R520S PP V2203-M-E3-WL-US1 1G493-00000 31.1/2600 139.8/1600 261 Interim Tier 4
24 R520α EU V2203-M-E2RP 1G789-00000 Stage III A
PP: Pan-Pacific-version, KTA, KCL, KTC

EU: European-version
III-M-8 2
WSM U17-3α/U17-3/U17 Service III. ENGINE
III. ENGINE
Service Section
A. ENGINE ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3

a. Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3
b. Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-5
c. Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-8
d. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-16
e. Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-17
f. Pump Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-20
g. Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-21
h. Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-25
i. Engine Outlook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-26
Engine WSM : SM-E3B SERIES
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) (8) (9)
(1) Anti-vibration rubber

(2) Cover (rubber sheet)
(3) Part R
(4) Bracket (engine, rear)
(1) (5) Anti-vibration rubber
(6) Bracket (engine, rear)
(7) Stopper (engine)
(8) Pipe joint (water temperature)
(2) (9) Sensor (temperature)
(3)
(6)
(4) (7)
(5)
III-S-3

010 RA211-4223-0 Bracket (engine, rear) 1
020 RA221-4212-0 Bracket (engine, rear) 1
025 RA221-4213-3 Stopper (engine) 1
026 01133-61020 Bolt 2
030 01133-61025 Bolt 6
040 68051-4216-0 Anti-vibration rubber 4
050 04512-60100 Spring washer 8
060 02118-60100 Nut 8
065 04013-60100 Plain washer 4
070 RC101-4217-0 Cover (rubber sheet) 4
III-S-4
b. Air Cleaner
<Outer element> P/N=6C060-99411
Filtering area: 0.45 m2, nominal, 10 μ
El element paper:
Clean efficiency: 99% (JIS 8 class)
<Inner element> P/N=T0270-93221
Filtering area: 135 cm2
250 mesh
(1) Outer element

(2) Inner element (safety element)
(3) Case
(4) Dust cover
(5) Clamps
1. 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-5
2. Outer element
(Element inner dia.)
(Case outer dia.)
Item Unit Standard Conditions

Specifications Air flow resistance kPa Below 2.747 Rated air flow rate: 2.0 m3/min (67ft2/min).
(mmH2O) (below 280) Test dust: JIS Z8901, Class 8 powder
Cleaning efficiency % Initial Full life Dust concentration: 1 g/m3
Air flow resistance: 2.94 kPa (300 mmH2O)
Above 99 Above 99.9
Full life for an increase
Dust containment g Above 50 (0.11 lbs)
Filtering area m2 0.45 (effective) (4.84 ft2)
Other conditions As per JIS D1612
Heat-resistant temperature -30°C ~ 90°C (-22°F ~ 194°F )
III-S-6
(14)
(15)
(16)

1 RA211-4220Δ Air cleaner assembly 1
2 67401-5429Δ Air cleaner band 1
3 RA221-4222Δ Hose (1, inlet) 1
4 15261-1172Δ Pipe band 1
5 15221-1172Δ Pipe band 1
6 RA221-4223Δ Hose (2, inlet) 1
7 15221-1172Δ Pipe band 1
Control item Spec. Defects 8 59700-4145Δ Clamp (wire harness) 1
Connecting of hose Position the hose Wrong angle 9 RA211-5323Δ Battery 1
(6) (2, inlet) with its end down- ↓ 10 RA221-5326Δ Retainer (battery) 1
(RA221-4223Δ) ward as shown Suction port tem-
11 T1270-4012Δ Bolt (hook) 1
below. perature rise
↓ 12 04013-60060 Plain washer 2
Engine power 13 02552-50060 Anti-rotation nut 2
drop 14 Position with the end straight down.
Ensure a clearance of 5 mm 0.2” or more between
15
the battery and return hose.
Rubber pad (fuel tank)
16
Apply instant adhesive.
III-S-7
c. Radiator
(EU-version)
(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)
10 mm, 0.39 inch or more to be ensured
A
(1) (1) (22)
B 0.87”
(13)
0.51”
(1)
(1)
(1) 10 mm (0.39”) or more
III-S-8
(PP-version)
Main difference from EU-version is the number of fan, 7 fans and so the different fan shroud.
(1) Clearance between radiator core (fin) and fan (Part A)

To be 20 mm. Fan to stretch evenly out of the fan shroud.
(2) Clearance between fan and fan shroud (Part B)

To be over 10 mm.
A B
(1) (1)
0.87”
(13)
0.51”
(1)
(1)
(1) 10 mm (0.39”) or more
III-S-9
(Structure)
( ) : in
Clamp Cap (pressure)
Cap
(1.89)
(φ0.39)
(2.20)
Hole
(φ1.10)
(φ1.18)
Through
(1.11)
(2.25)
(15.54)
(1.42)
(φ1.10)
(1.64)
(φ1.18)
(10.63)
(1.89) (11.89)
(2.20)
III-S-10
Radiator data
Diy Heading Unit (Conventional unit)
Performance specifications Condition Air flow m/s 8 (17.9 mph)
Water flow L/min 40 (10.57USGPM)
Temp difference °C 60 (140°F)
Radiator capacity kW 20.7 (17853 kcal/h)
Air resistance Pa 132.3 (13.5 mmH2O) (0.019psi)
Water resistance kPa ( mmHg)
Valve opening pressure Press kPa 2
147 (1.5 kgf/cm ) (21.34psi)
Vacuum kPa
Test pressure kPa 147 (1.5 kgf/cm2) (21.34psi)
Vibration durability Acceleration 6G
Direct Up/down
Cycle 22.3 Hz
Cycle 10°
Structural specifications Core type CF29-2
Core size Wide mm 351 (13.82 in)
Height mm 325 (12.80 in)
Thickness mm 36 (1.42 in)
Fin pitch mm 4.5/2 (0.18/0.08 in)
Radiation area Fin m2 3.78 (40.69 ft2)
Tube m2 0.89 (9.58 ft2)
Total m2 4.67 (50.27 ft2)
Front area m2 0.132 (1.42 ft2)
Water passage area cm2 12.7 (1.969 in2)
Water quantity L 1.3 (0.343 gal)
Dry weight kg 2.4 (5.29 lbs)
Surface treatment
Remarks Louver-less
III-S-11
III-S-12
18 21 17 19
(29)
22
20 21
6 13 9 12 16 15 1 4 3 2 5 22 23
10
11
24
14
(30)
26 25
27
28
(1) Assy radiator 1 (11) Trim (25) 1 (21) Hose clamp, threaded 3
(2) Shroud, fan 1 (12) Bolt 4 M6 4T (22) Hose clamp (1) 2
(3) Bolt 4 M6 4T (13) Oil cooler 1 (23) Hose clamp, threaded 1
(4) Trim (5) 1 (14) Bolt 2 M8 7T (24) Hose, drain 1
(5) Grommet (30) 1 (15) Radiator stay 1 (25) Pipe clip 2
(6) Bracket: oil cooler 1 (16) Bolt 1 M8 7T (26) Joint, drain 1
(7) Grommet, cover 1 (17) Cap assy 1 (27) Washer 1
(8) Grommet (200) 1 (18) Hose, upper 1 1 (28) Plug 1
(9) Grommet 3 1 (19) Hose, upper 2 1 (29) Hose clamp to be oriented horizontally
(10) Trim (135) 1 (20) Hose, lower 1 (30) Hose clamp to be oriented vertically
III-S-13
(1) (3)
(2)
(4)
(13)
(3)
(1) Hose (drain)

RA111-4243Δ
(2) Tank assembly (reserve)
RA221-4240Δ
(3) Secure the hose (2, inlet)
with the quick-on clamp.
(4) Tighten the wire harness
together with the quick-on
clamp.
No. Part Code Part Name Q’ty Remarks Item Points to remember
1 01125-60818 Bolt 1 M8 7T Fitting of radiator cush- Fit the rubber Poor fitting
2 RA221-4238Δ Shroud (fan) 1 ion (6C040-5858Δ) to hook tight into ↓
3 RA221-4231Δ Bracket (radiator) 1 bracket position. Greater vibrations
↓
4 01133-61025 Bolt 2 M10 x 1.25 7T Damage
5 60040-5858Δ Cushion (radiator) 2
6 01202-60616 Bolt 2 M6 4T
7 04015-60060 Plain washer 2
8 RA221-4248Δ Stay (reserve tank) 1 M8 7T
9 01125-60816 Bolt 2
Tank assembly
10 RA221-4240Δ 1
(reserve)
11 RA111-4243Δ Hose (drain) 1
12 55411-2179Δ Horn 1
13 Vinyl clamp
III-S-14

010 RA221-4230-0 Radiator assembly 1
020 RC411-4239-0 Cap 1
030 RC411-4251-0 Clamp 1
040 RC411-4254-0 Cap (pressure) 1
050 RA221-4238-2 Shroud (fan) 1
060 01205-60620 Bolt 4
070 RP821-4239-0 Trim (5) 1
080 RP301-4234-0 Grommet (30) 1
090 RA221-4237-0 Bracket (oil cooler) 1
100 5K281-6236-0 Grommet (cover) 1
105 68311-4238-0 Grommet (200) 1
110 68748-4253-0 Grommet 3 1
120 RC411-4127-0 Trim (135) 1
130 RP201-6997-0 Sealing rubber 4 1
140 01205-60616 Bolt 4
150 RA221-4231-0 Bracket (radiator) 1
160 01133-61020 Bolt 2
170 6C040-5858-0 Cushion (radiator) 2
180 RA221-4236-0 Stay (radiator) 1
190 01125-60818 Bolt 2

010 RC411-4231-0 Cap assembly 1
020 17214-7202-0 Cap assembly 1
030 01202-60616 Bolt 2
040 04015-60060 Plain washer 2
050 RA221-4232-0 Hose (1, upper) 1
060 RA221-4233-0 Hose (2, upper) 1
070 RA221-4234-0 Hose (lower) 1
080 09318-89045 Hose clamp 3
090 RA021-4271-0 Hose clamp (1) 2
100 09318-89039 Hose clamp 1
110 RA221-4235-0 Hose (drain) 1
120 33860-0459-0 Pipe clip 2
130 RP821-4231-0 Joint (drain) 1
140 04717-01000 Rubber-fitted washer 1
150 06331-35010 Plug 1
160 01133-61020 Bolt 2
170 RA221-4248-3 Stay (reserve tank) 1
180 01125-60816 Bolt 2
190 RA221-4240-0 Tank assembly (reserve) 1
200 04816-00380 O-ring 1
210 RA221-4250-0 Cap assembly 1
220 37410-8864-0 Cap 1
230 37410-8865-0 Hose 1 1
240 37410-8868-0 Grip 2
250 RP312-7093-0 Hose 1
260 RA111-4243-0 Hose (drain) 1
270 55411-2179-2 Horn 1
III-S-15
d. Thermostat
P/N=19434-73011
Applied model=
Identify with black marking
Performance:
ink on the shaded spot.
8mm
(0.31”)
Lift
Mark the
Mark the valve opening manufacturing
temperature here. date here.
Mark the
manufacturer
logo here.
71°C (160 °F) 85°C (185 °F)
Approx. 10°C
(50 °F)
(8)
Valve opening temp. Full lift temp.
(6) (5)
(1)
(1) Seat
(3) (2) Body
(2)
(3) Valve
(4) Spring
(4) (5) Stopper
(7) (6) Shaft
(7) Pellet
(8) Adjust pin
III-S-16
e. Muffler
(1) Fitting of the flange (muffler) (3) Ensuring of a clearance between pipe (muf-
Tightening torque: 23.5 ~ 27.5 N·m fler) outlet and counterweight hole
(2.4 ~ 2.8 kgf·m)
(2) (1)
<Failure case>
Poor tightness
↓
Emission leak
Unusual noise
(2) Place the hose clamp (RD411-6382Δ) with
the bolt at the machine back as shown at
left. Tighten up the bolt from above.
<Failure case> (3)
Poor tightness (4)
↓
Emission leak
Sound absorber damaged (1) Clearance to be over 20 mm (inch)
Unusual noise (2) Tail pipe
(3) Weight
(4) Tail pipe not to stretch out of the weight end.
<Failure case>
Tail pipe in contact with counterweight
↓
Unusual noise
Marketability reduced
Tail pipe stretching out

↓
Damage
III-S-17
(4) Fitting procedure

Temporary tightening of bolts (A), (B) and (C) ' No gap allowed at mating faces
Bolt (A) to be tightened up first ' Tightening torque 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m)
Bolt (B) to be tightened up second ' Tightening torque 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m)
Bolt (C) to be tightened up third ' Tightening torque 3.9 ~ 5.9 N·m (0.4 ~ 0.6 kgf·m)
<Failure case>
Gap found
Wrong fitting procedure
↓ (9)
Pipe or bracket cracked
↓
Damage

Packing
1 15313-1237Δ 1
(non-asbestos)
2 RA221-4246Δ Flange (muffler) 1
3 01133-61025Δ Bolt 2 M10 x 1.25 7T
4 RA221-4244Δ Muffler 1
5 RD411-6382Δ Hose clamp (32-44) 2
Thermal insulator
6 RD201-4183Δ 1
(muffler band)
7 RA221-5242Δ Bracket (muffler) 1
8 01135-61020 Bolt 4 M10 x 1.25 7T
9 Tighten above the slit of muffler.
III-S-18
(5) 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

010 15313-1237 Packing (non-asbestos) 1
020 RA221-4246-0 Flange (muffler) 1
030 01133-61025 Bolt 2
040 RA221-4244-0 Muffler 1
050 RD411-6382-0 Hose clamp (32-44) 2
060 RD201-4183-2 Thermal insulator (muffler band) 1
070 RA221-4242-0 Bracket (muffler) 1
080 01135-61020 Bolt 4
III-S-19
f. Pump Coupling
(1) Apply grease on spline section (1)
Proper amount to be applied (No overflow allowed)
No grease to be stuck on the rubber
Wipe off grease immediately as required.
(2) Tighten coupling bolts
(2)
(RB238-4262U) A
Tightening torque: 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m)
(35.4 ~ 41.2 ft·lbs)
* MEC (Micro Encapsulation)-treated bolts are used

here. In this case, therefore, do not apply any
screw adhesive. (3)
(4)
(5)
(1) Housing (pump)
RB238-4261Δ
(2) Coupling
RB238-4262Δ
(3) Coupling mounting bolt
(4) Apply grease to the spline.
(5) Finally cut off the tape from around.
010 Housing, pump

020 Bolt
030 Bolt
050 Pin, Straight
070 Coupling
080 Assy pump, Piston
090 Bolt
III-S-20
g. Fuel Tank
III-S-21
(11)
(1)
(2)
(3)
(4)
(8)
(7) (6) (10)

(5)
(9)
(1) Water separator

(2) Filter assembly (fuel)
(12) (3) Water separator
(4) Guide
(5) Fuel tank
(6) Arch
(13) (7) Pass the fuel hose above the
guide and tighten the vinyl
clamp to bind them together.
(8) Clamp
(9) Fuel tank (bottom)
(10) Fuel tank (top)
(11) Pump assembly (fuel)
(12) Engine injection pump
(13) Engine fuel return port
(14) Pass through this opening.
(14)
III-S-22
(1) Fitting of the sensor (fuel) (RA231-5125U) and plate (RA221-5115U)

Tightening torque of M5 machine screw:
2.0 ~ 2.94 N·m (0.2 ~ 0.3 kgf·m)
<Failure case>
Poor tightness
↓
Come-off
Over-tightness
↓
Damage
(1) Housing (pump)

(2) Fuel tank
(3) Fuel filter assembly
(4) Sensor (fuel)
(5) Washer-fitted machine screw
(6) Fuel level gauge assembly
(7) Plate
(8) Packing
(9) Washer-fitted machine screw
(10) 15.9 liters to remain from the suction level
(11) 2.1 liters to remain from the suction level
(10)
(11)
III-S-23

010 RA221-5110-0 Fuel tank assembly 1
020 68701-5112-0 Cap assembly (fuel) 1
030 35450-4106-0 Fuel filter assembly 1
040 10211-4134-0 Packing 1
050 RA221-5125-0 Sensor (fuel) 1
055 69254-7938-0 Bracket (coupler) 1
060 03024-50514 Washer-fitted machine screw 5
070 18400-4170-0 Fuel gauge assembly 1
080 3G700-1819-0 Cushion 1
090 RA221-5114-0 Cushion (1, fuel tank) 1
100 RA221-5113-2 Retainer (fuel tank) 1
110 01135-61020 Bolt 2
120 RA211-5116-0 Cushion (2, fuel tank) 1
(4)
(5)
(1)
(6)
(2)
(3)
(7)
(1) Clamp
(2) Pass above the dozer cable.
(3) Pass behind the tank L member.
(4) Top of tank
(5) Clamp
(6) Pass below the cover (tank, return).
(7) Bottom of tank
III-S-24
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

* mark 14911-42751U
# mark 14971-42751U
(13)
(10) (14)
(11)
(12)
(15)
Part A
(19)
(20)
(18)
(17) (16)
(1) Fuel tube (11) Engine injection pump

(2) Tube (1) (12) Engine fuel return port
(3) Fuel tube, Tube (420) (13) Pipe joint (T-S)
(4) Fuel tube (14) T pipe joint
(5) Fuel tube (15) Joint (fuel drain)
(6) Fuel tube (16) Fuel tank assembly
(7) Fuel tube (17) Filter assembly (fuel)
(8) Fuel tube (18) Fuel pipe assembly
(9) Fuel tube, Tube (470) (19) Pump assembly (fuel)
(10) Pump assembly (fuel) (20) Straight pipe joint
III-S-25
i. Engine Outlook
1. Top view 2. Side view
3. Inside view 4. Radiator
III-S-26
WORKSHOP MANUAL
DIESEL ENGINE
SM-E3B SERIES
TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of SM-E3B series. It is divided
into three parts, “General”, “Mechanism” and “Servicing”.
Q General
Information on the engine identification, the general precautions, maintenance check
list, check and maintenance and special tools are described.
Q 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. 9Y021-01875) for
the one which has not been described to this workshop manual.
Q Servicing
Information on the troubleshooting, servicing specification lists, tightening torque,
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.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
March 2007
© KUBOTA Corporation 2007
This engine WSM has been compiled by Kubota Kikai Service Ltd. in Sakai and the
Engine Division. Kubota produces basic standard engine WSM per its series. Adding
this WSM to Construction Machinery WSM is to meet requests from the dealers in
overseas, which is required when they overhaul and assemble. Engine performance is
optimized for each use so that some main data, such as engine output, torque and RPM
may differ from basic specifications. About those main specifications, please refer to the
data regarding engine mounted construction machinery at the Chapter III.
Thank you for you understanding and corporation.
July 2008
SM-E3B SERIES WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
Q IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
Q NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
1 KiSC issued 10, 2007 A

SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the engine
is running.
• 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.
• 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.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair or
fuel lines, sensors, or any other components between
the high-pressure fuel pump and injectors on engines
with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in the
ECU, and is applied to the injector.
Pay sufficient caution to electric shock when
performing work activities.

AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA

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

• 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.
PREVENT ACID BURNS

• 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.

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.

SM-E3B SERIES WSM SPECIFICATIONS
SPECIFICATIONS
Model Z482-E3B Z602-E3B
Number of Cylinders 2
Type Vertical, Water-cooled, 4 cycle IDI diesel engine
Bore × Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.)
Total Displacement 479.0 cm3 (29.23 cu.in.) 599.0 cm3 (36.55 cu.in.)
8.10 kW / 3600 min-1 (rpm) 10.1 kW / 3600 min-1 ( rpm)
ISO Net Continous
(10.9 HP / 3600 min-1 (rpm)) (13.5 HP / 3600 min-1 (rpm))
ISO / SAE Net Intermittent
SAE Gross Intermittent
Maximum Bare Speed 3800 min-1 (rpm)
Minimum Bare Idling Speed 900 to 1000 min-1 (rpm)
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “Throttle” type
Injection Timing 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 23.5 : 1 24 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine)
Starting System Electric Starting with Starter
Starting Motor 12 V, 0.8 kW 12 V, 1.0 kW
Starting Support Device By glow plug in combustion chamber
EGR None
Battery 12 V, 28 AH equivalent 12 V, 36 AH equivalent
Charging Alternator 12 V, 150 W 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Class CF lubricating oil as per API classification is recommended.
Lubricating Oil
For details on recommended lubricating oils, see page G-6, 9
Oil Pan Depth
2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals)
Lubricating Oil 101 mm (3.98 in.)
Capacity Oil Pan Depth
2.5 L (0.66 U.S.gals) –
121 mm (4.76 in.)
Weight (Dry) kg (lbs) 53.1 (117) 60.0 (132)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10336300

SM-E3B SERIES WSM SPECIFICATIONS
Model D722-E3B D782-E3B D902-E3B

Number of Cylinders 3
Type Vertical, Water-cooled, 4 cycle IDI diesel engine
67.0 × 68.0 mm 67.0 × 73.6 mm 72.0 × 73.6 mm
Bore × Stroke
(2.64 × 2.68 in.) (2.64 × 2.90 in.) (2.83 × 2.90 in.)
Total Displacement 719.0 cm3 (43.88 cu.in.) 778.0 cm3 (47.48 cu.in.) 898.0 cm3 (54.80 cu.in.)
12.0 kW / 3600 min-1 (rpm) 11.7 kW / 3200 min-1 (rpm) 15.2 kW / 3600 min-1 (rpm)
ISO Net Continuous
(16.4 HP / 3600 min-1 (rpm)) (15.7 HP / 3200 min-1 (rpm)) (20.4 HP / 3600 min-1 (rpm))
ISO / SAE Net Intermittent
SAE Gross Intermittent
Maximum Bare Speed 3800 min-1 (rpm) 3450 min-1 (rpm) 3800 min-1 (rpm)
Minimum Bare Idling Speed 900 to 1000 min-1 (rpm)
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “Throttle” type
Injection Timing 0.37 rad (21 °) before T.D.C. 0.30 rad (17 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2-3
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 23.5 : 1 24 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical type switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine)
Starting System Electric Starting with Starter
Starting Motor 12 V, 0.8 kW 12 V, 1.0 kW 12 V, 1.2 kW
Starting Support Device By glow plug in combustion chamber
EGR None
Battery 12 V, 36 AH equivalent 12 V, 52 AH equivalent
Charging Alternator 12 V, 150 W 12 V, 480 W
Fuel Diesel Fuel No.2-D (ASTM D975)
Class CF lubricating oil as per API classification is recommended.
Lubricating Oil
For details on recommended lubricating oils, see page G-6, 9
Oil Pan Depth
3.2 L (0.85 U.S.gals) – 3.7 L (0.98 U.S.gals)
Lubricating Oil 101 mm (3.98 in.)
Capacity Oil Pan Depth
3.8 L (1.0 U.S.gals) 3.6 L (0.95 U.S.gals) –
121 mm (4.76 in.)
Weight (Dry) kg (lbs) 63.0 (139) 63.5 (140) 72.0 (159)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10304910

SM-E3B SERIES WSM PERFORMANCE CURVES
PERFORMANCE CURVES
Q Z482-E3B
(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.

Q Z602-E3B
(1) Brake Horsepower (5) Gross Intermittent Torque (9) Net Intermittent B.S.F.C. (12) Gross B.H.P.
(2) Engine Speed (6) Net Intermittent Torque (10) Gross Torque (13) Overload B.H.P.
(3) B.S.F.C. (7) Gross Intermittent B.H.P. (11) Overload Torque (14) Overload B.S.F.C.
(4) Torque (8) Net Intermittent B.H.P.

Q D722-E3B
(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.

Q D782-E3B
(1) Brake Horsepower (5) Gross Intermittent Torque (9) Net Intermittent B.H.P. (13) Overload Torque
(2) Engine Speed (6) Net Intermittent Torque (10) Net Continuous B.H.P. (14) Gross B.H.P.
(3) B.S.F.C. (7) Net Continuous Torque (11) Net Intermittent B.S.F.C. (15) Overload B.H.P.
(4) Torque (8) Gross Intermittent B.H.P. (12) Gross Torque (16) Overload B.S.F.C.

Q D902-E3B
(1) Brake Horsepower (5) Gross Intermittent Torque (9) Net Intermittent B.S.F.C. (12) Gross B.H.P.
(2) Engine Speed (6) Net Intermittent Torque (10) Gross Torque (13) Overload B.H.P.
(3) B.S.F.C. (7) Gross Intermittent B.H.P. (11) Overload Torque (14) Overload B.S.F.C.
(4) Torque (8) Net Intermittent B.H.P.

SM-E3B SERIES WSM DIMENSIONS
DIMENSIONS
Q Z482-E3B

Q Z602-E3B

Q D722-E3B

Q D782-E3B

Q D902-E3B

GENERAL
CONTENTS
1. ENGINE IDENTIFICATION ............................................................................. G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER ................................ G-1
[2] E3B ENGINE............................................................................................. G-2
[3] CYLINDER NUMBER ............................................................................... G-2
2. GENERAL PRECAUTIONS ............................................................................ G-3
3. MAINTENANCE CHECK LIST ....................................................................... G-4
4. CHECK AND MAINTENANCE ....................................................................... G-7
[1] DAILY CHECK POINTS........................................................................... G-7
[2] CHECK POINTS OF INITIAL 50 HOURS ............................................. G-9
[3] CHECK POINT OF EVERY 50 HOURS ............................................. G-11
[4] CHECK POINT OF EVERY 75 HOURS ............................................. G-12
[5] CHECK POINTS OF EVERY 100 HOURS ......................................... G-13
[6] CHECK POINT OF EVERY 150 HOURS ........................................... G-16
[10]CHECK POINTS OF EVERY 1 OR 2 MONTHS ............................... G-20
[11]CHECK POINT OF EVERY YEAR....................................................... G-22
[12]CHECK POINT OF EVERY 800 HOURS ........................................... G-23
[13]CHECK POINTS OF EVERY 1500 HOURS ....................................... G-24
[14]CHECK POINTS OF EVERY 3000 HOURS ....................................... G-26
[15]CHECK POINTS OF EVERY 2 YEARS.............................................. G-29
5. SPECIAL TOOLS .......................................................................................... G-33
KiSC issued 10, 2007 A

SM-E3B SERIES WSM G 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.
Q Engine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
• Year of manufacture
Alphabet or Alphabet or
Year Year
Number Number
6 2006 H 2017
7 2007 J 2018
8 2008 K 2019
9 2009 L 2020
A 2010 M 2021
B 2011 N 2022
C 2012 P 2023
D 2013 R 2024
E 2014 S 2025
F 2015 T 2026
G 2016 V 2027
A : Engine Model Name and Serial

Number
W1010477
• Month of manufacture
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
March E0001 ~ E9999 F0001 ~ FZ999
April G0001 ~ G9999 H0001 ~ HZ999
May J0001 ~ J9999 K0001 ~ KZ999
June L0001 ~ L9999 M0001 ~ MZ999
July N0001 ~ N9999 P0001 ~ PZ999
August Q0001 ~ Q9999 R0001 ~ RZ999
September S0001 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999
* Alphabetical letters “I” and “O” are not used.
e.g. D902 - 7 B A001
(a) (b)(c) (d)
(a) Engine Model Name : D902
(b) Year : 7 indicates 2007
(c) Month : A or B indicates January
(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)
W1011076
G-1 KiSC issued 10, 2007 A

[2] E3B ENGINE

[Example : Engine Model Name D902-E3B-XXXX]
The emission controls previously implemented in various countries to prevent air pollution will be stepped up as
Non-Road Emission Standards continue to change. The timing or applicable date of the specific Non-Road Emission
regulations depends on the engine output classification.
Over the past several years, Kubota has been supplying diesel engines that comply with regulations in the
respective countries affected by Non-Road Emission regulations. For Kubota Engines, E3B will be the designation
that identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E3B series engines, use only replacement parts for that specific E3B engine,
designated by the appropriate E3B Kubota Parts List and perform all maintenance services listed in the appropriate
Kubota Operator's Manual or in the appropriate E3B Kubota Workshop Manual. Use of incorrect replacement parts
or replacement parts from other emission level engines (for example: E2B engines), may result in emission levels out
of compliance with the original E3B design and EPA or other applicable regulations.Please refer to the emission label
located on the engine head cover to identify Output classification and Emission Control Information. E3B engines are
identified with "ET" at the end of the Model designation, on the US EPA label. Please note : E3B is not marked on the
engine.
Category (1) Engine output classification EU regulation

K From 19 to less than 37 kW STAGE ΙΙΙA
J From 37 to less than 75 kW STAGE ΙΙΙA
I From 75 to less than 130 kW STAGE ΙΙΙA
Category (2) Engine output classification EPA regulation

Less than 19kW Tier 4
From 19 to less than 56 kW Interim Tier 4
ET
From 56 to less than 75 kW Tier 3
From 75 to less than 130 kW Tier 3
(1) EU regulation engine output classification category

(2) “E3B” engines are identified with “ET” at the end of the Model designation, on
the US EPA label.
“E3B” designates Tier 3 and some Interim Tier 4 / Tier 4 models, depending on
engine output classification.
W1031971
[3] 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.
W1011077

2. GENERAL PRECAUTIONS
• 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.
• 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.
• Before disassembling or servicing live wires, make sure to
always disconnect the grounding cable from the battery first.
• Remove oil and dirt from parts before measuring.
• Use only KUBOTA genuine parts for parts replacement to
maintain engine performance and to ensure safety.
• Gaskets and O-rings must be replaced during reassembly.
Apply grease to new O-rings or oil seals before assembling.
• When reassembling external or internal snap rings, position them
so that the sharp edge faces against the direction from which
force is applied.
• 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
W1011734

3. 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.
Service Interval
Item Every
50 75 100 150 200 400 500 1 or 2 1 800 1500 3000 2
hrs hrs hrs hrs hrs hrs hrs months year hrs hrs hrs years
*Checking fuel hoses and clamp ,
bands
(1) Oil pan depth
+ ,
(101 mm, 3.98 in.)
(2) Oil pan depth
Changing + ,
Engine oil (121 mm, 4.76 in.)
(3) Extended oil
pan depth + ,
(101 mm, 3.98 in.)
Checking fan belt tension and
,
damage
*Cleaning air cleaner element
(Replace the element after 6 times ,
cleaning)
Cleaning fuel filter (element type) ,
Checking battery electrolyte level ,
(1) Oil pan depth
+ ,
(101 mm, 3.98 in.)
Replacing oil (2) Oil pan depth
+ ,
filter cartridge (121 mm, 4.76 in.)
(3) Extended oil
pan depth + ,
(101 mm, 3.98 in.)
Checking radiator hoses and clamp ,
bands
*Checking intake air line ,
*Replacing fuel filter ,
Cleaning water jacket and radiator ,
interior
Replacing fan belt ,
(1) This oil pan depth is optional for Z482-E3B and D722-E3B.
(2) This oil pan depth is standard for Z482-E3B, D722-E3B and D782-E3B.
(3) This oil pan depth is standard for Z602-E3B and D902-E3B.
+ Change engine oil and replace oil filter cartridge after the first 50 hours of operation.
* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
W1029462

Service Interval
Every
Item
50 75 100 150 200 400 500 1 or 2 1 800 1500 3000 2
hrs hrs hrs hrs hrs hrs hrs months year hrs hrs hrs years
Recharging battery ,
*Replacing air cleaner element ,
Checking valve clearance ,
*Checking injection nozzle condition ,
*Checking injection timing ,
*Checking injection pump ,
*Replacing intake air line ,
Replacing battery ,
Replacing radiator hoses and clamp
,
bands
*Replacing fuel hoses and clamp
bands ,
Changing radiator coolant (L.L.C.) ,

* The items listed above (* marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
W1014630
CAUTION
• When changing or inspecting, be sure to level and stop the engine.

Q NOTE
Engine Oil :
• Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil
according to the engine type (with internal EGR, external EGR or non-EGR) and the Fuel Type Used :
(Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
Engine oil classification (API classification)
Fuel Type Engines with non-EGR
Engines with external EGR
Engines with internal EGR
CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change –
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))
Low Sulfur Fuel
[Sulfur Content <
CF or CI-4
0.05 % (500 ppm)] or
CF, CF-4, CG-4, CH-4 or CI-4 (Class CF-4, CG-4 and CH-4 engine oils
Ultra Low Sulfur Fuel
cannot be used on EGR type engines.)
[Sulfur Content <
0.0015 % (15 ppm)]
EGR : Exhaust Gas Re-circulation
W1024941
• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate Filter) and is
Not Recommended for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity according to
the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed
for use with low sulfur fuels, for On-Highway vehicle engines. When a Non-Road engine runs on high
sulfur fuel, it is advisable to use a "CF or better" classification engine oil with a high Total Base Number
(a minimum TBN of 10 is recommended).
Fuel :
• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is
preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable
emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a diesel fuel, change
the engine oil and oil filter at shorter intervals. (approximately half)
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313
JUN87)
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim Tier 4 standards,
the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these engines, when operated in US EPA
regulated areas. Therefore, please use No.2-D S500 or S15 diesel fuel as an alternative to No.2-D, and use
No.1-D S500 or S15 diesel fuel as an alternative to No.1-D for ambient temperatures below −10 °C (14 °F).
1) SAE : Society of Automotive Engineers

2) EN : European Norm
3) ASTM : American Society of Testing and Materials
4) US EPA : United States Environmental Protection Agency
5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

4. 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.
Q IMPORTANT
• When using an oil of different maker or viscosity from the
previous, drain old oil. Never mix two different types of oil.
Q NOTE
• Be sure to inspect the engine, locating it on a horizontal
place. If placed on gradients, accurately, oil quantity may
not be measured.
• 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.
(1) Dipstick
W1016222

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.
CAUTION
• 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.
Q IMPORTANT
• During filling the coolant, air must be vented from the engine
coolant passages. The air vents by jiggling the radiator
upper and lower hoses.
• 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.
• Do not use an antifreeze and scale inhibitor at the same time.
• Never mix the different type or brand of L.L.C..
(1) Radiator Cap A: FULL
(2) Recovery Tank B: LOW
W1035779

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil
CAUTION
• 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 (2) at the bottom of
the engine and drain the oil completely.
4. Screw the drain plug (2).
5. Fill new oil up to upper line on the dipstick (1).
Q IMPORTANT
previous one, remove all of the old oil.
• Never mix two different types of oil.
• Engine oil should have properties of API classification CF
(See page G-6).
• Use the proper SAE Engine Oil according to ambient
temperature.
• Upon an oil change, be sure to replace the gasket with new
one.
SAE 30 or SAE 10W-30
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
SAE 10W or SAE 10W-30
Below 0 °C (32 °F)
SAE 10W-40
Oil pan depth Engine oil capacity
Models 101 mm (3.98 in.) 121 mm (4.76 in.)
2.1 L 2.5 L
*Z482-E3B
0.55 U.S.gals 0.66 U.S.gals
3.2 L 3.8 L
*D722-E3B
3.6 L
D782-E3B –
0.95 U.S.gals
2.5 L
Z602-E3B –
0.66 U.S.gals
3.7 L
D902-E3B –
0.98 U.S.gals
* 101 mm (3.98 in.) oil pan depth is optional.
33 to 37 N·m
M12 × 1.25 3.3 to 3.8 kgf·m
Drain plug with 24 to 27 lbf·ft
copper gasket 64 to 73 N·m
Tightening
M22 × 1.5 6.5 to 7.5 kgf·m
torque
47 to 54 lbf·ft
Drain plug with 45 to 53 N·m
rubber coated M22 × 1.5 4.5 to 5.5 kgf·m
gasket 33 to 39 lbf·ft
(1) Dipstick (2) Drain Plug

W1016604

Replacing Oil Filter Cartridge
CAUTION
• Be sure to stop the engine before changing 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.
Q IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
Q NOTE
• The oil pan of 101 mm (3.98 in.) depth is optional for Z482-
E3B and D722-E3B. This service interval is every 150 hours.
(1) Engine Oil Filter Cartridge [a] Standard Type
[b] One-side Maintenance Type
W1017137

[3] CHECK POINT OF EVERY 50 HOURS

Checking Fuel Hose
1. If the clamp (2) is loose, apply oil to the threads and securely
retighten it.
2. The fuel hose (1) 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.
CAUTION
• 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). ([B] only.)
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.
Q NOTE
• 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) Fuel Hose [A] Cartridge Type
(2) Clamp [B] Element Type
(3) Air Vent Plug
(4) Fuel Cock
(5) Air Vent Cock
W1035921


Changing Engine Oil (for Optional Depth Oil Pans)
CAUTION
Q IMPORTANT
(See page G-6).
temperature.
one.
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W-40
Models 101 mm (3.98 in.) 121 mm (4.76 in.)
2.1 L 2.5 L
*Z482-E3B
3.2 L 3.8 L
*D722-E3B
3.6 L
D782-E3B –
0.95 U.S.gals
2.5 L
Z602-E3B –
0.66 U.S.gals
3.7 L
D902-E3B –
0.98 U.S.gals
33 to 37 N·m
M12 × 1.25 3.3 to 3.8 kgf·m
Tightening
M22 × 1.5 6.5 to 7.5 kgf·m
torque
47 to 54 lbf·ft

W1017177

[5] CHECK POINTS OF EVERY 100 HOURS

Changing Engine Oil (for Standard Depth Oil Pans)
CAUTION
Q IMPORTANT
(See page G-6).
temperature.
one.
Above 25 °C (77 °F)
SAE 10W-40
0 °C to 25 °C (32 °F to 77 °F)
SAE 10W-40
Below 0 °C (32 °F)
SAE 10W-40
Models 101 mm (3.98 in.) 121 mm (4.76 in.)
2.1 L 2.5 L
*Z482-E3B
3.2 L 3.8 L
*D722-E3B
3.6 L
D782-E3B –
0.95 U.S.gals
2.5 L
Z602-E3B –
0.66 U.S.gals
3.7 L
D902-E3B –
0.98 U.S.gals
33 to 37 N·m
M12 × 1.25 3.3 to 3.8 kgf·m
Tightening
M22 × 1.5 6.5 to 7.5 kgf·m
torque
47 to 54 lbf·ft

W1017548

Fan Belt Tension

1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, 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.
(A) Deflection
W1208957
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
W1209480
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 kgf/cm2,
30 psi).
Maintain reasonable distance between the nozzle and the filter.
Q NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
• Change the element once a year or every 6th cleaning.
W1045746

Cleaning Fuel Filter (Element Type only)

1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter 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.
Q IMPORTANT
• 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 (5) periodically.
(1) Cock Body (4) Filter Element
(2) Air Vent Plug (5) Filter Cup
(3) Fuel Cock (6) Retaining Ring
W1046058
Checking Battery Electrolyte Level
1. Check the battery electrolyte level.
2. If the level is below than lower level line (2), and the distilled water
to pour level of each cell.
(1) Upper Level Line (2) Lower Level Line
W1047154


Replacing Oil Filter Cartridge (for Optional Depth Oil Pans)
CAUTION
Q IMPORTANT
W1018457

Replacing Oil Filter Cartridge (for Standard Depth Oil Pans)
CAUTION
Q IMPORTANT
W1018643

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 tens to age. It must be
replaced every two years. Also replace the clamp and tighten it
securely.
(1) Upper Hose (2) Lower Hose
W1029518
Checking Intake Air Line

1. Check to see if the intake air hose(s) (1) and the breather hose
(3) are properly fixed every 200 hours of operation.
2. If the clamp (2) is loose, apply oil to the threads and retighten it
securely.
3. The intake air hose(s) (1) and the breather hose (3) are made of
rubber and tends to age. It must be changed every two years.
Also change the clamp (2) and tighten it securely.
Q IMPORTANT
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (3) Breather Hose
(2) Clamp
W1029631

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
W1050548
Replacing Fuel Filter Element (Element Type)
1. Close the fuel cock (3).
2. Unscrew the retaining ring (6) and remove the filter 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
W1050583


Cleaning Water Jacket and Radiator Interior
CAUTION
• Do not remove the radiator cap when the engine is hot. Then
loosen cap slightly to the stop to relieve any excess
pressure before removing cap completely.
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.
Q IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
• When the anti-freeze is mixed with fresh, soft water, the anti-
freeze mixing ratio must be less than 50 %.
• 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
W1038102

Anti-Freeze
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the maker of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
Q IMPORTANT
Vol % Freezing point Boiling point*
anti-freeze °C °F °C °F
40 –24 –11 106 223
50 –37 –35 108 226
* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
Q NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)
W1039218
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
Deflection (A) Factory spec. 0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
(1) Fan Belt (A) Deflection

W1052220

[10] CHECK POINTS OF EVERY 1 OR 2 MONTHS

Recharging
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
Use a voltmeter or hydrometer.
1) Slow Charging
1. Add distilled water if the electrolyte level is low. When charging,
the amount of electrolyte should be slightly lower than the
specified level to prevent overflow.
2. Connect the battery to the charging unit, following the
manufacture’s instructions.
3. As the electrolyte generates gas while charging, remove all port
caps.
4. The electrolyte temperature must not exceed 40 °C (104 °F)
during charging.
If it exceed 40 °C (104 °F), decrease the charging amperage or
stop charging for a while.
5. When charging several batteries in series, charging at the rate of
the smallest battery in the line.
2) Quick Charging
1. Determine the proper charging current and charging time with the
tester attached to the quick charger.
2. Determine the proper charging current as 1/1 of the battery
capacity. If the battery capacity exceeds 50 Ah, consider 50 A as
the maximum.
Q Precaution for Operating a Quick Charger
• Operating with a quick charger differs according to the type.
Consult the instruction manual and use accordingly.
W1052658

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
Q NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.260 Sp. Gr. 100 % Charged
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad
W1012763

[11] CHECK POINT OF EVERY YEAR

Replacing Air Cleaner Element
1. Remove used air cleaner element.
2. Replace new air cleaner element.
Q NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not run the engine with filter element removed.
W1020554


Checking Valve Clearance
Q IMPORTANT
• 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
feeler 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
feeler gauge.
Number of cylinders D722-E3B
Z482-E3B
Valve arrangement D782-E3B
Z602-E3B
D902-E3B
Adjustable cylinder Intake Exhaust Intake Exhaust

location of piston valve valve valve valve
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.
Intake and exhaust 0.145 to 0.185 mm
Factory spec.
valve clearance (cold) 0.00571 to 0.00728 in.
Q NOTE
• The sequence of cylinder numbers is given as No. 1, No. 2
and No. 3 starting from the gear case side.
• 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] Z482-E3B, Z602-E3B
(3) Alignment Mark [b] D722-E3B, D782-E3B, D902-E3B
W10113200


CAUTION
• Check the injection pressure and condition after confirming that there is nobody standing in the direction
the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a) Good (b) Bad
W10411400
Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester.
2. Slowly move the tester handle to measure the pressure at which
fuel begins jetting out from the nozzle.
3. If the measurement is not within the factory specifications,
replace the adjusting washer (1) in the nozzle holder to adjust it.
(Reference)
• Pressure variation with 0.025 mm (0.00098 in.) difference of
adjusting washer thickness.
Approx. 590 kPa (6.0 kgf/cm2, 85 psi)
13.73 to 14.70 MPa
Fuel injection pressure Factory spec. 140.0 to 150.0 kgf/cm2
1992 to 2133 psi
(1) Adjusting Washer

W10182100
Nozzle Valve Seat Tightness

2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2,
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.
130.0 kgf/cm2
1849 psi
W10412730

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)
• Assemble the nozzle in clean fuel oil.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf·m
26 to 28 lbf·ft
20 to 24 N·m
Tightening torque Overflow pipe retaining nut 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
W1018491


Injection Timing
1. Remove the injection pipes.
2. Remove the engine stop solenoid.
3. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (3) for
No. 1 cylinder.
4. After the fuel fills up to the hole of the delivery valve holder for No.
1 cylinder, turn back (clockwise) the flywheel around 1.6 rad
(90 °).
5. Turn the flywheel counterclockwise to set at around 0.44 rad
(25 °) before T.D.C..
6. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
7. Check to see the degree on flywheel.
The flywheel has mark “1TC”, “10” and “20” for the crank angle
before the top dead center of No. 1 cylinder.
8. Check to see if the timing angle on the flywheel is aligned with the
alignment mark (2).
9. If injection timing is out of adjustment, readjust the timing with
shims.
Z482/D722-E3B (3600 min-1 (rpm) spec.)
0.35 to 0.38 rad
Injection timing Factory spec.
(20 to 22 °) before T.D.C.
D782-E3B (3200 min-1 (rpm) spec.)

0.28 to 0.31 rad
Z602/D902-E3B (3600 min-1 (rpm) spec.)

0.34 to 0.36 rad
(1) Timing Line (5) Two-holes : 0.20 mm (0.0079 in.)

(2) Alignment Mark Two-holes : 0.175 mm (0.00689 in.)
(3) Delivery Valve Holder (6) One-hole : 0.25 mm (0.0098 in.)
(4) Shim (Soft Metal Gasket Shim) (7) Without hole : 0.30 mm (0.012 in.)
(8) Three-holes : 0.35 mm (0.014 in.)
W1023147

Injection Timing (Continued)

Q NOTE
• The liquid gasket is not required for assembling.
• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25
mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.) and
0.175 mm (0.00689 in.). Combine these shims for
adjustments.
• Addition or reduction of shim (0.025 mm, 0.00098 in.) delays
or advances the injection timing by approx. 0.0044 rad
(0.25 °).
• In disassembling and replacing the injection pump, be sure
to use the same number of new shims with the same
thickness.
• The 0.175 mm (0.00689 in.) thick shim is coated only on the
lower face. Therefore, do not use the 0.175 mm (0.00689 in.)
thick shim as the top shim of the combination (injection
pump side), because this can cause oil leakage.
• Refer to figure of the shim to check the thickness of the
shims.
• The injection timing might be changed by the application.
W1022861

Checking Injection Pump

(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 (2) jetted with the proper injection
pressure to the injection pump pressure tester (1). (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.
(Fuel Tightness of Delivery Valve)
3. Set a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by hands and raise the pressure to approx.
13.73 MPa (140.0 kgf/cm2, 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
140.0 to 130.0 kgf/cm2, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to
12.75 MPa (140.0 to 130.0 kgf/cm2, 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.
13.73 MPa
Fuel tightness of pump
Allowable limit 140.0 kgf/cm2
element
1991 psi
10 seconds
13.73 → 12.75 MPa
Factory spec.
140.0 → 130.0 kgf/cm2
Fuel tightness of 1991 → 1849 psi
delivery valve 5 seconds
13.73 → 12.75 MPa
Allowable limit
140.0 → 130.0 kgf/cm2
1991 → 1849 psi
Q NOTE
• Never try to disassemble the injection pump assembly. For
repairs, you are strongly requested to contact a Kubota-
authorized pump service shop.
(1) Injection Pump Pressure Tester (3) Protection Cover for Jetted Fuel
(2) Injection Nozzle
W1022357

[15] CHECK POINTS OF EVERY 2 YEARS

Replacing Intake Air Line
1. Loosen the clamp (2).
2. Remove the intake air hose (1) and clamp (2).
3. Replace new intake air hose (1) and new clamp (2).
4. Tighten the clamp (2).
Q NOTE
• To prevent serious damage to the engine, keep out any dust
inside the intake air line.
(1) Intake Air Hose (2) Clamp
W1023867
Replacing Battery
CAUTION
• When the battery is being activated, hydrogen and oxygen
gases in the battery are extremely explosive. Keep open
sparks and flames away from the battery at all times,
especially when charging the battery.
• When charging battery, remove battery vent plugs.
• When disconnecting the cable from the battery, start with
the negative terminal first. When connecting the cable to the
battery, start with the positive terminal first.
• Never check battery charge by placing a metal object across
the posts.
1. Disconnect the negative terminal and positive terminal.
2. Remove the battery holder.
3. Remove the used battery.
4. Replace the new battery.
5. Tighten the battery holder.
6. Connect the positive terminal.
7. Connect the negative terminal.
W1023996
Replacing Radiator Hoses and Clamp Bands
CAUTION
1. Drain the coolant.
2. Loosen the clamp bands.
3. Remove the upper hose (1) and lower hose (2).
4. Replace new upper / lower hose (1), (2) and clamp bands.
5. Tighten the clamp bands.
6. Fill with clean water and anti-freeze until the coolant level is just
below the port. Install the radiator cap securely.
(1) Upper Hose (2) Lower Hose
W1024178

Replacing Fuel Hoses and Clamp Bands

1. Loosen the clamp (2) and remove the fuel hose (1).
2. Replace new fuel hose (1) and new clamp (2).
3. Tighten the clamp (2).
CAUTION
• 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). ([B] only.)
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 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.
Q NOTE
• 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) Fuel Hose [A] Cartridge Type
(2) Clamp [B] Element Type
(3) Air Vent Plug
(4) Fuel Cock
W1024305

Cleaning Water Jacket and Radiator Interior
CAUTION
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.
Q IMPORTANT
• Do not start engine without coolant.
• Use clean, fresh, soft water and anti-freeze to fill the radiator
and recovery tank.
• 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
W1028063

Changing Radiator Coolant (L.L.C.) (Continued)

(Anti-freeze)
• There are two types of anti-freeze available: use the permanent
type (PT) for this engine.
• Before adding anti-freeze for the first time, clean the radiator
interior by pouring fresh, soft water and draining it a few times.
• The procedure for mixing water and anti-freeze differs according
to the maker of the anti-freeze and the ambient temperature.
Basically, it should be referred to SAE J1034 standard, more
specifically also to SAE J814c.
• Mix the anti-freeze with fresh, soft water, and then fill into the
radiator.
Q IMPORTANT
Vol % Freezing point Boiling point*
anti-freeze °C °F °C °F
40 –24 –11 106 223
50 –37 –35 108 226
* At 1.013 × 100000 Pa (760 mmHg) pressure (atmospheric). A
higher boiling point is obtained by using a radiator pressure cap
which permits the development of pressure within the cooling
system.
Q NOTE
• The above data represents industrial standards that
necessitate a minimum glycol content in the concentrated
anti-freeze.
• When the coolant level drops due to evaporation, add fresh,
soft water only to keep the anti-freeze mixing ratio less than
50 %. In case of leakage, add anti-freeze and fresh, soft
water in the specified mixing ratio.
• Anti-freeze absorbs moisture. Keep unused anti-freeze in a
tightly sealed container.
• Do not use radiator cleaning agents when anti-freeze has
been added to the coolant.
(Anti-freeze contains an anti-corrosive agent, which will
react with the radiator cleaning agent forming sludge which
will affect the engine parts.)
W1024852

5. SPECIAL TOOLS
Diesel Engine Compression Tester (for Injection Nozzle)
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
diagnosis 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
W1024200
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
diagnosis of need for major overhaul.
(1) Gauge (4) Adaptor K
(2) Hose Assembly (5) Adaptor L
(3) L Joint (6) Adaptor M
W1025289
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
W1024318

Q NOTE
• The following special tools are not provided, so make them referring to the figure.
Injection Pump Pressure Tester
Application: Use to check fuel tightness of injection pumps.
Pressure gauge full scale : More than 29.4 MPa
A
(300 kgf/cm2, 4270 psi)
B PF 1/2
C Copper gasket
D Flange (Mateiral Steel)
E Hex. nut 27 mm (1.1 in.) across the plat
F Adhesive application
G Fillet welding on the enter circumference
H Retaining nut
I 17 mm dia. (0.67 in. dia.)
J 8.0 mm dia. (0.31 in. dia.)
K 1.0 mm (0.039 in.)
L 17 mm dia. (0.67 in. dia.)
M 6.10 to 6.20 mm dia. (0.241 to 0.244 in. dia.)
N 8.0 mm (0.31 in.)
O 4.0 mm (0.16 in.)
P 11.97 to 11.99 mm dia. (0.4713 to 0.4720 in. dia.)
Q PF 1/2
R 23 mm (0.91 in.)
S 17 mm (0.67 in.)
T 4.0 mm (0.16 in.)
U 12.00 to 12.02 mm dia. (0.4725 to 0.4732 in. dia.)
V 100 mm (3.94 in.)
W M12 × P1.5
X 5.0 mm (0.20 in.)
W10252400
Valve Guide Replacing Tool
Application: Use to press out and press fit the valve guide.
A 220 mm (8.66 in.)
B 80 mm (3.1 in.)
C 40 mm (1.6 in.)
D 20 mm dia. (0.79 in. dia.)
E 9.960 to 9.980 mm dia. (0.3922 to 0.3929 in. dia.)
F 5.50 to 5.70 mm dia. (0.217 to 0.224 in. dia.)
G 25 mm dia. (0.98 in. dia.)
H 6.00 to 6.10 mm dia. (0.237 to 0.240 in. dia.)
I 5.0 mm (0.20 in.)
J 18 mm dia. (0.71 in. dia.)
K 10.6 to 10.7 mm dia. (0.418 to 0.421 in. dia.)
L 6.90 to 7.10 mm (0.272 to 0.279 in.)
C1 Chamfer 1.0 mm (0.039 in.)
C0.3 Chamfer 0.3 mm (0.01 in.)
W10250170

Bushing Replacing Tool

Application: Use to press out and 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 dia. (0.7835 to 0.7854 in. dia.)
F 25 mm dia. (0.98 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
2. For idle gear bushing
A 150 mm (5.91 in.)
B 23 mm (0.91 in.)
C 100 mm (3.94 in.)
D 19.90 to 19.95 mm dia. (0.7835 to 0.7854 in. dia.)
F 25 mm dia. (0.98 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
W12358870
Flywheel Stopper
Application: Use to loosen and tighten the flywheel screw.
A 20 mm (0.79 in.)
B 15 mm (0.59 in.)
C 10 mm dia. (0.39 in. dia.)
D 30 mm (1.2 in.)
E 8.0 mm (0.31 in.)
F 200 mm (7.87 in.)
W10259480

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 (2.8 in.)
C 40 mm radius (1.6 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. (1.886 to 1.887 in. dia.)
[Press Fit] for Z482/D722/D782-E3B

A 130 mm (5.12 in.)
B 72 mm (2.8 in.)
D 9.0 mm (0.35 in.)
E 24 mm (0.94 in.)
F 20 mm dia. (0.79 in. dia.)
G 68 mm dia. (2.7 in. dia.)
[Press Fit] for Z602/D902-E3B

A 130 mm (5.12 in.)
B 72 mm (2.8 in.)
D 9.0 mm (0.35 in.)
E 24 mm (0.94 in.)
F 20 mm dia. (0.79 in. dia.)
G 68 mm dia. (2.7 in. dia.)
W10261390

Crank Sleeve Setter (for Z482/D722/D782-E3B)

Application: Use to fix the crankshaft sleeve.
(1) Auxiliary Socket for Pushing
A 130 mm (5.12 in.)
B 112 mm (4.41 in.)
C 107 mm (4.21 in.)
D 82 mm (3.2 in.)
E 72 mm (2.8 in.)
F 67 mm (2.6 in.)
G 47 mm (1.8 in.)
H 37.00 to 37.20 mm (1.457 to 1.464 in.)
I 17 mm (0.67 in.)
J 5.0 mm dia. (0.20 in. dia.)
K 52 mm dia. (2.0 in. dia.)
L 40 mm dia. (1.6 in. dia.)
M 10 mm (0.39 in.)
N 33 mm (1.3 in.)
O 20 mm dia. (0.79 in. dia.)
P 40 mm dia. (1.6 in. dia.)
Q 63.10 to 63.15 mm dia. (2.485 to 2.486 in. dia.)
R 64 mm dia. (2.5 in. dia.)
S 75 mm dia. (3.0 in. dia.)
(2) Sleeve Guide

A 42 mm (1.7 in.)
B 12 mm (0.47 in.)
C 30 mm (1.2 in.)
D M10 × Pitch 1.25
E 2.0 mm (0.079 in.)
F 10 mm (0.39 in.)
G 2.0 mm (0.079 in.)
I 8.0 mm dia. (0.31 in. dia.)
J 1.8 mm (0.071 in.)
K 0.09 rad (5 °)
W1026961

MECHANISM
CONTENTS
1. ENGINE BODY ............................................................................................... M-1

[1] HALF-FLOATING HEAD COVER ............................................................ M-1
[2] CLOSED BREATHER............................................................................... M-1
[3] PISTON (Z602-E3B, D782-E3B, D902-E3B) ............................................ M-2
[4] OIL PAN (Z602-E3B, D902-E3B)............................................................. M-2
2. COOLING SYSTEM ........................................................................................ M-3
[1] COOLING FIN (Z602-E3B, D902-E3B).................................................... M-3

SM-E3B SERIES WSM DIESEL ENGINE
1. ENGINE BODY
[1] HALF-FLOATING HEAD COVER
The rubber packing is fitted in to maintain the cylinder
head cover 0.5 mm (0.02 in.) or so off the cylinder head.
This arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover (2) Rubber Packing
W1013327
[2] CLOSED BREATHER

Closed breather system has been adopted to prevent
the release of blow-by gas into the atmosphere.
After its oil content is filtered by oil shield (4), the blow-
by gas is fed back to the intake manifold through breather
valve (3) to be used for re-combustion.
(1) Cylinder Head Cover (4) Oil Shield
(2) Breather Hose (5) Rubber Packing
(3) Breather Valve
W1012956
M-1 KiSC issued 10, 2007 A

[3] PISTON (Z602-E3B, D782-E3B, D902-E3B)

Piston’s skirt is coated with molybdenum
disulfide+, which reduces the piston slap noise and
thus the entire operating noise.
+Molybdenum disulfide (MoS2)

The molybdenum disulfide (1) serves as a solid
lubricant, like a Graphite or Teflon. This material helps
resist metal wears even with little lube oil.
(1) Molybdenum Disulfide
W1013114
[4] OIL PAN (Z602-E3B, D902-E3B)

The oil pan is extended 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) Cylinder Block (3) Oil Pan
(2) Gear Case
W1013041

2. COOLING SYSTEM
[1] COOLING FIN (Z602-E3B, D902-E3B)
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
W1013135

SERVICING
CONTENTS
1. TROUBLESHOOTING ......................................................................................S-1
2. SERVICING SPECIFICATIONS ......................................................................S-4
3. TIGHTENING TORQUES ..............................................................................S-11
[1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-11
[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS
AND NUTS...............................................................................................S-12
4. CHECKING, DISASSEMBLING AND SERVICING......................................S-13
[1] CHECKING AND ADJUSTING ...............................................................S-13
(1) Engine Body........................................................................................S-13
(2) Lubricating System .............................................................................S-15
(3) Cooling System ...................................................................................S-15
(4) Fuel System ........................................................................................S-17
(5) Electrical System ................................................................................S-21
[2] DISASSEMBLING AND ASSEMBLING..................................................S-28
(1) Draining Engine Oil and Coolant.........................................................S-28
(2) External Components .........................................................................S-29
(3) Cylinder Head, Valves and Oil Pan.....................................................S-29
(4) Gear Case and Timing Gears .............................................................S-35
(5) Piston and Connecting Rod ................................................................S-42
(6) Flywheel and Crankshaft ....................................................................S-45
(7) Starter .................................................................................................S-49
(8) Dynamo...............................................................................................S-51
(9) Alternator ............................................................................................S-52
[3] SERVICING ..............................................................................................S-53
(1) Cylinder Head and Valves ..................................................................S-53
(2) Timing Gears ......................................................................................S-59
(3) Piston and Connecting Rod ................................................................S-61
(4) Crankshaft...........................................................................................S-64
(5) Cylinder...............................................................................................S-70
(6) Oil Pump .............................................................................................S-71
(7) Starter .................................................................................................S-72
(8) Alternator ............................................................................................S-75

1. TROUBLESHOOTING
Reference
Symptom Probable Cause Solution
Page
Engine Does Not No fuel Replenish fuel G-11
Start Air in the fuel system Bleed G-11
Water in the fuel system Change fuel and –
repair or replace fuel
system
Fuel hose clogged Clean or replace G-11
Fuel filter clogged Replace G-17
Excessively high viscosity of fuel or engine oil at Use specified fuel or 5, G-9
low temperature engine oil
Fuel with low cetane number Use specified fuel 5
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-29
Incorrect injection timing Adjust S-17, 18
Fuel camshaft worn Replace S-41
Injection nozzle clogged Clean or replace S-20, 21
Injection pump malfunctioning Repair or replace S-19, 35,
36, 37
Seizure of crankshaft, camshaft, piston, cylinder Repair or replace S-40 to 48
or bearing S-64 to 71
Compression leak from cylinder Replace head S-30, 31,
gasket, tighten 32
cylinder head screw,
glow plug and nozzle
holder
Improper valve timing Correct or replace S-40
timing gear
Piston ring and cylinder worn Replace S-43, 44,
63
Excessive valve clearance Adjust S-14
Stop solenoid malfunctioning Replace S-26, 27,
29, 36
Starter Does Not Run Battery discharged Charge G-20
Starter malfunctioning Repair or replace S-29,
72 to 75
Wiring disconnected Connect –
Engine Revolution Is Fuel filter clogged or dirty Replace G-17
Not Smooth Air cleaner clogged Clean or replace G-14, 17,
22
Fuel leak due to loose injection pipe retaining nut Tighten retaining nut S-29
36, 37
Incorrect nozzle injection pressure Adjust S-20
Injection nozzle stuck or clogged Repair or replace S-20, 21
Governor malfunctioning Repair S-41
W1046115
S-1 KiSC issued 10, 2007 A

Reference
Page
Either White or Blue Excessive engine oil Reduce to specified G-7
Exhaust Gas Is level
Observed Piston ring and cylinder worn or stuck Repair or replace S-43, 44,
63
Either Black or Dark Overload Reduce the load –
Gray Exhaust Gas Is Low grade fuel used Use specified fuel 5
Observed
Fuel filter clogged Replace G-17
Air cleaner clogged Clean or replace G-14, 17,
22
Deficient nozzle injection Repair or replace S-20, 21
nozzle
Deficient Output Incorrect injection timing Adjust S-17, 18
Engine’s moving parts seem to be seizing Repair or replace –
36, 37
nozzle
Compression leak Check the S-13
compression
pressure and repair
Excessive Lubricant Piston ring’s gap facing the same direction Shift ring gap S-43
Oil Consumption direction
Oil ring worn or stuck Replace S-43, 44
Piston ring groove worn Replace piston S-43, 44,
63
Valve stem and valve guide worn Replace S-33, 54,
55
Crankshaft bearing and crank pin bearing worn Replace S-47, 48,
65 to 69
Oil leaking due to defective seals or packing Replace –
Fuel Mixed into Injection pump’s plunger worn Repair or replace S-19, 35,
Lubricant Oil 36, 37
nozzle
Injection pump broken Replace S-35, 36,
37
Water Mixed into Head gasket defective Replace S-32
Lubricant Oil Cylinder block or cylinder head flawed Replace S-32, 54
W1047740

Reference
Page
Low Oil Pressure Engine oil insufficient Replenish G-7
Oil strainer clogged Clean S-34
Relief valve stuck with dirt Clean –
Relief valve spring weaken or broken Replace –
Excessive oil clearance of crankshaft bearing Replace S-47, 48,
66 to 69
Excessive oil clearance of crankpin bearing Replace S-42, 65
Excessive oil clearance of rocker arm Replace S-31, 57
Oil passage clogged Clean –
Different type of oil Use specified type of G-9
oil
Oil pump defective Replace S-41, 71,
72
High Oil Pressure Different type of oil Use specified type of G-9
oil
Relief valve defective Replace –
Engine Overheated Engine oil insufficient Replenish G-7
Fan belt broken or elongated Replace or adjust G-14
Coolant insufficient Replenish G-18, 19
Radiator net and radiator fin clogged with dust Clean –
Inside of radiator corroded Clean or replace G-18
Coolant flow route corroded Clean or replace G-18, 19
Radiator cap defective Replace –
Overload running Reduce the load –
Head gasket defective Replace S-32
Unsuitable fuel used Use specified fuel 5
Battery Quickly Battery electrolyte insufficient Replenish distilled G-15
Discharged water and charge
Fan belt slips Adjust belt tension or G-14
replace
Wiring disconnected Connect –
Rectifier defective Replace S-52, 76
Alternator defective Replace S-29, 52
Battery defective Replace G-29
W1049318

2. 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 Z482-E3B 2.85 to 3.23 MPa 2.26 MPa
D722-E3B 29.0 to 33.0 kgf/cm2 23.0 kgf/cm2
D782-E3B 413 to 469 psi 327 psi
Z602-E3B 3.53 to 4.02 MPa 2.55 MPa

D902-E3B 36.0 to 41.0 kgf/cm2 26.0 kgf/cm2
512 to 583 psi 370 psi
– 10 % or less
Difference among Cylinders
Top Clearance 0.50 to 0.70 mm –
0.020 to 0.027 in.
Cylinder Head Surface Flatness – 0.05 mm
0.002 in.
Valve Recessing Intake and Exhaust −0.10 to 0.10 mm 0.30 mm
−0.0039 to 0.0039 in. 0.012 in.
Valve Stem to Valve Guide Clearance 0.030 to 0.057 mm 0.10 mm
0.0012 to 0.0022 in. 0.0039 in.
Valve Stem O.D. 5.968 to 5.980 mm –

0.2350 to 0.2354 in.
Valve Guide I.D. 6.010 to 6.025 mm –

0.2367 to 0.2372 in.
Valve Face Angle 0.79 rad –
45 °
Valve Seat Angle 0.79 rad –
45 °
Width 2.12 mm –
0.0835 in.
Valve Spring Tilt – 1.2 mm
0.047 in.
Free Length 31.3 to 31.8 mm 28.4 mm

1.24 to 1.25 in. 1.12 in.
Setting Load / 65 N / 27.0 mm 55 N / 27.0 mm

Setting Length 6.6 kgf / 27.0 mm 5.6 kgf / 27.0 mm
15 lbf / 1.06 in. 12 lbf / 1.06 in.
W10138740

ENGINE BODY (Continued)

Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm
0.00063 to 0.0017 in. 0.0059 in.
Rocker Arm Shaft O.D. 10.473 to 10.484 mm –

0.41233 to 0.41275 in.
Rocker Arm I.D. 10.500 to 10.518 mm –

0.41339 to 0.41409 in.
Push Rod Alignment – 0.25 mm
0.0098 in.
Tappet to Tappet Guide Oil Clearance 0.016 to 0.052 mm 0.10 mm
0.00063 to 0.0020 in. 0.0039 in.
Tappet O.D. 17.966 to 17.984 mm –

0.70733 to 0.70803 in.
Tappet Guide I.D. 18.000 to 18.018 mm –

0.70867 to 0.70937 in.
Timing Gear
Crank Gear to Idle Gear Backlash 0.0430 to 0.124 mm 0.15 mm
0.00170 to 0.00488 in. 0.0059 in.
Idle Gear to Cam Gear Backlash 0.0470 to 0.123 mm 0.15 mm

0.00185 to 0.00484 in. 0.0059 in.
Idle Gear to Injection Pump Gear Backlash 0.0460 to 0.124 mm 0.15 mm

0.00182 to 0.00488 in. 0.0059 in.
Crank Gear to Oil Pump Drive Gear Backlash 0.0410 to 0.123 mm 0.15 mm
0.00162 to 0.00484 in. 0.0059 in.
Idle Gear Side Clearance 0.20 to 0.51 mm 0.80 mm
0.0079 to 0.020 in. 0.031 in.
Camshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
0.0059 to 0.012 in. 0.020 in.
Alignment – 0.01 mm
0.0004 in.
Cam Height Intake and 26.88 mm 26.83 mm
Exhaust 1.058 in. 1.056 in.
Camshaft Journal to Cylinder Block Bore Oil Clearance 0.050 to 0.091 mm 0.15 mm
0.0020 to 0.0035 in. 0.0059 in.
Camshaft Journal O.D. 32.934 to 32.950 mm –

1.2967 to 1.2972 in.
Cylinder Block Bore I.D. 33.000 to 33.025 mm –

1.2993 to 1.3001 in.
W1050953


Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.020 to 0.084 mm 0.10 mm
0.00079 to 0.0033 in. 0.0039 in.
Idle Gear Shaft O.D. 19.967 to 19.980 mm –

0.78611 to 0.78661 in.
Idle Gear Bushing I.D. 20.000 to 20.051 mm –

0.78740 to 0.78940 in.
Piston Pin Bore I.D. 20.000 to 20.013 mm 20.05 mm
0.78741 to 0.78791 in. 0.7894 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm
0.00056 to 0.0014 in. 0.0039 in.
Piston Pin O.D. 20.002 to 20.011 mm –

0.78748 to 0.78783 in.
Small End Bushing I.D. 20.025 to 20.040 mm –

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 0.0029 in. 0.0059 in.
Small End Bushing I.D. 20.026 to 20.077 mm –

0.78843 to 0.79043 in.
Piston Ring Gap Top Ring 0.15 to 0.30 mm 1.20 mm
[Z482-E3B] 0.0059 to 0.011 in. 0.0472 in.
[D722-E3B] Second Ring 0.30 to 0.45 mm 1.20 mm
[D782-E3B] 0.012 to 0.017 in. 0.0472 in.
Oil Ring 0.15 to 0.30 mm 1.20 mm
0.0059 to 0.011 in. 0.0472 in.
Piston Ring Gap Top Ring 0.20 to 0.35 mm 1.25 mm
[Z602-E3B] 0.0079 to 0.013 in. 0.0492 in.
[D902-E3B] Second Ring 0.35 to 0.50 mm 1.25 mm
0.014 to 0.019 in. 0.0492 in.
Oil Ring 0.20 to 0.35 mm 1.25 mm
0.0079 to 0.013 in. 0.0492 in.
Piston Ring to Piston Ring Groove
Second Ring Clearance 0.0900 to 0.120 mm 0.15 mm
0.00355 to 0.00472 in. 0.0059 in.
Oil Ring Clearance 0.040 to 0.080 mm 0.15 mm

0.0016 to 0.0031 in. 0.0059 in.
Connecting Rod Alignment – 0.05 mm
0.002 in.
Crankshaft Side Clearance 0.15 to 0.31 mm 0.50 mm
0.0059 to 0.012 in. 0.020 in.
Alignment – 0.02 mm
0.0008 in.
W10138740


Crankpin to Crankpin Bearing Oil Clearance 0.020 to 0.051 mm 0.15 mm
0.00079 to 0.0020 in. 0.0059 in.
Crankpin O.D. 33.959 to 33.975 mm –

1.3370 to 1.3375 in.
Crankpin Bearing I.D. 33.995 to 34.010 mm –

1.3384 to 1.3389 in.
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.0340 to 0.106 mm 0.20 mm
1 [Z482/D722/D782-E3B] 0.00134 to 0.00417 in. 0.0079 in.
Crankshaft Journal O.D. 39.934 to 39.950 mm –

1.5722 to 1.5728 in.
Crankshaft Bearing 1 I.D. 39.984 to 40.040 mm –

1.5742 to 1.5763 in.
1 [Z602/D902-E3B] 0.00134 to 0.00417 in. 0.0079 in.

1.7297 to 1.7303 in.

1.7317 to 1.7338 in.
2 (Flywheel Side) 0.0011 to 0.0023 in. 0.0079 in.

1.7297 to 1.7303 in.

1.7315 to 1.7320 in.
3 (Intermediate) 0.0011 to 0.0023 in. 0.0079 in.
[Z482/D722/D782-E3B]

1.5722 to 1.5728 in.

1.5740 to 1.5745 in.
3 (Intermediate) [Z602/D902-E3B] 0.0011 to 0.0023 in. 0.0079 in.

1.7297 to 1.7303 in.

1.7315 to 1.7320 in.
W10138740


Cylinder Liner I.D. 67.000 to 67.019 mm 67.150 mm
[Z482/D722/D782-E3B] 2.6378 to 2.6385 in. 2.6437 in.
[Z602/D902-E3B] 2.8347 to 2.8353 in. 2.8406 in.
[Oversize : 0.25 mm (0.0098 in.)] 2.6477 to 2.6483 in. 2.6535 in.
[Z482/D722/D782-E3B]
[Oversize : 0.25 mm (0.0098 in.)] 2.8445 to 2.8452 in. 2.8504 in.
[Z602/D902-E3B]
W10138740
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed More than 49 kPa –
0.50 kgf/cm2
7.1 psi
At Rated Speed 197 to 441 kPa 147 kPa

2.00 to 4.50 kgf/cm2 1.50 kgf/cm2
28.5 to 64.0 psi 21.3 psi
Inner Rotor to Outer Rotor Clearance 0.030 to 0.14 mm –
0.0012 to 0.0055 in.
Outer Rotor to Pump Body Clearance 0.070 to 0.15 mm –
0.0028 to 0.0059 in.
Inner Rotor to Cover Clearance 0.0750 to 0.135 mm –
0.00296 to 0.00531 in.
W10139730
COOLING SYSTEM
Fan Belt Tension 7.0 to 9.0 mm / 98 N –
0.28 to 0.35 in. / 98 N
(10 kgf, 22 lbf)
Thermostat Valve Opening 69.5 to 72.5 °C –
Temperature 157.1 to 162.5 °F
(At Beginning)
Valve Opening 85 °C –
Temperature 185 °F
(Opened
Completely)
Radiator Cap Pressure Falling 10 seconds or more –
Time 88 → 59 kPa
0.90 → 0.60 kgf/cm2
13 → 8.5 psi
Radiator Water Leakage No leak at specified –
Test Pressure pressure
W10135990

FUEL SYSTEM
Injection Pump Injection Timing 0.35 to 0.38 rad –
[Z482/D722-E3B] (3600 min-1 (rpm)) (20 to 22°)
before T.D.C.
[D782-E3B] (3200 min-1 (rpm)) (16 to 18°)
before T.D.C.
[Z602/D902-E3B] (3600 min-1 (rpm)) (19 to 21°)
before T.D.C.
Pump Element Fuel Tightness – 13.73 MPa
140.0 kgf/cm2
1991 psi
Delivery Valve Fuel Tightness 10 seconds 5 seconds
13.73 → 12.75 MPa 13.73 → 12.75 MPa
140.0 → 130.0 kgf/cm2 140.0 →
1991 → 1849 psi 130.0 kgf/cm2
1991 → 1849 psi
Injection Nozzle Injection Pressure 13.73 to 14.70 MPa –
140.0 to 150.0 kgf/cm2
1992 to 2133 psi
Injection Nozzle Valve Seat Valve Seat When the pressure is –
Tightness 12.75 MPa
(130.0 kgf/cm2, 1849
psi), the valve seat must
be fuel tightness.
W10139730

ELECTRICAL SYSTEM
Glow Plug Resistance Approx. 0.9 Ω –
Starter (Electromagnetic Drive Type)
Commutator O.D. 28.0 mm 27.0 mm
1.10 in. 1.06 in.
Difference O.D. Less than 0.05 mm 0.40 mm

0.002 in. 0.016 in.
Mica Undercut 0.50 to 0.80 mm 0.20 mm

0.020 to 0.031 in. 0.0079 in.
Brush Length 16.0 mm 10.5 mm

0.630 in. 0.413 in.
Starter (Planetary Gear Reduction Type)
Commutator O.D. 30.0 mm 29.0 mm
1.18 in. 1.14 in.
Difference O.D. Less than 0.02 mm 0.05 mm

0.0008 in. 0.002 in.
Mica Undercut 0.50 to 0.80 mm 0.20 mm

0.020 to 0.031 in. 0.0079 in.

0.551 in. 0.35 in.
Dynamo
No-load Output Voltage AC20V or more at –
5200 min-1 (rpm)
Regulating Output Voltage 14 to 15 V at –

5200 min-1 (rpm)
Alternator
Stator Resistance Less than 1.0 Ω –
Rotor Resistance 2.9 Ω –
Slip Ring O.D. 14.4 mm 14.0 mm

0.567 in. 0.551 in.

0.394 in. 0.33 in.
W1013973

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.
[1] 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 Unit
Diameter N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20
M10 40 to 45 4.0 to 4.6 29 to 33 48 to 55 4.9 to 5.7 36 to 41
M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66
W10371750
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)
W1012705

[2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND

NUTS
Q NOTE
• For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before
tightening.
• 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 N·m kgf·m lbf·ft
*Cylinder head cover screw M6 x 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Injection pipe retaining nut M12 x 1.5 25 to 34 2.5 to 3.5 18 to 25
Overflow pipe retaining nut M12 x 1.5 20 to 24 2.0 to 2.5 15 to 18
Nozzle holder assembly M20 x 1.5 49 to 68 5.0 to 7.0 37 to 50
Glow plug M8 x 1 7.9 to 14 0.80 to 1.5 5.8 to 10
*Rocker arm bracket nut M6 x 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
*Cylinder head screw M8 x 1.25 38 to 42 3.8 to 4.3 28 to 31
*Fan drive pulley screw M12 x 1.5 118 to 127 12.0 to 13.0 86.8 to 94.0
*Idle gear shaft mounting screw M6 x 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Oil pump mounting screw M8 x 1.25 17.7 to 21.5 1.80 to 2.20 13.1 to 15.9
*Connecting rod screw M7 x 0.75 27 to 30 2.7 to 3.1 20 to 22
*Flywheel screw M10 x 1.25 54 to 58 5.5 to 6.0 40 to 43
Bearing case cover mounting screw M6 x 1 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
*Main bearing case screw 2 M7 x 1 27 to 30 2.7 to 3.1 20 to 22
*Main bearing case screw 1 M6 x 1 13 to 15 1.3 to 1.6 9.4 to 11
Oil pressure switch PT 1/8 15 to 19 1.5 to 2.0 11 to 14
Nozzle holder – 35 to 39 3.5 to 4.0 26 to 28
Starter’s terminal B mounting nut
M8 7.9 to 9.8 0.80 to 1.0 5.8 to 7.2
(Electromagnetic drive type)
Starter’s terminal B mounting nut
M8 5.9 to 11 0.60 to 1.2 4.4 to 8.6
(Planetary gear reduction type)
Dynamo’s pulley nut M10 x 1.25 40 to 44 4.0 to 4.5 29 to 32
Alternator’s pulley nut – 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2
Drain plug with copper gasket M12 x 1.25 33 to 37 3.3 to 3.8 24 to 27
Drain plug with copper gasket M22 x 1.5 64 to 73 6.5 to 7.5 47 to 54
Drain plug with rubber coated gasket M22 x 1.5 45 to 53 4.5 to 5.5 33 to 39
W1013236

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression Pressure
1. Run the engine until it is warmed up.
2. Stop the engine.
3. [a] Nozzle Hole Adaptor Setting :
Remove the air cleaner, the muffler and all injection nozzles.
[b] Glow Plug Hole Adaptor Setting :
Remove the air cleaner, the muffler, the breather tube, the head
cover and all glow plugs.
4. [a] Nozzle Hole Adaptor Setting :
Set a compression tester (Code No. 07909-30208) with the
adaptor (Adaptor H, code No. 07909-31231) to the nozzle hole.
[b] Glow Plug Hole Adaptor Setting :
Set a compression tester (Code No. 07909-30208) with the
adaptor (Adaptor L, code No. 07909-31301) 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 (or
nozzle 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.
Q NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for performing this test.
• Variances in cylinder compression values should be under
10 %.
Z482-E3B 2.85 to 3.23 MPa
D722-E3B 29.0 to 33.0 kgf/cm2
Factory D782-E3B 413 to 469 psi
spec. 3.53 to 4.02 MPa
Z602-E3B
36.0 to 41.0 kgf/cm2
D902-E3B
Compression 512 to 583 psi
pressure Z482-E3B 2.26 MPa
D722-E3B 23.0 kgf/cm2
Allowable D782-E3B 327 psi
limit 2.55 MPa
Z602-E3B
26.0 kgf/cm2
D902-E3B
370 psi
[a] Nozzle Hole Adaptor Setting [b] Glow Plug Hole Adaptor Setting
W10178940

Checking Valve Clearance

Q IMPORTANT
• 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
feeler gauge.
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
feeler gauge.
Number of cylinders D722-E3B
Z482-E3B
Valve arrangement D782-E3B
Z602-E3B
D902-E3B
Adjustable cylinder Intake Exhaust Intake Exhaust

location of piston valve valve valve valve
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.
Intake and exhaust 0.145 to 0.185 mm
Factory spec.
valve clearance (cold) 0.00571 to 0.00728 in.
Q NOTE
• The sequence of cylinder numbers is given as No. 1, No. 2
and No. 3 starting from the gear case side.
• 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] Z482-E3B, Z602-E3B
(3) Alignment Mark [b] D722-E3B, D782-E3B, D902-E3B
W10172470

(2) Lubricating System

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.
• Engine oil insufficient
• Oil pump defective
• Oil strainer clogged
• Oil filter cartridge clogged
• Oil gallery clogged
• Excessive oil clearance
• Foreign matter in the relief valve
More than 49 kPa
At idle Factory
0.50 kgf/cm2
speed spec.
7.1 psi
197 to 441 kPa
Factory
Engine oil pressure 2.00 to 4.50 kgf/cm2
spec.
At rated 28.5 to 64.0 psi
speed 147 kPa
Allowable
1.50 kgf/cm2
limit
21.3 psi
(When reassembling)
• After checking the engine oil pressure, tighten the engine oil
pressure switch to the specified torque.
15 to 19 N·m
Tightening torque Oil pressure switch 1.5 to 2.0 kgf·m
11 to 14 lbf·ft
W10349520
(3) Cooling System

Fan Belt Tension
1. Measure the deflection (A), depressing the belt halfway between
the fan drive pulley and alternator pulley at specified force 98 N
(10 kgf, 22 lbf).
2. If the measurement is not within the factory specifications, 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.
(A) Deflection
W10356670

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
W1016443
CAUTION
• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.
Otherwise, hot water may gush out, scalding nearby people.
Radiator Cap Air Leakage
1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.
2. Apply the specified pressure of 88 kPa (0.90 kgf/cm2, 13 psi), and
measure the time for the pressure to fall to 59 kPa (0.60 kgf/cm2,
8.5 psi).
3. If the measurement is less than the factory specification, replace
the radiator cap.
More than 10 seconds
for pressure fall
Pressure falling time Factory spec. 88 → 59 kPa
(0.90 → 0.60 kgf/cm2,
13 → 8.5 psi)
(1) Radiator Tester (2) Adaptor

W1054156
Radiator Water Leakage
1. Pour a specified amount of water into the radiator.
2. Set a radiator tester (1) and an adaptor (2) and raise the water
pressure to the specified pressure.
3. Check the radiator for water leaks.
4. For water leak from the pinhole, replace the radiator or repair with
the radiator cement. When water leak is excessive, replace the
radiator.
Radiator water leakage No leak at specified
Factory spec.
test pressure pressure
Q NOTE
• The pressure of the leak test is different from each radiator
specification.
Thus, do the leak test, refer to the test pressure of each
radiator specification.
(1) Radiator Tester (2) Adaptor
W1016903

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. 8.0 mm (0.31 in.).
replace the thermostat.
Thermostat’s valve 69.5 to 72.5 °C
Factory spec.
opening temperature 157.1 to 162.5 °F
Temperature at which
85 °C
thermostat completely Factory spec.
185 °F
opens
W1035849
(4) Fuel System

Injection Timing
1. Remove the injection pipes.
3. Turn the flywheel counterclockwise (viewed from flywheel side)
until the fuel fills up to the hole of the delivery valve holder (3) for
No. 1 cylinder.
4. After the fuel fills up to the hole of the delivery valve holder for No.
1 cylinder, turn back (clockwise) the flywheel around 1.6 rad
(90 °).
5. Turn the flywheel counterclockwise to set at around 0.44 rad
(25 °) before T.D.C..
6. Slowly turn the flywheel counterclockwise and stop turning when
the fuel begins to come up, to get the present injection timing.
7. Check to see the degree on flywheel.
The flywheel has mark “1TC”, “10” and “20” for the crank angle
before the top dead center of No. 1 cylinder.
8. Check to see if the timing angle on the flywheel is aligned with the
alignment mark (2).
9. If injection timing is out of adjustment, readjust the timing with
shims.
Z482/D722-E3B (3600 min-1 (rpm) spec.)
0.35 to 0.38 rad
D782-E3B (3200 min-1 (rpm) spec.)

0.28 to 0.31 rad
Z602/D902-E3B (3600 min-1 (rpm) spec.)

0.34 to 0.36 rad
(1) Timing Line (5) Two-holes : 0.20 mm (0.0079 in.)

(2) Alignment Mark Two-holes : 0.175 mm (0.00689 in.)
(3) Delivery Valve Holder (6) One-hole : 0.25 mm (0.0098 in.)
(4) Shim (Soft Metal Gasket Shim) (7) Without hole : 0.30 mm (0.012 in.)
(8) Three-holes : 0.35 mm (0.014 in.)
W1018724

Injection Timing (Continued)

Q NOTE
• The liquid gasket is not required for assembling.
• Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25
mm (0.0098 in.), 0.30 mm (0.012 in.), 0.35 mm (0.014 in.) and
0.175 mm (0.00689 in.). Combine these shims for
adjustments.
• Addition or reduction of shim (0.025 mm, 0.00098 in.) delays
or advances the injection timing by approx. 0.0044 rad
(0.25 °).
• In disassembling and replacing the injection pump, be sure
to use the same number of new shims with the same
thickness.
• The 0.175 mm (0.00689 in.) thick shim is coated only on the
lower face. Therefore, do not use the 0.175 mm (0.00689 in.)
thick shim as the top shim of the combination (injection
pump side), because this can cause oil leakage.
• Refer to figure of the shim to check the thickness of the
shims.
• The injection timing might be changed by the application.
W1018986

Fuel Tightness of Pump Element

3. Install the injection pump pressure tester to the injection pump.
pressure to the injection pump pressure tester (1). (Refer to the
photo.)
5. Set the speed control lever to the maximum speed position.
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 140.0 kgf/cm2
element
1991 psi
Q NOTE
W1017430
Fuel Tightness of Delivery Valve
3. Set a pressure tester to the fuel injection pump.
pressure to the injection pump pressure tester (1).
6. Stop the starter when the fuel jets from the injection nozzle. After
that, turn the flywheel by hands and raise the pressure to approx.
13.73 MPa (140.0 kgf/cm2, 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
140.0 to 130.0 kgf/cm2, from 1991 to 1849 psi).
8. Measure the time needed to decrease the pressure from 13.73 to
12.75 MPa (140.0 to 130.0 kgf/cm2, 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.
140.0 → 130.0 kgf/cm2
Fuel tightness of 1991 → 1849 psi
delivery valve 5 seconds
13.73 → 12.75 MPa
Allowable limit
140.0 → 130.0 kgf/cm2
1991 → 1849 psi
Q NOTE
W1017786

CAUTION
• Check the nozzle injection pressure and condition after confirming that there is nobody standing in the
direction the fume goes.
• If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning
may be caused.
Nozzle Spraying Condition
1. Set the injection nozzle to a nozzle tester, and check the nozzle
spraying condition.
2. If the spraying condition is defective, replace the nozzle piece.
(a) Good (b) Bad
W10181310
Fuel Injection Pressure

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.
(Reference)
• Pressure variation with 0.025 mm (0.00098 in.) difference of
adjusting washer thickness.
Approx. 590 kPa (6.0 kgf/cm2, 85 psi)
13.73 to 14.70 MPa
Fuel injection pressure Factory spec. 140.0 to 150.0 kgf/cm2
1992 to 2133 psi
(1) Adjusting Washer

W10182100
Nozzle Valve Seat Tightness

2. Raise the fuel pressure, and keep at 12.75 MPa (130.0 kgf/cm2,
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.
130.0 kgf/cm2
1849 psi
W10183690

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)
• Assemble the nozzle in clean fuel oil.
• Install the push rod (4), noting its direction.
• After assembling the nozzle, be sure to adjust the fuel injection
pressure.
35 to 39 N·m
Nozzle holder 3.5 to 4.0 kgf·m
26 to 28 lbf·ft
20 to 24 N·m
Tightening torque Overflow pipe retaining nut 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
49 to 68 N·m
Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
(1) Nozzle Holder (5) Distance Piece

(2) Adjusting Washer (6) Nozzle Piece
(3) Nozzle Spring (7) Nozzle Retaining Nut
(4) Push Rod
W1018491
(5) Electrical System
CAUTION
• To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
• Never remove the battery cap while the engine is running.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely
with water immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
Q IMPORTANT
• If the machine is to be operated for a short time without battery (using a slave battery for starting), use
additional current (lights) while engine is running and insulate terminal of battery. If this advice is
disregarded, damage to alternator and regulator may result.
Battery Voltage
1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery
terminals.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and recharge the battery.
Battery voltage Factory spec. More than 12 V
(1) Positive Terminal (2) Negative Terminal

W10125620

Battery Specific Gravity

1. Check the specific gravity of the electrolyte in each cell with a
hydrometer.
2. When the electrolyte temperature differs from that at which the
hydrometer was calibrated, correct the specific gravity reading
following the formula mentioned in (Reference).
3. If the specific gravity is less than 1.215 (after it is corrected for
temperature), charge or replace the battery.
4. If the specific gravity differs between any two cells by more than
0.05, replace the battery.
Q NOTE
• Hold the hydrometer tube vertical without removing it from
the electrolyte.
• Do not suck too much electrolyte into the tube.
• Allow the float to move freely and hold the hydrometer at eye
level.
• The hydrometer reading must be taken at the highest
electrolyte level.
(Reference)
• Specific gravity slightly varies with temperature. To be exact, the
specific gravity decreases by 0.0007 with an increase of 1 °C
(0.0004 with an increase of 1 °F) in temperature, and increases
by 0.0007 with a decreases of 1 °C (0.0004 with a decrease of 1
°F).
Therefore, using 20 °C (68 °F) as a reference, the specific gravity
reading must be corrected by the following formula :
- Specific gravity at 20 °C = Measured value + 0.0007 ×
(electrolyte temperature : 20 °C)
- Specific gravity at 68 °F = Measured value + 0.0004 ×
(electrolyte temperature : 68 °F)
Specific Gravity State of Charge
1.140 Sp. Gr. Very Little Useful Capacity
1.110 Sp. Gr. Discharged
At an electrolyte temperature of 20 °C (68 °F)
(a) Good (c) Bad
(b) Bad
W1019017

Motor Test
CAUTION
• 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 from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the motor does not run, starter is failure.
Repair or replace the starter.
Q NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• C terminal : It is the terminal which connects the cable from
the motor to the magnet switch.
(1) C Terminal [A] Electromagnetic Drive Type
(2) Positive Terminal [B] Planetary Gear Reduction Type
(3) Negative Terminal
W1019297
Magnetic Switch Test
1. Disconnect the battery negative cable from the battery.
2. Disconnect the battery positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter’s body
and the battery negative terminal (3).
7. If the pinion gear does not pop out, the magnetic switch is failure.
Repair or replace the starter.
Q NOTE
• B terminal : It is the terminal which connects the cable from
the battery to the starter.
• S terminal : It is the terminal which connects the cable from
the starter switch to the magnet switch.
(1) S Terminal [A] Electromagnetic Drive Type
(2) Positive Terminal [B] Planetary Gear Reduction Type
(3) Negative Terminal
0000010743E

Magnet Switch Continuity Test

1. Check the continuity across the C terminal (1) and the B terminal
(2) with a circuit tester, pushing in the plunger.
2. If not continuous or if a certain value is indicated, replace the
magnet switch.
(1) C Terminal [A] Electromagnetic Drive Type
(2) B Terminal [B] Planetary Gear Reduction Type
0000010771E
No-load Dynamo Output

1. Disconnect the lead wires from the dynamo.
2. Start the engine and operate the dynamo at the specified speed.
3. Measure the output voltage with a volt meter.
If the measurement is not within the specified values, replace the
dynamo.
AC 20 V or more at
No-load output voltage Factory spec.
5200 min-1 (rpm)
W1021164

Continuity across Regulator’s Terminals

1. Measure with a circuit tester according to the list below.
Q NOTE
• For this test, use only Analog Meter and do not use a high
voltage tester such as a MΩ meter.
• This check sheet shows the results of the test conducted by
using the “Sanwa-made tester SP-10 and SP-15D” (Analog
Meter).
• Use of other testers than those above may show different
measured results. Ω shall be used as the unit for the
measuring range.
• The judgement should be as below table.
“ON” if the indicator moves, otherwise “OFF”.
Q Check Table (+ : ON, , : OFF)
Tester + Code colors
Terminal
Tester − Blue Black Blue Green Yellow Red
Terminal
Blue , , , , +
Black , , , , ,
Code Blue , , , , +
colors Green , , , , ,
Yellow + + + , +
Red , , , , ,
(1) Blue (4) Green

(2) Black (5) Yellow
(3) Blue (6) Red
W1021509
Regulating Voltage
1. Complete the charging circuit with a fully charged battery and
operate the dynamo at the specified speed.
2. Measure the output voltage with a volt meter.
3. If the measurement is not within the specified values, replace the
dynamo.
Regulating output 14 to 15 V at
Factory spec.
voltage 5200 min-1 (rpm)
W1022299

Alternator on Unit Test

(Before testing)
• Before alternator on unit test, check the battery terminal
connections, circuit connection, fan belt tension, charging
indicator lamp, fuses on the circuit, and abnormal noise from the
alternator.
• Prepare full charged battery for the test.
Q NOTE
• Be careful not to touch the rotating engine parts while
engine is running.
Keep safety distance from the engine rotating parts.
1. Start the engine.
2. When the engine is operating measure the voltage between two
battery terminals. If the voltage is between 13.8 V and 14.8 V,
the alternator is operating normally.
3. If the results of alternator on unit test are not within the
specifications, disassemble the alternator and check the each
component part for finding out the failure. See the
“DISASSEMBLING AND ASSEMBLING” and “SERVICING” for
alternator.
Regulating voltage at no 13.8 to 14.8 V at 25 °C
Factory spec.
load (77 °F)
0000010745E
Glow Plug Lead Terminal Voltage
1. Turn the key switch to the “GLOW (or PREHEAT)” position, and
measure the voltage with a circuit tester between the lead
terminal and the engine body.
2. If the voltage differs from the battery voltage, the wiring harness
or main switch is faulty.
Main switch key at
Voltage GLOW Approx. battery voltage
(or PREHEAT)
0000010725E
Glow Plug Continuity

1. Remove the glow plug.
2. Measure the resistance with a circuit tester between the glow
plug terminal and the glow plug housing.
3. If the factory specification is not indicated, glow plug is faulty.
Resistance Factory spec. Approx. 0.9 Ω
0000010726E
Engine Stop Solenoid Test (Energize to Stop Type)

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)
W1019658

Engine Stop Solenoid Test (Energize to Run Type)

1. Disconnect the 3P connector (3) from the engine stop solenoid
(1) wiring harness.
2. Remove the engine stop solenoid (1) from the engine.
3. Connect the jumper leads from the pulling coil terminal (6) to the
switch (7), and from switch (7) to the battery positive terminal
(10).
4. Connect the jumper leads from the holding coil terminal (5) to the
switch (8), and from switch (8) to the battery positive terminal
(10).
5. Connect the jumper leads from the ground terminal (4) to the
battery negative terminal (9).
6. When the switch (7) is turn on, the plunger pull into the solenoid
body and then the plunger comes out within approximately 1.2
seconds.
7. Turn on the switch (8) then turn on the switch (7), the plunger pull
into the solenoid body and it keeps in holding position after turn
off the switch (7),
8. If the plunger is not attracted, the engine stop solenoid is faulty.
Q NOTE
• This solenoid assembly includes reverse polarity protected
pulling coil timer module (2) to prevent solenoid burnout due
to engine over crank or misadjustment of linkage by limiting
the pull coil ON time.
Pull coil energized time Factory spec. 0.52 to 1.20 seconds
(1) Engine Stop Solenoid (6) Pulling Coil Terminal

(2) Pulling Coil Timer Module (7) Switch for Pulling Coil
(3) 3P Connector (8) Switch for Holding Coil
(4) Ground Terminal (9) Battery Negative Terminal
(5) Holding Coil Terminal (10) Battery Positive Terminal
W1022853

[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Engine Oil and Coolant
Draining Engine Oil
3. Remove the drain plug (2) to drain oil.
4. After draining, screw in the drain plug.
(When refilling)
• Fill the engine oil up to the upper line on the dipstick (1).
Q IMPORTANT
temperature.
(1) Dipstick (3) Oil Inlet Plug
(2) Drain Plug
W1023464
Draining Coolant
CAUTION
• 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
W1023496

(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)
• Check to see that there are no cracks on the belt surface.
Q IMPORTANT
• Keep the engine stop lever (7) to touch the stopper (6).
Tighten the engine stop solenoid mounting screw (4) so that
there be no gap between the engine stop lever and the
engine stop solenoid plunger (5).
• After reassembling the fan belt, be sure to adjust the fan belt
tension.
• Do not confuse the direction of the fan.
(1) Engine Stop Solenoid (6) Stopper
(2) Cooling Fan (7) Engine Stop Lever
(3) Fan Belt
(4) Engine Stop Solenoid Mounting A : 0 mm (0 in.)
Screw
(5) Plunger
W1023769
(3) Cylinder Head, Valves and Oil Pan

Cylinder Head Cover
1. Disconnect the breather hose (1).
2. Remove the cylinder head cover screws (2).
3. Remove the cylinder head cover (3).
(When reassembling)
• Check to see if the cylinder head cover gasket is not defective.
9.81 to 11.2 N·m
Tightening torque Cylinder head cover screw 1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
(1) Breather Hose (3) Cylinder Head Cover

(2) Cylinder Head Cover Screws
W1028468
Injection Pipes
1. Loosen the screws to the pipe clamp (2).
2. Detach the injection pipes (1).
(When reassembling)
• Sent compressed air into the pipes to blow out dust. Then,
reassemble the pipes in the reverse order.
25 to 34 N·m
Tightening torque Injection pipe retaining nut 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
(1) Injection Pipe (2) Pipe Clamp

W1028640

Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe (1).
2. Remove the nozzle holder assemblies (4).
3. Remove the copper gasket (5) and heat seal (6).
4. Remove the lead (2) from the glow plugs (3).
5. Remove the glow plugs (3).
(When reassembling)
• Replace the copper gasket and heat seal with new one.
20 to 24 N·m
Overflow pipe retaining nut 2.0 to 2.5 kgf·m
15 to 18 lbf·ft
49 to 68 N·m
Tightening torque Nozzle holder assembly 5.0 to 7.0 kgf·m
37 to 50 lbf·ft
7.9 to 14 N·m
Glow plug 0.80 to 1.5 kgf·m
5.8 to 10 lbf·ft
(1) Overflow Pipe (4) Nozzle Holder Assembly

(2) Lead (5) Copper Gasket
(3) Glow Plug (6) Heat Seal
W1024604
Nozzle Heat Seal Service Removal Procedure

Q IMPORTANT
• Use a plus (phillips head) screw driver (1) that has a
diameter which is bigger than the heat seal hole (Approx. 6.0
mm (0.24 in.)).
1. Drive screw driver (1) lightly into the heat seal hole.
2. Turn screw driver three or four times each way.
3. While turning the screw driver, slowly pull the heat seal (4) out
together with the injection nozzle gasket (3).
4. If the heat seal drops, repeat the above procedure.
(When reassembling)
• Heat seal and injection nozzle gasket must be changed when the
injection nozzle is removed for cleaning or for service.
(1) Plus Screw Driver (3) Injection Nozzle Gasket
(2) Injection Nozzle (4) Heat Seal
W1021255

Rocker Arm and Push Rod

1. Remove the rocker arm bracket screws (2).
2. Detach the rocker arm assembly (1).
3. Remove the push rods (3).
(When reassembling)
• When putting the push rods (3) onto the tappets (4), check to see
if their ends are properly engaged with the dimples.
Q IMPORTANT
• After installing the rocker arm, be sure to adjust the valve
clearance.
9.81 to 11.2 N·m
Tightening torque Rocker arm bracket screw 1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
(1) Rocker Arm Assembly (3) Push Rod

(2) Rocker Arm Bracket Screws (4) Tappet
W1021437

Cylinder Head and Cylinder Head Gasket

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. Remove the cylinder head gasket.
(When reassembling)
• Replace the cylinder head gasket with a new one.
• When mounting the gasket, set it to the pin pipe holes. Take care
not to mount it reversely.
• The cylinder head should be free of scratches and dust.
• Install the cylinder head, using care not to damage the gasket.
• After applying engine oil to the thread of screws, tighten them in
several steps and specified sequence (a) to (n or j).
Q NOTE
• Do not use O-ring on the pin pipe.
• It is not necessary to retighten the cylinder head screw and
to readjust valve clearance after engine warmed up.
38 to 42 N·m
Tightening torque Cylinder head screw 3.8 to 4.3 kgf·m
28 to 31 lbf·ft
(1) Pipe Clamp A : Gear Case Side

(2) Water Return Pipe (n or j) to (a) : To Loosen
(3) Pin Pipe (a) to (n or j) : To Tighten
[a] Z482-E3B, Z602-E3B
[b] D722-E3B, D782-E3B, D902-E3B
W1025645
Tappets
1. Remove the tappets (1) from the crankcase.
(When reassembling)
• Visually check the contact between tappets and cams for proper
rotation. If defect is found, replace tappets.
• Before installing the tappets, apply engine oil thinly around them.
Q IMPORTANT
• Do not change the combination of tappet and tappet guide.
(1) Tappet
W10209700

Valves
1. Remove the valve caps (4).
2. Remove the valve spring collet (3), pushing the valve spring
retainer (2) by valve spring replacer (1).
3. Remove the valve spring retainer (2), valve spring (5) and valve
stem seal (6).
4. Remove the valve (7).
(When reassembling)
• Wash the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After installing the valve spring collets, lightly tap the stem to
assure proper fit with a plastic hammer.
Q IMPORTANT
• Don’t change the combination of valve and valve guide.
(1) Valve Spring Replacer (5) Valve Spring
(2) Valve Spring Retainer (6) Valve Stem Seal
(3) Valve Spring Collet (7) Valve
(4) Valve Cap
W10211070
Thermostat Assembly
1. Remove the thermostat cover mounting screws (1), and remove
the thermostat cover (2).
2. Remove the thermostat assembly (4).
(When reassembling)
• Replace the gasket (3) with a new one.
(1) Thermostat Cover Mounting Screw (3) Thermostat Cover Gasket
(2) Thermostat Cover (4) Thermostat Assembly
W10363950
Water Pump Assembly (If necessary)

1. Loosen the alternator mounting screws, and remove the fan belt.
2. Remove the fan and fan pulley.
3. Remove the water pump assembly (1) from the gear case cover
(3).
(When reassembling)
• Replace the gasket (2) with a new one.
(1) Water Pump Assembly (3) Gear Case Cover
(2) Water Pump Gasket
W10403090

Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws (2).
2. Remove the oil pan (1) by lightly tapping the rim of the pan with
a wooden hammer.
3. Remove the oil strainer (3).
(When reassembling)
• After cleaning the oil strainer, check to see that the filter mesh in
clean, and install it.
• Visually check the O-ring (4), apply engine oil, and install it.
• Securely fit the O-ring to the oil strainer.
• To avoid uneven tightening, tighten oil pan mounting screws in
diagonal order form the center.
For Z482-E3B, Z602-E3B
• Using the hole (6) numbered “2”, install the oil strainer by
mounting screw
For D722-E3B, D782-E3B, D902-E3B
• Using the hole (5) numbered “3”, install the oil strainer by
mounting screw
Q IMPORTANT
• Scrape off the old adhesive completely. Wipe the sealing
surface clean using waste cloth soaked with gasoline. Now
apply new adhesive 3.0 to 5.0 mm (0.12 to 0.19 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 bolt
hole.
• Cut the nozzle of the “liquid gasket” (Three Bond 1207D or
equivalent) container at its second notch. Apply “liquid
gasket” about 3.0 to 5.0 mm (0.12 to 0.19 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 [a] Z482-E3B, Z602-E3B
(2) Oil Pan Mounting Screw [b] D722-E3B, D782-E3B, D902-E3B
(3) Oil Strainer
(4) O-ring
(5) Hole Numbered “3”
(6) Hole Numbered “2”
W10236610

(4) Gear Case and Timing Gears

Injection Pump, Fuel Feed Pump and Speed Control Plate
(for Energize to Stop Type Engine Stop Solenoid)
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)
• Hook the governor spring (4) to the governor lever (5) first and
install the speed control plate (2).
• Be sure to place the copper washers underneath two screws (8).
(Two screws (8) in the upper of the speed control plate (2).)
• Position the slot (7) on the fork lever just under the slot (6) on the
crankcase.
• 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).
Q NOTE
• The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.
• Addition or reduction of shim (0.05 mm, 0.002 in.) delays or
advances the injection timing by approx. 0.009 rad (0.5 °).
• 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) Screw and Copper Washer
(3) Fuel Feed Pump (9) Idling Adjusting Spring
(4) Governor Spring (10) Control Rod
(5) Governor Lever (11) Pin
(6) Slot (Crankcase Side)
W1027230


(for Energize to Run Type Engine Stop Solenoid)
Q NOTE
• Specific tool (1) :
1.2 mm (0.047 in.) diameter hard wire with its end hooked,
overall length 200 mm (7.87 in.).
The tip of wire is bent like the hook to hang governor
springs.
1. Remove the socket head screws (3), and remove the engine stop
solenoid (4).
2. Remove the screws and separate the speed control plate (6),
taking care not to damage the governor spring (7).
3. Disconnect the governor spring (7) and remove the speed control
plate (6) using the specific tool (1).
4. Remove the fuel feed pump (2).
5. Disconnect the start spring (8) from the bracket (9) using the
specific tool (1).
6. Remove the socket head screws and nuts, and remove the
injection pump (5).
(1) Specific Tool (6) Speed Control Plate
(2) Fuel Feed Pump (7) Governor Spring
(3) Socket Head Screw (8) Start Spring
(4) Engine Stop Solenoid (9) Bracket
(5) Injection Pump
W1148604


(for Energize to Run Type Engine Stop Solenoid) (Continued)
(When reassembling)
1. Move the fork lever (2) to the gear case side.
2. Hook the start spring (6) to the injection pump control rack pin (5).
3. Put the specific tool (7) through the fork lever hole of cylinder
block (9) and hook the start spring (6).
4. Keep this spring slightly extended and install the injection pump
(4). Make sure the control rod (8) should be pushed by the idling
adjusting spring (1) and the pin (5) on the rod engages with the
fork lever (2).
5. Hook the start spring (6) to the bracket (3) using the specific tool
(7).
6. Hook the governor springs (small and large) (14) to the governor
lever (13) using the specific tool (7) and install the speed control
plate (11). Be sure to place the copper washers underneath two
screws (12) in the upper of the speed control plate.
7. Install the engine stop solenoid rod (15) to the guide hole of
cylinder block (10) and fix the engine stop solenoid (16) with
socket head screws.
Q NOTE
• Be careful not to stretch the start spring (6) too long.
Otherwise it may get deformed permanently.
• Make sure the start spring (6) is tight on the bracket (3).
• The sealant is applied to both sides of the soft metal gasket
shim. The liquid gasket is not required for assembling.
• Addition or reduction of shim (0.05 mm, 0.002 in.) delays or
advances the injection timing by approx. 0.009 rad (0.5 °).
• In disassembling and replacing, be sure to use the same
number of new gasket shims with the same thickness.
(1) Idling Adjusting Spring (9) Fork Lever Hole of Cylinder Block
(2) Fork Lever (10) Guide Hole of Cylinder Block
(3) Bracket (11) Speed Control Plate
(4) Injection Pump (12) Screw and Copper Washer
(5) Injection Pump Control Rack Pin (13) Governor Lever
(6) Start Spring (14) Governor Spring
(7) Specific Tool (15) Engine Stop Solenoid Rod
(8) Injection Pump Control Rod (16) Engine Stop Solenoid
W1028534

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)
• Install the pulley to crankshaft, aligning the mark (1) on them.
• Apply engine oil to the fan drive pulley retaining screw. And
tighten it.
118 to 127 N·m
Tightening torque Fan drive pulley screw 12.0 to 13.0 kgf·m
86.8 to 94.0 lbf·ft
(1) Alignment Mark

W10181950

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)
• Apply a liquid gasket (Three Bond 1215 or equivalent) to both
sides of the gear case gasket.
• Be sure to set three O-rings inside the gear case.
Q NOTE
• The gear case for energize to run type stop solenoid and the
gear case for one-side maintenance are available to meet
customer’s requirements. (Option)
(1) Screw (Inside) [a] Gear Case for Energize to Run
(2) Start Spring Type Stop Solenoid (Option)
(3) Fork Lever 1 [b] Gear Case for One-side
(4) Gear Case Maintenance (Option)
W1029858

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) (if necessary).
(When reassembling)
• Apply engine oil to the idle gear shaft mounting screw (4). And
tighten them.
• Install the idle gear, aligning the mark (6) on the gears referring
to the photo.
9.81 to 11.2 N·m
Idle gear shaft mounting
Tightening torque 1.00 to 1.15 kgf·m
screw
7.24 to 8.31 lbf·ft
(1) Idle Gear (4) Idle Gear Shaft Mounting Screw

(2) Idle Gear Collar (5) Idle Gear Shaft
(3) External Snap Ring (6) Alignment Mark
W1030437
Camshaft
1. Remove the camshaft mounting screws (1) and draw out the
camshaft with gear (2) on it.
(When reassembling)
• When install the camshaft, apply engine oil to the camshaft
journals.
• Apply engine oil to the camshaft mounting screws. And tighten
them.
(1) Camshaft Mounting Screw (2) Camshaft Gear
W1030808

Fuel Camshaft
1. Remove the retaining plate (6).
2. Remove the fork lever holder mounting screws (8), then draw out
the injection pump gear (1) and fuel camshaft (7) with the
governor fork assembly.
(When reassembling)
• Hook the governor spring (5) to the fork lever 2 (4) before
installing the fork lever assembly to the crankcase.
(1) Injection Pump Gear (5) Governor Spring
(2) Governor Sleeve (6) Retaining Plate
(3) Fork Lever 1 (7) Fuel Camshaft
(4) Fork Lever 2 (8) Fork Lever Holder Mounting Screw
W10178820
Oil Pump and Crankshaft Gear

1. Remove the oil pump gear (7).
2. Remove the oil pump mounting screw (6) and the oil pump (5).
3. Remove the collar (4), O-ring (3) and crankshaft oil slinger (2).
For Z482-E3B, D722-E3B, D782-E3B
4. Remove the crankshaft gear (1) with a puller.
(When reassembling)
• Install the collar (4) after aligning the marks on the gears. (See
the photo at “Idle Gear”.)
18 to 21 N·m
Tightening torque Oil pump mounting screw 1.8 to 2.2 kgf·m
13 to 15 lbf·ft
(1) Crankshaft Gear (5) Oil Pump

(2) Crankshaft Oil Slinger (6) Oil Pump Mounting Screw
(3) O-ring (7) Oil Pump Gear
(4) Crankshaft Collar
W10180290
Oil Pump and Crankshaft Gear (One-side Maintenance Type)
1. Remove the oil pump mounting screw (6) and the oil pump (5).
2. Remove the collar (4), O-ring (3) and crankshaft oil slinger (2).
For Z482-E3B, D722-E3B, D782-E3B
3. Remove the crankshaft gear (1) with a puller.
(When reassembling)
• Install the collar (4) after aligning the marks on the gears. (See
the photo at “Idle Gear”.)
18 to 21 N·m
Tightening torque Oil pump mounting screw 1.8 to 2.2 kgf·m
13 to 15 lbf·ft
(1) Crankshaft Gear (5) Oil Pump

(2) Crankshaft Oil Slinger (6) Oil Pump Mounting Screw
(3) O-ring (7) Oil Pump Gear
(4) Crankshaft Collar
W10314010

(5) Piston and Connecting Rod

Connecting Rod Cap
1. Remove the connecting rod caps (1) using a bihexagonal 8 mm
socket.
(When reassembling)
• Align the marks (a) with each other. (Face the marks toward the
injection pump.)
• 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.
27 to 30 N·m
Tightening torque Connecting rod screw 2.7 to 3.1 kgf·m
20 to 22 lbf·ft
(1) Connecting Rod Cap (a) Mark

W10275480

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 pistons after the same method as above.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough engine
oil to the cylinder.
• When inserting the piston into the cylinder, face the mark on the
connecting rod to the injection pump.
Q IMPORTANT
• 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.
• When installing the piston into the cylinder, place the gaps
of all of the piston rings as shown in the figure.
• Carefully insert the piston using a piston ring compressor
(1). Otherwise, their chrome-plated section may be
scratched, causing trouble inside the cylinder.
Models Mark
Z482-E3B, D722-E3B 3
D782-E3B B
Z602-E3B, D902-E3B (3200 min-1 (rpm) spec.) 1C
Z602-E3B, D902-E3B (3600 min-1 (rpm) spec.) 2D
(1) Piston Ring Compressor (a) 0.79 rad (45 °)

(b) 0.79 rad (45 °)
(A) Top Ring Gap (c) 1.6 rad (90 °)
(B) Second Ring Gap (d) Mark
(C) Oil Ring Gap
(D) Piston Pin Hole
W10277450

Piston Ring and Connecting Rod

1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
• When installing the ring, assemble the rings so that the
manufacturer’s mark (12) near the gap faces the top of the piston.
• When installing the oil ring onto the piston, place the expander
joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin.
• When installing the connecting rod to the piston, immerse the
piston in 80 °C (176 °F) oil for 10 to 15 minutes and insert the
piston pin to the piston.
• When installing the connecting rod to the piston, align the mark
(9) on the connecting rod to the fan-shaped concave (8).
Q IMPORTANT
• Mark the same number on the connecting rod and the piston
so as not to change the combination.
(1) Top Ring (7) Piston Pin
(2) Second Ring (8) Fan-Shaped Concave
(3) Oil Ring (9) Mark
(4) Piston Pin Snap Ring (10) Expander Joint
(5) Piston (11) Oil Ring Gap
(6) Connecting Rod (12) Manufacturer’s Mark
W10281670

(6) Flywheel and Crankshaft

Flywheel
1. Secure the flywheel to keep it from turning using a flywheel
stopper. (Refer to “SPECIAL TOOLS”.)
2. Remove all flywheel screws (1) and then remove the flywheel (2).
(When reassembling)
• Set the No. 1 crankpin at the top dead center (T.D.C.).
• Align the “1TC” mark (a) on the outer surface of the flywheel
horizontally with the alignment mark (b) on the rear end plate.
• Apply engine oil to the threads and the undercut surface of the
flywheel screw and fit the screw.
54 to 58 N·m
Tightening torque Flywheel screw 5.5 to 6.0 kgf·m
40 to 43 lbf·ft
(1) Flywheel Screw (a) 1TC Mark

(2) Flywheel (b) Alignment Mark
W1030810
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 (5).
(When reassembling)
• Fit the bearing case gasket (3) and the bearing case cover gasket
(4) with correct directions.
• Install the bearing case cover (5) to position the casting mark
“UP” (a) on it upward.
• Apply engine oil to the oil seal (6) lip and take care that it is not
rolled when installing.
• Tighten the bearing case cover mounting screws with even force
on the diagonal line.
9.81 to 11.2 N·m
Bearing case cover
Tightening torque 1.00 to 1.15 kgf·m
mounting screw
7.24 to 8.31 lbf·ft
(1) Bearing Case Cover Mounting Screw (5) Bearing Case Cover
(Inside) (6) Oil Seal
(2) Bearing Case Cover Mounting Screw
(Outside) (a) Top Mark “UP”
(3) Bearing Case Gasket (b) Upside
(4) Bearing Case Cover Gasket
W1031168

Crankshaft Assembly
For Z482-E3B, D722-E3B
1. Remove the main bearing case screw 2 (1).
2. Draw out all the crankshaft.
For Z602-E3B
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 D782-E3B, D902-E3B
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)
• Clean the oil passage of the crankshaft with compressed air.
• Install the crankshaft assembly, aligning the screw hole of main
bearing case screw 2 with the screw hole of crankcase.
• 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.
27 to 30 N·m
Tightening torque Main bearing case screw 2 2.7 to 3.1 kgf·m
20 to 22 lbf·ft
(1) Main Bearing Case Screw 2 [a] Z482-E3B, Z602-E3B

[b] D722-E3B, D782-E3B, D902-E3B
A : Cut place for removing and [c] D782-E3B, D902-E3B
installing the crankshaft
(D782-E3B, D902-E3B)
W1031360

Main Bearing Case Assembly

(Z482-E3B, D722-E3B, D782-E3B)
1. Remove the two main bearing case screws 1 (4), and remove the
main bearing case assembly 1 (1), being careful with crankshaft
bearing 3 (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 (7) is installed in the main bearing case
assembly (3).
(When reassembling)
• Clean the oil passage in the main bearing cases.
• Apply clean engine oil to the bearings.
• Install the main bearing case assemblies in original positions.
Since diameters of main bearing cases vary, install them in order
of marking (b) (1 for Z482-E3B and 1, 2 for D722-E3B, D782-
E3B) from the gear case side. (Refer to the figure.).
• Match the alignment numbers (a) on the main bearing case
assembly 1 (1).
• Do the same for the main bearing case assembly 2 (2) and the
main bearing case assembly (3) too.
• When installing the main bearing case 1 and 2, face the mark
“FLYWHEEL” to the flywheel.
• Install the thrust bearing (7) with its oil groove facing outward.
• Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 to the specified torque.
13 to 15 N·m
9.4 to 11 lbf·ft
(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
(4) Main Bearing Case Screw 1
(5) Crankshaft Bearing 3
(7) Thrust Bearing
W1031597

Main Bearing Case Assembly (Z602-E3B, D902-E3B)

1. Remove the two main bearing case screws 1 (4), and remove the
main bearing case assembly 1 (1), being careful with crankshaft
bearing 3 (5) (9).
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)
• Clean the oil passage in the main bearing cases.
• Apply clean engine oil to the bearings.
• Install the main bearing case assemblies in original positions.
Since diameters of main bearing cases vary, install them in order
of marking (b) (1 for Z602-E3B and 1, 2 for D902-E3B) from the
gear case side. (Refer to the figure.).
• Be careful not to confuse the top and bottom of the crankshaft
bearing 3 (5) (9). (Install the bearing with the oil groove (c) up.)
• Match the alignment numbers (a) on the main bearing case
assembly 1 (1).
• Do the same for the main bearing case assembly 2 (2) and the
main bearing case assembly (3) too.
• When installing the main bearing case 1 and 2, face the mark
“FLYWHEEL” to the flywheel.
• Install the thrust bearing (8) with its oil groove facing outward.
• Confirm that the main bearing case moves smoothly after
tightening the main bearing case screw 1 to the specified torque.
13 to 15 N·m
9.4 to 11 lbf·ft
(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) Main Bearing Case Screw 1
(Upper, with Oil Groove)
(Upper, with Oil Groove)
(7) Crankshaft Bearing 2 (Lower)
(8) Thrust Bearing
(9) Crankshaft Bearing 3 (Lower)
W1034602

(7) Starter
Q Electromagnetic Drive Type
(1) Solenoid Switch Mounting Nut
(2) Starter Drive Housing
(3) Drive Lever
(4) Gasket
(5) Solenoid Switch
(6) B Terminal Nut
(7) C Terminal Nut
(8) Snap RIng
(9) Overrunning Clutch
(10) Armature
(11) Brush Spring
(12) Connecting Lead
(13) Rear End Frame
(14) Gasket
(15) Brake Spring
(16) Brake Shoe
(17) End Frame Cap
(18) Screw
(19) Yoke
(20) Brush
(21) Brush Holder
(22) Through Bolt
W1037593
1. Unscrew the C terminal nut (7), and disconnect the connecting lead (12).
2. Unscrew the solenoid switch mounting nuts (1), and remove the solenoid switch (5).
3. Remove the end frame cap (17).
4. Remove the brake shoe (16), brake spring (15) and gasket (14).
5. Unscrew the through bolts (22), and remove the rear end frame (13).
6. Remove the brush from the brush holder while holding the spring up.
7. Remove the brush holder (21).
8. Draw out the yoke (19) from the starter drive housing (2).
9. Draw out the armature (10) with the drive lever (3).
Q NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease (DENSO.CO.LTD. No. 50 or equivalent) to the parts indicated in the figure.
- Joint of solenoid switch (a)
- Bushing (b)
- Drive lever (c)
- Collar (d)
- Teeth of pinion gear (e)
- Armature shaft (f)
7.8 to 9.8 N·m
Tightening torque B terminal nut 0.80 to 1.0 kgf·m
5.8 to 7.2 lbf·ft
W1052309

Q Planetary Gear Reduction Type

(1) Magnetic Switch Mounting
Nut
(2) Housing
(3) Magnetic Switch
(4) B Terminal Nut
(5) C Terminal Nut
(6) Drive Lever
(7) Shaft Assembly
(8) Overrunning Clutch
(9) Connecting Lead
(10) Mounting Screw
(11) Armature
(12) Yoke
(13) Brush Holder
(14) Rear End Frame
(15) Through Bolt
W1222714
1. Unscrew the C terminal nut (5), and disconnect the connecting lead (9).
2. Unscrew the magnetic switch mounting nuts (1), and remove the magnetic switch (3) from the housing (2).
3. Unscrew the through bolts (15) and mounting screw (10), and remove the rear end frame (14).
4. Remove the brush from the brush holder while holding the spring up.
6. Draw out the armature (11) and yoke (12) from the housing.
7. Draw out the shaft assembly (7) with the drive lever (6) and overrunning clutch (8) from the housing.
(When reassembling)
5.9 to 11 N·m
Tightening torque B terminal nut 0.60 to 1.2 kgf·m
4.4 to 8.6 lbf·ft
W1012736

(8) Dynamo
(1) Shaft
(2) Pulley
(3) Rotor
(4) Collar
(5) Bearing
(6) Stator
(7) Plate
(8) Bearing
W1036558
1. Remove the nut and separate the plate (7).

2. Tap out the shaft (1) from the rotor (3).
3. Unscrew the screws and remove the stator (6).
(When reassembling)
• Take care the direction of the collar (4), the flat side should face to the pulley side
40 to 44 N·m
Tightening torque Pulley nut 4.0 to 4.5 kgf·m
29 to 32 lbf·ft
W1224556

(9) Alternator
(1) Pulley
(2) Drive End Frame
(3) Stator
(4) Bearing
(5) Retainer Plate
(6) Rotor
(7) Bearing
(8) Rear End Frame
(9) Rectifier
(10) IC Regulator
(11) Brush Holder
(12) Rear End Cover
W1224079
1. Remove the pulley (1).

2. Remove the rear end cover (12).
4. Remove the IC regulator (10).
5. Remove the four screws holding the stator lead wires.
6. Remove the rectifier (9).
7. Remove the rear end frame (8).
8. Press out the rotor (6) from drive end frame (2).
9. Remove the retainer plate (5).
10.Press out the bearing (4) from drive end frame (2) with a press and jig.
11.Lightly secure the rotor with a vise to prevent damage, and remove the bearing (7) with a puller.
(When reassembling)
58.4 to 78.9 N·m
Tightening torque Pulley nut 5.95 to 8.05 kgf·m
43.1 to 58.2 lbf·ft
W1224556

[3] SERVICING
(1) Cylinder Head and Valves
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.), 5.0 to 7.0 mm long (0.20 to 0.28 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 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.
Q NOTE
• 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.
0.020 to 0.027 in.
38 to 42 N·m
Tightening torque Cylinder head screw 3.8 to 4.3 kgf·m
28 to 31 lbf·ft
(1) Fuse
W1020190
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head’s four sides and two
diagonal 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.
Q IMPORTANT
• Do not place the straightedge on the combustion chamber.
• Be sure to check the valve recessing after correcting.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.002 in.
W1027737

Cylinder Head Flaw

1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with 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 read permeative liquid on the cylinder head
surface with the detergent (2).
5. Spray the cylinder head surface with white developer (3).
6. If flawed, it can be identified as red marks.
(1) Red Permeative Liquid (3) White Developer
(2) Detergent
W1076542
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,
replace the cylinder head.
-0.10 (protrusion) to
0.10 (recessing) mm
Factory spec.
Valve recessing -0.0039 (protrusion) to
(Intake and exhaust) 0.0039 (recessing) in.
0.30 (recessing) mm
Allowable limit
0.012 (recessing) in.
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
W10768800
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.
0.0012 to 0.0022 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.
0.2350 to 0.2354 in.
6.010 to 6.025 mm
Valve guide I.D. Factory spec.
0.2367 to 0.2372 in.
W10311740

Replacing Valve Guide

(When removing)
1. Press out the used valve guide using a valve guide replacing tool.
(Refer to “SPECIAL TOOLS”.)
(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. 6.010 to 6.025 mm
Factory spec.
(Intake and exhaust) 0.2367 to 0.2372 in.
Q IMPORTANT
• Do not hit the valve guide with a hammer during
replacement.
(A) When Removing (B) When Installing
W10314690
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
W10282190

Correcting Valve and Valve Seat

Q NOTE
• Before correcting the valve and seat, check the valve stem
and the I.D. of valve guide section, and repair them if
necessary.
• After correcting the valve seat, be sure to check the valve
recessing.
1) Correcting Valve
1. Correct the valve with a valve refacer.
0.79 rad
Valve face angle Factory spec.
45 °
2) Correcting Valve Seat
1. Slightly correct the seat surface with a 0.79 rad (45 °) valve seat
cutter.
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 0.26 rad (15 °) valve
seat cutter until the valve seat touches to the center of the valve
face (so that (1) equals (2) as shown in the figure.)
4. Grind the seat with a 0.79 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.
0.79 rad
Valve seat angle Factory spec.
45 °
(1) Valve Seat Width (a) 0.26 rad (15 °)

(2) Identical Dimensions (b) 0.79 rad (45 °)
(A) Check Contact
(B) Correct Seat Width
(C) Check Seat Surface
(D) Check Contact
W10283500
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.
Q IMPORTANT
• When valve lapping is performed, be sure to check the valve
recessing and adjust the valve clearance after assembling
the valve.
W10288140

Free Length and Tilt of Valve Spring

1. Measure the free length (B) 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 (A).
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.
1.2 mm
Tilt (A) Allowable limit
0.047 in.
31.3 to 31.8 mm
Factory spec.
1.24 to 1.25 in.
Free length (B)
28.4 mm
Allowable limit
1.12 in.
(A) Tilt (B) Free Length

W11157830
Valve Spring Setting Load
1. Place the valve spring on a tester and compress it to the same
length it is actually compressed the engine.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace it.
65 N / 27.0 mm
Factory spec. 6.6 kgf / 27.0 mm
Setting load / 15 lbf / 1.06 in.
Setting length 55 N / 27.0 mm
Allowable limit 5.6 kgf / 27.0 mm
12 lbf / 1.06 in.
W11177330
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 0.0017 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.
0.41233 to 0.41275 in.
10.500 to 10.518 mm
Rocker arm I.D. Factory spec.
0.41339 to 0.41409 in.
W11199710

Push Rod Alignment

1. Place the push rod on V blocks.
2. Measure the push rod alignment.
3. If the measurement exceeds the allowable limit, replace the push
rod.
0.25 mm
Push rod alignment Allowable limit
0.0098 in.
W11220210
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 0.0020 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.
0.70733 to 0.70803 in.
18.000 to 18.018 mm
Tappet guide bore I.D. Factory spec.
0.70867 to 0.70937 in.
W11231410

(2) Timing Gears

Timing Gear Backlash
1. Set a dial indicator (lever type) with its tip on the gear tooth.
2. Move the gear to measure the backlash, holding its mating gear.
3. If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and the gear.
4. If the oil clearance is proper, replace the gear.
0.0430 to 0.124 mm
Factory spec.
Backlash between idle 0.00170 to 0.00488 in.
gear and crank gear 0.15 mm
Allowable limit
0.0059 in.
0.0470 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.
0.0460 to 0.124 mm
Backlash between idle Factory spec.
0.00182 to 0.00488 in.
gear and injection pump
gear 0.15 mm
Allowable limit
0.0059 in.
0.0410 to 0.123 mm
Backlash between oil Factory spec.
0.00162 to 0.00484 in.
pump drive gear and
crank gear 0.15 mm
Allowable limit
0.0059 in.
W11264830
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.
3. If the measurement exceeds the allowable limit, replace the idle
gear collar.
0.20 to 0.51 mm
Factory spec.
0.0079 to 0.020 in.
Idle gear side clearance
0.80 mm
Allowable limit
0.031 in.
W11286770
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 font
and rear.
camshaft stopper.
0.15 to 0.31 mm
Factory spec.
Camshaft side 0.0059 to 0.012 in.
clearance 0.50 mm
Allowable limit
0.020 in.
W11299720

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.
W11312720
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 1.058 in.
and exhaust 26.83 mm
Allowable limit
1.056 in.
W11324040
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.
3. If the oil clearance exceeds the allowable limit, replace the
camshaft.
0.050 to 0.091 mm
Factory spec.
Oil clearance of 0.0020 to 0.0035 in.
camshaft journal 0.15 mm
Allowable limit
0.0059 in.
32.934 to 32.950 mm
Camshaft journal O.D. Factory spec.
1.2967 to 1.2972 in.
Camshaft Bearing I.D.
33.000 to 33.025 mm
(Cylinder block bore Factory spec.
1.2993 to 1.3001 in.
I.D.)
W11335580

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,
bushing.
4. If it still exceeds the allowable limit, replace the idle gear shaft.
0.020 to 0.084 mm
0.00079 to 0.0033 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.
0.78611 to 0.78661 in.
20.000 to 20.051 mm
Idle gear bushing I.D. Factory spec.
0.78741 to 0.78940 in.
W11356150
Replacing Idle Gear Bushing

(When removing)
1. Press out the used idle gear bushing using an idle gear bushing
replacing tool. (Refer to “SPECIAL TOOLS”.)
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press in a new brushing using an idle gear bushing replacing
tool, until it is flush with the end of the idle gear.
(A) When Removing (B) When Installing
W11373220
(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.
0.78741 to 0.78791 in.
Piston pin bore I.D.
20.05 mm
Allowable limit
0.7894 in.
W11406200

Oil Clearance between Piton 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,
bushing. If it still exceeds the allowable limit, replace the piston
pin.
0.014 to 0.038 mm
0.00056 to 0.0014 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.
W11420110
Replacing Small End Bushing
(When removing)
1. Press out the used bushing using a small end bushing replacing
tool. (Refer to “SPECIAL TOOLS”)
(When installing)
1. Clean a new small end bushing and small end hole, and apply
engine oil to them.
2. Using a small end bushing replacing tool, press in a new bushing
(service parts) taking due care to see that the position of the
connecting rod oil hole matches the bushing hole.
[Servicing parts dimension]
0.015 to 0.075 mm
0.00059 to 0.0029 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) 0.78843 to 0.79043 in.
(1) Seam (A) When Removing

(2) Oil Hole (B) When Installing
(a) 0.79 rad (45°)
W11437590
Connecting Rod Alignment

Q NOTE
• Since the I.D. of the connecting rod small end bushing is the
basis of this check, check bushing for wear beforehand.
1. Install the piston pin into the connecting rod.
2. Install the connecting rod on the connecting rod alignment tool.
3. Put a gauge over the piston pin, and move it against the face
plate.
4. 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.
Connecting rod 0.05 mm
Allowable limit
alignment 0.002 in.
W10314620

Piston Ring Gap

1. Insert the piston ring into the lower part of the cylinder (the least
worn out part) with a piston ring compressor and piston.
2. Measure the ring gap with a feeler gauge.
piston ring.
Factory 0.15 to 0.30 mm
spec. 0.0059 to 0.011 in.
Top ring
Allowable 1.20 mm
limit 0.0472 in.
Piston ring gap Factory 0.30 to 0.45 mm

[Z482-E3B] spec. 0.012 to 0.017 in.
Second ring
[D722-E3B] Allowable 1.20 mm
[D782-E3B] limit 0.0472 in.
spec. 0.0059 to 0.011 in.
Oil ring
Allowable 1.20 mm
limit 0.0472 in.
spec. 0.0079 to 0.013 in.
Top ring
Allowable 1.25 mm
limit 0.0492 in.
Piston ring gap spec. 0.014 to 0.019 in.
[Z602-E3B] Second ring
[D902-E3B] Allowable 1.25 mm
limit 0.0492 in.
spec. 0.0079 to 0.013 in.
Oil ring
Allowable 1.25 mm
limit 0.0492 in.
W11466710
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
feeler gauge.
3. If the clearance exceeds the allowable limit, replace the piston
ring.
4. If the clearance still exceeds the allowable limit after replacing the
ring, replace the piston.
spec. 0.00355 to 0.00472 in.
Second ring
Allowable 0.15 mm
Clearance between limit 0.0059 in.
piston ring and
piston ring groove Factory 0.040 to 0.080 mm
spec. 0.0016 to 0.0031 in.
Oil ring
Allowable 0.15 mm
limit 0.0059 in.
W11485500

(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 0.012 in.
clearance 0.50 mm
Allowable limit
0.020 in.
(Reference)
• Oversize thrust bearing
Oversize Bearing Code Number Marking
0.20 mm Thrust bearing 1 02 15261-23950 020 OS

0.0079 in. Thrust bearing 2 02 15261-23970 020 OS
0.40 mm Thrust bearing 1 04 15261-23960 040 OS

0.016 in. Thrust bearing 2 04 15261-23980 040 OS
• Oversize dimensions of crankshaft journal
0.20 mm 0.40 mm
Oversize
0.0079 in. 0.016 in.
46.10 to 46.30 mm 46.30 to 46.50 mm
Dimension A
1.815 to 1.822 in. 1.823 to 1.830 in.
23.40 to 23.45 mm 23.80 to 23.85 mm
Dimension B
0.9213 to 0.9232 in. 0.9370 to 0.9389 in.
1.8 to 2.2 mm radius 1.8 to 2.2 mm radius
Dimension C
0.071 to 0.086 in. radius 0.071 to 0.086 in. radius
(0.8S)
The crankshaft journal must be fine-finished to higher than ∇∇∇∇.
W11586190
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.
W11613530

Oil Clearance between Crankpin and Crankpin Bearing

1. Clean the crankpin and crankpin bearing.
2. Put a strip of plastigage on the center of the crankpin.
3. Install the connecting rod cap and tighten the connecting rod
screws to the specified torque, and remove the cap again.
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.
Q NOTE
• Never insert the plastigage into the crankpin oil hole.
• Be sure not to move the crankshaft while the connecting rod
screws are tightened.
0.020 to 0.051mm
0.00079 to 0.0020 in.
crankpin and crankpin
bearing 0.15 mm
Allowable limit
0.0059 in.
33.959 to 33.975 mm
Crankpin O.D. Factory spec.
1.3370 to 1.3375 in.
33.995 to 34.010 mm
Crankpin bearing I.D. Factory spec.
1.3384 to 1.3389 in.
(Reference)
• Undersize crankpin bearing
Undersize Bearing Code Number Marking
0.20 mm
Crankpin bearing 02 15861-22970 020 US
0.0079 in.
0.40 mm
Crankpin bearing 04 15861-22980 040 US
0.016 in.
• Undersize dimensions of crankpin
0.20 mm 0.40 mm
Undersize
0.0079 in. 0.016 in.
2.3 to 2.7 mm radius 2.3 to 2.7 mm radius
Dimension A
0.091 to 0.10 in.radius 0.091 to 0.10 in.radius
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
33.759 to 33.775 mm dia. 33.559 to 33.575 mm dia.
Dimension C
1.3291 to 1.3297 in. dia. 1.3213 to 1.3218 in. dia.
(0.8S)
The crankpin must be fine-finished to higher than ∇∇∇∇.
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
W11625390

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 the figure.
0.0340 to 0.106 mm
Oil Clearance between Factory spec.
0.00134 to 0.00417 in.
crankshaft journal and
crankshaft bearing 1 0.20 mm
Allowable limit
0.0079 in.
Z482-E3B
39.934 to 39.950 mm
D722-E3B
Factory 1.5722 to 1.5728 in.
Crankshaft journal O.D. D782-E3B
spec.
Z602-E3B 43.934 to 43.950 mm
D902-E3B 1.7297 to 1.7303 in.
Z482-E3B
39.984 to 40.040 mm
D722-E3B
Factory 1.5742 to 1.5763 in.
Crankshaft bearing 1 I.D. D782-E3B
spec.
Z602-E3B 43.984 to 44.040 mm
D902-E3B 1.7317 to 1.7338 in.
W10323470


Bearing 1 (Continued)
(Reference)
• Undersize crankshaft bearing 1
Undersize Models Bearing Code Number Marking
Z482-E3B
D722-E3B 15861-23910
0.20 mm D782-E3B Crankshaft
020 US
0.0079 in. bearing 1 02
Z602-E3B
1G460-23910
D902-E3B
Z482-E3B
D722-E3B 15861-23920
0.40 mm D782-E3B Crankshaft
040 US
0.016 in. bearing 1 04
Z602-E3B
1G460-23920
D902-E3B
• Undersize dimensions of crankshaft journal
0.20 mm 0.40 mm
Undersize Models
0.0079 in. 0.016 in.
Dimension 1.8 to 2.2 mm radius 1.8 to 2.2 mm radius
All models
A 0.071 to 0.086 in.radius 0.071 to 0.086 in.radius
*Dimension 1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
All models
B 0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
Z482-E3B
39.734 to 39.750 mm dia. 39.534 to 39.550 mm dia.
D722-E3B
Dimension 1.5644 to 1.5649 in. dia. 1.5565 to 1.5570 in. dia.
D782-E3B
C
Z602-E3B 43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.
D902-E3B 1.7219 to 1.7224 in. dia. 1.7140 to 1.7145 in. dia.
(0.8S)
(0.040 to 0.059 in.) relief.
W1044484
Replacing Crankshaft Bearing 1
(When removing)
1. Press out the used crankshaft bearing 1 using a crankshaft
bearing 1 replacing tool. (Refer to “SPECIAL TOOLS”.)
(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 to 0.3 mm
Dimension (A) Factory spec.
0 to 0.01 in.
(1) Seam [a] Z482-E3B, D722-E3B, D782-E3B

(2) Crankshaft Bearing 1 [b] Z602-E3B, D902-E3B
(3) Cylinder Block
(A) Dimension
(B) 0.37 rad (21 °)
W10342000


Bearing 2 and Crankshaft Bearing 3
1. Put a strip of plastigage 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.
Q NOTE
• 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 0.0011 to 0.0023 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) 1.7297 to 1.7303 in.
Crankshaft bearing 2 43.978 to 43.993 mm
Factory spec.
I.D. 1.7315 to 1.7320 in.
Z482-E3B
39.934 to 39.950 mm
D722-E3B
Crankshaft journal O.D. Factory 1.5722 to 1.5728 in.
D782-E3B
(Intermediate) spec.
Z602-E3B 43.934 to 43.950 mm
D902-E3B 1.7297 to 1.7303 in.
Z482-E3B
39.978 to 39.993 mm
D722-E3B
Factory 1.5740 to 1.5745 in.
Crankshaft bearing 3 I.D. D782-E3B
spec.
Z602-E3B 43.978 to 43.993 mm
D902-E3B 1.7315 to 1.7320 in.
W10344030


Bearing 2 and Crankshaft Bearing 3 (Continued)
(Reference)
• Undersize crankshaft bearing 2 and 3 (0.20 mm (0.0079 in.))
Models Bearing Code Number Marking
Z482-E3B Crankshaft bearing 2 02 15694-23930
D722-E3B
D782-E3B Crankshaft bearing 3 02 15861-23860
020 US
Z602-E3B Crankshaft bearing 2 02 1G460-23930
D902-E3B Crankshaft bearing 3 02 1G460-23940
• Undersize crankshaft bearing 2 and 3 (0.40 mm (0.016 in.))
Models Bearing Code Number Marking
Z482-E3B Crankshaft bearing 2 04 15694-23940
D722-E3B
D782-E3B Crankshaft bearing 3 04 15861-23870
040 US
Z602-E3B Crankshaft bearing 2 04 1G460-23950
D902-E3B Crankshaft bearing 3 04 1G460-23960
• Undersize dimensions of crankshaft journal
0.20 mm 0.40 mm
Undersize Models
0.0079 in. 0.016 in.
Dimension 1.8 to 2.2 mm radius 1.8 to 2.2 mm radius
All models
A 0.071 to 0.086 in.radius 0.071 to 0.086 in.radius
*Dimension 1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
All models
B 0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
Z482-E3B
39.734 to 39.750 mm dia. 39.534 to 39.550 mm dia.
D722-E3B
Dimension 1.5644 to 1.5649 in. dia. 1.5565 to 1.5570 in. dia.
D782-E3B
C
Z602-E3B 43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.
D902-E3B 1.7219 to 1.7224 in. dia. 1.7140 to 1.7145 in. dia.
Dimension 43.734 to 43.750 mm dia. 43.534 to 43.550 mm dia.
All models
D 1.7219 to 1.7224 in. dia. 1.7140 to 1.7145 in. dia.
(0.8S)
(0.040 to 0.059 in.) relief.
W1047088

Replacing Crankshaft Sleeve (Z482-E3B, D722-E3B, D782-E3B)

1. Remove the used crankshaft sleeve (2).
2. Set the sleeve guide (3) to the crankshaft (1).
3. Heat a new sleeve to a temperature between 150 and 200 °C
(302 and 392 °F), and fix the sleeve to the crankshaft as shown
in figure.
4. Press fit the sleeve using the auxiliary socket for pushing (4).
(Refer to “SPECIAL TOOLS”.)
Q NOTE
• Mount the sleeve with its largely chamfered surface facing
outward.
• Should heating is not enough, a sleeve might stop halfway,
so careful.
(1) Crankshaft (3) Sleeve Guide
(2) Crankshaft Sleeve (4) Auxiliary Socket for Pushing
W1048540
(5) Cylinder
Cylinder Wear
1. Measure the cylinder liner I.D. 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”.)
Z482-E3B
67.000 to 67.019 mm
D722-E3B
Factory 2.6378 to 2.6385 in.
D782-E3B
spec.
Z602-E3B 72.000 to 72.019 mm
D902-E3B 2.8347 to 2.8353 in.
Cylinder liner I.D.
Z482-E3B
67.150 mm
D722-E3B
Allowable 2.6437 in.
D782-E3B
limit
Z602-E3B 72.150 mm
D902-E3B 2.8406 in.
(A) Top (a) Right-angled to Piston Pin

(B) Middle (b) Piston Pin Direction
(C) Bottom (Skirt)
W10360060

Correcting Cylinder (Oversize)

1. When the cylinder is worn beyond the allowable limit, bore and
hone it to the specified dimension.
Z482-E3B
67.250 to 67.269 mm
D722-E3B
Factory 2.6477 to 2.6483 in.
D782-E3B
spec.
Z602-E3B 72.250 to 72.269 mm
D902-E3B 2.8445 to 2.8452 in.
Cylinder liner I.D.
Z482-E3B
67.400 mm
D722-E3B
Allowable 2.6535 in.
D782-E3B
limit
Z602-E3B 72.400 mm
D902-E3B 2.8504 in.
Hone to 2.2 to 3.0 μm Rz
Finishing (87 to 110 μin. Rz)
∇∇∇.
2. Replace the piston and piston rings with oversize ones.
Oversize : 0.25 mm (0.0098 in.)
Marking : 025
Q NOTE
• When the oversize cylinder is worn beyond the allowable
limit, replace the cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. [Oversize]
W10367470
(6) Oil Pump

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.
0.030 to 0.14 mm
Rotor lobe clearance Factory spec.
0.0012 to 0.0055 in.
W10378950
Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump
body with a thickness gauge.
2. If the clearance exceeds the factory specifications, replace the oil
Clearance between
0.070 to 0.15 mm
outer rotor and pump Factory spec.
0.0028 to 0.0059 in.
body
W10381420

Clearance between Rotor and Cover

1. Put a strip of plastigage 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.
4. If the clearance exceeds the factory specifications, replace oil
Clearance between rotor 0.0750 to 0.135 mm
Factory spec.
and cover 0.00296 to 0.00531 in.
W10382660
(7) Starter
Overrunning Clutch
1. Check the pinion and if worn or damage, replace the clutch
assembly.
2. Check that the pinion turns freely and smoothly in the
overrunning direction and does not slip in the cranking direction.
3. If the pinion slips or does not turn in both directions, replace the
overrunning clutch assembly.
Q NOTE
• Do not wash off the grease in the overrunning clutch with
the chemicals or oils.
[A] Electromagnetic Drive Type [B] Planetary Gear Reduction Type
W1156799

Commutator and Mica

1. Check the contact 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.
Electromagnetic 28.0 mm
Factory drive type 1.10 in.
spec. Planetary gear 30.0 mm
Commutator reduction type 1.18 in.
O.D. Electromagnetic 27.0 mm
Allowable drive type 1.06 in.
limit Planetary gear 29.0 mm
reduction type 1.14 in.
Electromagnetic Less than 0.05 mm

spec. Planetary gear Less than 0.02 mm
Difference of reduction type 0.0008 in.
O.D.’s Electromagnetic 0.40 mm
0.50 to 0.80 mm
Factory spec.
0.020 to 0.031 in.
Mica under cut
0.20 mm
Allowable limit
0.0079 in.
(1) Segment (a) Correct

(2) Depth of Mica (b) Incorrect
(3) Mica
W1155802

Brush Wear
1. If the connect face of the brush is dirty or dusty, clean it with
emery paper.
2. Measure the brush length (A) with vernier caliper.
3. If the length is than the allowable limit, replace the yoke assembly
and brush holder.
spec. Planetary gear 14.0 mm
Brush length A
W1156360
Brush Holder
1. Check the continuity across the brush holder and the holder
support with a circuit tester.
2. If it conducts, replace the brush holder.
W1156895
Armature Coil
1. Check the continuity across the commutator and armature coil
core with resistance range of circuit tester.
2. If it conducts, replace the armature.
3. Check the continuity across the segments of the commutator with
resistance range of circuit tester.
4. If it does not conduct, replace the armature.
W1156507

Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. If it dose not conduct, replace the yoke assembly.
3. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.
4. If it conducts, replace the yoke assembly.
(1) Lead (3) Yoke
(2) Bush
W1156968
(8) Alternator
Bearing
1. Check the bearing for smooth rotation.
2. If it does not rotate smoothly, replace it.
W1019790
Stator
1. Measure the resistance across each lead of the stator coil with
2. If the measurement is not within factory specification, replace it.
3. Check the continuity across each stator coil lead and core with
4. If infinity is not indicated, replace it.
Resistance Factory spec. Less than 1.0 Ω
W1019964
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 resistance
range of circuit tester.
4. If infinity is not indicated, replace it.
Resistance Factory spec. 2.9 Ω
W1020094

Slip Ring
1. Check the slip ring for score.
2. If scored, correct with an emery paper or on a lathe.
3. Measure the O.D. of slip ring with vernier calipers.
4. If the measurement is less than the allowable limit, replace it.
14.4 mm
Factory spec.
0.567 in.
Slip ring O.D.
14.0 mm
Allowable limit
0.551 in.
W1020208
Brush Wear
1. Measure the brush length with vernier calipers.
2. If the measurement is less than allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is defective, replace it.
10.0 mm
Factory spec.
0.394 in.
Brush length
8.4 mm
Allowable limit
0.33 in.
W1020329
Rectifier
1. Check the continuity across each diode of rectifier with resistance
range of circuit tester.
2. The rectifier is normal if the diode in the rectifier conducts in one
direction and does not conduct in the reverse direction.
W1020452
IC Regulator
1. Check the continuity across the B terminal (2) and the F terminal
(1) of IC regulator with resistance range of circuit tester.
2. The IC regulator is normal if the conducts in one direction and
does not conduct in the reverse direction.
(1) F Terminal (2) B Terminal
W1020645

EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE: (81)72-241-1129
FAX : (81)72-245-2484
E-mail : ksos-pub@kubota.co.jp
Printed in Japan 2007. 10, S, EI, EI, e Code No. 9Y111-00131

KUBOTA Corporation 2007. 03, S, EI, EI, e
WSM U17-3α/U17-3/U17 Mechanism IV. HYDRAULIC SYSTEM
Mechanism Section
A. HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-3

a. Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-3
b. Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-10
c. Swivel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-18
d. Travel Motor (Wheel Motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-32
e. Pilot Valve (Remote Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-42
f. Unload Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-51
g. Selector Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-52
h. Accessories of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-53
i. Service Port System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-59
j. TPSS (Two Pattern Selection System) : PP - version . . . . . . . . . . . . . . . . . . . . . . IV-M-61
k. Hydraulic Components Layout: U17-3α, U17/U17-3 . . . . . . . . . . . . . . . . . . . . . . . IV-M-65
l. Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-66
IV-M-1
IV-M-2
A. HYDRAULIC SYSTEM
a. 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
2. Pump coupling
(1.42) (0.16) ( ) : in
(1.10)
(0.55)
(φ4.72)
(φ4.80)
(3.94)
(φ2.36)
Two Point Pitch
(1.26 (0.3
IV-M-3
3. Pump hose adapter
P1 and P2 are common.
No. Part Name Q'ty Remarks

(1) Pump assembly (Piston) 1
(2) Pipe joint (L, G3/8 - G3/8) 1
(3) Pipe joint (L, G3/8 - G3/8) 1 R1/8 P1, P2, P3, P4
(4) Pipe joint (L, G3/8 - G3/8) 1
(5) Pipe joint (L, G3/8 - G1/4) 1
(6) O-ring 1
(7) Plug 4 For 3/8
(8) Flange (Suction) 1
(9) Bolt 4 M10 x 1.5 7T
(10) O-ring 1 S35
(11) Bolt 2 M12 x 1.25 7T
IV-M-4
4. 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) Packing (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-M-5
5. P-Q performance curve

Discharge: q1=q2 (cc/rev)
Pressure: P1+P2 (kgf/cm2)
Test condition Remark

Oil ISOVG46 3.44 kgf·m (24.88 ft·lbf) (33.7 N·m)
50 ± 5°C
Oil temp. (at P3=5 kgf/cm2 (0.49 psi) 71.1 MPa)
(122 ± 9°F)
RPM 2300 rpm 3.44 kgf·m (24.88 ft·lbf) (33.7 N·m)
Direction Clockwise (at P3=190 kgf/cm2 (18.6 psi) 2702.4 MPa)
Pump
4.5 cc/rev intake
q3
(0.274 cu.in/rev) torque
2.7 cc/rev
q4
(0.165 cu.in/rev)
40 kgf/cm2
P4 (568.9 psi)
(3.92 MPa)
IV-M-6
6. Pump Specifications, Type: PVD-00B-14P-5G3-4552A, Code No.: RA221-6111

P1, P2: 7.5 x 2 cm3/rev P3: 4.5 cm3/rev P4: 2.7 cm3/rev
1. Capacity
(0.46 cu.in/rev) (0.27 cu.in/rev) (0.16 cu.in/rev)
P1, P2: 21.6 MPa P3: 18.6 MPa P4: 3.9 MPa
2. Pressure 2)(3129
at bench (220 kgf/cm psi) (190 kgf/cm2) (40 kgf/cm2)
(3129 psi) (2702 psi) (569 psi)
Rated Speed: 2300 min-1 (rpm) Rotation Direction: Clockwise
3. Speed
Max. Speed: 2600 min-1 (rpm)
4. Suction pressure -0.02 ~ +0.04 MPa (-0.2 ~ +0.4 kgf/cm2) (-2.84 ~ +5.69 psi)
5. Oil ISO VG 32, 46, 68 Anti-wear hydraulic fluid
6. Oil temp Temp. range: -20 ~ +100°C ( -4 ~ +212°F)
7. Control Constant torque control
at P3= 0.49 MPa T=37.0 N·m (71.1 psi, 27.3 ft·lbf)
8. Torque
at P3= 20.6 MPa T=39.0 N·m (71.1 psi, 27.3 ft·lbf)
P1, P2: 17.3 l/min x 2 P3: 10.35 l/min P4: 6.21 l/min
9. Pump discharge
(4.57 US gal/min) (2.73 US gal/min) (1.64 US gal/min)
7. Discharge rate
P1/P2 maker-specified type PVD-00B-14P-5G3-4552A(F)
Pp maker-specified type
without load/
Service port flow rate L/min (USGPM) 27/- (7.13/-)
with load
Rated load pressure P1/P2 MPa (kgf/cm2) psi 21.6 (220) 3129
Rated load pressure P3/Pp MPa (kgf/cm2) psi 18.6 (190) 2702
Theoretical discharge rate P1/P2/P3/Pp cc/rev (cu.in/rev) 7.5/7.5/4.5/2.7 (0.46/0.46/0.27/0.16)
Theoretical discharge rate P1/P2 L/min (USGPM) 17.3/17.3 (4.57/4.57)
at rated output P3/Pp L/min (USGPM) 10.4/6.2 (2.75/1.64)
85% of theoretical discharge P1/P2 L/min (USGPM) 14.7/14.7 (3.89/3.89)
rate P3/Pp L/min (USGPM) 8.8/5.3 (2.32/1.40)
80% of theoretical discharge P1/P2 L/min (USGPM) 13.8/13.8 (3.66/3.66)
rate P3/Pp L/min (USGPM) 8.3/5.0 (2.19/1.32)
IV-M-7
8. Function
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
2) Function
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
grooves, as shown in Fig. 3. The discharge (b) Cylinder barrel
grooves P1 and P2 are located in the outer and Fig. 3 Operating principle
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-M-8
9. Principle of horse power control

The constant horse power control mechanism of this pump is equipped with a swash plate. The swash
plate angle is variably controlled by a simple spring to directly adjust the pump capacity.
The swash plate turns itself around the ball located behind. The load F1 from the piston is applied in the
direction as shown in the figure, generating a clockwise moment with respect to the swash plate. Against
this force, the spring (spring force F2) is provided to have a constant horse power. A specified load is pre-
set.
As the pressure rises, the above-mentioned clockwise moment also increases. When this moment
exceeds the counterclockwise moment by the spring force, the spring gets activated to lessen the swash
plate angle and to reduce the discharge rate. In this way, the horse power can be kept at a constant level.
When the pressure P3 is exerted on the rod, the clockwise moment proportional to the pressure works on
the swash plate. As shown in the P-Q characteristic, therefore, a shift is made to keep the horse power
constant with the gear pump included. (Total horse power control mechanism)
(1) Spring force F2

(2) Load F1
(3) Rod
(4) Spring
(5) Ball
(6) Shift
P-Q characteristic
(total horse power control)
Q1
Discharge rate ,
Q1
P1 + P2
Discharge pressure
IV-M-9
b. Control Valve
1. Relief valve specifications
Type of valve: CP CV NSC10-KP11-2
Manufacturer: Nabtesco
1) Bench set pressure specifications
No. Product name MPa (kgf/cm2) psi Remarks
(1) Main relief valve +1.0 +10

P1·P2: 21.6 -0.5 (220 -5 ) 3129 MRV-P1·MRV-P2·MRV-P3
+1.0 +10
P3: 18.6 -0.5 (190 -5 ) 2702
(2) Unti-void valve At swing cylinder rod ACV-B1
(3) Port relief valve 17.7 (180) 2560 At boom cylinder bottom CRV-B8 b1
(4) Port relief valve 27.5 (280) 3983 At boom cylinder rod CRV-b2
(5) Port relief valve 23.5 (240) 3414 Arm & bucket CRV-5A, CRV-B5, CRV-B9
(6)
2) List of pressures

Main relief valve
Machine set pressure MPa (kgf/cm2) psi 22.6 (230 ± 10) 3271
P1 Working part Bucket
Bench set pressure 2) +10
MPa (kgf/cm psi 21.6 (220 -5 ) 3129
P2 Working part Arm
Bench set pressure MPa (kgf/cm2) psi 21.6 (220 -5 )
+10
Machine set pressure MPa (kgf/cm2) psi (200 ± 10) 2845

P3 Working part Black
Bench set pressure MPa (kgf/cm2) psi +10
18.6 (190 -5 ) 2702
Pp Working part -
Bench set pressure 2) +2
MPa (kgf/cm psi 3.9 (40 -0 ) 569
Pilot secondary pressure MPa (kgf/cm2) psi 21.5 (22) 313 Bucket dump
Overload relief valve
Boom rod/bottom (b1, b2) MPa (kgf/cm2) psi 27.5/17.7 (280/180) 2983/2560
At bench test
Arm rod, bottom, bucket bottom

(b3, b4, b5) MPa (kgf/cm2) psi 23.5 (240) 3414
Swivel (C1) MPa (kgf/cm2) psi 13.2 (135) 1920
Boom bottom (b1) MPa (kgf/cm2) psi

On the machine
Boom rod (b2) MPa (kgf/cm2) psi

Arm rod, bottom, bucket bottom MPa (kgf/cm2) psi
Swivel (C1) MPa (kgf/cm2) psi
IV-M-10
Stamp product code (214749-01)
and serial No. on nameplate. Actuator port
Caution:
No wrong Pump port
Tank port assembling Plug PF 3/8 (2 locations) (A4 and B4 are plugs.)
2. Control valve (1)
Tank port
WSM U17-3α/U17-3/U17 Mechanism
ID marking
provided Tightening torque
T=13.7 14.7N m
{1.4 1.5kgf m}
IV-M-11
Thread depth 12
Actuator port
Check valve cover

Check valve spring
ID marking
provided
6 6 travel left & right
ID marking
provided
Stroke Swing, dozer, service,
Check valve C
Pilot port
Plug PF 1/4
(2 locations)
Swing Dozer Swivel Confluence Service Arm Travel Supply Travel Boom Bucket Discharge Unload confluence valve
4 mm stroke
Stroke (mm)
Pilot pressure
3. Control valve (2)

Valve specifications
• Rated pressure: 22.6 MPa {230 kgf/cm2} (3271 psi)
Swing (Under condition of 4 million boost-up actions)
• Rated flow rate: 15 L/min (3.96 USGPM)
Dozer • Relief valve set pressure level:
4.30 ~ 24.5 MPa {50 ~ 250 kgf/cm2} (711 ~ 3556 psi)
Swivel • Overload valve set pressure level:
4.30 ~ 24.5 MPa {50 ~ 250 kgf/cm2} (711 ~ 3556 psi)
Confluence • Spool length spring force (manual control)
[Travel] At neutral: 98.1 N {10 kgf} (22.1 lbf)
At stroke end: 131 N {13.4 kgf} (29.5 lbf)
Service [Others] At neutral: 83.4 N {8.5 kgf} (18.7 lbf)
At stroke end: 103 N {10.5 kgf} (23.2 lbf)
• Maximum pilot operating pressure:
Arm 4.90 MPa {50 kgf/cm2} (711 psi)
• Allowable tank pressure:
Below 0.98 MPa {10 kgf/cm2} (142 psi)
• Oil in use: General mineral hydraulic oil
Travel left
• Operating oil temperature range:
-20 ~ +90°C (100°C) (-4 ~ +194°F)
• Oil contamination level: Within Class NAS9
Supply
Operating conditions
• Relief valve set pressure
P1·P2: 21.4 +0.490 MPa {218 +50 kgf/cm2 at 16.6 L/min}
Travel right (3101 psi at 4.39 USGPM)
P3: 18.4 +0.49 0 MPa {188 +50 kgf/cm2 at 10.4 L/min}
(2674 psi at 2.75 USGPM)
• Operating flow rate
Boom
P1·P2: 16.6 L/min (4.39 psi)
P3: 10.4 L/min (2.75 psi)
Bucket • Service port flow rate (P2+P3): 27.0 L/min (7.13 USGPM)
• Overload valve set pressure
Discharge
A5·B5·B9: 23.3 +0.490 MPa {238 +50 kgf/cm2 at 5 L/min}
A8: 27.3 0 MPa {278 +50 kgf/cm2 at 5 L/min}
+0.49

B8: 17.5 +0.49
0 MPa {178 +50 kgf/cm2 at 5 L/min}
• Spool leak amount
Leak amount from A1, A8, B1 to i:
Below 3 cm3/min (0.183 in3/min)
Leak amount from others to i:
Below 7 cm3/min (0.427 in3/min)
(* 9.8 MPa {100 kgf/cm2}1422 psi) (Oil viscosity 37 cSt)
• Spool operating pressure with pilot on (See Charac-
teristics Chart.):
0.37 ~ 1.96 MPa {3.6 ~ 20 kgf/cm2} 51.2 ~ 284.5 psi
Po port pilot pressure: 3.50 MPa {35.7 kgf/cm2} 507.8 psi
-20 ~ +90°C (100°C ) (-4 ~ +194°F (212°F ))
Figures in { } are just for your reference.
IV-M-12
4. Control valve sectional view

1) Swing section: A-A, RB238-70011 4) Confluence section: D-D, RA221-70911
kgf/cm2} (2674 psi)
+0.49 +5
Setting: 18.4 0 MPa {188 0
Tightening torque 39.2 N·m at 10.4 L/min (2.75 USGPM)

Tightening torque T= 3.92 N·m {T= 0.4 kgf·m} (28.9 ft·lbf)
{4.0 kgf·m} (28.9 ft·lbf)
Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}(28.9 ~ 3.62 ft·lbf)
Apply Loctite #242 to avoid looseness. Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}(28.9 ~ 3.62 ft·lbf)
Apply Loctite #242 to avoid looseness.
2) Blade section: B-B, RA221-70021 5) Service port section: E-E, RA221-70041
Apply Loctite #242 to avoid looseness. Tightening torque T= 3.92 ~ 4.90 N·m {T= 0.4 ~ 0.5 kgf·m}(28.9 ~ 3.62 ft·lbf)
3) Dozer section: C-C, RA221-70031 6)Arm section: F-F, RA221-70051

MPa {238 0 kgf/cm2} (3385 psi)
+0.49 +5
Setting: 23.3 0
+0.49
Setting: 23.3 0 MPa {238
+5
kgf/cm2} at 5 L/min (1.32 USGPM)
0
Tightening torque T= 3.92 N·m
(3385 psi) {T= 0.4 kgf·m}
at 5 L/min (1.32 USGPM) (2.89 ft·lbf)
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m}
(2.89 ft·lbf)
IV-M-13
7) Travel R section: G-G, RA221-70061 10) Boom section: J-J, RA221-70071

MPa {178 0 kgf/cm2} (2532 psi)
+0.49 +5
Setting: 17.5 0
at 5 L/min (1.32 USGPM)
+0.49
Setting: 27.30
+5
MPa {278 kgf/cm }
0
2 Tightening torque T= 3.92 N·m
(3954 psi) {T= 0.4 kgf·m}
(2.89 ft·lbf)
at 5 L/min (1.32 USGPM)
(2.89 ft·lbf)
8) Inlet section: H-H, RB238-70941 11) Bucket section: K-K, RB238-70081

Setting: 21.4 0 MPa {218 0 kgf/cm2} (3101 psi)
+0.49 +5
kgf/cm2}
+0.49 +5
at 18.8 L/min (4.97 USGPM) Setting: 23.3 0 MPa {238 0
Setting: 21.4 0 MPa {218 0 kgf/cm2}
+0.49 +5
(3101 psi) (2.89 ft·lbf) at 5 L/min (1.32 USGPM)
Tightening torque T= 3.92 N·m
at 18.8 L/min (4.97 USGPM) {T= 0.4 kgf·m}
Tightening torque T= 3.92 N·m {T= 0.4 kgf·m} (2.89 ft·lbf)
(2.89 ft·lbf)
9) Travel L section: I-I, RA221-70091 12) Outlet: L-L, RB238-70971
Drilled ID hole
IV-M-14
5. Inner sectional view
Tightening torque T= 13.7 ~ 14.7 N·m

{T= 1.4 ~ 1.5 kgf·m}
(10.12 ~ 10.85 ft·lbf)
IV-M-15
6. Function of inlet section

1) When the safety lock lever is up-position
IV-M-16
2) When the safety lock lever is down-position
IV-M-17
c. Swivel Motor
1. Swivel system specifications
Maker Eaton Fluid Power Ltd.
Type 2-200DOS-E3888
Capacity cc/rev (in3/rev) 195 (11.9)
MPa 13.2
Brake V Pressure (kgf/cm2) (135) at bench
psi 1920
Locked L/min (USGPM) 1.0 (0.264)
Drain spec.
Rotating L/min (USGPM) 0.5 (0.132)
Swivel speed rpm 8.7 ± 0.9
Swivel speed (Three times rotation) sec. 20.8
Front horizontal, heaped, engine
Swivel startup sec. 2.1 ± 0.2
at max. rpm, 0 to 90° swivel
Front horizontal, heaped, 15°,
Swivel block performance mm/min (in/min) 120 (4.72)
engine at stop
> Front horizontal, heaped, engine
Allowable slope angle for swivel deg. (kg) 18 =
at max. rpm
Play at bucket tip mm (in) 73, 93 > (2.87, 3.66 >)
(How to measure the play at bucket tip)
1. Dump the arm and crowd the bucket. Position the bucket 1 m above the ground.
2. Push the bucket tip with a force of 5 kgf (11 lbf) or so. Take this position as "0", and push the bucket tip in the opposite direc-
tion with a force of 30 kgf (66.2 lbf).
3. Measure the displacement of the bucket tip.
4. Take the above steps more than 5 times, but without swing.
(How to measure the swivel block performance)
1. The swivel block performance must be checked with a hydraulic oil temperature of 45 ± 5°C (113 ± 9°F) on a 15-degree
slope.
IV-M-18
2. Component of swivel motor
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-M-19
3. Cross-sectional view of swivel motor
No. Part Name No. Part Name

30 Ball bearing A Flange body
40 Ball bearing B Pinion shaft
50 Plug C X-ring
60 Retainer D O-ring
70 Plate E Seal
80 Valve plate F O-ring
90 Valve plate G O-ring
100 Plate H Seal
110 Spring I Seal
120 Pin J O-ring
130 Drive K O-ring
140 Gear, roller L O-ring
150 Valve, drive M O-ring
160 Assy, valve N O-ring
170 Ball bearing O O-ring
180 Plug P Valve block
190 Spring Q Valve body
200 Plug R Valve housing
210 Bolt
IV-M-20
4. Swivel motor fittings

The outer diameter is same as that of current model. Relief pressure differs.
Control valve Front (A3) Control valve Rear (B3)
Control valve Rear (T1)
Mounting direction
Machine front side

(1) Motor assembly (Swivel) 1
(2) Pipe joint (S, G3/8-G1/4) 1 A
(3) Pipe joint (L, G1/4-G1/4) 1 For 3/8 A
(4) Pipe joint (L, G3/8-G1/4) 1 B
(5) Pipe joint (S, G3/8-13) 1 T
O-ring 1 T
(6) Pipe joint (L, G3/8-G3/8) 1 For 3/8 A, B
(7) Bolt 4 M14 x 1.5 T
IV-M-21
5. Function
1) Shaft output type
1. This type consists of ring 1, roller 2 and rotor (star) 3, as shown in the figure. The ring 1 is station-
ary, whereas the rotor (star) 3 turns under hydraulic pressure. The motor's output shaft is spline-
coupled with the rotor (star) 3. Hydraulic pressure is converted to a turning force in order to drive the
motor's shaft.
1 Ring 1
2 Roller
3 Rotor(star)
2
2. Rotating moment (torque) mechanism
F5
L3 L1
L2 L4
F1
F4 F2
F3
Low-speed torque = F1 x L1 + F2 x L2 +F3 x L3

(The torque produced in F5 is 0, because the arm length is 0.)
IV-M-22
2) Whole view
This component consists of the hydraulic motor (orbital motor) and the pinion assembly. In the hydraulic
motor, there are 12 holes of a valve P and 7 holes of the valve plate N, and the capacity per revolution
is 195 cm3. A pinion 2 supported by two bearing L & 3 is incorporated in the pinion assembly.
1 Bearing housing
2 Pinion gear
3 Bearing
L Roller bearing
N Valve plate
P Valve
V Drive
W Geroller
X Valve
] Valve housing
1 Housing L Valve-plate W O-ring b Pinion gear

2 Pinion gear M O-ring X Steel ball c Collor
3 Ball bearing N Valve Y Plug d O-ring
4 Spacer O Blancing plate Z O-ring e Front retainer
5 X-ring P Spring [ Housing f O-ring
6 Back-up ring Q Innerface seal \ Plug g Wear plate
7 Snap ring R Pin ] O-ring h Shaft face seal
8 Snap ring S Outer face seal ^ Flange i Retaining ring
9 O-ring T Drive _ O-ring
J Roller bearing U Rotor subassy ` Dust sel
K O-ring V Valve drive a Pinion gear assy
IV-M-23
3) Oil flow & power transfer 1

Hydraulic oil flown in through the brake valve is fed to the valve housing ]. As hydraulic oil is fed to port
A, this hydraulic oil flows into an oil hole of the valve P corresponding to port A, passes through an oil
hole of the valve plate N, and enters the geroller W to turn it. The valve P is turned through the valve
drive X to change a positional relation between 12 holes of the valve P and 7 holes of the valve plate
N. Consequently, a positional relation of oil to flow to the geroller shifts one after another and is con-
verted to turning force which is taken off by the drive V spline coupled with the geroller W. This turning
force is further transmitted to a pinion 2 supported by two bearings.
2 Pinion
N Valve plate
P Valve
V Drive
W Geroller
X Valve drive
] Valve housing
IV-M-24
4) Oil flow & power transfer 2

1 High-Pressure oil flown in the main port enters the rotor sub-assembly after passing through the
valve and valve plate. The rotor sub-assembly consists of a stator and a rotor while the stator has
seven rollers on its inner side is fixed to the housing. Besides, the inner rotor has six outer teeth.
Consequently, seven chambers form inside the rotor sub-assembly. And the rotor is made to be a
structure to make a planetary motion on the inner side of the stator.
2 On the other hand, the valve has oil holes at 12 spots, and high-pressure oil or return oil flows to half
the number of these oil holes at a time, respectively. Seven oil holes are opened in the valve plate
similar to the valve plate, and these oil holes are led to seven chambers of the rotor sub-assembly.
Consequently, contacting of seven oil holes of the valve plate with whatever of 12 oil holes of the
valve opens a line to the rotor sub-assembly.
3 The rotor of the rotor sub-assembly starts a planetary motion as depended on the hydraulic pressure
in this way and only the rotation found in planetary motion is taken out by the drive shaft to transmit
that rotation to the pinion. Besides, relation of the rotor is trasmitted to the valve drive shaft.
4 Rotating of the valve in this way shifts oil holes of the valve in contact with oil holes of the valve plate
one after another. Consequently, high-pressure oil to flow into the rotor sub-assembly also flows into
the different chambers one after another. In this way, the motor rotates continuously.
IV-M-25
5) Oil flow & rotating direction
(Sample illustration)
B Bearing is different.
A
Direction: Clockwise
1 Check valve
2 Disc valve (12 ports)
3 Plug for drain
8 4 Valve plate
5 Valve drive
6 Geroller
7 Main drive
7 8 Bearing
6
5
4
1 2 3
High-pressure oil flow The high-pressure oil coming in the motor flows through the disc
valve to the geroller, the star of which starts its planetary motion.
Lube oil flow Its own rotation alone is taken out by the main drive to drive the
Low-pressure oil flow output shaft. The disc valve is then driven by the disc drive. The
12 ports of the disc valve and the 7 ports of the valve plate shift
themselves to change the oil passage to the geroller in sequence.
(Sample illustration)
A B Bearing is different.
Direction: C.C.W.
IV-M-26
6) Oil flow in the geroller
A: Stator center B: Rotor center
Rotor
1/14 Rotation
Stator
Valve
1/7 Rotation
1/6 Rotation
With reference made to Fig. 1, as high-pressure oil is led to the respective chambers 2, 3 & 4, the rotor
rotates in the direction of arrow while touching the stator internally. Since the valve also rotates in keep-
ing with rotation of the rotor, a chamber to which high-pressure oil is led also shifts in the direction oppo-
site to arrow one after another. In Fig. 2, the rotor makes a 1/14 turn, and consequently, a chamber to
which high-pressure oil is led shifts to chambers 1, 7 & 6, one after another. Center point B of the rotor
shifts to point B’ around point A at this time and further shifts from point B’ to B” around point A in Fig. 3.
That is to say, the center point of the rotor makes a 6/7 turn from point B’ and then to point B” around
point A. In Fig. 4 furthermore, returning from point B” to point B’, a chamber to which high-pressure oil
flows in also makes a round. The dot-marked spot of the rotor makes a 1/6 turn at this time in the reverse
direction to the movement of point B. Therefore, one turn of the output shaft becomes 7 chambers × 6
rounds = 42 chambers and so achieved by inflow of high-pressure oil of 42-chamber volume.
High-low speed change: In this type, high-low speed can be controlled by delivery oil amount.
IV-M-27
7) Valve timing
(1) Assemble the valve.

• The valve timing is important to determine the direction
of motor’s rotation. Determine the direction with great
care, referring to the figure below.
Notice:
Motor should rotate in other way by incorrect timing.
Valve should be adjusted so that holes are aligned 15
degree as shown in Fig.
(2)
(2)
(1) A port
(2) B port
(3) From A port
(3)
IV-M-28
Mount the O-rings (large and small) and rotor subassy.

• Align the drain holes of the water plate with those of
the rotor subassy.
M O-ring (large)
O O-ring (small)
Drain hole
Mount the valve drive. Mount the valve plate onto

which the O-rings (large and small) are attached.
• Align the drain holes of the rotor subassy with those
of the valve plate.
M O-ring (large)
X Valve drive
Y O-ring (small)
Assemble the valve.

• The valve timing is important to determine the direc-
tion of motor’s rotation. Determine the direction with
great care, referring to the figure below.
Notice:
Motor should rotate in other way by incorrect timing.
Valve should be adjusted so that holes are aligned 15

degrees as shown in Fig.
IV-M-29
8) Theory of rotating direction change
Note:
The hatched zones and H indicate high pressure.
View C View B View A
High pressure
from port B
A port side
Finally shift the side port coun-

terclockwise by 15°.
• Setup procedure for normal rotation

a. Take as reference the spline of the valve drive that corresponds to the star's outer tooth crest. (Put a
marking to the spline.)
b. When setting up the valve, get the valve drive's spline (marked in the above step a) in phase with a
side port of the valve.
c. Now turn the unit counterclockwise by 15°, and the splines get in mesh.
High pressure
from port B
A port side
Finally shift the side port

clockwise by 15°.
• Setup procedure for reverse rotation

In the above step c, turn the unit clockwise by 15°, and the motor's runs in the reverse direction.
IV-M-30
1 Geroller
2 Valve
3 B port 1
4 A port 2
5 Valve drive
6 Shaft
3
6 5
(Additional explanation to understand the theory)

1) High pressure inlets from port B is indicated by arrow and the hatched zones which are total six in View
A and B.
2) In View B, only three high pressure ports which are the hatched zones are overlapped with valve ports
which are total seven.
Shape of valve port is .
3) In View C, only three high pressure ports deliver oil into the three rotor chambers.
These three high pressure oil generate the rotating torque to the rotor as shown in View C.
4) In case of turning the valve clockwise by 15°, pressure ports and chambers are changed to reverse rota-
tion.
IV-M-31
(1) 9 x M10 x 1.5 (through) [mm: (in)]
(9 equally spaced)
(2) 2 x G3/8 lube oil filler/discharge port
(3) Stop plug (2 locations right and left)
(4) G1/8 (PP port)
ø18 countersunk
1. Overview
(5) 2 x G1/4 (Drain port)

ø24 countersunk
(6) 2 x G3/8 (A and B ports)
ø28 countersunk
(7) 8 x M10 x 1.5 (through)
(8 equally spaced)
(8) Hydraulic circuit
WSM U17-3α/U17-3/U17 Mechanism
d. Travel Motor (Wheel Motor)
IV-M-32
This wheel motor (travel motor) is the one upgraded its output torque.
Turning direction (when viewed from output side)

Inlet Outlet Turning direction
B A Clockwise
A B Counterclockwise
2. Specifications
(1) Motor type ID mark
PHV - 1B0 - 12B - 9 - 8817A
R & D No.
Reduction ratio = 1/36.9
Motor torque
Motor size
NACHI travel motor PHV series
(2) Motor specifications

1581 N·m (161.2 kgf·m) (1165 ft·lbf) /
Max. theoretical output torque 1st/2nd
788.7 N·m (80.4 kgf·m) (581.5 ft·lbf)
Gear box
Max. output speed 37.6 / 75.4 min-1 at 17.3 LPM (4.58 USGPM)
Reduction ratio 1 / 36.96
Displacement 12.44 / 6.21 cm3/rev (0.76 / 0.38 in3 / rev)
Max. pressure 21.6 MPa (220 kgf/cm2) (3129 psi)
Motor Max. speed 1391 / 2786 min-1
Max oil flow 17.3 LPM (4.58 USGPM)
Hi - Low change pressure 0.5 MPa (5 kgf/cm2) (71 psi)
Equivalent capacity for one turn of motor assy. 459.8 / 229.5 cm3/rev (28.05 / 14.0 in3 / rev)
Operating oil ISO - VG46 or equivalent
Temperature -20 ~ 100 °C (-4 ~ 212 °F)
Filtering 10 μm (0.000394 in)
Others Gear box oil SAE -90 (API, Class : GL5), Gear oil
Gear box oil amount 330 cm3 (20.13 in3 )
Weight 17 kg (37.48 lbs)
Allowable drain back Operating condition 0.3 MPa (3 kgf/cm2) 42.7 psi
pressure Surge condition 1.0 MPa (10 kgf/cm2) 142.2 psi
IV-M-33
3. Structure
A-A cross section
IV-M-34
IV-M-35
(1) Spare Parts for Sub Assy

Sub Ass'y Sub Ass'y
CARRIER 2 SUB ASS'Y CYLINDER BARREL SUB ASS'Y
RB238-78021 RB238-78071
NO. DESCRIPTION QTY NO. DESCRIPTION QTY
(104) CARRIER 2 1 (204) CYLINDER BARREL 1
(107) B2 GEAR 3 (205) VALVE PLATE 1
(108) S1 GEAR 1 (206) PISTON 7
(111) B2 PIN 3 (207) SHOE 7
(117) NEEDLE 39 (208) SHOE HOLDER 1
(121) THRUST WASHER 6 (209) BARREL HOLDER 1
(123) SNAP RING 1 (212) PIN 3
(127) SPRING PIN 3 (213) SPRING C 1
(137) SNAP RING 3 (214) RETAINER 2
(221) SNAP RING
Sub Ass'y
BODY 1 SUB ASS'Y Sub Ass'y
RB238-78042 SEAL KIT (REDUCTION GEAR)
NO. DESCRIPTION QTY RB238-78031
(301) BODY 1 1 NO. DESCRIPTION QTY
(302) SPOOL 1 (129) O RING 1
(303) CHECK VALVE 2 (130) O RING 1
(304) SPRING GUIDE 2 (136) O RING 2
(305) SPOOL 1 (139) O RING 2
(306) SHUTTLE SPOOL 1
(307) SPRING V1 2 Sub Ass'y
(308) SPRING V2 2 SEAL KIT (HYDAULIC MOTOR)
(309) SPRING V3 1 RB238-78081
(310) PLUG 2 NO. DESCRIPTION QTY
(311) PLUG 2 (217) O RING 1
(312) PLUG 2 (218) O RING 1
(313) CHOKE 2 (219) OIL SEAL 1
(314) RING 2 (318) O RING 2
(315) PLUG 4 (319) O RING 2
(316) PLUG 2
(317) O RING 2
NO. DESCRIPTION
(318) O RING 2
101 BODY
(319) O RING 2
102 COVER
(320) CHOKE 1
106 B1 GEAR
(321) NEEDLE 2
112 SEAL RING
(322) METAL PLUG 6
113 O SNAP RING
(323) CHOKE 2
114 THRUST PLATE
(216) BEARING 1
115 SLIDE RING
(223) SPRING PIN 1
116 NEEDLE
118 FLOATING SEAT
Sub Ass'y 119 O RING
BODY 2 SUB ASS'Y 120 BEARING
RA251-78051 122 SNAP RING
NO. DESCRIPTION QTY 131 PLUG
(202) BODY 2 1 133 HYDRAULIC MOTOR
(211) CONTROL PISTON 1 134 THRUST WASHER
(219) OIL SEAL 1 135 PLUG
(225) METAL PLUG 1 138 RING
140 SNAP RING
Sub Ass'y
SHAFT SUB ASS'Y NO. DESCRIPTION
RA251-78061 210 SWASH PLATE
NO. DESCRIPTION QTY 220 BALL
(203) SHAFT 1 222 SCREW
(215) BEARING 1 224 PIN
IV-M-36
(2) 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-M-37
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 2nd 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-M-38
(3) 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 A’ 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 B’, 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-M-39
(4) Operating principle of wheel motor
(1) (2)
(6)
(7)
(5)
(3)
(5)
(4)
(1) Stationary part (5) Hydraulic motor

(2) Rotating part (6) Simple 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-M-40
(5) 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
spline-coupled with the hydraulic motor output (1) (2)
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
a1 and a2, providing travelling driving force. (4)
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
Za1, Za2: Number of teeth of gears a1 and a2
(3)
Because the PHV series travelling motor is of
the main body rotating type, the reduction ratio
is expressed as shown below.
(1) Stationary part
1 (2) Rotating part
R’ =
1-1/R (3) Simple planetary gear reducer (two-step)
(4) Carrier 2
IV-M-41
e. Pilot Valve (Remote Control Valve)

1. Structure
Maker: Kawasaki Precision Machinery Ltd.
Type: PV 48 M 2043 A
Code No. RA221-61721
1) Control diagram
Double operating angle Single-operating angle
Adjust nut (width across flat 22)

Fix the adjust nut with a spanner
when mountting the lever,
and tighten the lock nut
(customor's supply)
with 41.2 2.9N m {420 30kgf cm}.
(3038 217 ft lbf)
Lean center position

Stamping of model
name & serial No.
To be marked wit "Yellow

circle"paint for ident fication
No.2 port
(Outer DIA. of the port - part)
No.3 port
T port
P port
6-G1/4 Thread depth 12
(O-ring seal to JIS B 2351)
Spot facing DIA. 24 depth 1
( 0.94 depth 0.039)
Tightening torque 29.4 2.0 N m
{300 20kgf cm}. No.1 port
(2170 144.7 ft lbf)
No.4 port
IV-M-42
2) Specifications
1. Max. primary pressure: 6.9 MPa {70 kgf/cm2} (995.6 psi)
2. Max. back pressure: 0.3 MPa {3 kgf/cm2} (42.7 psi)
3. Rated flow: 15 L/min (915.4 USGPM)
4. Secondary pressure characteristics: Refer to the ‘Control diagram’ shown previous page
5. Operating torque: Refer to the ‘Control diagram’ shown previous page
6. Max. allowable external torque: Refer to the ‘Max. allowable external torque’ shown below
7. Hydraulic oil: mineral hydraulic oil
8. Oil temp. range: -20 °C ~ +90 °C (-4 °F ~ +194 °F)
9. Filter: A filter of 40 mesh and over should be applied at the entrance of port P for preventing the
spool sticking.
3) Operating specifications
1. Primary pressure: 3.9MPa {40 kgf/cm2} (568.9 psi)
4) Max. allowable external torque

Rated Intermittent
Bending torque 32.4 N·m {330 kgf·cm} (23.87 ft·lbf) 88.3 N·m {900 kgf·cm} (65.10 ft·lbf)
Torsional torque 20.6 N·m {210 kgf·cm} (15.2 ft·lbf) 30.9 N·m {315 kgf·cm} (22.8 ft·lbf)
Secondary pressure (kgf/cm2)
Secondary pressure (MPa)
Operating torque (kgf cm)

Single-operating torque
Operating torque (N m)
Secondary
pressure
Push - rod stroke (mm)
Operating angle (deg.)
IV-M-43
2. Sectional view
Hydraulic symbol
Grease is applied on each rotational

part of the universal joint.
Pay attention to the direction of
assembling the universal joint.
Grease is applied on
each top part.
No. Part name

101 Casing
151 Plate
201 Spool Shim for adjusting secondary
pressure 1 sheet with designed
211 Pulg thickness T = 0.4
212 Rod, push
213 Seal
214 O-ring
216 Seat, spring
217 Washer 2
221 Spring
241 Spring
301 Joint
302 Plate, circular
312 Nut, adjusting
501 Bellows
IV-M-44
3. Adaptors
P/V (both right and left)
(8)
(7)
(6)
(Quick coupler)
(5) Front
Rear
Left pilot valve Right pilot valve

No. Position for use Color of hose tape No. Position for use Color of hose tape
(1) Swivel Left Red (1) Bucket raking Pink
(2) Arm dumping Blue (2) Boom lowering Light blue
(3) Swivel Right Yellow (3) Bucket dumping Brown
(4) Arm raking Green (4) Boom raising Gray
P P-port White P P-port White
T T-port None T T-port None

(5) Pipe joint (S, G1/4-8.6) 5 Other than P-port
(6) Filter 1
P-port only
Pipe joint (S, G1/4-8.4) 1
(7) Valve, assembly (Pilot) 1
(8) Yellow paint 1
IV-M-45
4. Function
1) Basic function
The pilot valve is intended to control the stroke and direction of the control valve spool. To do this, the
output pressure of the pilot valve is applied to the end of the control valve spool.
To achieve this function, the pilot valve consists of the following elements.
(1) Inlet port (P) used to supply oil from the hydraulic pump
(2) Multiple outlet ports (1, 2, 3 and 4) used to apply the feed pressure of the inlet port to the end of the
control valve spool.
(3) Tank port (T) required to control the output pressure discussed above
(4) Spool used to connect the output ports to the inlet port or tank port
(5) Mechanism (including the spring for the above spool) used to control the output pressure
2) Functions of major parts

The spool (201) is designed to switch between two oil passages: one passage is for the pressure oil from
the hydraulic pump to go to the port P first and then to the output ports (1, 2, 3 and 4). The other is for the
pressure oil to go from the output port to the port T. The secondary pressure setting spring (241) exerts
upon this spool (201) to determine the output pressure.
The push rod (212) is integrated in the plug (211) and ready to slide to change the deflection of the sec-
ondary pressure setting spring (241).
The return spring (221) exerts upon the casing (101) and spring seat (216) to keep the push rod (212)
free of the output pressure and pressed in the zero-displacement direction. This ensures the neutral
return of the spool (201). This spring serves also as reaction spring to give the operator proper operating
feel.
IV-M-46
3) Operation
The behavior of the pilot valve is discussed, referring to the hydraulic circuit diagram (Fig. 1) and behav-
ior diagrams (Figs. 2, 3 and 4). Fig. 1 shows a typical application of the pilot valve.
(1) With the lever at neutral (See Fig. 2.)

The secondary pressure setting spring (241),
which determines the pilot valve output pres-
sure, does not exert upon the spool (201). The
spool (201) is therefore pressed down by the
return spring (221) (spring seat (216)), which
interconnects the output ports (2 and 4) and
the port T. In this state, the output pressure is
kept at the same level as the tank pressure.
IV-M-47
(2) With the lever being tilted (See Fig. 3.)

When the lever is tilted and the push rod (212)
gives a stroke, the spool (201) (spring seat
(216)) lowers, which interconnects the port P
and output ports (2 and 4). In this state, the oil
from the pilot pump flows to the ports (2 and 4)
and produces a pressure.
(3) With the lever held tilted (See Fig. 4.)

When the pressure at the ports (2 and 4) has
reached the level that corresponds to the force
of the spring (241), then the oil pressure and
spring force get balanced. When the pressure
at the ports (2 and 4) has risen above the set
level, the ports (2 and 4) and port P get closed,
whereas the ports (2 and 4) and port T get
open. When this pressure has dropped below
the set level, the ports (2 and 4) and port P get
open, whereas the ports (2 and 4) and port T
get closed.
(4) With the lever too tilted (depending on the model)

On some models, if the lever is tilted beyond a certain angle, the spool top end comes in contact with
the push rod bottom. This means that the output pressure is being applied to the port P.
In another construction, the spring and its seat are integrated in the push rod. If the lever is tilted
beyond a certain angle, the spring comes in contact with the push rod bottom. The spring force in
turn affects the secondary pressure gradient. Then there will be contact between the push rod bot-
tom and the spring seat top end, which keeps the output pressure applied to the port P.
IV-M-48
5. Cylinders’ section view

(Bucket, Arm) T.T.
(289.3 ~ 318.3 ft·lbf)
(20) (21)
(17)
(18) (19)
T.T. (376.1 ~ 405.1 ft·lbf)
[mm (in)]
(1) Cylinder tube (6) Backup-ring (11) DU-bushing Bucket Arm
(2) Cylinder rod (7) Scraper (12) Piston (17) Stroke 269 (10.59) 335.5 (13.21)
(3) Bushing (8) O-ring (13) Piston seal (18) Retracted L 529 (20.83) 589 ± 1.5 (23.19)
+3
0
(4) Cylinder head (9) Backup-ring (14) Wear-ring (19) Extended L 802 -05 (31.57) 924.5 ± 2.5 (36.40)
(5) Packing (10) O-ring (15) Lock nut, M24 (20) 325 (12.80) 387.5 (15.26)
(16) grease nipple (21) 79 (3.11) 76.5 (3.01)
(Boom) T.T.
(289.3 ~ 318.3 ft·lbf)
(3)
(1) (2)
T.T. (303.8 ~ 332.7 ft·lbf)
(1) Retracted L = 765 ± 1.5 (2) Extended L = 1234 ± 2.5 (3) Stroke = 469
(30.12 ± 0.059 in) (48.58 ± 0.098 in) (18.46 in)
(Blade) (1) (2)

(3)
T.T.
(253.1 ~ 289.3 ft·lbf)
T.T. (159.1 ~ 173.6 ft·lbf)
(13.70 ± 0.059 in) (18.11 ± 0.098 in) (4.41 in)
IV-M-49
(Swing)
(1) (2) (3)
(1) Retracted L = 610 +30 (2) Extended L = 940 -05 (3) Stroke = 330
(124.02 +0.118
0 in) (37.01 in) (12.99 in)
(Truck) (1) (2)

T.T.
(253.1 ~ 289.3 ft·lbf)
(3)
(18.82 ± 0.059 in) (28.66 ± 0.098 in) (9.84 in)
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 “A” (0.05 ml/100m) (0.0031 in3/ mations must not occur in any parts when external force 2
328.1ft) of “JIS B 8354” under following conditions. times as high as the main relief pressure 43.1 MPa (440
Oil pressure: 21.6 MPa (220 kgf/cm2) (3129 psi), kgf/cm2) (6248 psi) the cylinder thrust force (12240 kgf)
Oil temperature: 100°C (212°F), Speed: 16.6 m/min, (26989.2 lbf) is applied by 30000 times or more.
Sliding distance: 300 km (186.4 mile)
2. Dust Seal properties: 7. Rust prevention of plating:
Dust enter must be 11 mg (0.00039 oz) or less under fol- Must be rating number 9 or higher after 4 cycles (64 hour)
lowing conditions. of CASS testing. Thickness of platinf must be kept more
Speed: 16.6 m/min (54.46 ft/min), Stroke: 150 mm (5.91 in), than Ep-ICr30 (0.03 mm) (0.0012 in)
Number of repetitions: cycles,
Vibration applied to facility: 7.4 Hz 8. Cushion performance (Cushion type cylinder only):
3. Internal oil leakage: Cushion facility must be set in bottom side for contraction
Must be within 1 cm3 (0.061 in3) for 3 min under the condi- with following performance.
tion of the main relife pressure 21.6 MPa (220 kgf/cm2) Oil temperature: 30°C (86°F) / cushion time: 2 seconds or less
(3129 psi) applied to the stroke end (Oil temperature 50 ± Oil temperature: 50°C (122°F) / cushion time: 1 ± 0.3 seconds
5°C (122 ± 9°F)). Oil temperature: 80°C (176°F) / 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) (12.5 psi) applied to the bottom port after 3 or Piston rod rubbing part: Ni-Hcr or Hcr plating
more cycles with full stroke sliding under none load (Oil Thickness 9.03 mm (0.356 in) or more
temperature 50 ± 5°C (122 ± 9°F)). Hardness HV (25 g) 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 (0.079 ~ 0.118 in)
after pressure 2 times as high as the main relief pressure
43.1 MPa (440 kgf/cm2) (6258 psi) is applied by 40000
time or more.
IV-M-50
f. Unload Valve
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
2. Specifications
(1) Allowable voltage:DC 10.8 ~ 14.4V
(2) Current: 1.2 A at 20°C (68°F)
Power consump-
(3) 14.4W
tion:
(4) Coil resistance: Approx. 10 Ω at 20°C (68°F)
Red (5) Insulation: JIS C 4003 H
(6) Surge killer: Diode
(7)
Relief valve set 3.9 +0.2
0 MPa (40 +0.2
0 kgf/cm2)
Black
pressure: (568.9 psi) at 6 l/min (1.59USGPM)
(8)
Cracking 3.4 MPa (35 kgf/cm2)(497.8 psi)
pressure: at 2 l/min (0.53 USGPM)
p → A, B
Valve pressure
(9)
loss: 0.5 MPa (5.1 kgf/cm2)(72.7 psi) or
less at 6 l/min (1.59 USGPM)
A, B, G = G 1/4
(10)Port size: P, T = G 3/8
(JIS B2351 O-type)
(19)
IV-M-51
g. Selector Valve
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) (2986.9 psi) at 10.4 l/min (2.75
USGPM).
2) Inside leakage: 8 cc/min at 20.6 Mpa, 50°C (0.49 in3/min at 2986.9 psi 122°F)
IV-M-52
h. Accessories of Hydraulic Components

1. Check valve assy
(6)
(7) (8) (1) Shim
(2) Spring
(3) Name plate
(4) Plunger
(5) Spring
(10) (11)
(9)
[mm (in)]
(11)
Model (6) (7) (8) (9) (10)
HEX
KX36-3
67 55 φ26 30.02
KX41-3 EU G 1/2 27
(2.64) (2.17) (φ1.02) (1.182)
KX41-3V
U17-3α, 65 53 φ18.6 25.4
G 3/8 22
U17/U17-3 (2.56) (2.09) (φ0.73) (1)
Cracking pressure: 196 ± 29 KPa (2 ± 0.3 kgf/cm2)
(28.4 ± 4.3 psi)
U17-3α: Check valve = RB238-63802
2. Hydraulic filter
Specifications items Suction filter Return filter
1. Filtration area 1650 cm2 (255.75 in2) 3600 cm2 (558 in2)
2. Filtration level 105 μm (150 mesh) (0.0041 in) 10 μm nominal (0.00039 in)
3. Oil flow 80 l/min (21.13 USGPM) 70 l/min (18.49 USGPM)
4. Hex. spanner 41 mm 36 mm
5. Filter dia. φ 85 (φ 3.35 in) φ 90 (φ 3.54 in)
6. Filter length 105 (4.13 in) 125 (4.92 in)
7. Relief opening pressure 0.1MPa (1.0 ± 0.15 kgf/cm2)
(14.2 ± 2.13 psi)
8. Code number RB238-62151 RA011-62191
(Return filter) (Suction filter)
IV-M-53
3. Oil cooler
Core
Hole
Core
Core
Oil cooler specifications

Div. Item Unit Standard
Heat radiation kW (kcal/h) 4.81 (4140)
Ve=15L/min. Δt=75°C.to1=110°C (Ve=3.96 USGPM. Δt=167°F. to1=230°F )
Va=8m/s. Vw=-L/min (Va=17.9 mph)
Oil-side pressure loss kPa (kgf/cm2) psi 95 (0.97) 13.77
Performance specifications
Air-side pressure loss Pa (mmH2O) 118 (12.03)
Test pressure kPa (kgf/cm2) psi 981 (10) 142.2
Repeated pressure resistance kPa (kgf/cm2) psi 981 (10) 141.2 x 105 times
Static pressure breakdown kPa (kgf/cm2) psi 2.45 (25) 355.6
Type of core Drawn-cup type, louver-less, corrugated
275 (W) x 145 (H) x 32 (D) f.p = 4.0/2
Core dimensions
10.8 (W) x 5.71 (H) x 1.26 (D) (in)
Structural specifications Oil-side radiating area m2 (in2) 0.2228 (345.34)

Air-side radiating area m2 (in2) 1.1584 (1795.5)
Oil capacity L (US gal) 0.22 (0.0581)
Dry weight kg (lbs) 0.88 (1.94)
Remarks Black coating (powder)
IV-M-54
4. Accumulator (EU-version)
(1) Gas plug
(2) Shell
(3) Holder
(1) (4) Bladder
(5) Poppet
(6) Oil port
(2) (7) O-ring type
(8) Across
(3)
Specs
1. Gas: Nitrogen
2. Gas volume: 300 cc (18.31 in3)
(4) 3. Max. operating pressure:6.9 MPa (70 kgf/cm2)
(995.6 psi)
(5) 4. Initial gas pressure: 1.2 MPa (12kgf/cm2) (170.7)
at 20°C (68°F)
(6) 5. Operating oil temp.: -30 ~ 100°C (-22 ~ 212°C)
6. Weight: 1.1 kg (2.43 lbs)
Machine models used: U17-3α, U20-3, U25-3
(7) (8) warning

It contains nitrogen under high pressure.
Don’t allow fire or heat near it. Don’t try to disassem-
ble it.Wear eye protection and carefully drill a holl at
the point marked to release gas pressure before
disposal.
IV-M-55
5. Travel unloading function

Pp
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
P1 P2 P䋳
(1) Bucket
(2) Boom
(3) Travel Left
(4) Supply
(5) Travel Right
(6) Arm
(7) Service
(8) Confluence
(9) Swivel
(10) Dozer
(11) Swing
With the unload lever being raised, oil of P1 and P2 flows from the supply section directly to the return
circuit and results in no functions of P1 and P2 pump, from bucket (1) to service port (7) except pump 3
circuit.
When the unload lever is lowered, the supply section opens to supply oil of P1 and P2.
IV-M-56
6. Boom confluence
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
P䌢
(1) Bucket
(2) Boom
(3) Travel Left P1 P2 P3
(4) Supply
(5) Travel Right
(6) Arm
(7) Service
(8) Confluence
(9) Swivel
(10) Dozer
(11) Swing
When boom operation is performed, the boom is operated so that the joint valve is switched over to joint
P1 and P3.
7. Service port confluence
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Breaker
P1 P2 P3
When service port pedal is depressed, P2 and P3 pump’s oil will be supplied to service port section.
IV-M-57
8. Straight travel circuit
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
P䌢
P1 P2 P䋳
(1) Bucket
(2) Boom
(3) Travel Left
(4) Supply
(5) Travel Right
(6) Arm
(7) Service
(8) Confluence
(9) Swivel
(10) Dozer
(11) Swing
Since only the Boom and Service are jointed with P3, straight travel is possible.
When left and right travel levers are shifted, F or R, P1 supplies oil to the travel motor and P2, to the right
motor.
P3 supplies oil to the boom section.
Therefore, only boom and service port operations are possible together with travel function.
IV-M-58
i. Service Port System

1. Component layout
This pedal is used to operate attachments NOTE:
• When the service port is not in use, fold
the service port pedal forward. The pedal
gets fixed and can be used as footrest.
(1) Service port pedal

(A) Sends oil to the port (A)
(B) Sends oil to the port (B) (1) Service port pedal (A) “Fix”
(1) Port (A)

(2) Port (B)
• Push the right part of the pedal ( ) to send
oil to the port (A).
• Push the left part of the pedal ( ) to send
oil to the port (B).
No load conditions.
Max. Flow Volume 27.7 17.3
Theoretical L min. (USGPM) (7.32) (4.57)
18.6 21.56
Max. Pressure
(190) (220)
MPa (kgf/cm2) psi
2702 3129
IMPORTANT:
• When the service port is not used for a long
period, dirt particles can settle in the lower
part of the service port lines.
When the plugs on the service port lines are
removed to connect attachments, drain
approx. 100 cc (6.102 in3) of oil per side.
Concerning the choice of a breaker, contact
your dealer.
IV-M-59
2. 1-way or 2-way valve (EU-version)

The selection valve which select 1-way or 2-
way circuit of service port has been installed
on the control valve.
When the breaker will be used, position the
lever of selection valve to the "OPENED"
position (1-way circuit) to reduce the back
pressure.
IMPORTANT:
• When the equipment (auger, crusher,
telescopic arm, ...), which need 2-way cir-
cuit will be used, position the lever to the
"CLOSED" position.
Return change-over valve (1-2-way valve)
The change-over valve has two settings.
When "direct return flow" (3) is enabled, the return flow

is directed from the implement to the hydraulic oil tank.
The return flow is via the right port at the arm only.
When "indirect return flow" (2) is enabled, the return

flow is directed from the implement to the hydraulic oil
tank via the control valve. In that case, the return flow
may use the left or right port on the arm (depending on
the service port pedal position).
Move the change-over valve (1) to the required position

as shown on the sticker (see figure), depending on the
action of the implement being used (rotary or hammer-
ing).
IV-M-60
j. TPSS (Two Pattern Selection System) : PP - version

1. Location and overview
This TPSS valve is only for PP (Pan-pacific ; KTC, KTL,
KTA) version only.
This is a sort of selector valve between A (JD) pattern
and B (ISO, Kubota) pattern.
IV-M-61
2. Hose connection
Front view Rear view
(4)(5)(6)(7) (2) (8)
(3)
B
A (1)
(18)
(9)(10)(11)
Control valve side Pilot valve side
(15)(16)(19) (14)(21) (12)(22)

(20)
(13)(23)
3
B C 2
A D
4
1
(17)(25) (12)(26)
(16)(24)
No. Part Name Q'ty Remarks No. Part Name

(1) Valve assy 1 (18) Machine front
(2) Lever (1, TPSS) 1 (19) Blue · TPSS · B ~ CV · Pb5
(3) Nut 1 M10 4T (20) Gray · TPSS · C ~ CV · Pa8
(4) Lever (2, TPSS) 1 (21) Green · TPSS · 4 ~ PV · L4
(5) Pin 1 (22) Gray · TPSS · 3 ~ PV · R4
(6) Washer 1 (23) Blue · TPSS · 2 ~ PV · L2
(7) Snap pin 6 (24) Light blue · TPSS · A ~ CV · Pb8
(8) Lever grip 1 (25) Green · TPSS · D ~ CV · Pa5
(9) Bracket (TPSS) 1 (26) Light blue · TPSS · 1 ~ PV · R2
(10) Bolt 3 M10 7T
(11) Bolt 2 M10 7T
(12) Pipe joint (L, G1/4-G1/4) 2 1, 3 Port
(13) Adapter 1 2 Port
(14) Pipe joint (L, G1/4-G1/4) 1 4 Port
(15) Pipe joint (S, G1/4-G1/4) 1 B Port
(16) Pipe joint (QL, G1/4-8.4) 2 A, B Port
(17) Pipe joint (S, G1/4-G8.4) 2 C, D Port
IV-M-62
3. TPSS port connection

A pattern (J.D. pattern)
Pilot valve secondary outlet TPSS inlet port TPSS outlet port Main control valve pilot port
P/V right side 2 1 B C/V Pb5 Arm dump
P/V left side 2 2 A C/V Pb8 Boom up
P/V right side 4 3 D C/V Pa8 Boom down
P/V left side 4 4 C C/V Pa5 Arm crowd
B pattern (Kubota pattern)

P/V right side 2 1 A C/V Pb8 Boom up
P/V left side 2 2 B C/V Pb5 Arm dump
P/V right side 4 3 C C/V Pa8 Boom down
P/V left side 4 4 D C/V Pa5 Arm crowd
IV-M-63
4. Technical data
Specifications
Test conditions:
1. Rated output: 4.0 MPa (40.8 kgf/cm2)
2. Hydraulic oil: ISO VG46 or equivalent
3. Oil temperature: 50 ± 5°C
Valve specifications:
Schematic symbol 1. Internal leak:
Below 300 ml/min at 3.92 MPa (40 kgf/cm2)
(With all ports fitted and tightened to 26.5 N·m
(2.7 kgf·m))
2. Lever operating torque:
Below 19.5 N·m (2.0 kgf·m) (under no load)
(With all ports fitted and tightened to 26.5 N·m
(2.7 kgf·m))
Notes:
1. Coating color: No coating (plated)
2. Apply grease to the sliding surfaces of parts (2),
(4), (10) and (13).
Locktite 26L 3. Set the valve in pattern "B" before shipment.
4. Do not overtighten the lever (6): below the torque
Sectional view Z - Z M10x1.25, thread depth 15
of 80 N-m.
No. Parts Name Material Q'ty Remarks

View Y (1) Name plate Alumium 1
PPC/V side (2) Collar Steel 1
(3) Plate Cast iron 1 Ni
Locktite 26L
(4) Plate Alumium 1 Ni
(5) Plate Steel 1 Ni
Pattern A (6) Lever Steel 1 Zn
(8) Hollow bolt Steel 1 Low head M16 x
60 x 2.0 Zn
(9) Screw Steel wire 2 #2 x 4.8
(10) Pin Steel 1 JIS B1354-1988
D5 x 35 Bush
(11) O-ring Rubber 1 1B AS568-904
(12) O-ring Rubber 2 1B JASO F404
1019
(13) O-ring Rubber 2 S80 1A NOK
Pattern B
No. Screw size Tightening torque

MAIN C/V side (6) 7/16 20UNF 9.8 ± 1.0 N·m (1.0 ± 0.1 kgf·m)
7.23 ± 0.7 ft·lbs
(8) M16 78 ± 7.8 N·m (8.0 ± 0.8 kgf·m)
57.9 ± 5.8 ft·lbs
G1/4 Adaptor 26.5 ± 2.5 N·m (2.7 ± 0.25 kgf·m)
19.5 ± 2.0 ft·lbs
Port size: 1 ~ 4, A ~ D
G1/4 O-ring seal (JIS B 2351)
IV-M-64
k. Hydraulic Components Layout: U17-3α, U17/U17-3
(16) (18) (21) (22) (4)
(1)
(13) (5) (3)
No. PART NAME
(2)
1 Main pump
2 Pilot valve, L
(7)
3 Pilot valve, R
4 Accumulator
(14)
5 Unload valve
6 Control valve
(8) 7 Swivel motor
(17) 8 Rotary joint
(26) 9 Travel motor, L
10 Travel motor, R
11 Change valve for SP
(1 way, 2 way)
12 Change valve: Dozer-track
13 Hydraulic oil tank
14 Oil cooler
15 Boom cylinder
16 Arm cylinder
17 Bucket cylinder
18 Swing cylinder
19 Dozer cylinder
20 Track cylinder
21 Suction filter
22 Return filter
(6) (11) (9) 23 Track rollers
24 Grease tension cylinder
(15) (12) (19) (20)

25 Idler
(25) (24) (23)
26 TPSS valve (PP-version)
IV-M-65
l. Hydraulic Circuit Diagram

1) U17-3α, EU-version
(psi)
3129
3129
2702
569
2560
3983
3414
3414
3414
1920
Fujikoshi PVD-00B-15P-5G3-4982A
PUMP P1 P2 P3 P4
ENGINE SPEED (rpm) 2300 2300 2300 2300
DISPLACEMENT (cc/rpm) 7.5 7.5 4.5 2.7
DISCHARGE CAPACITY (l/min) 17.3 17.3 10.4 6.2
U17-3 EU
IV-M-66
2) U17-3α, EU-version: Track extension
(psi)
3129
3129
2702
569
2560
3983
3414
3414
3414
1920
PUMP P1 P2 P3 P4
ENGINE SPEED (rpm) 2300 2300 2300 2300
U17-3 EU
IV-M-67
3. U17-3α, EU-version: Service port flow
(psi)
3129
3129
2702
569
2560
3983
3414
3414
3414
1920
PUMP P1 P2 P3 P4
ENGINE SPEED (rpm) 2300 2300 2300 2300
U17-3 EU
IV-M-68
4. U-17, PP-version
PUMP P1 P2 P3 P4
ENGINE SPEED (rpm) 2300 2300 2300 2300
DISPLACEMENT cc/rev 7.5 7.5 4.5 2.7
(in3/rev) (0.46) (0.46) (0.27) (0.16)
DISCHARGE CAPACITY LMP 17.3 17.3 10.4 6.2
(GPM) (4.57) (4.57) (2.75) (1.64)
(psi)
3129
3129
2702
569
2560
3983
3414
3414
3414
1920
TPSS Valve
IV-M-69
5. U-17, PP-version: Three operation; boom up, arm extend, swivel R, A (JD)-pattern
PUMP P1 P2 P3 P4
ENGINE SPEED (rpm) 2300 2300 2300 2300
(in3/rev) (0.46) (0.46) (0.27) (0.16)
(GPM) (4.57) (4.57) (2.75) (1.64)
(psi)
3129
3129
2702
569
2560
3983
3414
3414
3414
1920
TPSS Valve
IV-M-70
6. U-17, PP-version: Travel forward, high speed and boom down, B (ISO, Kubota)-pattern
PUMP P1 P2 P3 P4
ENGINE SPEED (rpm) 2300 2300 2300 2300
(in3/rev) (0.46) (0.46) (0.27) (0.16)
(GPM) (4.57) (4.57) (2.75) (1.64)
(psi)
3129
3129
2702
569
2560
3983
3414
3414
3414
1920
TPSS Valve
IV-M-71
IV-M-72
WSM U17-3α/U17-3/U17 Service IV. HYDRAULIC SYSTEM
Service Section
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
B. TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-15
a. Testing Instruments & Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-15
b. Pump Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-17
c. Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-18
d. Drain Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-28
e. Measurement of Block Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-30
f. Operating Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-32
g. Straight Travel Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-34
h. Swivel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-35
i. Travel System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-38
j. Cylinder natural fall amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-43
k. Control and Traveling lever operating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-43
l. Lever stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-43
C. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-45
a. Pump Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-45
b. Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-46
c. Swivel Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-48
d. Traveling Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-49
e. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-50
f. Service Port Flow Amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-52
g. Motor Oil Drain Amount Test Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-52
D. DISASSEMBLING AND REASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-53
a. Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-53
b. Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-68
c. Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-111
d. Swivel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-143
e. Rotary Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-157
f. Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-169
g. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-188
h. Change Valve (Dozer, Track). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-197
i. Unload Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-199
j. Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-203
k. Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-206
l. Third Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-207
m. TPSS Valve (PP-version Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-209
n. Hydraulic Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-215
IV-S-1
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. (PP-version)
Slow speed and weak 2) The TPSS valve is in improper operation. Disassemble the valve and
power. (PP-version) 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
B. TESTING
a. Testing Instruments & Special Tools
1) Gauges and special tools for pressure testing
1. Pressure hose
2. Pressure gauge: 2.94 MPa, 30 kgf/cm2, 427 psi
For secondary pilot pressure test.
For primary pilot pressure test.
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-15
2) Flow meter and special tools for flow testing

(5) (4) (3) (2) (1) Flow meter: Flowtech Inc. made
(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-16
b. Pump Flow
1) Measuring procedure
1. Connect the tester to the pump outlet. Be care-
ful not to confuse the tester’s pipe connections.
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).
6. Calculate the volumetric efficiency and judge
the performance.
(1) Hydraulic oil tank (2) Pump
(3) Flow tester (4) Control valve 2) Checking the pump performance
To inspect the pump performance, apply the
Pump discharge side specified pressure to the pump discharge side.
Measure the discharge rate at the specified rpm
P1 P2 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
engine at its maximum rpm.
2. The volumetric efficiency is the ratio of the
discharge rate per pump turn (cc/rev) to the
theoretical discharge rate (calculated value). 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
P3 P4 (EU-version) the pump usually runs at lower rpm when
measuring the pump flow at loaded condition.
P1 P2
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,
122 ± 9°F.
P3 P4 (PP-version)
7777772#
IV-S-17
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 after removing the plug (1/8 PT).
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 ± 9 °F
4.2 ± 0.3 MPa

Reference Value 43 ± 3 kgf / cm2
P1 P2 611 ± 43 psi
Note:
In case of engine 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).
P3 P4 (EU-version)
P1 P2
(1)
P3 P4 (PP-version) (1) Pilot pump pressure port
IV-S-18
2) Secondary pressure
1. Remove step.
2. Connect a joint for measurement to the arrow-
marked point and set pressure gauge on it.
3. Start the engine and run it at the maximum speed.
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.
7. Hydraulic oil temp.: 50 ± 5°C, 122 ± 9°F
8. Pilot valve is at its max. stroke and control valve
spool is being fully shifted.
(1)
1.96 ± 0.1 MPa
Reference Value
at idle speed 20 ± 1 kgf/cm2
284 ± 14 psi
2.1 ± 0.2 MPa
(1) Pilot pump pressure port Reference Value
at max.speed 21 ± 2 kgf/cm2
299 ± 28 psi
(Boom-up)
(1)
(2)
(3)
(4)
(1) Pilot valve assy

(2) Paint mark
(3) Pipe joint (G1/4 - 8,4) and filter
(4) Pipe joint (G1/4 - 8,6)
IV-S-19
(2) Main relief valve

1) Measurement method
P1 P2 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.
2. Start the engine and run it at the maximum
speed.
valve.
4. Get the following main relief valves activated.
5. Take 2 or 3 measurements to have their respec-
tive exact readings.
7. Recommended testing actuators.
P1: Bucket dump
P2: Travel R (Arm)
P3: Dozer up
Read the circuit diagram and take the appropri-
P3 P4 (PP-version) ate actuators not to mix up the main relief pres-
sure and overload relief pressure.
P1 P2 8. Specifications: Refer to page.
Location of the main relief valve

a2
P3 P4 (EU-version)
7777772$ a3 a1
a1: P1 main relief valve
P3 (2) P1 (1)
(1) Arm overload valve

(2) Boom overload valve
IV-S-20
3) Adjustment of main relief valve

P1 P2 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.
4. Run the engine at the maximum speed. Move
the levers and make sure the pressure setting.
valve.
(Location of overload relief valve)

P3 P4 (PP-version) b4 a2 b1 b5
a3 b3 a1 b2
b1: Boom bottom a1: P1 main relief valve
b2: Boom rod a2: P2 main relief valve
b3: Arm bottom a3: P3 main relief valve
b4: Arm rod
P3 (1) P1 (2) b5: Bucket bottom
Main relief valve pressure rises by approximately 30

kgf/cm2 (2.9 MPa, 427 psi) at 60 degree turns of
adjusting screw.
(1) Arm overload valve

(2) Boom overload valve
IV-S-21
(3) Overload relief valve

P1 P2 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 0.98 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
activated.
Measure the pressure setting.
6. Take 2 or 3 measurements to have exact readings.
8. Specifications: Refer to page
P3 P4 (EU-version)
P1 P2
(Adjust a1 main relief valve)
P3 P4 (PP-version)
P3 (1) P1 (2)
b4 a2 b1 b5
(Adjust boom-up over load relief valve)
(1) Arm
(2) Boom
a3 b3 a1 b2
b1: Boom bottom
b2: Boom rod
b3: Arm bottom
b4: Arm rod
b5: Bucket bottom
IV-S-22
2) Location of overload relief valves
(1) Outlet (7) Arm

(2) Bucket (8) Service
(3) Boom (9) Combination
(4) Travel, LH (10) Swivel
(5) Inlet (11) Dozer
(6) Travel, RH (12) Swing
IV-S-23
3) Adjustment of overload relief valve

P1 P2 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 1500 rpm for b1, b2, b3, b4,
b5.
valve.
4. Move the levers and make sure the pressure
setting.
6. Specifications: Refer to page.
P3 P4 (EU-version)
P1 P2
(Test boom down overload pressure)
P3 P4 (PP-version)
P3 (1) P1 (2)
(1) Arm
(2) Boom
IV-S-24
4) FYI (For your information)
Testing boom-up overload relief pressure
a. Symptoms Found
1. A boom-up overload relief pressure value shows lower than its bench test pressure value when you
test the pressure in light of the foregoing description.
2. Max. boom-up overload relief pressure value comes not at max. engine speed but around 1500 ~
2000 rpm.
These two symptoms are peculiar to U17/U17-3 and KX41-3, which hydraulic circuit diagrams are con-
sist of P1 and P3 confluence flow and bleed-off control valves of boom-up line.
b. Reason Found
Followings are the study result based on the machine test.
1. Why is the max. boom-up overload pressure lower than its bench pressure value?
Because: 1) Boom-up circuit has two pump lines, P1 and P3.
Additionally bleed-off orifice is incorporated inside the spool.
At engine max. speed, P3 main line reaches to its relief pressure condition.
Due to a horse power control system with variable displacement pump and bleed-off line, an
oil flow amount into boom-up circuit decreases and thus overload relief pressure value
becomes lower than the bench test pressure.
2) Following graphs show this symptom.
Graph C: Boom overload relief pressure
Graph D: Max. boom-up pressure
Graph E: P3 pressure indicates this fact.
In this graph, why is P3 pressure decreases at boom-up operation?
Because P3 pump is a gear pump and this confluence circuit has bleed-off orifice
also.
The lower the pump flow, the greater the bleed-off function and thus P3 line pres-
sure decreases.
Then horse power control system recover its swash plate angle to supply enough
oil to the boom-up circuit.
2. Why does the boom-up overload relief pressure become higher at 1500 ~ 2000 rpm than at its max
engine speed?
Because: 1) At engine max. speed, P3 pump main line reaches to its relief pressure and the pump swash
plate returns to minimum displacement position when pump 1 being applied by its max.
relief pressure.
On the contrary, at engine 's lower speed, P3 pump main line does not reach its max. pres-
sure.
See graph “E... P3 pressure”.
Therefore, due to its horsepower control system, pump swash plate angle still keep positive
to provide some amount of oil flow to boom-up circuit.
Additionally, engine's torque stays its highest conditions even at 1500 ~ 2000 rpm.
This theoretical description can be supported by the test result of “G. Boom-up overload
relief pressure vs RPM at P3 line” is dumped to tank.
As P3 line is dumped to tank, P3 pump has no load and engine and pump has enough
horsepower to keep the swash plate positive condition to supply enough oil to boom-up cir-
cuit.
In order to understand above explanation, you're requested to refer to P-Q performance

curb in WSM.
IV-S-25
3. How can boom-up overload relief pressure be inspected then?

Answer: Fortunately you can exchange boom-up overload relief valve and bucket crowd overload relief
valve and function the bucket crowd, then you can obtain exact value as you expected as
shown in Graph G. that we confirmed. Of course, you are required to increase main relief pres-
sure up to around 30 MPa (3060 kgf/cm2, 4352 psi).
Boom-up 1
A. Current pump pressure condition C. Boom overload relief pressure Boom-up 2
25.0 Boom down
Pump 1
Pump 2 30.0
20.0
Pilot pump 25.0
15.0
Pressure
20.0
Pressure
10.0 15.0
10.0
5.0
5.0
0.0 0.0
5)
)
00
00
00
00
00
00
00
00
00
0)
91
95
45
46
20
18
15
13
22
20
18
15
13
(9
(9
(2
(2
le
le
ax
ax
Id
Id
Engine speed
M
Engine speed
M
P3 pressure at boom-up D. Max. boom-up pressure trend vs RPM
E. P3 pressure
P3 pressure at dozer
24.0
25.0 23.5
20.0 23.0
Pressure
Pressure
15.0 22.5
10.0 22.0
5.0 21.5
21.0
0.0
)
00
00
00
00
00
0)
20.5
95
46
22
20
18
15
13
(9
1100 1200 1423 1530 1660 1750 1800 1960 2070 2180 2200 2480
(2
le
ax
Id
M
Engine speed Engine speed
G. Boom-up overload relief pressure at P3 with no load

30.0
29.0 Boom-up 1
28.0 Boom-up 2
27.0
Boom-up &
26.0
Pressure
bucket dump
25.0
Bucket crowd
24.0
28.0MPa relief
23.0 valve
22.0
21.0
)
0)
00
00
00
95
0
0
47
22
20
18
15
13
(9
(2
le
ax
Id
Engine speed
M
IV-S-26
(4) Swivel brake valve pressure

P1 P2 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 Max rpm and 1500 rpm, mea-
sure the relief pressure.
6. Specifications: Refer to page.
P1 P2
P3 P4 (EU-version)
(4) Swivel left relief valve P3 P4 (PP-version)

(5) Swivel right relief valve
(Swivel motor, relief valve)
IV-S-27
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 discon-
nected.
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.
(1)
Never place your body under the crawler.
(1) Drain port

(2) 2nd speed pilot line (4) (2) (3)
(3) Main high pressure hoses
(4) Drain hose
(Travel motor lock condition)
Motor, Left Motor, Right

(1) (4) (4) (1)
(2)
(F)
(F)
(3)
(3) (R)
(R) (2)
(1) Drain port

(2) 2nd speed pilot line
(3) Main high pressure hoses
(4) Drain hose
IV-S-28
(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
receive drain oil in a suitable reservoir.
4. Swivel the machine one minute at max. engine
rpm and measure amount of hydraulic oil in the
reservoir.
Make sure nobody is around swivel radius area.
5. Reference value: Refer to page.
(1)
Vacuum the hydraulic system line to prevent
oil leakage while fitting hoses.
(1) Vacuum pump, compression air type
(3) (2) Drain port
(3) Measuring cylinder
(2)
(Swivel motor lock condition)
IV-S-29
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 engine stop condition.
5. Load on the bucket should be as follows.
U17/U17-3, U17-3α:72 kg (159 lbs)-exclude bucket
weight
30 degrees >= or 120 mm (0.40 ft)
Reference Engine idle
>
= at swivel bearing race
Value
Engine stop
IV-S-30
(2) Traveling
1. Park the machine on a 20 deg. slope. Keep
front at traveling position.
2. Put marks on the truck frame and the crawler.
3. Measure 10 minutes slip-distance without
engine running.
4. Hydraulic oil temp.: 50 ± 5°C, 122 ± 9°F.
300 mm/10 min

Reference Value
0.98 ft/10 min
IV-S-31
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 measurement 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 swivellings.
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 ± 9°F.
3. Ground is flat.
4. Measure time after several pre-operation.
(2) Boom cylinder

1. Arm and bucket cylinder should 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]
Reference Up 1.9 ~ 2.5
Value Down 2.2 ~ 2.8
(3) Arm cylinder

1. Position the boom and arm as shown at left.
2. Measure the arm cylinder full stroke operating time.
[sec]
Reference Crowd 3.2 ~ 3.8
Value Dump 2.1 ~ 2.7
IV-S-32
(4) Bucket cylinder

1. Position the boom and arm as shown at left.
2. Measure the bucket cylinder full stroke operating time.
[sec]
Reference Crowd 2.5 ~ 3.1
Value Dump 1.6 ~ 2.2
(5) Swing cylinder

1. Position the boom, arm and bucket as shown at left.
(with the bottom of the bucket about 1 m (3.3 ft) above
from the ground.)
2. Measure the swing cylinder full stroke operating time.
(right to left and left to right)
[sec]
Reference Left 4.3 ~ 4.9
Value Right 3.4 ~ 4.0
(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 Down 1.6 ~ 2.2
Value Up 1.8 ~ 2.4
IV-S-33
(7) Swivel speed

1. Position the boom, arm and bucket as shown at left.
2. Measure three times rotation time.
[sec/three turns]
Reference Value 18.8 ~ 23.1
(8) Traveling speed

1. Travel the machine until getting max. speed.
2. After getting max. speed, measure the 10 m (33 ft)
traveling time.
[sec]
Reference 1F 15.0 ~ 18.0
Value 2F 8.2 ~ 10
1
(Rubber track)
g. Straight Travel Performance

1. Travel the machine until 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-34
h. Swivel System Diagnosis

(1) Main check points
1. First make sure that the swivel system alone is in trouble.
2. See if the trouble is with both right and left turns or with one way alone.
3. Check to see how often the trouble occurs.
The numbers below indicate the cause numbers that are in the Swivel Trouble Chart.
(4) (3) (9) (4)
(6) (5)
Swivel
(8)
(7) (6)
(2)
(1)
4. If the trouble is with one way alone, reverse the right and left hoses and see if the trouble occurs with the
other way alone.
5. If the trouble occurs with the other way in the above step, it means that the cause exists in the upstream.
If not, it means that the cause exists in the downstream.
6. Hose reversing locations (-)
(2) Pilot valve ~ (1) Selector valve (AC, multi) ~ (9) Control valve ~ (8) Swivel motor
7. Reversing the right and left parts
(2) Pilot valve (5) Brake
(2) Checking the pilot valve spool performance

1. Move the swivel lever and check the performance of
the spools.
2. If the pilot valve spool is problematic, check it for poor
performance, foreign substances, scratches, deforma-
tion and other defects.
3. If the trouble is with only one way of the swivel,
reverse the snap-on coupler hoses below the valves
and see if the trouble occurs with the other way.
IV-S-35
(3) Checking the control valve spool performance (stuck)

1. Check to see if the spool of the swivel section moves
smoothly.
2. If not, check for foreign substances, scratches and
deformation.
(4) Measuring the secondary pressure of pilot valve

1. Measure the secondary pressure between the
pilot valve and control valve.
2. Make sure the reading is as specified.
* The photo shows a measurement with the
bucket at dumping position.
(5) Checking the brake valve pressure

1. Measure the brake valve pressure.
(Apply the bucket tip against something fixed and
make the measurement.)
2. Make sure the reading is as specified.
3. Readjust the relief valve, or disassemble and

clean up the valve.
a: For right swivel b: For left swivel c: Drain
IV-S-36
(6)Checking the anti-void valve movement and seating

1. Check the anti-void valve for poor performance,
scratches, foreign substances and other defects.
(7)Checking the motor drain amount

1. Remove the step.
2. Disconnect the drain hose (between the swivel
motor and drain pipe) from the drain pipe. Apply a
plug to one end of a spare drain hose (about 30
cm, 0.98 ft). Connect this hose to the pipe.
3. Do the swiveling and lock the swivel (apply the
bucket tip against something fixed), and measure
the drain amount.
* The photo shows a preparatory step. For
actual measurement, sit on the operator's
seat.
IV-S-37
i. Travel System Diagnosis

(1) Diagnosis
Before checking the entire machine, make sure a trouble is with the travel system alone.
Trouble Possible cause Correction
Machine’s failure to (1) Travel lever linkage stuck or out of position. Readjust or replace the linkage.
travel. (2) Control valve spool stuck. Disassemble, clean or replace the control valve.
(3) Swivel joint leaky inside. Disassemble the swivel joint and replace the sealing.
(4) Counterbalance valve spool stuck. Disassemble, clean or replace the counterbalance
valve.
(5) Too much motor drain. Measure the drain amount. Disassemble or replace
the motor.
(6) Motor damaged inside. Disassemble or replace the motor.
Travel speed too (1) Travel lever linkage malfunctioning. Readjust the linkage.
slow or no travel (2) Control valve spool malfunctioning. Disassemble, clean or replace the control valve.
force.
(3) Swivel joint leaky inside. Disassemble the swivel joint and replace the sealing.
(4) Counterbalance valve spool malfunctioning. Disassemble, clean or replace the counterbalance
valve.
(5) Too much motor drain. Measure the drain amount. Disassemble or replace
the motor.
(6) Motor damaged inside. Disassemble or replace the motor.
(7) Communicating valve spool stuck. Clean or replace the communicating valve. Clean the
filter.
Travel not straight. (1) Right and left travel lever linkages out of sync. Readjust the linkages.
(Travel system alone (2) Right and left control valve spools out of sync. Disassemble, clean or replace the control valves.
in operation)
(3) One of swivel joints leaky inside. Disassemble the swivel joint and replace the sealing.
(4) Counterbalance valve spool stuck. Disassemble, clean or replace the counterbalance
valve.
(5) Too much motor drain difference between right Measure the drain amount. Disassemble or replace
and left. the motor.
(6) One of motors damaged inside. Disassemble or replace the motor.
Check to see if there is a difference in the flow rate or pressure of the right-travel and left-travel pumps or if
the one of the delivery hoses is in trouble. In such cases, the machine fails to run straight. What's worse,
there will be problems with other controls.
Failure to stop prop- (1) Travel lever linkage stuck or failing to return. Readjust the linkage.
erly. (2) Control valve spool stuck or failing to return. Disassemble, clean or replace the control valve.
(4) Counterbalance valve spool stuck or failing to Disassemble, clean or replace the counterbalance
return. valve.
Failure to change the (8) Selector valve's failure to switch the travel bi- Disassemble, clean or replace the selector valve.
gears. speed stage.
(9) High/low-speed selector valve spool of travel Disassemble, clean or replace the high/low-speed
motor malfunctioning. selector valve.
(10) Limit switch malfunctioning. Check or replace the limit switch.
(11) Solenoid or limit switch wire harness broken. Check or replace the wire harness.
IV-S-38
(2) Main points
(9) (9)
(6) (6)
(7) (7)
(4) (4)
(5) (3)
(3)
(1) Travel control lever and linkage

(2) Control valve spool
(3) High pressure hose
(4) Counterbalance valve (1) (1)
(5) Drain port
(6) Travel motor (2) (2)
(7) High speed selector valve
(8) Travel high-low solenoid valve
(9) High speed piston
(8)
IV-S-39
(3) Inlet dump spool check

1. For disassembling and reassembling the control
valve, refer to the Hydraulic System Section.
2. Remove the caps and spools. Check and clean
them up.
3. Clean up the filters too that are in the caps.
(4) Checking the counterbalance valve and high/low-speed selector valve (travel motor)
1. For disassembling and reassembling the valves,
(1)
refer to the Hydraulic System Section.
2. Remove the plugs and spools. Check and clean
them up.
(1) (Fujikoshi-made)
(2) Counterbalance valve
(3) High/low-speed selector valve
(2)
(3)
IV-S-40
(5) Checking the swivel joint for internal leak

Make sure there is no problem with the line between the pump and swivel joint.
1. Disconnect the hose (between the swivel joint and travel motor) from the motor. Apply a plug to the hose
end.
2. Move the travel lever back and forth to make sure the main relief pressure rises up to the specified level.
3. If the swivel joint may be leaky, check it with the following points in mind: A leak at right backward travel
(e) in the sketch relates to the variable track width (narrow) (a) (upper) and left backward travel (h)
(lower).
CAUTION
• When applying a pressure, be careful not to confuse the control parts and the operating directions.
• When disconnecting the hose, pay attention to oil flow-out. In the neutral state, the hose is connected
with the tank circuit.
Hose routing
(1)
(2) (3)
(4)
(1) Left track Swivel joint side Travel motor/cylinder side

(2) Dozer a Variable track width (narrow) Cylinder rod side
(3) Right track
b Dozer up Cylinder rod side
(4) Variable track cylinder
c Dozer down Cylinder bottom side
d Drain Right/left drain ports
e Right backward Right A (bottom)
f Right forward Right B (top)
g Bi-speed pilot Right/left travel bi-speed
h Left backward Left B (bottom)
I Left forward Left A (top)
j Variable track width (wide) Cylinder bottom side
IV-S-41
(6) Blade cylinder (bottom) (c)

(7) Track cylinder (rod) (a)
(8) Travel bi-speed signal (g)
(9) Travel (left) top port (l)
(10)Travel drain (d)
(11)Travel (left) bottom port (h)
(12)Left
(1) (4)
(5)
(2)
(7)
(3) (6)
(13)Travel (right) top port (f)

(14)Travel drain (d)
(15)Travel (right) bottom port (e)
(16)Travel bi-speed signal (g)
(17)Blade cylinder (rod) (b)
(8) (12) (18)Track cylinder (bottom) (j)
(19)Right
(9)
(10) (14) (13)

(11)
IV-S-42
j. Cylinder natural fall amount

1. Locate the machine on the flat ground, and put the
load the bucket. Bucket heaped capacity load (72 kgf,
159 lbw).
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
k. 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 temperature must be 50 ± 5°C, 122 ± 9°F.
l. 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 grip.
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-43
IV-S-44
C. SPECIFICATIONS
a. Pump Specifications
No. Machine model Remarks
Unit STD value
1 Manufacturer Fujikoshi
2 Pump type PVD-00B-15P-5G3-49822A
3 Pump rated RPM 2300
4 Theoretical dis- p1 cc/rev 7.5
charge amount cu.in./rev 0.46
capacity
p2 cc/rev 7.5
cu.in./rev 0.46
p3 cc/rev 4.5
cu.in./rev 0.27
p4 cc/rev 2.7
cu.in./rev 0.16
5 Theoretical p1 L/min 17.3 Recommended limit:
delivery amount USGPM 4.57 ηV = 85%
at rated rpm: Service limit: ηV = 80%
p2 L/min 17.3
USGPM 4.57
p3 L/min 10.4
USGPM 2.73
p4 L/min 6.2
USGPM 1.64
6 Actual delivery Pressure P1 P2 P3

amount Flow amount Engine Flow amount Engine Flow amount Engine
Mpa kgf/cm 2 psi L/min USGPM RPM L/min USGPM RPM L/min USGPM RPM
0.0 0 0.000 19.4 4.78 2590 19.1 4.70 2565 11.2 2.76 2570
2.0 20 284 18.8 4.63 2565 18.9 4.65 2550 11.1 2.73 2555
3.9 40 569 18.7 4.60 2550 18.7 4.60 2535 11.1 2.73 2550
5.9 60 853 18.4 4.53 2530 18.6 4.58 2520 11.0 2.71 2540
7.8 80 1138 18.3 4.51 2510 18.4 4.53 2500 11.0 2.71 2530
9.8 100 1422 18.0 4.43 2485 18.2 4.48 2480 10.9 2.68 2515
11.8 120 1707 17.9 4.41 2475 18.1 4.46 2460 10.7 2.63 2500
13.7 140 1991 17.7 4.36 2455 17.9 4.41 2445 10.6 2.61 2490
15.7 160 2276 17.5 4.31 2440 17.8 4.38 2430 10.5 2.59 2480
17.7 180 2560 17.3 4.26 2420 17.6 4.33 2420 10.5 2.59 2470
19.6 200 2845 17.0 4.19 2405 17.4 4.28 2400 10.2 2.51 2460
21.6 220 3129 15.6 3.84 2405 15.8 3.89 2400
(Above data “6. Actual delivery amount” is just for your information on one new machine's sample value only.)
IV-S-45
b. Relief Valve
(1) Bench set data
No. Type of valve Unit Value Allowance Value Allowance Remarks
1 a1: Main relief valve of P1 MPa 21.6 +1.0 -0.5 at 17.4 l/min
220 +10 -5 (4.6 USGPM)
kgf/cm2
Bar 216 +9.8 -4.9
psi 3128 +142 -71
2 220 +10 -5 (4.6 USGPM)
kgf/cm
Bar 216 +9.8 -4.9
psi 3128 +142 -71
190 +10 -5 (4.6 USGPM)
kgf/cm2
Bar 186 +9.8 -4.9
psi 2702 +142 -71
4 ap: Primary pilot system pressure MPa 3.9 +0.3 -0.2
kgf/cm2 40 +3 -2
Bar 39.2 +3 -2
psi 569 +43 -28
5 as: Secondary pilot system pressure MPa 2.2 0.3 0.0
kgf/cm2 22 3 0
Bar 21.6 2.9 -0.2
psi 313 43 -3
6 b5: Overload relief valve of bucket bottom MPa 23.5 0.5 0.0 at 5.0 l/min
2 240 5 0 (1.3 USGPM)
kgf/cm
Bar 235 5 0.0
psi 3413 71 0
7 b2: Overload relief valve of boom rod MPa 27.5 0.5 0.0 at 5.0 l/min
2 280 5 0 (1.3 USGPM)
kgf/cm
Bar 275 5 0.0
psi 3982 71 0
8 b1: Overload relief valve of boom bottom MPa 17.7 0.5 0.0 at 5.0 l/min
180 5 0 (1.3 USGPM)
kgf/cm2
Bar 177 5 0.0
psi 2560 71 0
9 b3, b4: Overload relief valve of arm, rod and MPa 23.5 0.5 0.0 at 5.0 l/min
bottom 240 5 0 (1.3 USGPM)
kgf/cm2
Bar 235 5 0.0
psi 3413 71 0
10 c1: Overload relief valve of swivel motor MPa 13.2 0.5 0.0 at 5.0 l/min
R&L 135 5 0 (1.3 USGPM)
kgf/cm2
Bar 132 5 0.0
psi 1920 71 0
IV-S-46
(2) Machine set data (at the pump gauge port)

No. Type of valve Actuator Unit Value Allowance Value Allowance Remarks
1 a1: Main relief valve Bucket dump MPa 22.6 1.0 -1.0 at Max. speed
of P1 kgf/cm 2 230 10 -10
Bar 226 10 -10
psi 3271 142 -142
2 a2: Main relief valve Arm MPa 22.1 1.0 -1.0 at Max. speed
of P2 kgf/cm2 225 10 -10
Bar 221 10 -10
psi 3200 142 -142
3 a3: Main relief valve Blade up MPa 19.7 1.0 -1.0 at Max. speed
of P3 kgf/cm 2 201 10 -10
Bar 197 10 -10
psi 2858 142 -142
4 ap: Primary pilot sys- Engine start MPa 4.2 0.3 -0.3 at Max. speed
tem pressure Safety lever up 43 3 -3
kgf/cm2
Bar 42 3 -2.9
psi 611 43 -43
5 as: Secondary pilot Control lever shift MPa 2.1 0.2 -0.2 at Max. speed
system pressure end (boom, arm, 21 2 -2
kgf/cm2
bucket, swivel)
Bar 21 2 -2.0
psi 299 28 -28
6 b5: Overload relief Bucket crowd MPa 25.5 1.5 -1.5 at 1500 rpm
valve of bucket bot- kgf/cm 2 260 15 -15
tom
Bar 255 15 -14.7
psi 3697 213 -213
7 b2: Overload relief Boom up MPa 28.4 1.5 -1.5 at 1500 rpm
valve of boom rod kgf/cm2 290 15 -15
Bar 284 15 -14.7
psi 4124 213 -213
8 b1: Overload relief Boom down MPa 19.1 1.5 -1.5 at 1500 rpm
valve of boom bot- kgf/cm2 195 15 -15
tom
Bar 191 15 -14.7
psi 2773 213 -213
9 b3, b4: Overload Arm MPa 24.5 1.5 -1.5 at 1500 rpm
relief valve of arm, kgf/cm 2 250 15 -15
rod and bottom
Bar 245 15 -14.7
psi 3555 213 -213
10 c1: Overload relief Swivel MPa 17.7 1.5 -1.5 at Max. speed
valve of swivel motor kgf/cm2 180 15 -15
R&L
Bar 177 15 -14.7
psi 2560 213 -213
11 c1: Overload relief Swivel MPa 15.7 1.5 -1.5 at 1500 rpm
valve of swivel motor kgf/cm 2 160 15 -15
R&L
Bar 157 15 -14.7
psi 2275 213 -213
IV-S-47
c. Swivel Performance
Machine model
Remarks
Unit
Manufacturer Eaton Fluid Power Ltd.
Model 2-200DOS-E3888
Displacement cc/rev cu.in/rev 195 48.01
Max. oil flow L/min USGPM 30 8
Motor speed rpm 53.3 at 10.4 L/min
Brake valve pressure MPa psi 13.2 1920
kgf/cm2 135
Drain amount at lock L/min USGPM 2.0 0.53
Drain amount while rotating L/min USGPM 0.25 0.07
Swivel speed rpm 8.7
3 times rotation swivel speed sec 19.8 ± 2.2
Swivel block performance deg. 30 > 1 min. 20 degree slope
Capable swivel rotation angle deg. 18 <
Play at the tip of bucket mm inch 53 2.1
Brake release pressure MPa psi 13.2 1920
kgf/cm 2 135
IV-S-48
d. Traveling Performance
1 Motor Displacement Low speed 11.36 cm3/rev 0.69 cu.in/rev
High speed 6.21 cm3/rev 0.38 cu.in/rev
2 Gearbox ratio 1 : 36.96
3 Total displacement High speed 419.9 3
cm /rev 25.62 cu.in/rev
Low speed 229.5 cm3/rev 14.01 cu.in/rev
4 Max. pressure 21.6 MPa 3128.4 psi
220.0 kgf/cm 2 216 bar
5 Max. flow 17.3 L/min 4.57 USGPM
6 Max. drain pressure Continuous 0.1 MPa 14.2 psi
1.0 kgf/cm 2 1 bar
Peak 0.5 MPa 71.1 psi
5.0 kgf/cm 2 5 bar
7 Max. motor output torque (theoretical) High speed 39.0 Nm at 216 bar 28.8 ft•lbs at 3132 psi
Low speed 21.3 Nm at 216 bar 15.7 ft•lbs at 3132 psi
8 Max. motor output speed (theoretical) High speed 2786 rpm
Low speed 1523 rpm
9 Max. gearbox output torque (theoreti- High speed 788.5 Nm 581.6 ft•lbs
cal) Low speed 1443.0 Nm 1064.4 ft•lbs
10 Max. gearbox output speed (theoreti- High speed 75.4 rpm
cal) Low speed 41.2 rpm
11 Counter balance spool operating pressure 0.59 MPa 85.3 psi
6.0 kgf/cm2 6 bar
12 Check valve cracking pressure 0.03 MPa 4.3 psi
0.3 kgf/cm2 0.3 bar
13 Hydraulic motor oil ISO VG46
14 Gearbox oil type Gear oil SAE-90-CD
15 Gearbox oil: quantity 330 cm3 20.14 cu.in
16 Oil temperature -20°C/ 100°C -4°F/ 212°F
17 Total weight 17.0 kg ±10% 37 lbs ±10%
18 Climbing ability 30°
19 Max. traction force 1F 12.7 kN 2855 lbw
2F 7.1 kN 1596 lbw
20 Traveling block performance less than 300 mm less than 11.811 in
21 Traveling speed Rubber/Steel crawler 1F 2.3 km/h 1.43 mph
2F 4.1 km/h 2.55 mph
22 10 m traveling time 1F 15.7 sec
2F 8.8 sec
23 Straight travel performance 1,2F less than 600 mm less than 23.62 in
24 Drain amount at lock 1F 4.0 >
= LPM 1.06 >= GPM
2F 4.0 >
= LPM 1.06 >
= GPM
25 Drain amount while rotating 1F 0.5 >
= LPM 0.13 >
= GPM
2F 0.5 >
= LPM 0.13 >
= GPM
26 Hi-speed change pressure 1st → 2nd 0.5 MPa 5 kgf/cm2
27 Manufacturer Fujikoshi
28 Motor type PHV-120
29 Sprocket, PCD 277.18 mm 10.91 in
30 Kubota part No. RB238-61292
IV-S-49
e. Cylinder
(1) Speed
(unit: sec.)
Unit (A) (B) Remarks
Boom cylinder Up 2.1 ± 0.3 2.9 GL to Max. height (exclude cushion time)
Boom cylinder Down 2.4 ± 0.3 3.2 Max. height to GL
Boom cylinder cushion 0.5 ~ 1.5 1.8
Arm cylinder Crowd 3.3 ± 0.3 4.3 Cylinder full stroke
Arm cylinder Dump 2.2 ± 0.3 3.0
Bucket cylinder Crowd 2.7 ± 0.3 3.6 Cylinder full stroke
Bucket cylinder Dump 1.8 ± 0.3 2.5
Swing cylinder Left 4.6 ± 0.3 5.9 Cylinder full stroke
Swing cylinder Right 3.7 ± 0.3 4.8
Blade cylinder Up 1.7 ± 0.3 2.4 Cylinder full stroke
Blade cylinder Down 2.1 ± 0.3 2.9
Truck cylinder Extend - - Cylinder full stroke
Truck cylinder Retract - -
(A) New machine reference value

(B) Allowable limit
(2) Natural fall

Unit (A) (B) (C) Remarks
Load weight kg 72 0 (=Bucket heaped capacity x earth specific gravity 1.8) in the
lbs 158.7 0.0 bucket
Boom cylinder mm 25 125 6 Boom raise, Arm extend, Bucket crowd, Bucket load: heaped
inch 0.98 4.92 0.24 capacity 10 min Engine stop
Arm cylinder mm 15 75 4
inch 0.59 2.95 0.16
Bucket cylinder mm 10 50 2
inch 0.39 1.97 0.08
Dozer cylinder mm 25 125 1
inch 0.98 4.92 0.04
Swing block mm 6 30 90 degrees swivel 100 times
inch 0.24 1.18
Oil temp.:50 ± 5°C, 10 minutes (A) New machine reference value

122 ± 9°F (B) Allowable limit
(C)No bucket load(Sample date)
(Measuring procedure)
1. Equip the machine with standard bucket. Arm stretched and bucket bottom 1 m above ground
2. Air-vent all the cylinders. Load piled up (JIS), specific gravity 1.8
3. Measure the gravity fall for 10 minutes.
IV-S-50
(3)Cylinder maintenance data
No. Unit Boom Arm Bucket Dozer Swing Track Remarks

mm 40-30 40-30 40-30 40-30 40-30 34-30
A I.D.
in. 1.57-1.18 1.57-1.18 1.57-1.18 1.57-1.18 1.57-1.18 1.34-1.18
mm
B I.D. ↑ ↑ ↑ ↑ ↑ ↑
in.
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 60
F Tube I.D.
in. 2.36 2.36 2.36 2.36 2.17 2.36
mm 70 70 70 70 65 70
G Tube O.D.
in. 2.76 2.76 2.76 2.76 2.56 2.76
mm 35 32 32 32 32 30
H
in. 1.38 1.26 1.26 1.26 1.26 1.18
Max. retraction/ mm 765/1234 589/924.5 529/802 348/460 610/940 478/72.8
I
extended length in. 30.11/48.6 23.2/36.4 20.83/31.6 13.7/18.1 24.02/37.0 18.8/28.7
mm 35 32.5 32 32 32 28
J
in. 1.38 1.28 1.26 1.26 1.26 1.10
mm 469 335.5 269 112 326 250
K Stroke
in. 18.46 13.2 10.6 4.41 12.8 9.84
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.
Cylinder head N·m 390 ~ 430 390 ~ 430 390 ~ 430 215.6 ~ 235.2 215.6 ~ 235.2 137.2 ~ 156.8
M tightening kgf·m 40 ~ 44 40 ~ 44 40 ~ 44 22 ~ 24 22 ~ 24 14 ~ 16
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 tighten-
kgf·m 42 ~ 46 52 ~ 56 52 ~ 56 35 ~ 40 35 ~ 40 35 ~ 40
N ing 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 M24 x 1.5 M22 x 1.5 M22 x 1.5 M22 x 1.5
Seal kit No.
IV-S-51
f. Service Port Flow Amount

(Test sample data: U17-3α)
Qs=Q2+Q3
Pressure
Flow amount Engine
Mpa kgf/cm2 psi L/min USGPM RPM
0.0 0 0 30.0 7.39 2520

2.0 20 284 29.7 7.31 2500
3.9 40 569 29.3 7.21 2475
5.9 60 853 29.0 7.14 2450
7.8 80 1138 28.7 7.07 2430
9.8 100 1422 28.2 6.94 2405
11.8 120 1706 27.0 6.65 2395
13.7 140 1991 24.6 6.06 2395
15.7 160 2275 22.2 5.47 2395
17.7 180 2560 10.5 2.59 2400
19.6 200 2844 9.1 2.24 2405
Note: Above data is just for your information, not the specifications.
g. Motor Oil Drain Amount Test Sample

(Test sample data: U17-3α)
(1) Travel motor

Right & Left
cc/min cu.in./min
1st (40 ~ 50 kgf/cm 2) 10 ~ 50 0.61 ~ 3.05
2nd (60 ~ 80 kgf/cm2) 20 ~ 100 1.22 ~ 6.10
Lock (240 ~ 270 kgf/cm2) 200 ~ 1000 12.21 ~ 61.03
(2) Swivel motor

Right
cc/min cu.in./min
Swiveling condition (70 kgf/cm2) 70 ~ 130 4.27 ~ 7.93
Lock condition (180 kgf/cm2) 440 ~ 1000 26.85 ~ 61.03
Note: Above data is just for your information, not the specifications.
IV-S-52
D. DISASSEMBLING AND REASSEMBLING

a. Pump
(1) Pump coupling
(1)
Greasing of spline Apply an appropriate Burnt spline
amount of grease. ↓
(2) (Do not allow oozing out.) Detaching impossible
Tightening torque of 48.1 ~ 55.9 N·m Poor tightness
A coupling mounting (4.9 ~ 5.7 kgf·m) ↓
bolt (RB238-4262Δ) (35.5 ~ 41.2 ft·lbf) Come-off
* MEC-treated * Do not apply thread Too tight
adhesive. ↓
(3) Damage
Thread adhesive used

↓
Adhesive deposit on
rubber
(4) ↓
Chemical reaction to
degrade the rubber
↓
Damaged coupling
(1) Pump housing

(2) Coupling
(3) Bolt
(4) Spline (Apply grease)
(5) Finally cut off the tape applied around.
(5)

010 RB238-4261-2 Housing 1
020 01123-60825 Bolt 5
030 01123-60825 Bolt 2
040 02114-60080 Nut 2
050 05012-00814 pin 1
060 - -
070 RB238-4262-0 Coupling 1
080 RA221-6111-0 Piston pump 1
090 01133-61230 Bolt 2
IV-S-53
(2) Adaptor installation

Fitting direction and angle Fit according to the figure. Wrong angle
of hydraulic adaptor Avoid any close contact with other parts along the hose route. ↓
Difficult hose connections
Mounting of pump Tightening torque Poor tightness
77.5 ~ 90.2 N·m (7.9 ~ 9.2 kgf·m) (57.2 ~ 66.5 ft·lbf) ↓
Bolt loose and coming off
Mounting of adaptor Apply oil (New UDT, M80B or equivalent) to the O-ring. No oiling on O-ring
↓
Chipped O-ring
G3/8 Poor tightness
37.2 ~ 42.1 N·m (3.8 ~ 4.3 kgf·m) (27.4 ~ 31.1 ft·lbf) ↓
Looseness and oil leak
↓
Damage
P1 P2
(PP-version)
10 8
P3 Pp
11 1 3 2 7 13 7 7 12 4 6 5
1 Pump assembly (piston) 1 P1, P2
2 Pipe joint (L, G3/8-G3/8) 1
4 Pipe joint (3-3-35) 1 P1
P3 P4
6 O-ring 1
P2
7 Plug (seal) 3 R1/8 P1, P2, P3
8 Flange (suction) 1
9 Bolt 4 M10 x 1.5 7T
10 O-ring 1 S35
11 Bolt 2 M12 x 1.25 7T
13 Pipe joint (L, R1/8-R1/8) 1
IV-S-54
(EU-version)
10 8

1 Pump assembly (piston) 1
11 1 3 2 7 13 7 7 12 4 6 5
2 Pipe joint (L, G3/8-G3/8) 1 P1, P2
4 Pipe joint (3-3-35) 1
6 O-ring 1 P1
P3
7 Adapter 3 R1/8 P1, P2, P3
P4
8 Flange (suction) 1
9 Bolt 4 M10 x 1.5 7T P2
10 O-ring 1 S35
11 Bolt 2 M12 x 1.25 7T
13 Pipe joint (L, R1/8-R1/8) 1
IV-S-55
(3) 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-56
Ref. No. Part Name Q’ty Ref. No. Part Name Q’ty
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-57
(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 illustration)
of the setscrew for ease of pressure adjustment after assembly.
Sample data: L = 20 mm (0.79 in)

(New pump)
IV-S-58
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-59
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-60
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) Piston, shoe and shoe holder

(2) Spring
(3) Cylinder barrel
(4) Retainer
(5) Snap spring
(6) Pin
10. Remount the snap ring.
IV-S-61
IV-S-62
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. Fitting the cylinder barrel kit
Install the retainer (24), spring C (14), retainer
(24) and snap ring (33) in this order to the cen-
ter opening of cylinder barrel (4). To the other
end, fit the shoe holder (8) carefully in place,
which has the needle (11), barrel holder (9) and
ten piston shoe assemblies incorporated.
3. Fitting the stopper pin A and B kits (1) (5)

Install the two pan-shaped springs (33) to the
stopper pin A (25) to make the stopper pin A kit.
Similarly, install the two pan-shaped springs
(2) (6)
(33) to the stopper pin B (26) to make the stop-
(3) (7)
per pin B kit. (4) (8)
Be careful not to confuse the direction of the
pan-shaped springs. See Fig. 5.
(1) Stopper pin A kit (5) Stopper pin B kit

(2) Stopper pin A (25) (6) Stopper pin B (26)
(3) Pan-shaped spring (33) (7) Pan-shaped spring (33)
(4) Pan-shaped spring (33) (8) Pan-shaped spring (33)
IV-S-63
4. Fitting the body S kit (Photo 2)

Install the stopper pin A kit, stopper pin B kit
and rod (21) to the body S. Next put the oscil-
lating pin (12) into the hole of swash plate (10)
and put them into the hole of body S.
Then apply the spring T (15) to the spring
holder (18). Put the spherical part of spring
holder (18) into the hole of swash plate (10).
5. Attach a new packing to the positioning pin on

the body S.
(1)
(1) Gasket (2)

(2) Pin (2-places)
6. Mount the valve plate.

Carefully locate the valve plate by positioning it
with the spring pin on the body H.
The side with the notch groove on the valve
plate is the face sliding on the cylinder barrel.
Pay utmost attention not to locate the wrong
side.
(4)
(3)
(1)
(1) Valve plate

(2) Spring pin
(3) Hair groove
(4) Spring guide
(2)
IV-S-64
7. Mount the two bolts (M10 x 65) for temporary

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.
Tool: 14-mm spanner

8-mm hexagonal wrench
Tightening Torque: 53.9 ~ 63.7 N·m (1)

5.5 ~ 6.5 kgf·m
39.8 ~ 46.9 kgf·m
(1) Bolt (M10 x 65)
8. Mount the gear pump
Tightening Torque: 19.6 ~ 21.6 N·m

2.0 ~ 2.4 kgf·m
14.5 ~ 15.9 ft·lbf
IV-S-65
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 (0.002 in)
>
(1) Piston assembly

(2) Cylinder Barrel
c) Check that the play of the piston and shoe (1) (2)
in the shaft direction satisfy the following
condition:
ε = 0.2 mm (0.008 in)
>
ε
Play of Piston and Shoe
(1) Shoe
(2) Piston
2. Shaft
Check that the wear of the oil seal mounting (1)
part is at a maximum of 0.025 mm (0.001 in).
Shaft Check
(1) Oil Seal Mounting Part
IV-S-66
3. Main pump P-Q performance
Discharge: q1 = q2 (cc/rev)
Pressure: P1+P2 (kgf/cm2)
Test condition Remark

Oil ISOVG46 3.44 kgf·m
Oil temp 50 ± 5°C (at P3=5 kgf/cm2)
RPM 2300 rpm 3.44 kgf·m
Direction Clockwise Pump intake torque (at P3=190 kgf/cm2)
q3 4.5 cc/rev
q4 2.7 cc/rev
P4 40 kgf/cm2
P1 and P2 capacity = 7.2 cc/rev (0.44 cu.in)
IV-S-67
Stamp product code (214749-01) "Side E"
and serial No. on nameplate. Setting Actuator port
Caution: "Side E"
No wrong Pump port Setting
Tank port assembling Plug PF 3/8 (2 locations) (A4 and B4 are plugs.)
Setting
b. Control Valve
WSM U17-3α/U17-3/U17 Service
(1) Control Valve assy
Tank port
ID marking
provided Tightening torque
T=13.7 14.7N m
{1.4 1.5kgf m}
IV-S-68
Thread depth 12
Actuator port
Check valve cover

Check valve spring
ID marking
provided
6 6 travel left & right
ID marking
provided
Stroke Swing, dozer, service,
Check valve C
Pilot port
"Side E" "Side E" Plug PF 1/4
Setting Setting (2 locations) Setting
Swing Dozer Swivel Confluence Service Arm Travel Supply Travel Boom Bucket Discharge Unload confluence valve
4 mm stroke
Stroke (mm)
Pilot pressure
FYI (For your information)

Valve specifications (original maker’s bench valve)
Swing • Rated pressure: 22.6 MPa {230 kgf/cm2}
• Rated flow rate: 15 L/min
Dozer
• Relief valve set pressure level:
4.30 ~ 24.5 MPa {50 ~ 250 kgf/cm2}
Swivel
• Overload valve set pressure level:
4.30 ~ 24.5 MPa {50 ~ 250 kgf/cm2}
Confluence • Spool length spring force (manual control)
[Travel] At neutral: 98.1 N {10 kgf}
At stroke end: 131 N {13.4 kgf}
Service [Others] At neutral: 83.4 N {8.5 kgf}
At stroke end: 103 N {10.5 kgf}
• Maximum pilot operating pressure:
4.90 MPa {50 kgf/cm2}
Arm
• Allowable tank pressure:
Below 0.98 MPa {10 kgf/cm2}
• Oil in use: General mineral hydraulic oil
Travel left • Operating oil temperature range:
-20 ~ +90°C (100°C)
• Oil contamination level: Within Class NAS9
Supply Operating conditions

• Relief valve set pressure
P1·P2: 21.4 +0.49
0 MPa {218 +50 kgf/cm2 at 16.6 L/min}
P3: 18.4 +0.49
0 MPa {188 +50 kgf/cm2 at 10.4 L/min}
Travel right
• Operating flow rate
P1·P2: 16.6 L/min
P3: 10.4 L/min
Boom • Service port flow rate (P2+P3): 27.0 L/min under no
load.
• Overload valve set pressure
Bucket A5·B5·B9: 23.3 +0.49
Discharge A8: 27.3 0 MPa {278 +50 kgf/cm2 at 5 L/min}
+0.49
B8: 17.5 +0.49

• Spool leak amount
Leak amount from A1, A8, B1 to i: Below 3 cm3/min
Leak amount from others to i: Below 7 cm3/min
(* 9.8 MPa {100 kgf/cm2}) (Oil viscosity 37 cSt)
• Spool operating pressure with pilot on (See Charac-
teristics Chart.):
0.37 ~ 1.96 MPa {3.6 ~ 20 kgf/cm2}
Po port pilot pressure: 3.50 MPa {35.7 kgf/cm2}
-20 ~ +90°C (100°C)
Figures in { } are just for your reference.
IV-S-69

Setup method and tightening torque Apply oil (New UDT, M80B or equivalent) to the O-ring. No oiling on the O-ring
of valve adaptor Tightening torque ↓
G1/4 O-ring port 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) (35.4 ~ 41.2 ft·lbf) Chipped O-ring
Fitting of hose connection adaptor ↓
G3/8 O-ring port Apply oil (New UDT, M80B or equivalent) to the O-ring. Oil leak
Fitting of hose connection adaptor Tightening torque
48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) (35.4 ~ 41.2 ft·lbf)
G1/8 O-ring port Apply oil (New UDT, M80B or equivalent) to the O-ring. Poor tightness
Fitting of hose connection adaptor Tightening torque ↓
48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) (35.4 ~ 41.2 ft·lbf) Oil leak
G1/2 O-ring port Apply oil (New UDT, M80B or equivalent) to the O-ring.
Fitting of hose connection adaptor Tightening torque
48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) (35.4 ~ 41.2 ft·lbf)
Fitting angle of hydraulic Fit the adaptor as shown in the figure. Hose's contact with nearby parts
A adaptor ↓
Rubbing, oil leak
(PP-version)
IV-S-70
A1 ‚a1
24°~26°
A2 ‚a2
Pb3
A3 ‚a3
Pa3
P3
T2 Pb8 '
Pa8 '
A4 ‚a4
24°~26°
Pb5
A5 ‚a5
Pa5
A6 ‚a6
P1 P2
24°~26°
Pp
A7 ‚a7
24°~26°
A8 ‚a8
Pa8 Pb8
Pa9 A9 ‚a9
Pb9
IV-S-71
T3 T1
40°~42°
Front 40°~42° Rear

5°
(EU-version)

PP-version
A T1·T3 D Travel left
12
12
26
10 23
27 23 3 19
8
2
B Bucket E P1·P2 19
11
25 5 4 6
18 13
30
C Boom F Travel right

11
7
23 3 19
25 17 20 24 25
5
24
14
G Arm J Swivel 11
11
20 24
25 24 21 24 25 24
7
5 22 17 4
25 5 6
H Service H Service K Blade

41
11
41
24 4
40 44
43 42
SP type
I P3·T2 L Swing
11
23 16 17 25 24 7
25 24 15 24
5 14
IV-S-72
No. Part Code Part Name Q’ty No. Part Code Part Name Q’ty
1 RA228-6113Δ Control valve assy 1 16 RC411-6400Δ Pipe joint (L, 3/8-3/8) 1
2 01125-60816 Bolt 4 17 RC418-6613Δ Pipe joint (S, G1/8-G1/4) 3
3 68881-3493Δ Elbow with washer 2 18 RC631-9234Δ Pipe joint (S, G3/8-G3/8) 1
4 69254-7849Δ Pipe joint (L, G1/4-G1/4) 3 19 RP201-6181Δ Pipe joint (L, G3/8-G3/8) 4
5 RA131-6195Δ Pipe joint (L, G1/8-G1/4) 5 20 RA021-6325Δ Pipe joint (S, G1/4-G1/4) 2
6 RA131-6199Δ Pipe joint (L, G1/8-G1/4) 3 21 RP431-7969Δ Pipe joint (S, G2-G2) 1
7 RA221-6315Δ Pipe joint (S, G1/4-G1/4) 3 22 RA221-6314Δ Pipe joint (S, G1/4-G1/4) 1
8 RA221-6316Δ Pipe joint (S, G3/8-G3/8) 1 23 RA221-6319Δ Pipe joint (S, G3/8-14) 1
9 RA228-9256Δ T-joint (3-3-3) 1 24 RA221-6316Δ Pipe joint (S, G3/8-G3/8) 1
10 RB238-6380Δ Valve assy 1 25 RP201-6181Δ Pipe joint (L, G3/8-G3/8) 2
RB238-6381Δ Body 1 26 RP421-6192Δ Pipe joint (S, G3/8-G3/8) 1
RB237-6382Δ Popet 1 27 RB511-6398Δ T-joint (3-3-3) 1
RB237-6384Δ Spring 1 28 RD118-9489Δ Pipe joint (L, G3/8-G1/2) 1
RB237-6383Δ Washer 1 29 RA228-9257Δ Pipe joint (L, G3-16-141) 1
04611-00140 Circlip hole 1 30 04817-00140 O-ring 6
11 RB411-6376Δ Pipe joint (L, G1/4-G1/4) 10 31 04817-00110 O-ring 10
12 RB411-6391Δ L-joint (G3/8-13) 2 32 04817-00080 O-ring 8
13 RB411-6403Δ Straight joint (3-3-35) 1 33
14 RC101-6382Δ T-joint (F2) 2 34
15 RC411-6393Δ Pipe joint (Bushing G1/4) 1 35
IV-S-73
EU-version
G Arm J Swivel
11 11
7 20 31 32 31 21 31 32 31
5 22 17 4
32 5 6
H Service K Blade
28
27
31 4 11
25
30 26 24
I P3·T2 L Swing
11
30 16 17 32 7
15 31
32 31
5 14
No. Part Code Part Name Q’ty No. Part Code Part Name Q’ty
1 RA228-6113Δ Control valve assy 1 16 RC411-6400Δ Pipe joint (L, 3/8-3/8) 1
2 01125-60816 Bolt 4 17 RC418-6613Δ Pipe joint (S, G1/8-G1/4) 3
3 68881-3493Δ Elbow with washer 2 18 RC631-9234Δ Pipe joint (S, G3/8-G3/8) 1
4 69254-7849Δ Pipe joint (L, G1/4-G1/4) 3 19 RP201-6181Δ Pipe joint (L, G3/8-G3/8) 4
5 RA131-6195Δ Pipe joint (L, G1/8-G1/4) 5 20 RA021-6325Δ Pipe joint (S, G1/4-G1/4) 2
6 RA131-6199Δ Pipe joint (L, G1/8-G1/4) 3 21 RP431-7969Δ Pipe joint (S, G2-G2) 1
7 RA221-6315Δ Pipe joint (S, G1/4-G1/4) 3 22 RA221-6314Δ Pipe joint (S, G1/4-G1/4) 1
8 RA221-6316Δ Pipe joint (S, G3/8-G3/8) 1 23 RA221-6319Δ Pipe joint (S, G3/8-14) 1
9 RA228-9256Δ T-joint (3-3-3) 1 24 RA221-6316Δ Pipe joint (S, G3/8-G3/8) 1
10 RB238-6380Δ Valve assy 1 25 RP201-6181Δ Pipe joint (L, G3/8-G3/8) 2
RB238-6381Δ Body 1 26 RP421-6192Δ Pipe joint (S, G3/8-G3/8) 1
RB237-6382Δ Popet 1 27
RB237-6384Δ Spring 1 28 RP20-6181Δ Pipe joint (L, G3/8-G3/8) 1
RB237-6383Δ Washer 1 29 RB411-6391Δ L-joint (G3/18-13) 1
04611-00140 Circlip hole 1 30 04817-00140 O-ring 6
11 RB411-6376Δ Pipe joint (L, G1/4-G1/4) 10 31 04817-00110 O-ring 10
12 RB411-6391Δ L-joint (G3/8-13) 2 32 04817-00080 O-ring 8
13 RB411-6403Δ Straight joint (3-3-35) 1 33
14 RC101-6382Δ T-joint (F2) 2 34
15 RC411-6393Δ Pipe joint (Bushing G1/4) 1 35
IV-S-74
(Sample photo)
(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
IV-S-75
IV-S-76

Fitting of the control valve (8) Tightening torque Poor tightness
23.5 ~ 27.5 N·m (2.4 ~ 2.8 kgf·m) ↓
(Apply screw adhesive.) Bolt loose
↓
Come-off, damaged
Connecting of all the rods to the con- Connect all the rods as specified. Wrong fitting
trol valve ↓
Malfunction
Fitting of the snap pin (05525-51000) Fit them as specified. Wrong fitting
and plain washer (04011-50100) for ↓
the right-hand travel link only Malfunction
(9)
1 3 2 4 5 1 5
8
Travel
Service Swing 6
right
Travel left Dozer
STD type SP type

No. Part Name Q’ty Remarks No. Part Name Q’ty Remarks
1 Link (plate 1) 2 Travel left, dozer 5 Link (control) 1 Service
2 Link (M8) 1 Travel right 6 Snap pin 1
3 Pin (10-M8) 1 7 Headed pin 1
4 Nut 1
5 Link (control) 1 Swing (9) To be connected on SP type machines only
6 Snap pin 4
7 Headed pin 4
8 Bolt 4
IV-S-77
(4) Inner parts of control valve
Swing
Dozer
Swivel
Combination
Service
Arm
Travel, RH
Inlet
Travel, LH
Boom
Bucket
Outlet
Tightening Torque
IV-S-78
1) Swing section
(1)
(1) Plug (G3/8), 39.2 ~ 49.6 N·m (4.0 ~ 5.0 kgf·m) (29.0 ~ 36.2 ft·lbs)
Tightening Torque
1 Housing 1 6 Bolt 2
2a Spool 1 7 Check valve 1
2b O-ring 1 Same as No. 3 8 Spring 1
2c Back up ring 1 Same as No. 4 9 O-ring 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 O-ring 1
3 O-ring 1 14 Plug 1
4 Back up ring 1 15 Anti-void valve 1
5 Retainer 1
IV-S-79
2) Dozer section
2g Bolt 1
3 O-ring 1
4 Back up ring 1
5 Retainer 1
IV-S-80
3) Swivel section
1 Housing 1 8 Spring 1
2a Spool 1 9 O-ring 1
2b Retainer 1 10 Plug 1
2c Spring 1
2d Spring retainer 1
2e Bolt 1
3 O-ring 2
4 Cap A 1
5 Bolt 4
6 Cap B 1
7 Check valve 1
IV-S-81
4) Combination section
Tightening Torque: Do not make

assembling
mistakes
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 O-ring 2
4 Cap A 1
5 Bolt 4 Tightening torque: 5.88 ~ 6.86 N·m
0.6 ~ 0.7 kgf·m
6 Cap B 1
7 Check valve 1
IV-S-82
5) Service section
2g Bolt 1
3 O-ring 1
4 Back up ring 1
5 Retainer 1
IV-S-83
6) Arm section
Do not make assembling mistakes
Tightening Tightening
Torque Torque
Tightening
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 O-ring 2
4 Cap A 1
5 Bolt 4
6 Cap B 1
7 Check valve 1
IV-S-84
7) Travel section (RH)
(2)
(4)
(3)
(1)
(1) Screw, 1.96 ~ 2.94 N·m(0.2 ~ 0.3 kgf·m) (3) Bolt, M5 x 45, 5.9 ~ 6.9 N·m (0.5 ~ 0.7 kgf·m)
(1.44 ~ 2.17 ft·lbs) (3.62 ~ 5.06 ft·lbs)
(2) O-ring, 1B P11 (4) O-ring, AS1B 127
Tightening Torque
Strict observation
1 Housing 1 6 Bolt 2 M5 x 10
2b O-ring 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 O-ring 1
4 Back up ring 1
5 Retainer 1
IV-S-85
8) Inlet section
(2)
(1)
(1) Plug (PF1/8) 9.8 ~ 14.7 N·m (1.0 ~ 1.5 kgf·m) (2) O-ring, 1B P8
(7.23 ~ 10.9 ft·lbs)
Do not make
assembling
Tightening mistakes
Torque Do not make assembling mistakes
Tightening
Torque
Do not make
assembling
mistakes
Tightening
Torque Strict observation
1 Housing 1 8 O-ring 1
2b Spring retainer B 1 10 Spring 1
2c Spring 1
2d Spring retainer A 1
2e Bolt 1
3 O-ring 2
4 Cap A 1
5 Bolt 4 M5 x 20
6 Cap B 1
7 Plug (PF1/8) 1
IV-S-86
9) Travelling section (LH)
(6)
(3) (5)
(7) (4)
(1)
(2)
(1) O-ring, 1AP-10A (3) O-ring, 1B P11 (6) Plug (G1/4) 24.5 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m)
(2) Back-up ring, T3P10A (4) O-ring, AS1B127 (18.1 ~ 21.7 ft·lbs)
(5) O-ring, 1B P-10 (7) Bolt, M4 x 45, 5.9 ~ 6.9 N·m (0.6 ~ 0.7 kgf·m)
(4.34 ~ 5.06 ft·lbs)
Tightening Torque
Strict observation
1 Housing 1 6 Bolt 2 M5 x 10
2b O-ring 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 O-ring 1
4 Back up ring 1
5 Retainer 1
IV-S-87
10) Boom section

(1)
Tightening Tightening
Torque Torque
Tightening
Strict observation Torque
2c Spring 1
2d Spring Retainer A 1
2e Bolt 1
3 O-ring 2
4 Cap A 1
5 Bolt 4
6 Cap B 1
7 Check valve 1
IV-S-88
11) Bucket section
(2)
(1)
(1) M5 x 20, torque: 5.9 ~ 6.9 N·m (0.6 ~ 0.7 kgf·m) (4.34 ~ 5.06 ft·lbs)
(2) Plug torque: 24.5 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) (18.1 ~ 21.7 ft·lbs)
Tightening
Torque
Tightening
Torque
Strict observation
2c Spring 1 11 O-ring 1
2d Spring Retainer A 1 12 Plug (PF3/8) 1
2e Bolt 1 13 Check valve 1
3 O-ring 2 14 Spring 1
4 Cap A 1
5 Bolt 4
6 Cap B 1
7 Check valve 1
IV-S-89
12) Outlet section

1 Housing 1
2 O-ring 1
3 Plug (PF1/4) 1
4 O-ring 1
5 Plug (PF3/8) 1
(2)
a
b
a (1)
d (2)
c
d
(1) Outlet section

(2) Nut torque: 13.7 ~ 14.7 N·m (1.4 ~ 1.5 kgf·m) (10.1 ~ 10.8 ft·lbs)
IV-S-90

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-91
2) Disassemble of each C/V section

1. Control valve assy 2. Swing section
3. Dozer section 4. Swivel section
5. Combination section 6. Service section
IV-S-92
7. Arm section 8. Travel, RH section
9. Inlet section 10. Travel, LH section
11. Boom section 12. Bucket & outlet section
IV-S-93
• 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 4 mm, 6 mm, 8 mm
spanner One each 13 mm, 19 mm, 22 mm
Socket wrench One each 13 mm, 19 mm, 22 mm
Torque wrench 1 1.96 ~ 19.6 N·m (0.2 ~ 2.0 kgf·m) (1.45 ~ 14.5 ft·lbs)
Torque wrench 1 19.6 ~ 98.1 N·m (2.0 ~ 10 kgf·m) (14.5 ~ 72.3 ft·lbs)
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-94
• Disassembling of travel, dozer, service section

Travel, 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-95
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-96
• 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.
2. Removal of Plug (PF3/8)

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

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 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
edge of the spool and damaged by the edge.
Spool assembly
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-97

• 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.
5. 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-98
3) 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 at the time of assembly.
IV-S-99
4) 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 ~ 14.7 N·m (1.4 ~ 1.5 kgf·m) (10.1 ~ 10.8 ft·lbs)
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-100
• Dozer, and Service section Switching Valve

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 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) (18.1 ~ 21.7 ft·lbs)
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 ~ 6.86 N·m (0.6 ~ 0.7 kgf·m) (4.34 ~ 5.06 ft·lbs)
• M5 cross slot screws (6) tightening torque
1.96 ~ 2.94 N·m (0.2 ~ 0.3 kgf·m) (1.45 ~ 2.17 ft·lbs)
Check that the spool

turns lightly.
IV-S-102
• Arm, Boom and 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.


24.5 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) (18.1 ~ 21.7 ft·lbs)

O-ring used
9: O-ring 1BP11

part (1).
driver.
Temporary
securing

IV-S-103
3. 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) (28.9 ft·lbs)
O-ring used
17a: O-ring 1BP14
IV-S-104
• Left and Right Travel section
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 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) (18.1 ~ 21.7 ft·lbs)
O-ring used
7: O-ring 1BP11

part (1).
driver.
Temporary
securing

IV-S-105

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

5.88 ~ 6.86 N·m (0.6 ~ 0.7 kgf·m) (4.34 ~ 5.06 ft·lbs)
1.96 ~ 2.94 N·m (0.2 ~ 0.3 kgf·m) (1.45 ~ 2.17 ft·lbs)

turns lightly.
IV-S-106
• Swing section


24.5 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) (18.1 ~ 21.7 ft·lbs)

O-ring used
9: O-ring 1BP11

part (1).
driver.
Temporary
securing
spool will rotate lightly.
4: Backup ring T3P10A
IV-S-107

Check that the main part is the disassembled one and that the direction of the spool is the same.
the parts.

5.88 ~ 6.86 N·m (0.6 ~ 0.7 kgf·m) (4.34 ~ 5.06 ft·lbs)
1.96 ~ 2.94 N·m (0.2 ~ 0.3 kgf·m) (1.45 ~ 2.17 ft·lbs)

turns lightly.
4. Assembling Plug (PF3/8)

Mount the O-ring (13) to the plug (14).
Lightly screw the plug (14) into the main part (1) and tighten the plug with an 8-mm hexagon spanner.
• Plug (14) tightening torque

39.2 ~ 49.0 N·m (4.0 ~ 5.0 kgf·m) (28.9 ~ 36.2 ft·lbs)
O-ring used
13: O-ring 1BP14
IV-S-108
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) (28.9 ft·lbs)
Note:
Do not use the 8-mm hexagon
hole for removal.
IV-S-109
5) 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 does not need to be replaced unless one of the following occurs: The sliding part is dam-
aged 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-110
c. Pilot Valve
(1) Installation
(1)
(2) (3)
(5)
(6)
(4)
(1) Lever directions (4) Front

(2) PV right (5) Nut
(3) PV left 02052-60140

Left (RB101-6561Δ) ↓
Setup dimensions of operation See Left. Malpositioned
lever (Reference value) ↓
Control failure
Lever move-up position See Left. Malpositioned
Do not pull the hose by force. ↓
Kinky hose
↓
Damaged hose, oil leak
Tightening torque of lever lock For both sides Turning lever
nut (02052-60140) 39.0 ~ 43.0 N·m (4.0 ~ 4.4 kgf·m) (28.9 ~ 31.8 ft·lbs) ↓
Do not turn the hex PV nut. Control failure
Loose lever Within 2 mm Too loose
↓
Unspecified stroke
↓
Interference with nearby parts
Left (RB101-6561Δ) ↓
Right (RB101-6562Δ) Control failure
Fitting direction of grip lock nut Have the stepped (processed) side toward the grip. Wrong direction
(RC301-6524Δ) ↓
Tube not fixed properly
Tightening torque Poor tightness
25.0 ~ 27.0 N·m (2.5 ~ 2.8 kgf·m) (18.1 ~ 20.3 ft·lbs) ↓
Loose
↓
Control failure
Horn harness routing Pass the harness through the opening of the pilot valve. Contact
Install the vinyl tube (RB101-5339Δ) down into the opening of ↓
the lever. Apply tape to the other end. With the lever move- Cover peel-off
↓
ment in mind, give the harness length some allowance. Short-circuit
IV-S-111
(7) (8)
(9)
(10)
(7) Reference value

(8) Grip to face forward
(9) Lever to face inward
(10) Lever lock position
(11)
(11) Within 2 mm (0.08 in) out of position

(12) Plain washer
(12) (13) Nut
(14) Bellows
(15) Position the stepped side opposite to
the grip. Fit the bellows' rubber projec-
(13) tion tightly to the step.
(14)
(15)
(16)
(21)
(20)
(17)
(18) (16) Insert the protective tube down into the

opening.
(17) Tube (vinyl)
(22) (18) Apply tape to the end.
(19) Connector
(19) (20) Design value
(21) Nut
IV-S-112
(2) Component of pilot valve

Control lever, LH 010 Bracket, control lh
020 Trim
030 Cushion
040 Nut
050 Collar
060 Bush
070 Washer, plain
080 Pin, snap
090 Assy bracket, cont. lh
100 Bush
110 Bush
120 Bolt
130 Washer, plain
140 Spring
150 Switch, limit
160 Screw, csk-hd
170 Bolt
180 Assy valve, pilot lh
190 Bolt, hex-soc-hd
200 Washer, spring
210 Blank
220 Bracket, wristrest lh
230 Bolt
240 Wristrest
250 Nut
260 Washer, spring
Control lever, RH
010 Bracket, control rh
020 Assy valve, pilot rh
030 Bolt, hex-soc-hd
040 Washer, spring
050 Clamp
060 Clamp
070 Sponge, control rs
100 Bolt
110 Plate partition
120 Bracket, wristrest rh
130 Bolt
140 Wristrest
150 Nut
160 Washer, spring
IV-S-113
(3) Inner parts

Pilot valve assy
(1)
(1)
(2) (2)
(3)
(4)
(1) Seal, HS70

(2) O-ring, P-20, HS90
(3) Joint, 47.1 ± 2.9 N·m (4.8 ± 0.3 kgf·m) (34.7 ± 2.2 ft·lbs)
(4) Nut, 68.6 ± 4.9 N·m (7 ± 0.5 kgf·m) (50.6 ± 3.6 ft·lbs)
IV-S-114
(4)Function
The behavior of the pilot valve is discussed, referring to the hydraulic circuit diagram (Fig. 1) and behavior
explanations (Figs. 2 thru 4). Fig. 1 shows a typical pilot valve circuit.
(1) Pilot valve

(2) Pilot pump
(3) Main pump
(4) Control valve
(5) Hydraulic motor
(6) Hydraulic cylinder
Fig. 1 Pilot valve circuit

1. Handle at neutral position (See Fig. 2.)
The secondary pressure setting spring (241) that
determines the pilot valve output pressure is not work-
ing on the spool (201). The spool (201) is therefore
pushed up by the return spring (221) (spring seat
(216)). This makes for a passage through the output
216 ports (2, 4) and port T. Finally the output pressure
241 becomes the same as the tank pressure.
221 2. Handle tilted down (See Fig. 3.)
201 When the handle gets tilted down and the push rod
(212) moves through its stroke, the spool (201) (spring
Ports (2, 4)
seat (216)) shifts down to make for a passage through
Fig. 2 Handle at neutral position the port P and ports (2, 4). Now the oil being fed from
the pilot pump flows into the ports (2, 4), generating a
pressure.
3. Handle being held (See Fig. 4.)
When the pressure at ports (2, 4) has reached the
212 level that corresponds to the force of spring (241) with
the handle tilted down, the hydraulic pressure and the
spring force get balanced with each other. If the pres-
216
sure at ports (2, 4) rises above its setting, the ports (2,
4) come shut against the port P and open to the port T.
201
If the pressure at ports (2, 4) drops below its setting,
the ports (2, 4) come open to the port P and shut
Ports (2, 4) against the port T. In this way, the secondary pressure
Fig. 3 Handle tilted down is kept constant.
4. Behavior with the handle tilted more (different from
model to model)
On some models, if the handle is tilted deeper than a
certain angle, the spool's top end comes into the push
rod's internal bottom. The output pressure is thus
applied at the port P.
In the construction in which the push rod is equipped
internally with the spring seat and spring, a deeper tilt
241
of the handle brings the push rod's internal bottom in
(7) contact with the spring. Such spring force affects the
(7) Port T secondary pressure curve, which makes the push
(8) (8) Port P
rod's internal bottom and the spring seat's top end into
Ports (2, 4)
contact with each other. The output pressure is thus
Fig. 4 Handle being held applied at the port P.
(With secondary pressure above setting)
IV-S-115
Horn switch
Right P / V Left P / V
2 1
Yellow paint (Front side)
32 T 32 T
P 4 3 P
About 250 mm
(9.8 in.)
(9.8 in.)
About 250 mm
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 (68499-83741)
4. Quick coupler adaptor
• Filter is installed on P port of each side of pilot valve.
• Adaptor tightening torque:24.5 ~ 29.4 N·m
(G1/4) 2.5 ~ 3.0 kgf·m
18.1 ~21.7 ft·lbf
IV-S-116
Right pilot valves RB238-6172Δ

Location Hose tape color
1 Bucket crowded Peach
2 Boom down Light blue
3 Bucket dump Brown
4 Boom up Gray
P Port P White, 2 pcs.
T Port T
Left pilot valves RB238-6171Δ

Location Hose tape color
1 Swivel left Red
2 Arm dump Blue
3 Swivel right Yellow
4 Arm crowded Green
P Port P White
T Port T Yellow
No. Part No. Part Name Q’ty Remarks

1 RB238-6171Δ Valve assembly (pilot, L) 1
2 RB238-6172Δ Valve assembly (pilot, R) 1
3 68499-8374Δ Filter 2 Left/right pilot valves, Port P
4 RD411-6176Δ Pipe joint (S. G1/4-8.4) 12 Left/right pilot valves, all ports
04811-00110 O-ring 2 For 1/4, left/right pilot valves, Port P
IV-S-117
7
(4)
6 (7)
17
up down 5
Pa8 Pa5 Pa8' Pa3
Pa9 T (5)
A9 A8 A7 P1 A6 A5 A4 P3 A3 A2 A1
T3
B
(3)
(6) Pilot hose connection
B9 B8 B7 P2 B6 B5 B4 B3 B2 B1 A
T1 T2
2 1
4 P
Pb8' Pb3
(6)
Pb9 Pb8 Pp Pb5
P1
16 9
13 down up P3 P4
P2
15 3
IV-S-118
10
12
F F
2 2
T 3 T 3 EU-version
(1) Pilot valve LH
14 P 11 P (2) Pilot valve RH
1 1
(1) 4 4
(2) (3) Control valve
8 (4) Accumulator
(5) Unload valve
(6) Pump
(7) Hydraulic oil tank
Length
No. Connecting point Application Code No. Q’ty Tape color Hose type Remarks
mm (in.)
1 Pump (P4) ~ Accumulator P4 RA228-6324Δ 1 720 (28.3) G1/4 PF2104 G1/4
2 Accumulator ~ Unload valve (P) P4 RA228-6329Δ 1 460 (18.1) G1/4 PLT04 G1/4
3 Unload valve (B) ~ CV (Pp1) Travel lock RA221-6325Δ 1 1240 (48.8) Pink x 1 G1/4 PLT04 G1/4
4 Unload valve (A) ~ SJ (G) Hi - signal RA221-6447Δ 1 650 (25.6) White x 1 G1/4 PLT04 G1/4
5 PV (L,P) ~ Unload valve (B, M) PV (L, P) RA228-6326Δ 1 1610 (63.4) White x 1 Quick PLT04 G1/4
6 PV (R,P) ~ Unload valve (B, U) PV (R, P) RA228-6327Δ 1 400 (15.7) Red x 1 Quick PLT04 G1/4
(7) Pilot hose (Size 1/4)
7 PV (L,T) ~ Oil tank PV (L, drain) RA228-6338Δ 1 1140 (44.9) Yellow x1 Quick PLT04 G1/4
8 PV (R,T) ~ Oil tank PV (R, drain) RA228-6339Δ 1 485 (19.1) Quick PLT04 G1/4
9 PV (R,4) ~ CV (Pa8) Boom - up RA228-6341Δ 1 1500 (59.1) Gray x 2 Quick PLT04 G1/4
10 PV (R,2) ~ CV (Pb8’) Boom - down RA228-6342Δ 1 1460 (57.5) Light Blue x 2 Quick PLT04 G1/4
11 PV (R,3) ~ CV (Pa9) Bucket dump RA228-6345Δ 1 1510 (59.4) Brown x2 Quick PLT04 G1/4
12 PV (R,1) ~ CV (Pb9) Bucket crowd RA228-6346Δ 1 1340 (52.8) Pink x 2 Quick PLT04 G1/4
13 PV (L,2) ~ CV (Pb5) Arm dump RA228-6343Δ 1 930 (36.6) Blue x 2 Quick PLT04 G1/4
14 PV (L,4) ~ CV (Pa5) Arm crowd RA228-6344Δ 1 1270 (50.0) Green x 2 Quick PLT04 G1/4
15 PV (L,1) ~ CV (Pb3) Swivel, L RA228-6347Δ 1 990 (39.0) Red x 2 Quick PLT04 G1/4
IV-S-119
16 PV (L,3) ~ CV (Pa3) Swivel, R RA228-6348Δ 1 1170 (46.1) Yellow x 2 Quick PLT04 G1/4
17 CV (Pb8) ~ CV (Pb8’) Boom-down combined RA221-6351Δ 1 190 (7.48) G1/4 PF1704 G1/4
18 CV (Pa8) ~ CV (Pa8’) Boom-up combined RA221-6352Δ 1 410 (16.1) G1/4 PF1704 G1/4
1) Pilot hose LH
010 Hose, hydraulic

020 Hose, hydraulic
030 Hose, hydraulic
040 Hose, hydraulic
050 Hose, hydraulic
060 O-ring
070 Filter
080 Joint, pipe
090 O-ring
IV-S-120
2) Pilot hose RH
010 Hose, hydraulic

020 Hose, hydraulic
030 Hose, hydraulic
040 Hose, hydraulic
050 Hose, hydraulic
060 O-ring
070 Filter
080 Joint, pipe
090 O-ring
IV-S-121
3) Pilot hose (Pilot valve T port)
010 Flange, suction

020 Bolt
030 O-ring
040 Hose, suction
050 J-Clamp, hose
4) Pilot hose (Pump to Unload valve)
010 Joint, pipe

020 O-ring
030 Joint, pipe
040 O-ring
050 Joint, pipe
060 Joint, pipe
070 O-ring
080 O-ring
090 Plug
100 Hose, hydraulic
110 Hose, hydraulic
120 Hose, hydraulic
130 Hose, hydraulic
IV-S-122
5) Pilot hose (Unload valve to R /J and C / V)
010 Hose, hydraulic

020 Accumulator
030 Joint, pipe
040 Bolt
050 Joint, pipe
060 O-ring
070 Joint g
080 O-ring
090 Assy valve, check
100 Poppet
110 Spring
120 Retainer, spring
130 Cir clip, internal
140 Joint
150 Joint, elbow
010 Joint, elbow

020 O-ring
030 Joint, pipe
040 O-ring
050 Hose, hydraulic
060 Hose, hydraulic
070 Pipe, return
080 Bolt
090 Hose
100 Clamp, hose
110 Hose
120 Tube
130 Clamp, hose
140 Hose
150 Clamp, hose
160 Joint, pipe
170 Hose
180 Clip, pipe
IV-S-123
IV-S-124
010 Cooler, oil

020 Bolt
030 Hose
040 Hose
050 Tube
060 Clamp, hose
IV-S-125
(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-126
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 μ 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-127
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-128
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-129
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-130
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-131
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-132
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-
pressure spring (241) warped. Then slide this spring seat
sideways 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-133
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-134
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.
• Keep the kerosene clean enough. Otherwise 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-135
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-136
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
Tightening 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-137
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-138
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.
Photo 7-32
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-139
• 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 to photo 7-37
IV-S-140
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-141
5) Troubleshooting
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-142
d. Swivel Motor
(1) Component of swivel motor

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-143
(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 Plug 1 R1/8 30 Spring (2)
{6 X-ring 1 31 Plug (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 2 K 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-144
(3) Adaptor Installation

No. Part Code Part Name Q'ty Remarks
1 RB238-6128Δ Swivel motor assy 1
2 RA221-6192Δ Pipe-joint (S, G3/8-G1/4) 2 A
3 RB411-6376Δ Pipe-joint (L, G1/4-G1/4) 2 3/8 use A
4 RA221-6191Δ Pipe-joint (L, G3/8-G1/4) 1 B
5 RP201-6185Δ Pipe-joint (L, G3/8-14) 1 T
0481-00140 O-ring 1 T
6 01133-51440 Bolt 4 M14 x 1.5 7T
Front
C/V Rear (T1)
C/V Front (A3) C/V Rear (B3)
No. Part Code Part Name Q'ty Remarks

1 RB238-6128-0 Swivel motor assy 1 15 kg (33.0 lbs)
2 01133-51440 Bolt 4 M14 x 1.5P x 40L7T
7777772#
IV-S-145
010 Joint, pipe

020 O-ring
030 Joint, pipe
040 O-ring
050 Joint, pipe
060 O-ring
070 Hose, hydraulic
080 Hose, hydraulic
IV-S-146
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-147
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-148
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-149
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-150
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-151
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-152
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-153
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-154
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-155
4) Troubleshooting
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-156
e. Rotary Joint
(1) Installation
Swivel joint fitted in place (at swivel frame)

1 RA221-6232Δ Shaft (swivel joint) 1
2 RB401-6242Δ Ring (backup) 1
3 RB401-6236Δ Ring (D) 1
4 RA211-6243Δ Ring (backup) 1
5 RB401-6244Δ O-ring 1
6 RA211-6244Δ Collar 1
7 RB238-6231Δ Body (swivel joint) 4
8 RA111-6247Δ Plug (R1/8) 1
9 RA211-6245Δ Collar 4
10 04612-00480 Shaft circlip 1
11 04810-50600 O-ring 1
12 RA111-6247Δ Plug (R1/8) 4
13 RB238-2319Δ Base (swivel joint) 1
14 01133-61025 Bolt 2 M10 x 1.25

Fitting of swivel Tightening torque Loose
joint assembly of bolt ↓
and base 48.1 ~ 55.9 N·m Come-off
(swivel joint) (4.9 ~ 5.7 kgf·m) ↓
(RB238-2319Δ) (35.4 ~ 41.2 ft·lbs) Oil leak
Apply thread
adhesive (Loctite
271).
Fit as shown in Poor setup
the figure. ↓
Piping impos-
sible
Fitting of plug Tighten the plug Stretching
(R1/8) without stretching out of the end
out of the shaft ↓
end. Piping impos-
sible
Base (swivel joint) fitted in place on the track frame

(Cylinder for adjusting the track width)
IV-S-157
(2) Adaptors
No. Part Code Part Name Q’ty Item Points to remember
1 RA231-6230Δ Swivel joint assembly 1 M12 x 1.25 7T Fitting direc- Fit the adaptor Hose's contact with
A tion and angle as shown in the nearby parts
2 01133-61230 Bolt 4
of hydraulic figure. ↓
adaptor Rubbing, oil leak
3 68728-7615Δ Adaptor 1 B
4 RP301-6186Δ Pipe joint (L, G1/4-G1/4) 1 C
5 RA131-6192Δ Pipe joint (L, G1/4-G1/8) 1 G
Shaft side
6 RP421-6183Δ Pipe joint (L, G1/4-10) 1 D (1) (6) (7)

5 7
7 RP201-6181Δ Pipe joint (L, G3/8-G3/8) 4 E, F, H, I
8 RA131-6195Δ Pipe joint (L, G1/8-G1/4) 2 A, J (8)
(2) 6
7 F
04817-00110 O-ring 4 For 1/4 B, C, D, G
04817-00080 O-ring 2 For 1/8 A, J (3)
E D
(9)
7 G
J 8
H C
9 RP201-6181Δ Pipe joint (L, G3/8-G3/8) 4 e, f, h, i (4) A
7
10 RB411-6376Δ Pipe joint (L, G1/4-G1/4) 4 b, c, g
Body side
I B (10)
11 69254-7849Δ Pipe joint (L, G1/4-G1/4) 2 e, j (5)
8 (11)
12 RA221-6185Δ Pipe joint (L, G1/4-G1/4) 2 d (12)
(14) 4
04817-00110 O-ring 2 For 1/8 a, j (13)
3
(1) Travel bi-speed signal G A J
E
(2) Travel (right) top port I
(3) Travel (left) top port C
(4) Travel (left) bottom port 0°
B
(5) Track cylinder (rod) H
(6) Front (15) (18)
(7) Travel (right) top port 10 9
(8) Travel drain
(9) Track cylinder (bottom) (19)
(10) Parallel 12
(11) Parallel 22~24°
(12) Blade cylinder (bottom)
(13) Blade cylinder (rod) 51~53° 33~35°
(14) Position the adaptors for ports E, H and I upward. 41~43°
(15) Blade cylinder (bottom) (c) 25~27°
(16) Track cylinder (rod) (a) (16)
(17) Travel bi-speed signal (g) 11 19~21°
(21) (22)
(18) Travel (left) top port (i) (17) (20)
(19) Travel drain (d) 10 9
(20) Travel (left) bottom port (h) 6~8°
(21) Left
(22) Rear
(23) Travel (right) top port (f)
(24) Travel drain (d)
(25) Travel bi-speed signal (g) (23) (26)
9 D 10 F
(26) Blade cylinder (rod) (b) C
(27) Travel (right) bottom port (e)
(28) Track cylinder (bottom) (j) (24)
12
(29) Right
(30) Front
30~32°
41~43°
(27)
32~34° 9
10~12°
(28)
16~18° 11
(29) (30)
(25)
48~50° 10
IV-S-158
(3) Components of Rotary Joint
No. Part Name Q’ty No. Part Name Q’ty

010 Housing 1 090 Collar 1
020 Shaft 1 100 External circlip 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-159
(4) 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-160
No. Mounting position Part No. Reference Part Name Q’ty Dimension: mm (in.) Tape color on hose
5 R/J (l) ~ Travel M left A RB238-63911 Hydraulic hose (3/8) 1 790 (31.1)
6 R/J (h) ~ Travel M left B RB238-63911 Hydraulic hose (3/8) 1 790 (31.1)
7 R/J (f) ~ Travel M right B RB238-63911 Hydraulic hose (3/8) 1 790 (31.1)
8 R/J (e) ~ Travel M right A RB238-63911 Hydraulic hose (3/8) 1 790 (31.1)
9 R/J (g) ~ Travel M left PP RB238-63922 Hydraulic hose (1/4) 1 810 (31.9) White x 1
10 R/J (g) ~ Travel M right PP RB238-63922 Hydraulic hose (1/4) 1 810 (31.9) White x 1
11 R/J (d) ~ Travel M left DR RB238-63931 Hydraulic hose (1/4) 1 740 (29.1)
12 R/J (d) ~ Travel M right DR RB238-63931 Hydraulic hose (1/4) 1 740 (29.1)
13 R/J (b) ~ Intermediate joint RB238-64811 Hydraulic hose (1/4) 1 310 (12.2)
14 R/J (c) ~ Intermediate joint RB238-64831 Hydraulic hose (1/4) 1 310 (12.2)
15 Intermediate joint RB238-64821 Hydraulic hose (1/4) 310 (12.2)
~ Dozer cylinder rod
16 Intermediate joint RB238-64821 Hydraulic hose (1/4) 310 (12.2)
~ Dozer cylinder bottom
17 R/J (j) RB238-64851 Hydraulic hose (1/4) 950 (37.4)
~ Track cylinder bottom
18 R/J (a) RB238-64861 Hydraulic hose (1/4) 710 (28.0)
~ Track cylinder rod
IV-S-161
2) Hose connection to the rotary joint shaft
(1) Control valve (3) Hydraulic oil tank

(2) Change valve (4) Unload valve
IV-S-162
Part No. Dimension: Tape color

No. Connecting point Application Part Name Q’ty
Reference mm (in.) on hose
5 CV(A7) ~ RJ(I) Travel left forward RB238-64411 Hydraulic hose (3/8) 1 620 (24.4) Blue x 1
6 CV(B7) ~ RJ(H) Travel left backward RB238-64421 Hydraulic hose (3/8) 1 580 (15.4) Red x 1
7 CV(A6) ~ RJ(F) Travel right forward RB238-64431 Hydraulic hose (3/8) 1 390 (15.4) Green x 1
8 CV(B6) ~ RJ(E) Travel right backward RB238-64441 Hydraulic hose (3/8) 1 460 (18.1) Yellow x 1
9 Variable leg V A1 Dozer up (rod) RB238-64731 Hydraulic hose (1/4) 1 420 (16.5)
~ RJ (B)
10 Variable leg V A2 Dozer down (bottom) RB238-64741 Hydraulic hose (1/4) 1 560 (22.0)
~ RJ (C)
11 Variable leg V B2 Track extend (bottom) RB238-64752 Hydraulic hose (1/4) 1 570 (22.4) White x 1
~ RJ (J)
12 Variable leg V B1 Track retract (rod) RB238-64762 Hydraulic hose (1/4) 1 430 (16.9) White x 2
~ RJ (A)
13 RJ(D) ~ Oil tank Traveling drain RB238-63761 Hose (drain 3) 1 330 (13.0)
14 RJ(G) ~ Unload valve 2nd signal RB238-63271 Hydraulic hose (1/4) 1 350 (13.8)
High speed signal
IV-S-163
(5) Oil piping

Oil piping (Travel LH)
010 Joint, pipe
020 O-ring
030 Joint, pipe
040 O-ring
050 Adapter
060 O-ring
070 Joint, pipe
080 O-ring
090 Joint, pipe
100 O-ring
110 Joint, pipe
120 O-ring
130 Joint, pipe
140 O-ring
150 Joint, pipe
160 O-ring
170 Joint, pipe
180 O-ring
190 Hose, hydraulic
200 Hose, hydraulic
210 Hose, hydraulic
220 Hose, hydraulic
230 Hose, hydraulic
240 Hose, hydraulic
250 Hose, hydraulic
260 Band, cord
Oil piping (Travel RH)

010 Joint, pipe
020 O-ring
030 Joint, pipe
040 O-ring
050 Adapter
060 O-ring
070 Joint, pipe
080 O-ring
090 Joint, pipe
100 O-ring
110 Joint, pipe
120 O-ring
130 Joint, pipe
140 O-ring
150 Joint, pipe
160 O-ring
170 Hose, hydraulic
180 Hose, hydraulic
190 Hose, hydraulic
200 Hose, hydraulic
210 Hose, hydraulic
IV-S-164
Oil piping (Blade)

010 Adapter
020 O-ring
030 Cover
040 Bolt
050 Joint, pipe
060 O-ring
070 Adapter
080 Joint, pipe
085 O-ring
090 Hose, hydraulic
100 Hose, hydraulic
110 Hose, hydraulic
120 Hose, hydraulic
130 Hose, hydraulic
140 Hose, hydraulic
150 Hose, hydraulic
160 Hose, hydraulic
170 Joint, blade
180 Bolt
Oil piping (Track)

010 Joint, pipe
020 O-ring
030 Joint, pipe
040 O-ring
050 Hose, hydraulic
060 Hose, hydraulic
070 Hose, hydraulic
080 Hose, hydraulic
IV-S-165
(6) 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) beforehand.
2. Apply grease over the inner and outer surface of the D-ring (5), (11) beforehand.
3. Apply screw adhesive (Loctite 271) on the Bolt (14).
Tightening torque: 48.1 ~ 55.9 N·m
4.9 ~ 5.7 kgf·m
35.5 ~ 41.2 ft·lbf
IV-S-166
(7) 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 from 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-167
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-168
f. Travel Motor
(1) Component 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 Circlip, 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 Circlip, 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 Circlip, 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 Circlip, 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-169
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 1 set
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-170

Fitting direction of the track Place the frame with its port side facing forward. Hoses impossible to connect
frame
Travel motor tightening torque 60.8 ~ 70.6 N·m (6.2 ~ 7.2 kgf·m) Poor tightness
A Track frame Apply screw adhesive. (Loctite 271 or equivalent) ↓
Sprocket Bolt loose
↓
Come-off
Fitting of the adapters Port A Wrong part
Adapter (68561-3483Δ) ↓
Port B Hoses impossible to connect
Straight pipe joint (68311-6432Δ)
G3/8 Poor tightness
37.2 ~ 42.1 N·m (3.8 ~ 4.3 kgf·m) ↓
Port DR Looseness, oil leak, damage
Pipe joint (S, G1/4-G1/4) (RB238-6141Δ)
G1/4
24.5 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m)
Port PP
Pipe joint (S, G1/8-G1/4) (RB238-6149Δ)
G1/8
7.8 ~ 11.8 N·m (0.8 ~ 1.2 kgf·m)
Apply oil (New UDT, M80B or equivalent) to the O-rings. No oil on O-rings
↓
O-rings seized
↓
Oil leak
4 5 1
6 3
PP DR
7
A
9 8
B
11 10
2
Travel motor (LH)
No. Part Name Q’ty

1 Drive sprocket 2
2 Hex socket bolt 18
6 3 Motor assembly (wheel) 2
DR 4 Hex socket bolt 16
8 9 5 Spring washer 16
B
A 6 Pipe joint (S, G1/4-G1/4) 2
10 11 7 Pipe joint (S, G1/8-G1/4) 2
PP 8 Adapter 2
7 9 O-ring 2
10 Straight pipe joint 2
11 O-ring 2
Travel motor (RH)
IV-S-171
(3) Hose connection

Dozer Hoses indicated with thick lines are travel-related hose
S/J side Traveling motor, cylinder side

Left track Right track
a. Extend track (retracted) Cylinder, rod side
b. Dozer up Cylinder, rod side
c. Dozer down Cylinder, bottom side
d. Drain Left and right drain port
e. Right reverse travel Right A (lower side)
f. Right forward travel Right B (upper side)
g. 2nd speed pilot Left and right travel in 2nd speed
Extend track
h. Left reverse travel Left B (lower side)
i. Left forward travel Left A (upper side)
j. Extend track (retracted) Cylinder, bottom side
Mounting position Part Name Q’ty Dimension (mm) Tape color on hose
1 R/J (l) ~ Travel M left A Hydraulic hose (3/8) 1 880
R/J (n) ~ Travel M left B Hydraulic hose (3/8) 1 850 White x 1
R/J (f) ~ Travel M right B Hydraulic hose (3/8) 1 880
R/J (e) ~ Travel M right A Hydraulic hose (3/8) 1 850 White x 1
2 R/J (g) ~ Travel M left PP Hydraulic hose (1/4) 1 875 White x 1
R/J (g) ~ Travel M right PP Hydraulic hose (1/4) 1 875 White x 1
3 R/J (d) ~ Travel M left DR Hydraulic hose (1/4) 1 855
R/J (d) ~ Travel M right DR Hydraulic hose (1/4) 1 855
4 R/J (b) ~ Intermediate joint Hydraulic hose (1/4) 1 250
R/J (c) ~ Intermediate joint Hydraulic hose (1/4) 1 250
5 Intermediate joint ~ Dozer cylinder rod Hydraulic hose (1/4) 1 350
Intermediate joint ~ Dozer cylinder bottom Hydraulic hose (1/4) 1 350
6 R/J (j) ~ Track cylinder bottom Hydraulic hose (1/4) 1 895
7 R/J (a) ~ Track cylinder rod Hydraulic hose (1/4) 1 720
Hose routing (swivel joint to travel motor)
Machine's left side Machine's right side
3 3
1 1
1 1
2
2
IV-S-172
Procedure for Wheel Motor Hose Mounting (Recommended)

Motor (Left)
(1) (2) Recommended Procedure
1 All adapters
↓
(3) 2 Hose drain
(4) ↓
(5) 3 Hose travel A port
↓
PHV- 120- 37- 9- 8 158A

(6)
4 Hose travel B port
↓
5 Hose travel 2nd speed
(7)
(8)
(1) High-height adapter
(2) White
(3) Drain
(4) Travel 2nd speed
(5) Travel A port (forward)
(6) Travel B port (backward)
(7) White
(8) Low-height adapter
Motor (Right)
(1) Recommended Procedure
1 All adapters
↓
(2) 2 Hose drain
↓
(3) 3 Hose travel B port
↓
PHV- 120- 37- 9- 8 158A
(4)
4 Hose travel A port
↓
(5)
5 Travel 2nd speed adapter
↓
(6) 6 Hose travel 2nd speed
(7) (8)
(1) High-height adapter
(2) Drain
(3) Travel B port (forward)
(4) Travel A port (backward)
(5) Travel 2nd speed
(6) White
(7) White
(8) Low-height adapter
IV-S-173
(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 burrs.
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-174
• 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-175
5. Tighten the plugs each with an O-ring.

Tightening torque: 127 ~ 167 N·m
13 ~ 17 kgf·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-176
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-177
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.

• Apply grease between the oil seal lips.
• Insert the oil seal in the direction shown.
• Press-fit the parallel pin.
(1) Pin
(2) Oil seal
(3) Body 2
(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-178
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-179
20. Fit the assembly of piston and shoe to the shoe

holder to make the shoe holder assembly.
(1) Shoe holder
(2) Piston
21. Insert their pairs of the parallel pins in the cylin-

der barrel.
CAUTION
Be careful not to miss the pins in disassembling
and reassembling.
22. Fit the retainer holder to the cylinder barrel.

(1) Retainer holder
23. Join the shoe holder assembly and barrel

holder to make the cylinder barrel assembly.
CAUTION
Apply hydraulic oil into the seven holes of the
cylinder barrel.
IV-S-180
24. Fit the cylinder barrel assembly to the body 2

so that the shoe comes in contact with the
swash plate.
• Be careful not to let the piston fall out.
(1) Body 2
(2) Cylinder barrel assy
25. Fit the valve plate to the body 1.

1. Apply hydraulic oil over the sliding surface
(copper face) of the valve plate.
2. Preferably apply grease over the back (iron
face) of the valve plate. This helps keep the
plate in position.Mount the valve plate so
that the copper face of the valve plate will
be on the upper side (i.e., cylinder barrel
side).
(1) Body 1
(2) Valve plate
26. Tighten the hex socket bolts (7 locations).

Tightening torque of bolts (M8):
28.4 ~ 30.4 N·m
2.8 ~ 3.1 kgf·m
20.9 ~ 22.4 ft·lbf
Width across flats: 5 mm
In gripping the motor in a vise, apply aluminum
plates or the like around to protect the body.
IV-S-181
• Decelerator
1. Install the floating seal and O-ring to the

hydraulic motor.
CAUTION
Preferably apply grease to the O-ring for easier
fitness.
(1) Floating seal
(2) O-ring
2. Insert the seal ring, with the O-ring in place, to

the body.
CAUTION
• Apply grease to the O-ring
• Make sure the sealing face faces upward.
3. Fit the bearing inner ring and the steel balls

with retainer, in this order, to the hydraulic
motor. (1 set)
CAUTION
• Be careful not to confuse the directions of the
bearing inner ring and retainer. (See the sec-
tional view.)
• Be careful not to miss the steel balls because
they may come off the retainer.
(1) Steel balls with retainer

(2) Bearing inner ring
7777772#
IV-S-182
4. Insert the seal ring with the O-ring set into the
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
Insertion side Sealing side
5. Mount the hydraulic motor to the body.

CAUTION
Grip the decelerator flange and hydraulic motor
flange in a C clamp or hydraulic press.
6. Fit the steel balls with retainer and the bearing

inner ring, in this order, to the hydraulic motor.
CAUTION
Be careful not to confuse the directions of the
bearing inner ring and retainer. (See the sec-
tional view.)
(1) Bearing inner ring

(2) Steel balls with retainer
(1) (2)
IV-S-183
7. Secure the bearing with the snap rings.

CAUTION
Adjust the bearing preload with the thickness of
the snap rings.
8. Fit the rings, thrust washers, gears B1 and nee-

dles, in this order, to the pins B1 of the hydrau-
lic motor.
CAUTION
PHV-80
Ring: 3 pcs.
Thrust washer: 3 pcs.
Gear B1: 3 pcs.
Needle: 15 pcs./location
PHV-120
Ring: 4 pcs.
Thrust washer: 4 pcs.
Gear B1: 4 pcs.
Needle: 15 pcs./location
(1) Ring
(2) Thrust washer
(3) B1 gear
(4) Needle
Thrust plate side Washer side
9. Fit the thrust plate in position and apply the

snap rings to secure it.
CAUTION
• Make sure the thrust plate's convex side
faces upward.
• Quantities of snap rings
PHV-80: 3 pcs.
PHV-120: 4 pcs.
• The snap rings have the front and back. Fit
them with the edgy side facing upward
(toward the cover).
• Do not allow too-wide-opening snap rings
that may not function. Replace such rings
with new ones.
(1) Thrust plate
(2) Snap ring
IV-S-184
10. Insert S1 gear into carrier 2 and secure the S2

gear with the snap ring.
• The snap ring has two sides. Mount the snap
ring so that the edge will face upward (cover
side). Ԛ
• Do not widen the snap ring in excess, or oth- ԙ
erwise the tension will be lost when the snap
ring is mounted. If the tension is lost, replace Ԙ
7777772#
the snap ring with a new one.
(1) Carrier 2
(2) Gear S1
(3) Snap ring
Edge side
(3) 7777772#
(1)
(2)
11. Mount the three thrust washers, followed by the

three B2 gears, needle, and three thrust wash-
ers, to carrier 2 and secure them with the three Ԛ
snap rings.
• The snap ring has two sides. Mount the snap
ring so that the edge will face upward (cover Ԙ ԙ Ԙ ԛ
7777772#
side).
• Do not widen the snap ring in excess, or oth-
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.
Q’ty
(1) Thrust washer 6 7777772#
(2) Gear B2 3
(3) Needle 39
(4) Snap ring 3
Edge side
(2) (3) (1)
(4)
(1)
IV-S-185
12. Mount the carrier 2 assembly to the main com-

ponent.
13. Mount the O-ring to the main component.

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

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

• Pay attention not to damage the O-ring.
• Mount the cover so that the characters
"DRAIN" will be at the crane on the main
component.
(1) Cover (marked with "DRAIN")
(2) Cover crane
[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-186
16. 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 crane.)
[Disassembly]
The snap ring can be removed with ease if the
edge of the snap ring is moved to the crane of
the main component with a screwdriver and
hammer.
(1) Snap ring edge
17. 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-187
g. Cylinder
(1) Components and specifications
1) Boom cylinder: Kubota Seiki - made
010 Assy cylinder, boom 110 Ring, back up

020 Kit cylinder tube 120 O-ring (S-60, 1-A)
030 Bush (354545) 130 Bush
040 Kit piston-rod 140 Piston
050 Bush (354545) 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 (G-55, 1-B) 200 Nipple, grease
T.T.
(3)
(1) (2)
T.T.
IV-S-188
2) Arm cylinder: Kubota Seiki - made
010 Assy cylinder, arm 110 Ring, back up

030 Bush (304045) 130 Bush
070 Gasket 170 Nut, center lock
080 Ring, back up 180 Nipple, grease
090 Scraper
100 O-ring (G-55, 1-B)
T.T.
(20) (21)
(17)
(18) (19)
T.T.
[mm]
(2) Cylinder rod (7) Scraper (12) Piston (17) Stroke 269 335.5
+3
(3) Bushing (8) O-ring (13) Piston seal (18) Retracted L 529 0 589 ± 1.5
(4) Cylinder head (9) Backup-ring (14) Wear-ring (19) Extended L 802 -05 924.5 ± 2.5
(5) Packing (10) O-ring (15) Lock nut, M24 (20) 325 387.5
(16) grease nipple (21) 79 76.5
IV-S-189
3) Bucket cylinder: Kubota Seiki - made
010 Assy cylinder, bucket 110 Ring, back up

030 Bush (304045) 130 Bush
070 Gasket 170 Nut, center lock
090 Scraper
100 O-ring (G-55, 1-B)
T.T.
(20) (21)
(17)
(18) (19)
T.T.
[mm]
(2) Cylinder rod (7) Scraper (12) Piston (17) Stroke 269 335.5
+3
(3) Bushing (8) O-ring (13) Piston seal (18) Retracted L 529 0 589 ± 1.5
(4) Cylinder head (9) Backup-ring (14) Wear-ring (19) Extended L 802 -05 924.5 ± 2.5
(5) Packing (10) O-ring (15) Lock nut, M24 (20) 325 387.5
(16) grease nipple (21) 79 76.5
IV-S-190
4) Dozer cylinder: Kubota Seiki - made
010 Assy cylinder, blade 110 Ring, back up

030 Bush (304045) 130 Bush
070 Gasket 170 Nut, lock
090 Scraper
100 O-ring (G-55, 1-B)
(1) (2)
(3)
(4)
T.T.
T.T.
(1) Retracted L = 348 ± 1.5 (2) Extended L = 460 ± 2.5 (3) Stroke = 112 (4) or more
IV-S-191
5) Swing cylinder: Kubota Seiki - made
010 Assy cylinder, swing 110 Ring, back up

020 Kit cylinder tube 120 O-ring (S56, 1-A)
030 Bush (304035) 130 Bush
070 Gasket 170 Nut, lock
090 Scraper
100 O-ring (G-50, 1-A)
(1) (2) (3)
(1) Retracted L = 610 +30 (2) Extended L = 940 -05 (3) Stroke = 326
IV-S-192
6) Track cylinder: Kubota Seiki - made
010 Assy cylinder, track 110 Ring, back up

020 Kit cylinder tube 120
030 Bush 130 Piston
040 Kit piston-rod 140 Seal, piston
050 Bush 150 Circlip
060 Cylinder head 160 Nut, lock
070 Gasket
080 Ring, back up
090 Scraper
100 O-ring (P-50)
T.T.
(1) (2)
(3)
φ60
φ70
IV-S-193

1) Disassembling
1. Place the cylinder on a vise and place support.

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

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

cylinder head.
6 Pipe
7 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)
1 Plug screw
IV-S-194
7. Apply a wrench to the hex nut of the piston.

Loosen the nut.
Cylinder Spanner Screw Torque N·m (kgf·m)

Boom 41 mm M24 x 1.5 410.0 ~ 450.0 (42 ~ 46)
Arm 36 mm M24 x 1.5 510.0 ~ 550.0 (52 ~ 56)
Bucket 36 mm M24 x 1.5 510.0 ~ 550.0 (52 ~ 56)
Swing 32 mm M22 x 1.5 343.0 ~ 392.0 (35 ~ 40)
Dozer 32 mm M22 x 1.5 343.0 ~ 392.0 (35 ~ 40)
Track 32 mm M22 x 1.5 343.0 ~ 392.0 (35 ~ 40)
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 --- cousin)
1 Tube
2 Ball
3 Spring
4 Plug
IV-S-195
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, 0.002 in.
• Allowable value ... warp within 0.5 mm, 0.0197 in.
2. Clearance between piston rod and bushing

1. Measure the piston rod O.D. and cylinder head
bushing I.D. and determine the clearance.
Rod size Clearance
Reference φ25 to φ40 mm less than 0.25 mm

value φ45 to φ75 mm less than 0.30 mm
Allowable φ25 to φ40 mm 0.4 mm
limit φ45 to φ75 mm 0.5 mm
Reference φ0.9843 to 1.5748 in less than 0.010 in
value φ1.7717 to 2.9528 in less than 0.012 in
Allowable φ0.9843 to 1.5748 in 0.0158 in
limit φ1.7717 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. determine the clearance.
Rod size Clearance

less than φ60 mm 0.05 to 0.30 mm
Reference
φ65 to φ115 mm 0.05 to 0.35 mm
value
more than φ120 mm 0.05 to 0.40 mm
less than φ60 mm 0.60 mm
Allowable
φ65 to φ115 mm 0.70 mm
limit
more than φ120 mm 0.80 mm
φ2.3622 in less 0.0020 to 0.0118 in
Reference
φ2.5590 to 4.5276 in 0.0020 to 0.0138 in
value
φ4.7244 in more 0.0020 to 0.0157 in
φ0.9843 to 1.5748 in 0.0236 in
Allowable
φ1.7717 to 2.9528 in 0.0276 in
limit
φ4.7244 in more 0.0315 in
IV-S-196
h. Change Valve (Dozer, Track)

(1) Location and adaptor
1 Fitting the Pipe joint (S, G1/4-G1/4) (RA221-
adaptor 6195Δ) for B1 and B2 ports
Adaptor for A1 and A2 ports
(68728-7615Δ)
Pipe joint (S, G1/4-G1/4) (RA111-
6313Δ) for P1 and P2 ports
Apply oil (New UDT, M80B or
equivalent) to the O-ring.
G1/4
24.5 ~ 29.4 N·m
(2.5 ~ 3.0 kgf·m)
(18.1 ~ 21.7 ft·lbf)
2 Fitting the Hand-tighten the grip until it does
lever grip not turn any longer.
(10)
3 Fitting the 17.7 ~ 20.6 N·m
selector (1.8 ~ 2.1 kgf·m)
valve (13.0 ~ 15.2 ft·lbf)
Apply screw adhesive (Loctite
271 or equivalent).
No. Part Name Q’ty Remarks 4 5 6

1 Valve assem- 1
bly (selector) 1
A1 A2
2 Bolt 2 M8 7T P1 P2
3
3 Lever 1
(telescopic)
4 Nut 1 4T
5 Spring washer 1 14 12 C/V (B2) C/V (A2) 12 14 S/J (J) S/J (A)
14 11 11 14
6 Plain washer 1
7 Rod 1 9 8
(telescopic) 7
8 Plain washer 1 15
9 Snap pin 1
10 Gearshift lever 1 M8 (Resin)
grip
11 Adaptor 2 A1·A2 B1 B2
12 Pipe joint 2 P1·P2
(S, G1/4-G1/4) 10
13 Pipe joint 2 B1·B2 A1 A2
(S, G1/4-G1/4)
14 O-ring 4 1/4 B1,2 · P1, 2 P1 13 13
P2
15 Rod (telescopic) S/J (C) S/J (B)
To be connected in this position
B1 B2
IV-S-197
(2) Components of change valve (Dozer, Track)
1) Specifications
1. Hydraulic oil: ISO VG46 or equivalent
2. Oil temperature:
-20 ~ +100°C (in-tank oil temperature)
3. Pressure (main relief setting):
20.6 MPa (210 kgf/cm2) (at 9.5 L/min)
4. Flow rate: 9.5 L/min
2) Selectable connections
No. Location (connection)
P1 Control valve
P2 Control valve
A1 Dozer cylinder, rod side
A2 Dozer cylinder, bottom side
No. Part Name Q’ty Remarks B1 Telescopic cylinder, rod side
1 Valve assembly (selector) 1 B2 Telescopic cylinder, bottom side
2 O-ring 2 HN-B
3 Ring (backup) 2 Bias cut for P21
4 Spacer (1) 1 t3.2
5 Hex socket bolt 2 M8 x 1.25 x16
6 Spring washer 2 No. 2 for M8
7 Threaded plug 4 MT6 x 0.75
IV-S-198
i. Unload Valve
(1) Location and adaptor
1 Fitting the valve assembly Tightening torque
(unload) 17.7 ~ 20.6 N·m
(1.8 ~ 2.1 kgf·m)
(13.0 ~ 15.2 ft·lbf)
2 Orientation and angle of Position the adaptor as
hydraulic adaptor shown in the figure.
3 Fitting the hydraulic adaptor G1/4
24.5 ~ 29.4 N·m
(2.5 ~ 3.0 kgf·m)
(18.1 ~ 21.7 ft·lbf)
G3/8
37.2 ~ 42.1 N·m
(3.8 ~ 4.3 kgf·m)
(27.5 ~ 31.1 ft·lbf)
Apply oil (New UDT,
M80B or equivalent) to
the O-ring.

(EU-version)
1 Valve assembly (unload) 1
2 Straight pipe joint (drain) 1 T (9)
O-ring 1 For G3/8 P

3 Pipe joint (L, G1/4-G1/4) 1 B
4 Tee joint (F2) 1 B
5 Elbow joint with washer 1 B
O-ring 1 For G1/4 A 8
6 Pipe joint (L, G1/4-G1/4) 1 A
7 Pipe joint (L, F3/8-F1/4) 1 P
O-ring 1 For G1/4 A
8 Bolt 2 M10 x 1.5 7T
(10)
9 Hydraulic tank
10 Tank cover 2 (11)
11 PV·P (right) T
12 PV·P (left) 5
4
13 Unload
14 2-speed (12)
3
15 SJ·2-speed signal (G)
16 CV·Pb (13) B
17 Pipe joint (accumulator)
A
(14)
6
P
(17) (16)
1 7 (15)
IV-S-199
(PP-version)
No. Part Name Q’ty Remarks (9)
1 Valve assembly (unload) 1
2 Straight pipe joint (drain) 1 T
O-ring 1 For G3/8 P
3 Pipe joint (L, G1/4-G1/4) 1 B
4 Tee joint (F2) 1 B
5 Elbow joint with washer 1 B
O-ring 1 For G1/4 A
6 Pipe joint (L, G1/4-G1/4) 1 A
7 Straight pipe joint 1 P 8
O-ring 1 For G1/4 A
8 Bolt 2 M10 x 1.5 7T (10)
9 Hydraulic tank
10 Tank cover 2 (11)
11 PV·P (right) T
12 PV·P (left)
4
13 Unload
14 2-speed 5
15 SJ·2-speed signal (G)
(12)
16 Pump·P4
17 CV·Pb (13) B
A
3 (14)
(17)
1 7 6
(16)
(15)
IV-S-200
(2) Structure and specifications
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) Allowable voltage: DC 10.8 ~ 14.4V

(2) Current: 1.2 A at 20°C
Power consump-
(3) 14.4W
tion:
(4) Coil resistance: Approx. 10 Ω at 20°C
(5) Insulation: JIS C 4003 H
(6) Surge killer: Diode
Red
2
3.9 +20 MPa (40 +0.2
0 kgf/cm )
Relief valve set
(7) +28
569 0 psi
pressure:
at 6 l/min
Black
(8)
Cracking 3.4 MPa (35kgf/cm2) 498 psi
pressure: at 2 l/min
p → A, B
Valve pressure
(9)
loss: 0.5 MPa (5.1 kgf/cm2) 73 psi
or less at 6 l/min
A, B, G = G 1/4
(10) Port size: P, T = G 3/8
(JIS B2351 O-type)
(19)
IV-S-201
(3) 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-202
j. Accumulator
(1) Installation
(12)
(13)
(11)
(14)
4 5 8 6 7
10
3 2 1
No. Part Name Q’ty Remarks 1 Connecting the pipe Tightening torque
joint (accumulator) 48.1 ~ 55.9 N·m
1 Accumulator 1
(4.9 ~ 5.7 kgf·m)
2 Pipe joint (accumulator) 1 (35.4 ~ 41.2 ft·lbf)
3 Bolt 2 7T 2 Orientation and angle Position the adaptor as shown
of accumulator hydrau- in the figure.
lic adaptor
5 Straight pipe joint (G3) 1 3 Fitting the accumulator G1/4
6 Valve assembly (check) 1 hydraulic adaptor 24.5 ~ 29.4 N·m
Body (check) 1 (2.5 ~ 3.0 kgf·m)
(18.1 ~ 21.7 ft·lbf)
Poppet 1 G3/8
Spring 1 37.2 ~ 42.1 N·m
(3.8 ~ 4.3 kgf·m)
Spring retainer 1
(27.5 ~ 31.1 ft·lbf)
Circlip 1 Apply oil (New UDT, M80B or
7 Elbow joint 1 equivalent) to the O-ring.
8 Elbow joint (1) 1
9 Hydraulic hose (1/4) 1
10 Hydraulic hose (1/4) 1
11 Do not confuse the direction of the notch.
12 Pump assembly (piston)
13 Unload valve
14 Arch frame
IV-S-203
(2) Accumulator performance test

1) Raise the Boom, Arm and Bucket, approx. 1 ~ 2 m
(39.4 ~ 78.7 in.) above ground height.
2) With the safety lock lever in the operation position,

turn the main key to the STOP position to stop the
engine.
3) Once the engine has stopped, turn the main key to

the RUN position, stroke the boom pilot control to
the Up position, start to record the time duration
(using a stopwatch).
IV-S-204
4) After 3 minutes, ensure boom, arm and bucket can

be lowered to a safe position.
Specifications Discharge time

New machine 3 min
Service limit 1 min
IV-S-205
k. Oil Tank
(1) Installation
010 Oil tank 1 120 Rubber-fitted washer 1
020 Cover (tank, return) 1 130 Bolt 3 M10 x 25 L
030 Filter (return) 1 140 Tee joint (F2) 1
040 O-ring 1 G-120 Class 1, A 150 O-ring 1 P11 Class 1, A
050 Plug (oil filler) 1 160 Thermal insulator (oil tank) 1
060 O-ring 1 G30 Class 1, A 170 Sound absorber (oil tank, 2) 1
070 Bolt 6 M8 x 14L 180 Sound absorber (oil tank, 3) 1
080 Filter (suction) 1 190 Sound absorber (oil tank, 4) 1
090 Gauge (oil level) 1 200 Sound absorber (oil tank, 5) 1
100 O-ring 1 P-25 Class 1, A 210 Sound absorber (oil tank, 6) 1
110 Plug 1 220 Sound absorber (oil tank, 7) 1
(2) Filter element

(Return filter) (Suction filter)
Nominal 10 μ Nominal 105 mesh

Percolation area: 3600cm2 Percolation area: 650 cm2
IV-S-206
l. Third Line
010 Hose, hydraulic
020 Aassy valve
030 Bolt
040 Plate
050 Bolt
060 Hose
070 Clamp, hose
010 Hose, hydraulic

020 Hose, hydraulic
030 Joint, pipe
040 Bracket, sp
050 Bolt
060 Plug
IV-S-207
(8) (9)
(10)

1 Hydraulic hose (1/2, third line) 1
2 Valve assembly (third line) 1
3 Bolt (M5-45) 2
4 Plate (third line) 1
5 Bolt 2 7T
6 Hose (5/8, third line) 1
7 Hose clamp (19-28) 2
8 A (hose angle)
9 Lever position when delivered
IV-S-208
m.TPSS Valve (PP-version Only)

(1) Dismounting and remounting
1. Location of TPSS valve
Lever position and control pattern
Lever outer ward → A pattern

(Upper photo) (John Deer pattern)
Lever in ward → B pattern

(Lower photo) (Kubota pattern)
2. Hose connection and fittings
TPSS port connection

A pattern (J. D. pattern)
P/V right side 2 1 B C/V Pb5 Arm dump
P/V left side 2 2 A C/V Pb8 Boom up
P/V right side 4 3 D C/V Pa8 Boom down
P/V left side 4 4 C C/V Pa5 Arm crowd
B pattern (Kubota pattern)

P/V right side 2 1 A C/V Pb8 Boom up
P/V left side 2 2 B C/V Pb5 Arm dump
P/V right side 4 3 C C/V Pa8 Boom down
P/V left side 4 4 D C/V Pa5 Arm crowd
IV-S-209
(9)
(8)
(2)
(4) (7)
(1)
(5)
(3)
(6)
(10)
(1) Gray · TPSS · 3 ~ PV · R4

(2) Gray · TPSS · C ~ CV · Pa8
(3) Light blue · TPSS · 1 ~ PV · R2
(4) Light blue · TPSS · A ~ CV · Pb8
(5) Blue · TPSS · 2 ~ PV · L2
(6) Blue · TPSS · B ~ CV · Pb5
(7) Green · TPSS · 4 ~ PV · L4
(8) Green · TPSS · D ~ CV · Pa5
(9) Ensure enough clearance here and clamp up.
(10)Pass below the TPSS valve. (PV · CV: red, yellow)
(1) ~ (8) Hydraulic hose (1/4”)
IV-S-210
3. Disconnect 4 hoses.
4. Disconnect 4 quick coupler hoses.

1) Push the hose.
2) Then pull out the hose with holding the black

socket.
3) View after disconnecting the quick coupler.
IV-S-211
5. Remove the mounting bolts.
6. Outer view of the TPSS valve.

Front view Rear view
(4)(5)(6)(7) (2) (8)
(1) Valve assy 1
(2) Lever (1, TPSS) 1
(3) Nut 1 M10 4T
(4) Lever (2, TPSS) 1
(3) (5) Pin 1
B (6) Washer 1
A (1) (7) Snap pin 6
(8) Lever grip 1
(9) Bracket (TPSS) 1
(10) Bolt 3 M10 7T
(11) Bolt 2 M10 7T
(12) Pipe joint (L, G1/4-G1/4) 2 1, 3 Port
(13) Adapter 1 2 Port
(18)
(14) Pipe joint (L, G1/4-G1/4) 1 4 Port
(15) Pipe joint (S, G1/4-G1/4) 1 B Port
(9)(10)(11) (16) Pipe joint (QL, G1/4-8.4) 2 A, B Port
Pilot valve side (17) Pipe joint (S, G1/4-G8.4) 2 C, D Port
Control valve side
(18) Machine front 3 M10 7T
(19) Blue · 2 M10 7T
(15)(16)(19) (14)(21)
(20)
(12)(22) (13)(23) TPSS · B ~ CV · Pb5
(20) Gray · 2 1, 3 Port
TPSS · C ~ CV · Pa8
(21) Green · 1 2 Port
TPSS · 4 ~ PV · L4
3 (22) Gray · 1 4 Port
B C 2 TPSS · 3 ~ PV · R4
(23) Blue · 3 M10 7T
TPSS · 2 ~ PV · L2
A D
4 (24) Light blue · 2 M10 7T
TPSS · A ~ CV · Pb5
1
(25) Green · 2 1, 3 Port
TPSS · D ~ CV · Pa8
(26) Light blue · 1 2 Port
(17)(25) (12)(26) TPSS · 1 ~ PV · R2
(16)(24)
IV-S-212
(2) Disassembly and reassembly

1. Set the TPSS valve in the vise.
2. Loosen the mounting bolt.

(When reassembly)
Socket head bolt: 12 mm
Tightening torque:
Apply screw lock agent.
3. Port position
Port 3 should be top, aleigning to the name plate.
4. Take out the cover roller.
IV-S-213
5. Take out the center roller.
6. Take out the center spacer.
(1) (2) 7. When reassembly:
1) Check the O-ring.

2) Align the pin and hold as shown in the photo.
3) Pin position
Upper picture shows A pattern (John Deen pattern)
Lower picture shows B pattern (Kubota pattern)
(1) Pin hole (2) Align pin

(1) (2)
(1) Pin hole (2) Alignment pin
IV-S-214
n. Hydraulic Hose

(1) List of high-pressure hoses (front)
No. Connecting point Application Part No. Part Name Q’ty Length Tape color Hose type Remarks
(mm)
1 Control valve (A8) ~ Boom cylinder (rod) Boom up (rod) RA221-64113 Hydraulic hose (1/4) 1 3290 G1/4 PF2104 G1/4
2 Control valve (B8) ~ Boom cylinder (bottom) Boom down (bottom) RA221-64123 Hydraulic hose (1/4) 1 3080 Yellow x 2 G1/4 PF2104 G1/4
3 Control valve (A5) ~ Arm cylinder (bottom) Arm crowded (bottom) RA221-64213 Hydraulic hose (1/4) 1 2860 Blue x 2 G1/4 PF2104 G1/4
4 Control valve (B5) ~ Arm cylinder (rod) Arm dump (rod) RA221-64224 Hydraulic hose (1/4) 1 3020 Green x 2 G1/4 PF2104 G1/4
Bucket crowded (bot-
5 Control valve (B9) ~ Bucket cylinder (bottom) tom) RA228-64311 Hydraulic hose (1/4) 1 3860 White x 2 G1/4 PF2104 G1/4
6 Control valve (A9) ~ Bucket cylinder (rod) Bucket dump (rod) RA228-64321 Hydraulic hose (1/4) 1 4060 Red x 2 G1/4 PF2104 G1/4
SP (left step-down for SP type
7 Control valve (B8) ~ Arm left high pressure) RA228-92411 Hydraulic hose (3/8) 1 3360 White x 1 G3/8 PF2106 G3/8 machine only
SP (right step-down SP type
8 Control valve (A8) ~ Arm right for high pressure) RA228-92421 Hydraulic hose (3/8) 1 3440 Black x 1 G3/8 PF2106 G3/8 machine only
(2) List of high-pressure hoses (lower structure)

IV-S-215
Length
No. Connecting point Application Part No. Part Name Q’ty Tape color Hose type Remarks
(mm)
1 Swivel joint (i) ~ Travel motor left A Travel left forward RA231-64451 Hydraulic hose (3/8) 1 880 G3/8 PF2106 G3/8
2 Swivel joint (h) ~ Travel motor left B Travel left backward RA231-64441 Hydraulic hose (3/8) 1 850 White x 1 G3/8 PF2106 G3/8
3 Swivel joint (f) ~ Travel motor right B Travel right forward RA231-64451 Hydraulic hose (3/8) 1 880 G3/8 PF2106 G3/8
4 Swivel joint (e) ~ Travel motor right A Travel right backward RA231-64441 Hydraulic hose (3/8) 1 850 White x 1 G3/8 PF2106 G3/8
5 Swivel joint (g) ~ Travel motor left PP Travel left dual-speed RA231-64461 Hydraulic hose (1/4) 1 780 White x 1 G1/4 PLT04 G1/4
signal
Travel right dual-
6 Swivel joint (g) ~ Travel motor right PP RA231-64461 Hydraulic hose (1/4) 1 780 White x 1 G1/4 PLT04 G1/4
speed signal
7 Swivel joint (d) ~ Travel motor left T1 Travel drain left RA231-64391 Hydraulic hose (1/4) 1 715 G1/4 PLT04 G1/4
8 Swivel joint (d) ~ Travel motor right T2 Travel drain right RA231-64391 Hydraulic hose (1/4) 1 715 G1/4 PLT04 G1/4
9 Swivel joint (b) ~ Relay Dozer up RB238-64811 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4
10 Swivel joint (c) ~ Relay Dozer down RB238-64831 Hydraulic hose (1/4) 1 310 G1/4 PF2106 G1/4

11 Relay ~ Dozer cylinder rod Dozer up RA228-64821 Hydraulic hose (1/4) 1 350 G1/4 PF2106 G1/4
12 Relay ~ Dozer cylinder bottom Dozer down RA228-64821 Hydraulic hose (1/4) 1 350 G1/4 PF2106 G1/4
13 Swivel joint (a) ~ Track cylinder rod Track narrowed RA221-64491 Hydraulic hose (1/4) 1 660 G1/4 PF1704 G1/4
14 Swivel joint (j) ~ Track cylinder bottom Track widened RA221-64481 Hydraulic hose (1/4) 1 930 G1/4 PF1704 G1/4
(3) List of high-pressure hoses (upper structure)

Length
No. Connecting point Application Part No. Part Name Q’ty (mm) Tape color Hose type Remarks
1 Pump (P1) ~ Control valve (P1) P1 RA221-63211 Hydraulic hose (3/8) 1 1155 White x 1 G3/8 PF2106 G3/8
2 Pump (P2) ~ Control valve (P2) P2 RA231-63221 Hydraulic hose (3/8) 1 1100 Red x 1 G3/8 PF2106 G3/8
3 Pump (P3) ~ Control valve (P3) P3 RA231-63231 Hydraulic hose (3/8) 1 1105 Pink x 1 G3/8 PF2106 G3/8
4 Control valve (A7) ~ Swivel joint (I) Travel left backward RA221-64411 Hydraulic hose (3/8) 1 560 Yellow x 1 G3/8 PF2106 G3/8
5 Control valve (B7) ~ Swivel joint (H) Travel left forward RA221-64421 Hydraulic hose (3/8) 1 450 Green x 1 G3/8 PF2106 G3/8
6 Control valve (A6) ~ Swivel joint (F) Travel right backward RA221-64431 Hydraulic hose (3/8) 1 400 Blue x 1 G3/8 PF2106 G3/8
7 Control valve (B6) ~ Swivel joint (E) Travel right forward RA221-64441 Hydraulic hose (3/8) 1 335 Red x 1 G3/8 PF2106 G3/8
8 Control valve (B3) ~ Swivel motor (B) Swivel left RA221-64511 Hydraulic hose (1/4) 1 410 Gray x 1 G1/4 PF1704 G1/4
9 Control valve (A3) ~ Swivel motor (A) Swivel right RA221-64521 Hydraulic hose (1/4) 1 410 Light blue x 1 G1/4 PF1704 G1/4
10 Control valve (A1) ~ Swing cylinder (bottom) Swing left RA221-64611 Hydraulic hose (1/4) 1 820 Yellow x 1 G1/4 PF2104 G1/4
11 Control valve (B1) ~ Swing cylinder (rod) Swing right RA221-64621 Hydraulic hose (1/4) 1 950 Orange x 1 G1/4 PF2104 G1/4
Control valve (B2) ~ Variable track width valve
12 P1 CV dozer up RB238-64811 Hydraulic hose (1/4) 1 515 G1/4 PF2104 G1/4
13 Control valve (A2) ~ Variable track width valve CV dozer down RB238-64821 Hydraulic hose (1/4) 1 540 G1/4 PF2104 G1/4
P2
IV-S-216
Track widened (bot-

14 Variable track width valve A1~Swivel joint (J) RB238-64831 Hydraulic hose (1/4) 1 290 White x 1 G1/4 PF1704 G1/4
tom)
15 Variable track width valve A2~Swivel joint (A) Track narrowed (rod) RB238-64841 Hydraulic hose (1/4) 1 360 White x 2 G1/4 PF1704 G1/4
16 Variable track width valve B2~Swivel joint (B) Dozer up (rod) RB238-64851 Hydraulic hose (1/4) 1 330 G1/4 PF2104 G1/4
17 Variable track width valve B1~Swivel joint (C) Dozer down (bottom) RB238-64861 Hydraulic hose (1/4) 1 250 G1/4 PF2104 G1/4

(4) List of high-pressure hoses (pilot)

EU-version
Length
(mm)
1 Pump (P4) ~ Accumulator P4 RA238-6324Δ Hydraulic hose (3/8) 1 720 G3/8 PF2106 G3/8
2 Accumulator ~ Unload valve (P) P4 RC461-6356Δ Hydraulic hose (1/4) 1 370 G1/4 PLT04 G1/4
3 Unload valve (B) ~ Control valve (Pp1) Travel lock RA221-6325Δ Hydraulic hose (1/4) 1 1240 Pink x 1 G1/4 PLT04 G1/4
4 Unload valve (A) ~ Swivel joint (G) Dual-speed signal RA221-6447Δ Hydraulic hose (1/4) 1 650 White x 1 G1/4 PLT04 G1/4
5 Pilot valve (left P) ~ Unload valve (B, center) PV (left P) RA228-6326Δ Hydraulic hose (1/4) 1 1610 White x 1 Quick PLT04 G1/4
6 Pilot valve (right P) ~ Unload valve (B, top) PV (right P) RA228-6327Δ Hydraulic hose (1/4) 1 400 Red x 1 Quick PLT04 G1/4
7 Pilot valve (left T) ~ Oil tank PV left drain RA228-6338Δ Hydraulic hose (1/4) 1 1140 Yellow x 1 Quick PLT04 G1/4
8 Pilot valve (right T) ~ Oil tank PV right drain RA228-6339Δ Hydraulic hose (1/4) 1 485 Quick PLT04 G1/4
9 Pilot valve (right 4) ~ Control valve (Pa8) Boom up RA228-6341Δ Hydraulic hose (1/4) 1 1500 Gray x 2 Quick PLT04 G1/4
10 Pilot valve (right 2) ~ Control valve (Pb8') Boom down RA228-6342Δ Hydraulic hose (1/4) 1 1460 Light blue x 2 Quick PLT04 G1/4
11 Pilot valve (right 3) ~ Control valve (Pa9) Bucket dump RA228-6345Δ Hydraulic hose (1/4) 1 1510 Brown x 2 Quick PLT04 G1/4
12 Pilot valve (right 1) ~ Control valve (Pb9) Bucket crowded RA228-6346Δ Hydraulic hose (1/4) 1 1340 Pink x 2 Quick PLT04 G1/4
13 Pilot valve (left 2) ~ Control valve (Pb5) Arm dump RA228-6343Δ Hydraulic hose (1/4) 1 930 Blue x 2 Quick PLT04 G1/4
IV-S-217
14 Pilot valve (left 4) ~ Control valve (Pa5) Arm crowded RA228-6344Δ Hydraulic hose (1/4) 1 1270 Green x 2 Quick PLT04 G1/4
15 Pilot valve (left 1) ~ Control valve (Pb3) Swivel left RA228-6347Δ Hydraulic hose (1/4) 1 990 Red x 2 Quick PLT04 G1/4
16 Pilot valve (left 3) ~ Control valve (Pa3) Swivel right RA228-6348Δ Hydraulic hose (1/4) 1 1170 Yellow x 2 Quick PLT04 G1/4
Boom down/conflu-
17 Control valve (Pb8) ~ Control valve (Pb8') ence RA221-6351Δ Hydraulic hose (1/4) 1 190 G1/4 PLT04 G1/4
18 Control valve (Pa8) ~ Control valve (Pa8') Boom up/confluence RA221-6352Δ Hydraulic hose (1/4) 1 410 G1/4 PLT04 G1/4

(5) List of high-pressure hoses (pilot)

PP-version
Length
(mm)
1 Pump (P4) ~ Unload valve (P) P4 RA231-6324Δ Hydraulic hose (3/8) 1 345 G3/8 PF1706 G3/8
2 Unload valve (B) ~ Control valve (Pp1) Travel lock RA221-6325Δ Hydraulic hose (1/4) 1 1240 Pink x 1 G1/4 PLT04 G1/4
3 Unload valve (A) ~ Swivel joint (G) Dual-speed signal RA221-6447Δ Hydraulic hose (1/4) 1 650 White x 1 G1/4 PLT04 G1/4
4 Pilot valve (left P) ~ Unload valve (B, center) PV (left P) RA228-6326Δ Hydraulic hose (1/4) 1 1610 White x 1 Quick PLT04 G1/4
5 Pilot valve (right P) ~ Unload valve (B, top) PV (right P) RA228-6327Δ Hydraulic hose (1/4) 1 400 Red x 1 Quick PLT04 G1/4
6 Pilot valve (left T) ~ Oil tank PV left drain RA228-6338Δ Hydraulic hose (1/4) 1 1140 Yellow x 1 Quick PLT04 G1/4
7 Pilot valve (right T) ~ Oil tank PV right drain RA228-6339Δ Hydraulic hose (1/4) 1 485 Quick PLT04 G1/4
8 Pilot valve (right 4) ~ TPSS (3) Boom up RA228-6361Δ Hydraulic hose (1/4) 1 1045 Gray x 2 Quick PLT04 G1/4
9 TPSS (C) ~ Control valve (Pa8) Boom up RA228-6362Δ Hydraulic hose (1/4) 1 370 Gray x 2 Quick PLT04 G1/4
10 Pilot valve (right 2) ~ TPSS (1) Boom down RA228-6363Δ Hydraulic hose (1/4) 1 1065 Light blue x 2 Quick PLT04 G1/4
11 TPSS (A) ~ Control valve (Pb8) Boom down RA228-6364Δ Hydraulic hose (1/4) 1 370 Light blue x 2 Quick PLT04 G1/4
12 Pilot valve (right 1) ~ Control valve (Pb9) Bucket crowded RA221-6346Δ Hydraulic hose (1/4) 1 1280 Pink x 2 Quick PLT04 G1/4
13 Pilot valve (right 3) ~ Control valve (Pa9) Bucket dump RA221-6345Δ Hydraulic hose (1/4) 1 1430 Brown x 2 Quick PLT04 G1/4
IV-S-218
14 Pilot valve (left 1) ~ Control valve (Pb3) Swivel left RA228-6365Δ Hydraulic hose (1/4) 1 1040 Red x 2 Quick PLT04 G1/4
15 Pilot valve (left 3) ~ Control valve (Pa3) Swivel right RA228-6366Δ Hydraulic hose (1/4) 1 1230 Yellow x 2 Quick PLT04 G1/4
16 Plot valve (left 2) ~ TPSS (2) Arm dump RA228-6367Δ Hydraulic hose (1/4) 1 605 Blue x 2 Quick PLT04 G1/4
17 TPSS (B) ~ Control valve (Pb5) Arm dump RA228-6368Δ Hydraulic hose (1/4) 1 215 Blue x 2 Quick PLT04 G1/4
18 Plot valve (left 4) ~ TPSS (4) Arm crowded RA228-6369Δ Hydraulic hose (1/4) 1 605 Green x 2 Quick PLT04 G1/4
19 TPSS (D) ~ Control valve (Pa5) Arm crowded RA228-6371Δ Hydraulic hose (1/4) 1 530 Green x 2 Quick PLT04 G1/4
Boom down/conflu-
20 Control valve (Pb8) ~ Control valve (Pb8') ence RA221-6351Δ Hydraulic hose (1/4) 1 190 G1/4 PLT04 G1/4
21 Control valve (Pa8) ~ Control valve (Pa8’) Boom up/confluence RA221-6352Δ Hydraulic hose (1/4) 1 410 G1/4 PLT04 G1/4

(6) List of suction hoses

Dimension (mm) Hose clamp used Remarks
No. Connecting point Application Part No. Part Name Q’ty
Inner Outer
Length diameter diameter Part No. Part Name
1 Hydraulic tank ~ Pump Suction RA231-63111 Hose (suction) 1 165 32 44 Formed hose
(7) List of low-pressure hoses

Dimension (mm) Hose clamp used Remarks
No. Connecting point Application Part No. Part Name Q’ty
Inner Outer
Length diameter diameter Part No. Part Name
1 Return pipe ~ Oil cooler front Oil cooler OUT RA231-63771 Hose (1/2) 1 280 13 19.8 DKE08
2 Control valve (T3) ~ Oil cooler back Oil cooler IN RA231-63781 Hose (1/2) 1 1070 13 19.8 DKE08
3 Control valve (T2) ~ Return pipe Oil cooler bypass RA221-63731 Hose (1/2) 1 350 13 19.8 DKE08
4 Return pipe ~ Oil tank Return RA221-63711 Hose (3/4) 1 1050 19.3 27.7 DKE12
5 Swivel motor (T) ~ Control valve (T1) Swivel motor drain RA221-63751 Hose (1/2) 1 220 13 19.8 DKE08
6 Unload valve (T) ~ Oil tank Unload valve return RA221-63731 Hose (1/2) 1 350 13 19.8 DKE08
IV-S-219
7 Swivel joint (D) ~ Oil tank Travel drain RA221-63761 Hose (3/8) 1 370 9.7 15.9 DKE06

(8) Hydraulic hose circuit <delivery, travel, swivel. blade, swing (S/J)>

13
9 (20) (21)
16
Pa8 Pa5 Pa8 ' Pa3
A1 A2
Pa9
12 P1
P2
A7 A6 A3 A2 A1
P1 P3
A9 A8 A5 A4 8 B1 B2
T3
(18) A B
17
B7
B9 B8 B4 T2
11
T1
Œã
?i P2 B6 B5 B3 B2 B1
Pb8 ' Pb3
Pb9 Pb8 Pp Pb5
T
(19)
IV-S-220
15
Upper-structure hoses 14 10
No. Location Part No. Q’ty
1 Pump (P1) ~ Control valve (P1) White P1 RA221-63211 1
7
2 Pump (P2) ~ Control valve (P2) Red P2 RA231-63221 1
3 Pump (P3) ~ Control valve (P3) Pink P3 RA231-63231 1 1
4 Control valve (A7)~ Swivel joint (I) Yellow Travel left forward RA221-64411 1 3
6 2
5 Control valve (B7)~ Swivel joint (H) Green Travel left backward RA221-64421 1
6 Control valve (A6)~ Swivel joint (F) Blue Travel right forward RA221-64431 1 F (22)
7 Control valve (B6)~ Swivel joint (E) Red Travel right backward RA221-64441 1 4
D P1
8 Control valve (B3)~ Swivel motor (B) Gray Swivel left RA221-64511 1
9 Control valve (A3)~ Swivel motor (A) Light blue Swivel right RA221-64522 1 P3
5 E
10 Control valve (A1)~ Swing cylinder (bottom) Yellow Swing left RA221-64611 1
11 Control valve (B1)~ Swing cylinder (rod) Orange Swing right RA221-64621 1 H G
12 Control valve (B2)~ Selector valve (P1) Pink CV dozer up RA221-64812 1 C
13 Control valve (A2)~ Selector valve (P2) CV dozer down RA221-64821 1 J

14 Swivel joint (B) ~ Selector valve (B2) Dozer up (rod) RA221-64851 1 P2
15 Swivel joint (C) ~ Selector valve (B1) Dozer down (bottom) RA221-64861 1 I A
B
16 Swivel joint (J) ~ Selector valve (A1) Track wide (bottom) RA221-64832 1
17 Swivel joint (A) ~ Selector valve (A2) Track narrow (rod) RA221-64842 1
S/J
(18) Control valve

(19) Swivel motor
(20) Selector valve
(21) Swing cylinder
(22) Pump
(9) Pilot hose circuit

7 (25)
6 (23)
17
(18) (19) 5
Pa8 Pa5 Pa8 ' Pa3
Pa9 T (24)
A9 A8 A7 P1 A6 A5 A4 P3 A3 A2 A1
T3
(20) B
B9 B8 B7 P2 B6 B5 B4 B3 B2 B1 A
T1 T2
2 1
4 P
Pb8 ' Pb3
(26)
Pb9 Pb8 Pp Pb5 P1
16 9 P3
IV-S-221
13 P4
(21) (22)
15 3 P2
10
Pilot hose
12 No. Location Part No. Q’ty
(29) (28)
1 Pump (P4) ~ Accumulator P4 RA238-6324Δ 1
2 2 2 Accumulator ~ Unload valve (P) P4 RC461-6356Δ 1
T 3 T 3 3 Unload valve (B) ~ Control valve (Pp1) Pink Travel lock RA221-6325Δ 1
4 Pilot valve (left P) ~ Unload valve (B, center)White PV (left P) RA228-6326Δ 1
14 P 11 P 5 Pilot valve (right P)~Unload valve (B, top) Red PV (right P) RA228-6327Δ 1
1 1 6 Pilot valve (left T) ~ Oil tank Yellow PV left drain RA228-6338Δ 1
(30) 4 4 (27) 7 Pilot valve (right T)~Oil tank PV right drain RA228-6339Δ 1
8 8 Pilot valve (right 4)~Control valve (Pa8) Gray Boom up RA228-6341Δ 1

(18) Top 9 Pilot valve (right 2)~Control valve (Pb8') Light blue Boom down RA228-6342Δ 1
(19) Bottom
(20) Control valve 10 Pilot valve (right 3)~Control valve (Pa9) Brown Bucket dump RA228-6345Δ 1
(21) Bottom 11 Pilot valve (right 1)~Control valve (Pb9) Pink Bucket crowded RA228-6346Δ 1
(22) Top
(23) Hydraulic tank 12 Pilot valve (left 2) ~ Control valve (Pb5) Blue Arm dump RA228-6343Δ 1
(24) Unload valve 13 Pilot valve (left 4) ~ Control valve (Pa5) Green Arm crowded RA228-6344Δ 1
(25) Accumulator 14 Pilot valve (left 1) ~ Control valve (Pb3) Red Swivel left RA228-6347Δ 1
(26) Pump
(27) Pilot valve, left 15 Pilot valve (left 3) ~ Control valve (Pa3) Yellow Swivel right RA228-6348Δ 1
* The pilot valve is shown as a see-through view from above. (28) Front 16 Control valve (Pb8)~Control valve (Pb8') Boom down/confluence RA221-6351Δ 1
(29) Front
(30) Pilot valve, right 17 Control valve (Pa8)~Control valve (Pa8') Boom up/confluence RA221-6352Δ 1
(10) Pilot hose circuit (TPSS)

7 (25)
6 (23)
17
(18) (19) 5
Pa8 Pa5 Pa8 ' Pa3
Pa9 T (24)
A9 A8 A7 P1 A6 A5 A4 P3 A3 A2 A1
T3
(20) B
B9 B8 B7 P2 B6 B5 B4 B3 B2 B1 A
T1 T2
2 1
4 P
Pb8 ' Pb3
(26)
Pb9 Pb8 Pp Pb5 P1
16 9 P3
IV-S-222
13 P4
(21) (22)
15 3 P2
Pilot hose
No. Location Part No. Q’ty
10
1 Pump (P4) ~ Unload valve (P) P4 RA231-6324Δ 1
2 Pilot valve (right T)~Oil tank PV right drain RA228-6339Δ 1
12 3 Pilot valve (left T) ~ Oil tank Yellow PV left drain RA228-6338Δ 1
(29) (28)
4 Pilot valve (right P)~Unload valve (B, top) Red PV (right P) RA228-6327Δ 1
2 2 5 Pilot valve (left P) ~ Unload valve (B, center)White PV (left P) RA228-6326Δ 1
T 3 T 3 6 Unload valve (B) ~ Control valve (Pp1) White Travel lock RA221-6325Δ 1
7 Control valve (Pa8)~Control valve (Pa8’) Boom up/confluence RA221-6352Δ 1
14 P 11 P 8 Control valve (Pb8)~Control valve (Pb8’) Boom down/confluence RA221-6351Δ 1
1 1 9 Pilot valve (right 4)~TPSS (3) Gray Boom up RA228-6361Δ 1
(30) 4 4 (27) 10 Pilot valve (right 2)~TPSS (1) Light blue Boom down RA228-6363Δ 1
8 11 Pilot valve (right 1)~Control valve (Pb9) Pink Bucket crowded RA221-6345Δ 1

12 Pilot valve (right 3)~Control valve (Pa9) Brown Bucket dump RA221-6346Δ 1
13 Pilot valve (left 1) ~ Control valve (Pb3) Red Swivel left RA228-6365Δ 1
14 Pilot valve (left 3) ~ Control valve (Pa3) Yellow Swivel right RA228-6366Δ 1
15 Pilot valve (left 2) ~ TPSS (2) Blue Arm dump RA228-6367Δ 1
(21) Top (28) Pump
(22) Bottom (29) Pilot valve, left 16 Pilot valve (left 4) ~ TPSS (4) Green Arm crowded RA228-6369Δ 1
(23) Control valve (30) Front 17 TPSS (B) ~ Control valve (Pb5) Blue Arm dump RA221-6368Δ 1
(24) Bottom (31) Front 18 TPSS (D) ~ Control valve (Pa5) Green Arm crowded RA228-6371Δ
(25) Top (32) Pilot valve, right
* The pilot valve is shown as a see-through view from above. (26) Hydraulic tank (33) A pattern 19 TPSS (A) ~ Control valve (Pb8’) Light blue Boom down RA228-6364Δ
(27) Unload valve (34) B pattern 20 TPSS (C) ~ Control valve (Pa8) Gray Boom up RA228-6362Δ
(10) Pilot hose circuit (TPSS)

13
9 (20) (21)
16
Pa8 Pa5 Pa8 ' Pa3
A1 A2
Pa9
12 P1
P2
A7 A6 A3 A2 A1
P1 P3
A9 A8 A5 A4 8 B1 B2
T3
(18) A B
17
B7
B9 B8 B4 T2
11
T1
Œã
?i P2 B6 B5 B3 B2 B1
Pb8 ' Pb3
Pb9 Pb8 Pp Pb5
T
(19)
IV-S-223
15
14 10
7
1
3
6 2
F (22)
4
Low pressure hose D P1
No. Location Part No. Q’ty P3

5 E
1 Return pipe ~ Oil cooler front Oil cooler OUT RA231-63771 1
H G
2 Control valve (T3)~ Oil cooler back Oil cooler IN RA231-63781 1
C
3 Control valve (T2)~ Return pipe Oil cooler bypass RA221-63731 1
J
4 Return pipe ~ Oil tank Return RA221-63711 1

P2
5 Swivel motor (T) ~ Control valve (T1) Swivel motor drain RA221-63751 1
I A
6 Unload valve (T) ~ OIl tank Unload valve return RA221-63731 1 B
7 Swivel joint (D) ~ Oil tank Travel drain RA221-63761 1 S/J
(8) Control valve
(9) Swivel motor
(10) Oil tank
(11) Unload valve
(12) Oil cooler
(13) Return pipe
(11) Hydraulic hose routing (delivery, return, swivel, swing)

(6) (7)
(8)
(9)
(1)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(4)
(2) (3) (5)
IV-S-224

(1) Pass below the Super-Change V or the Multi V. (9) Unload valve - Control valve (PP)
(2) Hose clamp (10) Pump (P1) - Control valve (P1)
(3) Travel drain (11) Unload valve - Swivel joint (dual-speed signal)
(4) Pass the delivery hose below the support bar. (12) Swing cylinder bottom - Control valve (A1)
(5) Pass the return hose through the vertical rib. (13) Pump (P2) - Control valve (P2)
(6) Hose clamp details (14) Swing cylinder rod - Control valve (B1)
(7) Be careful not to twist the hose when connecting it between the unload valve (15) Pump (P3) - Control valve (P3)
and pilot valve (left P). (16) Ensure a clearance of over 5 mm between the battery and oil cooler hose.
(8) Bolt
(12) Hydraulic hose routing (travel, selector valve)

(1) (2) (3) (4) (5)
IV-S-225

(6) (7)
(1) Swivel motor drain

(2) Color code: Green
(3) Color code: Blue
(4) Color code: Yellow
(5) Color code: Red
(6) Color code: Brown (outside)
(7) Color code: Pink (inside)
(13)
IV-S-226
(14)
IV-S-227
IV-S-228
WSM U17-3α/U17-3/U17 Mechanism V. ELECTRICAL SYSTEM
Mechanism Section
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-3
a. New Functions of Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-3
B. KUBOTA INTELLIGENT CONTROL SYSTEM (KICS) . . . . . . . . . . . . . . . . . . . . . . . . V-M-7
a. Features of Digital Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-7
b. Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-12
c. Servide Mode Menues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-15
d. Auto Idoling (AI) Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-35
e. Main Component’s Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-36
f. Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-42
g. Service Mode Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-50
h. Electrical Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-53
i. Electric Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-54
j. Electrical Wiring Diagram, Revised Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-55
V-M-1
V-M-2
A. GENERAL
a. New Functions of Electrical System
1. Kubota Intelligent Control System (KICS)
Kubota’s Advanced Control System favorably accepted in the market worldwide has been incorporated in
U17-3α and U17/U17-3 models.
2. Digital panel
Important Note:
Currently digital panel shows a model name of KX41-3 not U17-3α nor U17/U17-3.
3. Anti-theft system is standard-version for EU-version machine.

In details, refer to the separate section on “Anti-Theft System”.
(1) Main key SW

(2) Travel hi-low SW
(3) Meter panel
(4) Auto glow controller (3)
(5) Glow relay
(6) Change valve (4)
(7) Fuel sensor (2) (1)
(8) Fuel pump
(9) Horn (5)
(10) Work lamp
(11) Starter (6)
(12) Battery (7)
(13) SBF (Slow blow fuse)
(14) Fuse box
(14)
(9) (8) (13)
(10)
(12)
(11)
V-M-3
4. Key and key switch

1) Key and key cover 2) Insert the key.
3) Turn the key to run. 4) Turn the key to start the engine.
V-M-4
5. Machine model indication

KICS control system functions and menus of U17-3α,
U17/U17-3 are all identical with KX41-3.
As shown in the photo left, the model name KX41-3 will
be indicated on the panel screen when you turn the key
to run position while pushing on the display selector
switch.
This is exactly what the U17-3α and U17/U17-3 are
made.
In the service mode also, when ‘machine set up’ menu
to be processed, select the machine model of KX41-3.
V-M-5
V-M-6
B. KUBOTA INTELLIGENT CONTROL SYSTEM (KICS)

a. Features of Digital Meter
(1) Advanced performance:
• Digital display: Eleven multi-language for EU-version
English and French for KCL-version
English only for KTC, KTA-version
• Display icon and alarm sound for the warning on machine conditions and indication of maintenance
items.
• Machine operational and performance set-up procedures are incorporated.
• Max. flow amount of S/P1 can be adjustable according to the meter panel display.
• Display of anti-theft system is incorporated and programmed in collaboration with anti-theft controller
and antenna unit.
(2) 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.
• Remaining fuel (see fig. 3 on the right-hand side)
• Oil pressure (see fig. 4 on the right-hand side)
• Charge (see fig. 5 on the right-hand side)
• Overvoltage
• 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
• Low t ravel speed reset at the time of restarting the engine (if the engine is turned OFF with
high - low switch set to the high range).
• Engine start check (preventing the engine from starting with the lever unlocked).
• Starter motor automatic disconnection Auto release
• Auto glow, auto intake heater (KX080-3)
• Built-in hour meter and display
• Built-in tachometer and display
6. Expansion function for this minor change :
• Monitoring with theft prevention set up
• Service port (thumb) hand-held proportional control (S/P 1)
• Air-conditioner idling control
• Auto idling
• Service port control ON-OFF switch
V-M-7
(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
(KCL-ver)
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
V-M-8
V-M-9
V-M-10
V-M-11
b. 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.
V-M-12
2. LCD display list

Below list shows all LCD letter indications for both oparating mode and service mode.
In operating mode, data 003 ~ 022 and 082, 084 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, 018, 019, 020, 021 won’t come up
to show.)
<Operating mode menu list>

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 failure or disconnect of knob switch.
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 12 V sensor supply line shortage.
data020 The letter on the LCD indicates the warning of 5 V 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.
data082 These indicates where machine was manufactured.
data084 This indicates that operator is suggested to lift up unload lever(safety lock lever).
V-M-13
Caution and warning indications

(1) Lift up the lock lever to start engine (2) At key on position
(3) In case oil sw and charge lines broken (4) Fuel shortage
(5) Battery charge warning (6) Engine oil pressure warning
(7) Lift down the lock lever for service port (8) Maintenance indications
sw function
V-M-14
c. Servide Mode Menues

1. Outline
Service mode is basically for dealer’s service personel.
This mode is so designed to initialize machine’s condition, additional attachment and control system.
and also diagnose machine trouble. Display indication items are listed in page, 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. Upper view of meter panel
(1) Display selecter switch

(2) Main key switch
2. While pushing the display selecter switch, turn

the main key switch to ON position.
3. Start menu of the service mode.
4. Select the language.
Sample photos: KX91-3α2
V-M-15
3. Main menues and functions

3-1 Selection Method of 11 Languages (EU-version only)
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.
While pressing the display Direction of arrow ;

selector switch, turn the main Push the display selector switch
key ON. for long time
Push the display selector switch

for short time
KX080-3
31
Fig.1. Service Mode Language Selection Screen

(EU-version)
KTC, KTA-version :
Only English language is available.
KCL-version
English and French languages are possible to select.
V-M-16
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 mode menus
(1)E ngine -> 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
KX91-3α, KX101-3α, KX121-3S/α, and KX161-3S/α gear ratio: 68
KX080-3 gear ratio: 76
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.
V-M-17
(2) 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.
(3) E. oil : Engine oil switch ON and OFF.
(4) 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.
(5) Lever : Lever lock, switch ON and OFF
(6) Travel : high switch ON and OFF
(7) Start : Start position of key switch, ON and OFF
(8) Water : Water temperature voltage and water temperature (°C).
(9) 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.
(10) AI SW: Auto idling switch, ON or OFF
(11) Press:Auto idling pressure switch, ON or OFF
This pressure is NC (Normal close) type
Switch contact point is ON. When AI sensing line pressure is 2.45 ± 0.3MPa
(Terminal CN-1-8 of 22pin coupler has 12V) (25 ± 3 kgf/cm2) 356 ± 43 psi or higher
Switch contact point is OFF. When AI sensing line pressure is 1.96 ± 0.3 MPa
(Terminal CN-1-8 of 22pin coupler has 0V) (20 ± 3 kgf/cm2) 284 ± 43 psi or lower
(12) Motor: AI motor current amount.

(13) Accel: Real time accel sensor voltage and pre-set Max. and Min. value.
(14) Gover: Real time governor sensor voltage and pre-set Max. and Min. value.
(15) Compressor: Compressor clutch relay, ON or OFF
(16) S/P: S/P selection switch, ON or OFF
(17) Breaker: Breaker switch, ON or OFF
(18) S/P: S/P1 knob switch output voltage and pre-set Max. and Min. voltage.
Real time current amount to S/P1 solenoid.
Right upper value is to S/P1 left solenoid.
Right lower value is to S/P1 right solenoid.
(19) Non anti-theft ver.:Anti-theft controller (ECU) is not connected, or no communication with the ECU with
some reason.
(20) Key no communication:It is possible to communicate with ECU but not with the key. (Key, antenna or
coupler defects.)
(21) Black key: Inserted key type and registered or not.
(22) Red key: Inserted key type and registered or not.
V-M-18
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 number can be deleted by selecting Diagnosis and Delete record. (See fig. 4.)
But fail record hour meter remains.
The message "Fail record deleted" will be displayed when the record is deleted.
By pressing the display selector switch 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
V-M-19
3-5 Machine model setup
Model settings can be made by selecting Set up and Set up machine. (See fig. 6.)
When [Set up] is selected, [Engine start] is displayed at engine speeds below 800 rpm. The menu stays
disabled until the engine gets started. When the engine rpm has reached 800 rpm, the display changes
itself as shown below, enabling to select on the menu. This is to avoid troubles that would be caused by
making AI or S/P settings without running the engine.
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 set-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.
KX080-3
Fig.6 Machine model set-up
V-M-20
3-6 Set up AI
Select [Set up] first and then [Set up AI], and make the AI settings. (Fig. 7)
Fig. 7 AI setting
3-7 Set up machine

Select Set up , Other menu and Set up machine , and make the machine settings.For
machine settings, select the model information and country of manufacture.
With the country of manufacture selected, the Europe-destined or North America-destined types
can be identified.
If the model information includes AI as optional, the AI item is displayed enabled or disabled.
3-8 Overheat set-up

Note:
By selecting Diagnosis , Set up , Engine start , Set up AI , Other menu , 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 10 °C

temperature increments/decrements
Fig. 8 Overheat Settings
In default condition, Overheat warning is OFF for North America and Oceania - version
and ON for EU - version.
3-9 Simple mode set-up

Simple-mode settings can be made by selecting Set up, Engine start, Set up machine, and Simple mode.
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. But currently, this simple mode is not used even for chinese market.
V-M-21
3-10 Set up S/P knob

Select Set up , Other menu , Set up S/P knob , and make the thumb settings. (Fig. 9)
The left-end, middle and right-end settings of the knob are put in the EEPROM. 3-ton-class and larger
machines are standard equipped with the thumb setting.
Fig.9 Set up S/P knob
3-11 Set up S/P valve

Select Set up , Other menu , Set up S/P valve , and make the thumb valve settings. (Fig. 10)
The initial current starts from 650 mA on model KX-080-3, and from 4350 mA on other models.
As the current gradually increases at 10 mA/s, the spool opens itself little by little according to its
opening characteristic. A thumb and other attachments can be operated through the service ports. Just
when the attachment is activated, the operator is supposed to push the switch. In this way, the
attachment start-up point can be put in memory. The right and left valve start-up points are measured.
(For details, refer to S/P.)
Fig.10 Set up S/P valve
3-12 Set up S/P feeling adjust

Select Set up , Other menu , Set up S/P feeling adjust , and make the thumb start-up point
correction. (Fig. 11)
The S/P valve setting start-up points can be offset. (For details, refer to S/P.)
Fig11. Set up S/P feeling adjust
V-M-22
3-13 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.
(1) Lever lock switch (OFF When lever is down).
(2) Fuel sensor (Reading of 2 V or more, or sway 0.2 V or more).
(3) Water temperature (Water temperature of 140 °C or more, or -30 °C or lower.).
(4) Acceleration sensor (below 0.25V, above 4.75V or fluctuations of over 0.2V): Enabled on AI version
machines only
(5) Governor sensor (below 0.25V, above 4.75V or fluctuations of over 0.2V): Enabled on AI version
machines only
(6) S/P sensor (below 0.25V, above 4.75V or fluctuations of over 0.2V): Enabled on S/P version machines
only
(7) Oil switch (OFF When engine stops and Key is ON).
(8) 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.
3-14 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
V-M-23
3-15 AI motor manual drive
Select Other menu →, AI motor drive , and the AI motor can be controlled with the following switches.
With [AI motor drive] selected, pressing the working light switch turns the motor in the normal direction
and pressing the center switch turns it in the reverse direction.
3-16 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
3-17 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
V-M-24
3-18 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, KX71-3 and
super series models 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.
Service Hour Meter with North American and Oceania Specifications
Fig. 2
V-M-25
EU - version machine
A message appears initial at 50-hour intervals and 250-hour intervals (i.e., every 250, 500, 750, and 1000
hours).
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. (The message reappears on the hour meter designated next.)
50 100 250 300 500 550 750 800 1000
1 Engine oil every 500 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 500 hrs
Hydraulic return filter
6 every 500 hrs
element replace
Hydraulic suction filter
7 every 1000 hrs
element
First operation
The maintenance message disappears automatically in about 10 seconds.

When the key is turned from OFF to RUN, the maintenance message reappears and disappears again automatically in
about 10 seconds.
When the working lamp switch of the panel is pushed for more then 3 seconds, the message disappears.
But from the view point of service of maintenance policy in EU market, this deletion method should be announeed
only to the dealers but not to the customers.
In case a meter panel were replaced due to any trouble with it, the service hour meter is set to "0". Contact your
KUBOTA dealer for details.
V-M-26
3-19 Servive hour meter check

The service hour meter can be checked and altered by selecting Diagnosis , Set up , 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.
3-20 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.
But from the view point of service maintenance policy in EU market, this deletion method should be
announced only to the dealers but not to the customers.
Note:
Change in Service Hour Meter
North American specifications: By default, set to “auto” to make it disapper “Service warning” on the panel.
European specifications: By default, set to “manual” to make it disapper “Service warning” on the panel.
Turn off the service warning indication with the working lamp switch pressed for 3 seconds.
3-21 Set-up time

The hour meter used for model settings can be checked by selecting Other menu, Other menu, and Set up
hour meter.
3-22 Software version

The software version can be checked by selecting Other menu, Other menu, and Soft version.
V-M-27
3-23 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 “Reset” to low speed when key is switched “OFF” or safety lock lever is lifted.
V-M-28
3-24 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 (5 V) 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] G
KX080-3 10 ± 2 (2.64 ± 0.53)
KX41-3,
5 ± 3 (1.32 ± 0.79㧕
U17-3α, U17-3/U17
KX61-3, U20-3 7 ± 3 (1.85 ± 0.79)
KX71-3, U25-3 7 ± 3 (1.85 ± 0.79)
KX91-3S/ 5 ± 2 (1.32 ± 0.53)
KX101-3 5 ± 2 (1.32 ± 0.53)
KX121-3S/ 12 ± 2 (3.17 ± 0.53)
KX161-3S/ 12 ± 2 (3.17 ± 0.53)
Voltage and fuel map U35S, U35-3S/ 5 ± 2 (1.32 ± 0.53)

U45S, U45-3S/ 12 ± 2 (3.17 ± 0.53)
Circuit diagram & function(Water temp sensor) (Fuel sensor)
(1)Fuel sensor (2)Water temp sensor (3)Meter (4)AD voltage

(Calculation example) Voltage value is 0.899 for example.
Theoretically, water sensor’s resistance is 179.76
V-M-29
Meter display
1) The LCD with four vertical dots and 37 horizontal dots is used to display the fuel gauge.
Fuel level L(G) KX080-3 KX41-3,

U17-3α, U17-3/U17
115 ± 5 19 ± 3
Full in tank (30.38 ± 1.32) (5.02 ± 0.79)
96 ± 5 17 ± 3
Sensor upper limit (25.36 ± 1.32) (4.49 ± 0.79)
10 ± 2 5±3
Sensor lower limit (2.64 ± 0.53) (1.32 ± 0.79) (Sample data : KX41-3)
KX61-3, 71-3 KX121-3S/α, 161-3S/α,

Fuel level (Litter) KX91-3S/α, 101-3α U35, U35-3S/
U20-3, U25-3 U45-3S/ , U45S
Full in tank 42 ± 3 (11.10 ± 0.79) 48 ± 5 (12.68 ± 1.32) 42 ± 5(11.10 ± 1.32) 65 ± 5 (17.17 ± 1.32)
Sensor upper limit 41 ± 3 (10.83 ± 0.79) 40 ± 3 (10.57 ± 0.79) 40 ± 3(10.57 ± 0.79) 58 ± 5(15.32 ± 1.32)
Sensor lower limit 7 ± 3 (1.85 ± 0.79) 5 ± 2 (1.32 ± 0.53) 5 ± 2 (1.32 ± 0.53) 12 ± 2 (3.17 ± 0.53)
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.
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.
V-M-30
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.
• Beep sound disappears approx 10 seconds after reaching to full of fuel.

• If fuel fank isn’t full, keep sound continues to sound for two minutes in order to alarm.
V-M-31
3-25 Starter 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
starter 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. (Starter 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.)
As for the other models except KX41-3, the start of the engine is judged at 800 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. (Preventionof
starter burnout damage)
The reason the above period is set to 30 seconds is that it will be possible to start the engine
byenergizing the starter three times for 10 seconds after auto glowing even in winter at a temperatureas
low as -17 °C.)
6) As shown in the diagram, if the meter panel is damaged or the or the couplers of the meter panel are
disconnected, then engine won’t start.
Just because the auto release relay is Normally Open type and so battery current won’t be supplied to
the strater moter. This is also for the safety.
START
AC(ON)
AUTO RELEASE RELAY (NO)

OFF
SAFETY SW
R&L
STARTER
MOTOR
5V
rpm
Meter panel (CONTROLUNIT)
V-M-32
3-26 Service mode menu list

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.
S/P is abbriviation of auxiliary port and indicates the switch condition, on or off.
data048
Breaker indicates the breaker switch condition ,on or off.
S/P 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
V-M-33
<Service mode menu list>

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 indicate 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.
V-M-34
d. Auto Idoling (AI) Control System

(1) Engine speed sensor
The engine speed sensor is a quick-response prox- 0.7 ± 0.2 mm
imity switch. When the teeth of a gear pass close,
the magnetic field inside the switch changes and the
variation is converted to pulses.
The number of pulses for "t" seconds is counted by
the microcomputer. The engine speed is then com-
puted in the following equation. KX080-3
gear teeth:G=76
2 x 60 Fuel pump gear
Gxt [rpm]
Such speed data is used for the starter's automatic

release system.
Model Gear teeth No.

KX080-3 76
KX41-3, S, U17-3α, U17-3/U17 46
KX61-3,71-3, S,
54
Pulse
U20-3 , 25 , U25
KX91-3, 121-3, 161-3, S,
68
U35, U45, U50, S,
Convert circuit
Sensor chip
This sensor is composed of a sensor and a

rotor. The sensor has a coil wound up around
a magnet, and the rotor is of iron with teeth. As
the rotor turns, the magnetic flux varies at its
peaks and troughs according to the turning
speed. Such frequency-dependent change of N
the magnetic force line generates an induced A B
electromotive force in the coil. The resulting
signal is fed to the controller to detect the turn-
ing speed.
Time for the rotor to move in one-tooth distance

A
+ V:
B -
V: Induced electromotive force
V-M-35
e. Main Component’s
p Function
(1) Auto release function
1. 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)
KX41-3 KX080-3, KX61-3 ~ 161-3S/α, U20-3 ~ U45-3S/α
1000 >
= Nx 800 >
= Nx ON
ON (Within 6 seconds)
1001 ~ 1150 801 ~ 950
OFF (After 6 seconds)
> > ON (Within 0.5 seconds)
1151 = Nx 951 = Nx
OFF (After 0.5 seconds)
The reason why KX41-3 has different sensing speed is that idling speed of KX41-3 is 1300 rpm
which is higher than any other machines.
V-M-36
2) If the engine has started but the key switch fails to return (key switch failure)
a.Key switch start signal

T2 sec
c.Release relay solenoid Switch turned 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.
3) If the key switch fails to return and the engine speed sensor is also in trouble
a.Key switch start signal

30 sec
Switch
c.Release relay solenoid
turned 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"
2.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)
KX080-3 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.
V-M-37
4) Check if the wrong model settings are made.

Depending on the model, the start of the engine is judged at 1000 rpm or below for KX41-3. There-
fore, 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. Other than KX41-3, the stant of the engine is detected at 800
rpm.
3. Operational flow chart

3-1
V-M-38
3-2
V-M-39
3-3
< Engine speed and condition of auto release relay >

Engine speed : Nx
Time : T 1, T2 Auto release relay
KX080-3, KX61-3 ~ KX161-3S/α KX41-3
U20-3 ~ U45-3S/α, U45S U17-3α, U17-3/U17
800 >
= Nx 1000 >
= Nx ON
Within 6 seconds ON
801 ~ 950 1001 ~ 1150
After 6 seconds OFF
> > Within 0.5 seconds ON
951 = Nx 1151 = Nx
After 0.5 seconds OFF
starter relay = Auto release relay
V-M-40
(2) Travel hi-speed control circuit
R C
ST
AC
B (1)
OFF
(1)
1 2 (4)
Hi-Low SW
(2)
EEPROM
Program
(Meter panel) (3)
DR
P1 P2
Troubleshooting: Travel hi-speed malfunction

1. Turn the key switch to the ON position to see if 12 V is applied to terminal 2 of the travel hi-speed switch.
2. Press the travel hi-speed switch to see if the 12 V signal comes to terminal 1.
3. Turn on and off the travel hi-speed switch and check the continuity and discontinuity.
4. Check the continuity of the travel hi-speed solenoid coil and measure its resistance.
5. If there is no problem with the above steps, it means the electrical system functions. Now go to the
hydraulic system.
6. Possible troubles with the hydraulic system include stuck solenoid spool, poorly performing pilot pump,
malfunctioning primary relief valve, stuck Hi-Lo selector spool, etc.
V-M-41
f. Failure Diagnosis
1. Failure display and diagnosis criteria
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 intervals.
• 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
Operating mode service mode point address
1 Fuel - 5-minute Yellow Replenish fuel --- --- Fuel scarcity rate is 90% min. after
intervals 60-s sampling
2 Engine oil 2 Engine oil Continually Red Returns to nor- --- 66, 86 At 5 V (normal).
mal The following conditions continue
10 s: oil = L and 800 rpm min.
3 Charge 3 Charge Momentarily Red Returns to nor- --- 65, 85 At 5 V (normal).
mal The following conditions continue
10 s: charge = L and 800 rpm min.
4 High voltage 4 High voltage Continually Red Turn key OFF AI AUX 67, 87 At 5 V (normal).
A power supply voltage of 18 V
min. continues 3 s.
5 Overheat 5 Overheat Continually Red 112°C ± max. AI AUX 77, 97 At 5 V (normal).
(EU only) The following conditions continue:
Engine revolution of 800 rpm min.
with overheat warning
When the water temperature sensor is nor-
mal, a water temperature of (124 ± ) °C min.
continues 5 s.
( : Adjustable between -10 °C and +10 °C.)
31 Lift up - Momentarily Yellow Wait for 5 s, Engine does not --- The key is shifted to the start position with the
unload lever then disappear start lever lock moved down.
32 Service - Momentarily Yellow Wait for 10 s --- --- The specified hour meter is set.
hour
33 Key is - Momentarily Yellow Wait for 3 s Engine does not --- Theft prevention specifications
wrong start The wrong key is used to start the engine.
The specifications are presently under con-
sideration.
34 Different - Momentarily Yellow Wait for 3 s Engine does not --- Theft prevention specifications
key start The different key is used to start the engine.
The specifications are presently under con-
sideration.
51 Coolant - Momentarily Red Turn key OFF --- 82, 102 At 5 V (normal).
sensor (EU A water temperature of -30 °C max.
only) or 140 °C min. continues for 1 s.
- 52 Fuel sensor Momentarily Red Turn key OFF --- 81, 101 At 5 V (normal).
The fuel sensor at 2 V min. continues for 10 s.
53 Sensor sup- 53 Sensor sup- Momentarily Red Turn key OFF LCD turns OFF 79, 99 5-V short-circuiting detection terminal at H
ply short 5V ply short 5V AI AUX 5-V out- level continues for 0.1 s.
put turns OFF
54 Sensor sup- 54 Sensor sup- Momentarily Red Turn key OFF AI AUX always 0 80, 100 At 5 V (normal).
ply short 12V ply short 12V rpm The 12-V short-circuiting detection terminal at
H level continues for 0.1 s.
55 Meter con- - Momentarily Red Turn key OFF AI AUX 78, 98 The rightmost 16 bits of the added value of
troller error addresses 36 through 50 do not coincide
with the value of address 64.
- 61 AI motor Momentarily Red Press acceler- --- 83, 103 At 5 V (normal).
restricted ator AI specifications
A motor current of 6 A min. continues for 3 s.
V-M-42
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.
2-1Error 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
2-2Number 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
V-M-43
2-3Erasing 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
~
61
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:KX71-3, KX91-3, 4:KX101-3, 5:KX-121-3, 6:KX161-3, 7:KX080-3 ···
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
V-M-44
Address No. Type Contents Explain

38 Accel sensor value at max.
39 Accel sensor value at mini.
40 Gov. sensor value at AI
41 AI control data Gov. sensor value at max. accel
42 Gov. sensor value at mini. accel
43 Idle-up gov. sensor value
44 Idle-up gov. sensor off set no. 0 ~ 150
(0.25 V = 409 = 0 x 199)
45 Knob SW left end (Min. 1023 x 8)
0.5 V = 818 = 0 x 332)
46 Knob SW neutral (N. 1023 x 8) 2.5 V = 4092 = 0 x FFC
Thumb control data 4.5 V = 7366 = 0 x 1CC6
47 Knob SW right end (Max. 1023 x 8)
(4.75 V = 7775 = 0 x 1E5F)
48 Right (released):
49 Left (held):
50 Language combination 0 : milti 1 : English 2 : English, French
51 Overheat control Overheat warning selection Overheat warning
52 data Overheat water temp. adjust -10 ~ +10
54
Mashine hour set mashine hour meter
55
Nothing occurs at 0. When preset at 1 or higher,
56
Maintenance display number each key-on counts up to 10 and returns to 0.
57 Machine hour & time
Warning time
58
59 Service hour meter
60 Service hour meter Usually the same value as on the hour meter.
61 1: Service warning given permanently.
Right (held): Cushion finely
62
adjusted.
S/P control data
Left (released): Cushion
63
finely adjusted.
Fig. EEPROM Addresses for overseas
V-M-45
Address No. Contents of failure Data bit

64 Check sum, 36 ~ 50
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 S/P control
73 22 S/P solenoid L short The leftmost 12 bits display the hour meter value of
the last error. The rightmost four bits display the
74 23 S/P solenoid L break accumulated number of errors.
75 24 S/P solenoid R short
76 25 S/P solenoid R break
77 5 Overheat
78 55 Meter controller error
79 54 Sensor supply short 5V
80 53 Sensor supply short 12V
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 S/P control
93 22 S/P solenoid L short
The leftmost 12 bits display the hour meter value of
94 23 S/P solenoid L break
the last error. The rightmost four bits are dummy bits.
95 24 S/P solenoid R short
96 25 S/P solenoid R break
97 5 Overheat
98 55 Meter controller error
99 54 Sensor supply short 12 V
100 53 Sensor supply short 5 V
101 52 Fuel sensor
102 51 Coolant sensor
103 61 AI motor retricted
124
S/P 1 flow control 0 ~ 3 bits for the right, 7 ~ 10 bits for the left
125
Fig. EEPROM Addresses for Error Log
V-M-46
FYI (For your information)

The following information is for those who are interested in the control system more in detail.
a. 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.
b. Pulse Width Modulation (PWM)

Pulse width modulation (PWM) is a powerful technique for controlling analog circuits with a processor's digi-
tal outputs. PWM is employed in a wide variety of applications, ranging from measurement and communica-
tions to power control and conversion.
12V Pulse-width modulation control works by switching the power
supplied to the motor on and off very rapidly. The DC voltage is
converted to a square-wave signal, alternating between fully on
0V (nearly 12v) and zero, giving the motor a series of power "kicks".
0.2
(1)
1.0 If the switching frequency is high enough, the motor runs at a
12V steady speed due to its fly-wheel momentum.
By adjusting the duty cycle of the signal (modulating the width of

0V 0.5 the pulse, hence the 'PWM') ie, the time fraction it is "on", the
(2)
1.0 average power can be varied, and hence the motor speed.
12V
(1) 20% Duty Cycle
(2) 50% Duty Cycle
(3) 80% Duty Cycle
0V
0.8 (3)
1.0
Advantages are,
1. The output transistor is either on or off, not partly on as with normal regulation, so less power is wasted
as heat and smaller heat-sinks can be used.
2. With a suitable circuit there is little voltage loss across the output transistor, so the top end of the control
range gets nearer to the supply voltage than linear regulator circuits.
3. The full-power pulsing action will run motor at a much lower speed than an equivalent steady voltage.
V-M-47
The frequency of this pulse is commonly referred to as kHz control. The higher this frequency is, the finer the
control becomes, but the FET may fail to follow up the control in some cases. The PWM wave, on the other
hand, can be defined as “rectangular wave the pulse width of which changes with time”. Interestingly, rectan-
gular waves give out various sounds according to their duty ratio: from saw-tooth wave to square wave (nar-
row sine curve), and in between them.
In this method, the pulse width is controlled to regulate the average output voltage and any output voltage
can be taken out of a constant supply voltage. (See below.)
(4)
(1) Small pulse width
(3) (2) Large pulse width
(6) (3) Supply voltage
(4) PWM period
(5) Average voltage low
(6) Average voltage high
(5)
(1) (2)
AI electric motors use electromagnetic force and have a coil built in. The inductance of a coil makes the cur-
rent flow in somewhat smooth patterns.
PWM frequency
The torque generated by a motor is proportional to the current. The higher the PWM frequency is, the
smoother the current waveform is. In other words, raise the PWM frequency, and the torque fluctuates less.
Noise-causing harmonic components are also reduced.
This, however, has downsizes, such as greater loss of electrical steel sheet and drive elements (transistors,
FETs, etc.). The final PWM frequency is determined by trade-off between these positive and negative char-
acteristics.
Duty ratio Analog level
9 0.9
8 0.8
7 0.7
6 0.6
5 0.5
4 0.4
3 0.3
2 0.2
1 0.1
0 0
V-M-48
c. Function of meter panel
Display data
Meter panel
Fail history data
Water temp.error
Display data
Operational data Engin oil press.error
display
hrs
Liquid crystal Display

Warning
lamp
Display
Work lamp SW SP SW selector SW
Display Display
direction direction
CPU
Display data
Input data control
control Driver output
control
Sensor signal Actnator condition

input input
Driver output signal
Sensors(Input) Actuators(Output)
* Governor sensor * Solenoid valve
Data * Acceleration sensor * AI motor
communication * Engine pressure sensor * Glow relay
* AI pressure sensor * AI hold relay
* Engine speed sensor * Anti-theft relays
*
*
*
Sensor signal input
Anti theft controller
Outline:
Various sensor signals are fed to the CPU that is incorporated in the LCD meter. They are compared with
the settings of the input data controller. After being controlled with the program, the resulting drive output
signals are sent to actuators (solenoid valve and AI motor, for example). When the selector switch, AI switch
or work light switch is pressed, the display output controller issues a display command and its relevant icon
is picked up from the data storage and displayed on the LCD display.
V-M-49
g. Service Mode Flow Chart

1. General
1-1 There are sevral flow charts, depending on the models or machine - versions as below.
1) KX41-3, KX61-3, and KX71-3 have one identical service mode flow chart.
Refer to the correspondent WSM.
2) KX91-3S, U35S and U35-3S for KTC, KCL and KTA have the flow chart which dosen’t include AI -
version but includes S/P (Service port) - version.
3) KX121-3S, 161-3S and U45-3S for KTC, KCL and KTA have the flow chart which includes AI - ver-
sion and S/P (Service port) - version.
4) EU - version models of KX91-3 , 101-3 , 121-3 , 161-3 , U35-3 and U45-3 have AI (Auto idle)
and S/P (Service port) - version.
5) The service mode flow chart of anti-theft version will be added to the EU - version machine in the
appropriate future.
This will be announced later in the manual for the anti-theft-version.
1-2 How to enter the service mode?

While pushing the display-select-switch, turn the main key to ON position. Then you’ll be in the service
mode.
The model name which was pre-set will come to appear on the LCD screen.
1-3 What do the arrows indicate?

vertial to down ; You’re required to push the selector switch for a short time. Just one touch push.
Then you’ll proceed to the down menu.
vertial to up ; Similar to above. Just one touch push.
Then you’ll return to the top menu of the same column.
horizonal to right ; Push the selector switch for a long time until you hear a pi-sound.
Then You’ll proceed to the next right.
horizonal to left ; Similar to above. Push for a long time.
This is only attached to the Back tier .
This arrow indicates to go back to the top menu of the previous tier.
1-4 This service mode flow chart is diivded into two zones.
One is for ordinary service personnel to carry out the troubleshooting of the machine if needed.
The other is for only the authorized personnel to proceed several important machine set-up, adjustment
and troubleshoothing in detail.
Those are ; 1) Machine model set-up

2) AI - or Non - AI version selection
3) Engine idle speed set-up
4) Service port system set-up
5) Service warning set-up
6) Circuit check for wire harness disconnection
7) etc.
V-M-50
1-5 What should you do in the following case?

Cases action to be taken
(1) Renewal of a meter panel. 1) Machine model set-up
Customer purchased a new meter panel from the spare 2) AI or Non - AI selection
part center. 3) AI set-up (Idle & max.speed)
Or change the meter panel to another machine model. 4) Service warning set-up
5) S/P knob set-up
6) S/P valve set-up
7) Overheat warning set-up
(2) Replace from a canopy to a cab or vice versa. 1) Idle speed set-up
(3) Renew a S/P knob 1) S/P knob initial set-up
(4) Renew a S/P valve 1) S/P valve initial set-up
(5) Change a service port attachment 1) S/P feeling adjustment
(6) Different native language speaking operator or service 1) Selection of language
presonnel This is only EU - version and KCL - version.
Battery circuit
1 (AC)
2 (Start) OFF
3 Key SW
Cab relay
15A
M
Light SW
Stater motor
60A
50A
Battery
Alternator
1. Keep in mind that the battery voltage is applied through the above circuit all the time.
2. A 60A fuse is added close to the alternator, otherwise part of the harness may get short-circuited due to the
alternator's current generated while the engine is running. In this way, the devices and harness can be
protected against burn-out.
V-M-51
V-M-52
h. Electrical Component Layout

1Key switch panel 2Horn 3Relay Anti-theft antenna 4Unload valve
Back of engine
5Stop solenoid 6Fuse, slow-blow fuse



Thermal unit 7Lock lever limit switch 8Glow
 




 
 
Ground 9Battery KStarter motor



QFuel sensor PHorn OLamp NFuel pump 2High-speed switch Alternator
V-M-53
i. Electric Circuit Diagram

Key SW
CN-14-3 Lever Lock Lever lock,L SW Lever lock solenoid
off 5A CN-11-2 CN-11-1 CN-17-3 CN-17-1
on CN-14-1
CN-12-1 CN-12-2
start CN-17-2 CN-17-4
CN-14-2
Anti theft Lever lock relay
Travel alarm power source

CN-455-1
CN-455-2
CN-2-18 Motor Power supply
Meter Sub
5A CN-1-12 +B
Lever Lock sw CN-1-11

CN-2-14 AI self-hold Relay
Start SW CN-1-9
CN-1-1 AC-1
Meter Main Glow relay
10A CN-115
CN-17-4 CN-17-3 Glow plug
Fuel sensor
CN-23-1 CN-2-2 Fuel Sensor Glow Relay CN-17-1 CN-17-2
5V CN-1-21
CN-110 CN-2-15 +5V
CN-17-3 CN-17-1
CN-2-16 Analog-GND
Auto release Relay CN-17-4 CN-17-2 CN-17-1 CN-17-3
CN-1-22 CN-17-4 CN-17-2
CN-32-1 CN-32-2 Water temp Sensor Auto release relay
CN-2-1 Working lamp Relay Anti theft starter relay
CN-1-13
Water temp.sensor(auto glow)
JS Control(R) Motor Pot Compressor crutch Relay
GND CN-2-4
CN422-8 CN422-2 CN-1-14
pot CN-2-3 Accel pot
+5V CN422-3 AUX Control ON-OFF LED
CN422-1 CN-2-5 AUX. control pot CN-1-16
HornSW-vcc HornSW
CN422-7 CN422-4 Breaker Lock sw AI operation LED
BrakerLockSW-vcc BrakerLockSW CN-1-4
CN422-6 CN-1-15
CN422-5
SW AUX. Control ON-OFF sw Travel hi-low solenoid
CN-1-5 Travel Hi-Low Sol
Travel Hi-Low Travel hi-low lock SW CN-2-10 CN-13-2
Travel Hi-Low sw CN-13-1
5A CN-15-2 CN-15-1 CN-1-6
Travel hi-low lamp
CN-1-7 AI operation sw
CN-1-8 AI pressure sw CN-13-1 CN-13-1
CN-306-4 CN-1-10 Compressor crutch sw

CN-306-2
CN-306-3 CN-306-1
Anti theft Horn relay Spare sw Motor(+)
CN-1-2
Horn relay Horn Motor(-) CN-2-20
Horn CN-46
CN-33-3
10A CN-306-3 CN-306-1 CN-2-19
CN-306-2
Power_Source(12V)
CN-306-4 CN-45 Engine speed sensor
5V 3
Eng. rpm Solenoid_Out_1 Main to Engine AUX. L solenoid
CN-33-2 CN-1-17 AUX. sol(+)-L PMM_IN1 1
CN-1-18 5 CN-428-1
SWP-4p-1 CN-428-2
PMM_IN2 Solenoid_Out_2 Main to Engine AUX. R solenoid
AUX. sol(+)-R 2
RS-485-con
CN-2-13 RS-485(+) CN-1-19 6 CN-427-1
AUX. sol(-) Power_Source(GND) SWP-4p-2 CN-427-2
CN-33-1 CN-55-2 CN-18-2 CN-2-12 RS-485(-) 4
CN-1-20
CN-55-1 CN-18-1
Flash cnt
CN-2-9
CN-2-11 Txd-1
CN-1-3 12V out(RF-unit) Rxd-1 Charge sw
CN-2-8 CN-2-7
unti thieft sub +B
10A CN-1-7
CN-1-6 GND CN-1-3 Signal-GND oil sw Engine oil SW
CN-2-6 CN-28
CN-1-12 RF-GND
CN-41-1 50A
CN-2-8 Cont Power in

unti thieft main Anti theft Relay CN-2-17 Motor-GND
5A CN-1-9 AC Power in
CN-1-1
CN-1-5 Anti theft horn Relay
AC Power in
CN-1-2
CN-1-2 GND
CN-2-1 CN-2-11
Txd(RF-unit) CN-2-5 Txd(RF-unit) RS-485(+)
CN-1-3
Rxd(RF-unit) CN-2-4 Rxd(RF-unit) RS-485(-)
unti thieft LED
CN-37
Anti theft RF Unit CN-2-4 CN-2-10
Anti theft Unit
Starter
CN-114
‚l
Battery Alternator
60A CN-113
Alternaator
10A CN-25-1
CN-25-2
Work Light CN-302-2 CN-302-4

20A CN-18-1 CN-55-1 CN-100 Work lamp
CN-302-3 CN-302-1
Relay source CN-18-2 CN-55-2 CN-100
Light relay
5A Fuel pump
CN-24-1
CN-56-3 CN-57-3
CN-24-2
CN-57-1
CN-56-1
CN-17-3 CN-17-1
CN-17-2 CN-36-2
Wiper Motor CN-17-2 CN-17-4
Heater relay GND Anti theft ESS relay CN-36-1
Heater fan CN-305-6
10A CN-305-1 M
CN-305-2
CN-305-3 CN-303-1 +1 S+
CN-305-4
CN-304-4
Hi CN-303-2
CN-304-3
Engine stop solenoid

CN-17-2
Lo
CN-17-2
CN-17-2
CN-304-1 off
CN-303-4
Heater switch
Wiper sw
CN-17-2 off CN-17-2
Cab relay ‚l on CN-17-2
Wiper/Washer
10A CN-16-4 Heater(Aurora)) CN-17-2 Washer Motor
CN-308-3 CN-308-1 CN-17-2 CN-17-2
Auxiliary ‚l
15A CN-16-2 CN-17-2
CN-308-2 CN-308-4
CN-16-1 Cab power source Cab Work light
CN-17-2
Room Light room light CN-17-2
5A CN-16-3 CN-17-2 Cab Work light
CN-17-2
CN-17-2 CN-17-2
CN-103-1 Cab GND
Cigarette lighter
15A CN-317-1
Power consent
CN-317-2
Beacon switch Beacon

CN-472-5 CN-472-1 CN-600-4 CN-628-2 CN-628-2
Cab Power Source

CN-472-6 ‚l
CN-472-3
V-M-54
j. Electrical Wiring Diagram, Revised Version

0.5-R/Y
0.5-L
0.5-B/Y
0.5-L/Y
Horn-sw
GND
pot
EC/USA
+5V CN422
4 3 2 1
JSControl(R)
8 7 6 5 dewtsch-8pf
Br-lock-sw-Vcc
Br-lock-sw-sw
DT06-08SA-CE05
Horn-sw-Vcc
Blank
0.5-
0.5-
Travel ho-low Lock sw

1 2 CNT3
TNS-3pm
3 6092-0013
7283-4421 7282-4421
090II-2pf 090II-2pm
’Ê?M ’Ê?M
—¬—ÊÝ’èSW
0.5-L
CN6 CN7
HM090-2pm Without Antitheft
1 2 6187-2801 0.5-Br/w 485+ 0.5-Br/w
1
CNT5
1
0.5-Br 0.5-ƒcƒCƒXƒgƒyƒAƒP?[ƒuƒ‹ 0.5-ƒcƒCƒXƒgƒyƒAƒP?[ƒuƒ‹ Anti theft Antenna unit
2
2
485- 1 2 3
0.5- HM090-6pm
4 5 6 6189-6171
meter?ibig?j 7283-5834
CN1 0.5f-W(AVX)
11 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 20 19 18 17 16 15 14 13 12 11 meter(small) CNT4
CN2 Anti theft unit
EU(Antitheft)
040_3-20pf
0.85
EU(Antitheft) 4 3 2 1
SWP-12pf
0.85-B
2-B 8 7 6 5
BeaconSW 7123-7923-40
12 11 10 9
Free Lock 1 7122-2820-30
2.3II-6pf CN(A)250-2pm
2 1 2
4F0670-000 CN456
6 5 4 3 Auto release relay Travel Alarm Power source(cap)
Light- CN34
com nc Light+ 2 1
coil contact
4 3 CN250-2pf
com
1.25-G
coil
7123-2820-30
0.5-B
CN250-2pf CN455
7123-2820-60 1 Travel Alarm Power source(US)
EU(without Antitheft)
0.5-B 2
EU(Antitheft)
2
1
1.25-Y
0.85-
Beacon Power source CN12
JFC-2pf(L)
EU(without Antitheft)/USA 2 1 PB185-02046
CN(A)250-2pm CN302 Light relay 0.85-B/W EU(without Antitheft)/USA Lever lock solenoid(EU)
7122-2820-60 2 1 + -
2
1
coil contact
Beacon Power source(cap) 4 3 CN12
com CN11
Worklight
coil
Wiper Roomlight
Lever lock SW, L LeverLockSolenoid(US)

0.5-Br/W
0.5-G EU(Antitheft) JFC-2pf(B)
3
1
3
2
1
1 2
PB185-02026 CN13
4
4
2
2
etc
Travel hi-low solenoid(EU)

EU(without Antitheft)/USA 2 1
CN60 CN16
Cab Power source(cap) 15A 2f-R EU(without Antitheft)/USA EU + -
Cab Power source CN14 Auxiliary
3-B/W
Key switch CN13
10A 1.25-G Wiper/Washer CN317 Travel_hi-low_Solenoid(US)
2 1 ac 15A 1.25-G Cigarette lighter Power source
1 CN103 st 1.25-G
3 1 1 2
Cab GND com 0.85-L
5A 0.5-Br/W Room light 2
3-B
3-R
20A 2f-R/W Work light +-
1 2
CNT1
EU(Antitheft)
Travel hi-low lamp
0.5-L
CN306 090-2pf-lamp
Horn(+)
coil
0.5-B Horn relay 7323-1520-80

3 4coil
Horn
1.25-L
10A CN45
1.25-B
1.25-
1 2
2 1 1
contact
5A Lever lock coil contact 0.85-L

0.5-G
com
4 3
EU(Antitheft)
CN308 coil com
1
Cab relay 10A 0.5- Alternator
1.25-B
3-R 0.5-B Horn(-)
Travel Hi-Low CN46
5A 0.5-
0.5-B
Fuel Pump
5A 0.85- Meter Sub 1 CN24
2
10A 0.85- Meter Main
EU(Antitheft)
10A Anti theft sub 0.5- ‚q‚a‚Q‚R‚V?|‚T‚R‚R‚U¢
1.25
5A Anti theft main

0.85- ƒƒCƒ„ƒn?[ƒlƒX?iƒtƒƒ“ƒg?j
coil
3 4coil
Main to ?ywork lamp?z

Harness(Work-lamp)
1 2
?ymain?z to work lamp

contact
com
5A 0.5-Y/R relay source Antitheft Power Source
CN459 1 CN100
CN55
CN250-1pf Anti thieft ESS relay
CN18
7123-2810 3-R/W Working lamp(+)
EU(without Antitheft) 0.85-Y
1.25-Y
1
0.5-B
0.5- 1
2 2
0.5-
0.85-B
0.5- 0.85-B
CN100
0.5f-L(AVX)
Fuel Sensor
CN17 Working lamp(-)
1.25-B
3-RW
Glow relay
1.25-B
2 1 0.5-B
coil coil M5 Fuel Sensor GND
4 3
com NO CN101
3-B
M8 GND
3-R
RA231-5341Δ 3-B
CN102
Harness (Main theft) 3-RW EU(Antitheft)

M8 GND
3-R
RA238-5341Δ
EU
Harness (Main theft)-(EU) 3 2 1
RA238-5331Δ 6 5 4 0.5-B
Harness (Main)-(USA) FW-L-6F(7323-8969)

6pf
RA231-5331Δ
5-R
AUX_Controller
0.5-W/R
Harness (Main)-(CHN) 0.5-R/G
0.5-R/G
+
0.5f-B
- + -
0.5-R
RA221-5322Δ
2 1 2 1
174352-2(7323-8321)
Battery Cable (+)
174352-2(7323-8321)
SBF(alternator) AUX.[L]control_SOL AUX.[R]control_SOL
60A CN428 CN427
RA231-5326Δ
Battery Cable (-)
50A
SBF(main)
5-R
3-B/W
0.5f-B(AVX)
CN41
2f-R/W
2f-R/W
3-B/R(AVX)
1 Battery
2 1
2 1 store pull
M4 M6
1
2
‚k‚`’[Žq CN28 3 2 1 CN36

M8 ƒoƒbƒeƒŠ?[?{’[Žq CN25 CN32 E. oil switch
Vcc Vout GND E. stop solenoid
CN114 CN113 Water temp. senser
CN37 CN115 Alternator
CN33
Startor(+B) Starter(50) Alternator(+B) E, speed sensor
Glow plug
V-M-55
V-M-56
WSM U17-3α/U17-3/U17 Service V. ELECTRICAL SYSTEM
Service Section
A. TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-3
a. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-3
b. Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-4
c. Panel Relevant (Key Switch: ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-5
d. Panel Relevant (Engine Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-6
e. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-7
B. TROUBLE/ALARM DISPLAYS AND CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . . V-S-9
C. INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-11
a. Coupler Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-11
b. Components Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-12
c. Fuse Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-15
d. Harness Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-16
e. Battery Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-16
f. Measuring Instruments and Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-17
D. WIRE HARNESS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-19
a. Precautions in Clamping the Electrical Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-19
b. Harness Layout, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-21
c. Engine's Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-22
d. Engine's Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-25
e. Cabling the Unload and Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-26
f. Routing the Front Electrical Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-28
g. High-speed Switch, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-29
h. Electrical Cabling (Engine Room, Fuel Sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-30
i. Electrical Cabling route (Unload, Horn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-31
j. Electrical Cabling (Horn and Dual-speed Wire Harnesses in Right-hand Console) V-S-32
E. MAIN COMPONENTS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-33
a. Checking the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-33
b. Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-33
c. Checking the Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-34
d. Checking the Glow Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-35
e. Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-36
f. Unload Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-37
g. Hi-Low Travel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-39
h. Checking the Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-40
i. Checking the Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-43
j. Checking the Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-45
k. Engine Stop Solenoid and Coil Commander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-47
l. Checking the Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-48
m. Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-49
n. Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-51
o. Installation of Canopy Light for KTA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-52
V-S-1
F. ANTI-THEFT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-S-55

a. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-S-55
b. Anti-theft system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-S-56
c. Troubleshooting: Display indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-S-59
V-S-2
A. TROUBLESHOOTING
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-
essary 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)
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?
If not specified, no current flows.
3. “Earth”
Is the system completely grounded?
If not grounded as specified, the electrical circuitry fails to function well.
4. “Insulation”
Are the system’s insulation resistances as specified?
If an electric leak occurs, the current gets out of spec and the electrical devices malfunction.
V-S-3
b. Engine
Trouble Check item Remedy
1. The starter does (1)Check the slow-blow fuse (50A) and fuse (10A) for blowouts. Check or replace.
not run. (2)Check the battery terminal for looseness. Retighten.
(3)Hold the starter switch in the starting position and check if a Charge or replace.
voltage of 10.5 V or more appears between the both ends (+, –)
of the battery.
(4)Hold the starter switch in the starting position and check if a Repair or replace.
voltage of 9V 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 (1)Turn On the key switch and check if fuel overflows into the tank. Check visually.
but the engine (2)Turn On the key switch and check by hand if the fuel pump is Replace.
does not start. running.
(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 Repair or replace.
engine stop solenoid coupler.
3. The cold- (1)Check if the battery voltage is normal. Charge or replace.
temperature (2)Check the glow relay fuse for blowouts. Replace.
starting property
(3)Check by hand if the glow relay is running. Replace.
is poor.
(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-4
c. Panel Relevant (Key Switch: ON)

1. The glow lamp fails (1)Feel the glow relay by hand to see if it is activated. Replace.
to light up. (2)See if the meter-side coupler is disconnected. Repair or replace.
(3)See if a voltage is applied to the large meter coupler (9). Replace.
(4)See if the lamp is broken. Replace.
2. The charge lamp (1)See if the fuse (10A) is blown out. Replace
fails to light up. (2)See if the alternator coupler is disconnected. Repair or replace.
(3)See if the meter-side coupler is disconnected. Repair or replace.
(4)See if the lamp is broken. Replace
3. The oil lamp fails to (1)See if the fuse (10A) is blown out. Replace.
light up. (2)See if the oil switch coupler is disconnected. Repair or replace.
(3)See if a voltage is applied to the oil switch coupler. Repair or replace.
(4)Disconnect the harness terminal from the oil switch and
ground it to the machine body. See if the lamp lights up.
(5)Measure the engine oil pressure. Repair.
4. The fuel short (1)See if the fuse (10A) is blown out. Replace.
warning lamp fails to (2)See if the charge and oil lamps are both on. Repair or replace.
light up. ON: Normal
OFF: Defective
(3)Ground the harness terminal of the fuel sensor to the Repair or replace.
machine body.
ON: Normal
OFF: Harness broken
(4)See if the panel lamp bulb is broken. Replace.
V-S-5
d. Panel Relevant (Engine Starting)

1. The charge lamp (1)See if the 50A fuse is blown out. Replace.
fails to go out. (2)See if the alternator terminal B or coupler is disconnected. Repair or replace.
(3)See if the alternator functions as specified. Repair or replace.
2. The oil lamp fails to (1)See if the oil amount is as specified. Add.
go out. (2)See if the oil switch coupler is disconnected. Repair or replace.
(3)See if a voltage is applied to the oil switch coupler. Replace.
(4)Measure the engine oil pressure. Repair.
3. The water (1)See if the fuse (10A) is blown out. Replace.
temperature gauge (2)See if the water temperature gauge coupler is disconnected. Repair or replace.
fails to function.
(4)See if a voltage is applied to the water temperature gauge Replace.
coupler.
(5)See if the water temperature sensor functions as specified. Replace.
4. The fuel short (1)See if the fuel is enough inside.
warning lamp fails to (2)See if the fuel sensor functions as specified. Replace
light up.
5. The fuel gauge fails (1)See if the fuse (10A) is blown out. Replace.
to function. (2)See if the fuel sensor coupler is disconnected. Repair or replace.
(4)See if a voltage is applied to the fuel sensor coupler. Replace.
(5)See if the fuel sensor functions as specified.
V-S-6
e. Others
1. The machine does (1)Check the fuse (5A) for blowouts. Replace
not run in spite of (2)Check the lever lock solenoid coupler and switch coupler for Repair or replace
the machine lock disconnection.
lever being
(3)Interchange the lever lock solenoid coupler and 2nd-speed Repair or replace
released.
solenoid coupler.
(4)Check if a voltage is applied to the lever lock solenoid coupler Repair or replace
and switch coupler.
(5)Check the solenoid valve. Repair or replace
(6)Check if the lever lock switch is normal. Replace
2. The travel speed (1)Check the fuse for blowouts. Replace
does not change in (2)Check the 2nd-speed solenoid coupler and switch coupler for Replace
spite of the two- disconnection.
speed pedal being
(3)Interchange the 2nd-speed solenoid coupler and lever lock Repair or replace
pressed.
solenoid coupler.
(4)Check if a voltage is applied to the 2nd-speed solenoid Replace
coupler and switch coupler.
(5)Check the solenoid valve. Replace
(6)Check if the 2nd switch is normal. Replace
3. The horn does not (1)Check the fuse for blowouts. Replace
sound in spite of the (2)Check the harness from the grip (horn switch) for breaking. Repair or replace
horn switch being
(3)Check the horn coupler and grip (horn switch) coupler for Repair or replace
pressed.
disconnection.
(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 (1)Check the fuse for blowouts. Replace
does not go on in (2)Check the working light terminal and switch coupler for Repair or replace
spite of the working disconnection.
light switch being
(3)Check if a voltage is applied to the working light terminal. Replace
pressed.
(4)Check the lamp for blowouts.
V-S-7
V-S-8
B.TROUBLE/ALARM DISPLAYS AND CHECKPOINTS

Quick Diagnosis
1. Meter readings being displayed ⇒ Meters functioning
2. Trouble/alarm displays to be checked
3. Failure log displays to be checked
4. Wire harness connectors to be diagnosed and checking in tester mode
1. Meter panel and couplers 2. Meter readings to be as specified? 3. Checking for unusual meter readings
4. Checking the failure log 5. Calling the tester mode for detained 6. Machine model on the screen KX41-3
1 → : Start the engine. 2 − : Nothing particular (no display) 3 Engine : ENG checking instead of U17/U17-3.
No. Location Display when in order Display/alarm when in trouble Failure log display Wire harness breakdown diagnosis Checking in tester mode Possible cause/correction/remarks
Refuel to specified level - - - 1 Fuel amount drop below 7L 1 Add fuel to specified level.
1 Fuel level Dots marked according to level
No fuel level dots marked Fuel sensor broken Voltage over 2V, beep tone Voltage over 2V 2 Wire harness coupler broken 1 No fuel level alarm displayed
displayed → OFF - 1 10A fuse blown out 1 No operating sound heard from fuel pump
OFF, flashing and beep tone OFF 1 60A fuse blown out 1 Check the fan belt for breakage or slippage.
± displayed → ON 2 Get the engine started in tester mode. See if the
2 Charging system − + → OFF Charging error inspected 1 Terminal B broken
Charging error in several min- battery voltage soon becomes 13 ∼ 15V.
utes - ON 1 Terminal L short-circuited 3 Check for disconnection by turning on and off the
charger in tester mode. (OFF when disconnected)
displayed → OFF - 1 IG/L coupler broken 4 Check the alternator itself for damage.
OFF, flashing and beep tone OFF
Engine oil indicator - 1 Wire harness coupler broken 1 Add engine oil to specified level.
Engine oil indicator ON 2 Detach the oil switch and measure the oil pres-
3 Engine oil Engine oil indicator ON → OFF Engine oil pressure out 1 Engine oil too low, or short-
Engine oil pressure out of spec - ON sure.
of spec circuit 3 Check the oil switch itself for damage.
in several minutes →
1 Glow time too long (about 10 seconds) regard-
1 Wire harness coupler broken
Water tempera- Dots marked according to tem- No temperature dot indicator dis- Water temperature sen- Water temperature indicator flash- less of cooling water temperature
4 Over 4.8V displayed 2 Sensor itself in trouble
ture sensor perature played sor in trouble ing, and beep tone 2 Water temperature up, but its indicator not dis-
played
Engine failure to get started - - - 1 Meter's 10A fuse blown out
With the key OFF, press the Hour meter failure to get dis- 1 Meter's 5A fuse blown out
Power supply sys- switch, and the hour meter played even by pressing the - - - 2 Short-circuit along meter's 5V 1 LCD meter in trouble, only alarm lamp on
5
tem gets displayed. switch with the key OFF line
Overvoltage error and unusual 1 Possible to get alternator or the like in trouble
- Overvoltage error - - 1 Getting started at 24V
charging to be checked
Machine operable with no spe- Machine inoperable even with 1 With lever lock ON, the engine can get started.
- - - 1 Wire harness coupler broken
cific display lever lock ON no specific display lever lock ON The machine cannot run, however.
Solenoid valve for 2 Check continuity between the lever lock switch
6
lever lock function 1 Short-circuit terminals.
- Lever lock in trouble Lever lock in trouble - Lever lock OFF 3 Check continuity between controller and sole-
2 Solenoid valve in trouble
noid valve.
V-S-9
V-S-10
C. INSPECTION
a. Coupler Check
CONTINUITY AND VOLTAGE TEST FOR CONNECTOR
Following procedures shall be followed for testing continu-
ity and voltage at connector in order to prevent improper
contact and deterioration of waterproof in connector.
CONVENTIONAL (NON-WATERPROOF) CONNECTOR

Check shall be done by inserting a probing needle from
harness side.
WATER PROOF CONNECTOR

Caution
Do not insert probing needle from harness side as it
will deteriorates waterproof and cause for rusting.
CHECK FOR IMPROPER ENGAGEMENT OF TERMI-

NAL
When terminal stopper of connector is out of order,
engagement of male and female terminals becomes
improper even when connector itself is engaged perfectly
and terminal sometimes slips out to rear side of connector.
Ascertain, therefore, that each terminal does not come off
connector by pulling each harness wire.
ENGAGING AND DISENGAGING OF CONNECTOR

TERMINAL
Connector which gives loose engagement shall be recti-
fied by removing female terminal from connector housing
and raise its lance to establish securer engagement.
Removal of connector housing and raise its lance to
establish securer engagement. Removal of connector ter-
minal used for control circuit shall be done in the following
manner.
COMPUTER CONNECTOR
(1) Insert screwdriver [1.4 mm (.06 in.) width] as shown in the
figure, disengage front holder and remove it.
(2) Insert harness of terminal to be rectified deep into connec-
tor from harness side and hold it there.
V-S-11
b. Components Check
1) Visual and aural checks
Check relay operation, blower motor rotation, light illumina-
tion, etc. visually or aurally. The flow of current is invisible
but can be checked by the operation of the parts.
2) Simple checks
For example, if a headlight does not come on and a faulty
fuse or poor grounding is suspected, replace the fuse with
a new one or ground the light to the body by a Jumper wire
to determine which part is responsible for the problem.
3) Checking with instruments

Use and appropriate instrument in an adequate range and
read the indication correctly. You must have sufficient
knowledge and experience to handle instruments correctly.
4) Inspection instruments
In inspection, make use of the following instruments.
1. Test lights
A test light consists of a 12 V bulb and lead wires. It is used
to check voltages or short-circuits.
2. Self-power test light

A self-power test light consists of bulb, battery and lead
wires connected in series. it is used to check continuity or
grounding.
V-S-12
3. Jumper wire
A jumper wire is used to close an open circuit. Never use
one to connect a power supply directly to a load.
4. Voltmeter
A voltmeter is used to measure the circuit voltage.Nor-
mally, the positive (red lead) probe is applied to the point of
voltage measurement and the negative (black lead) probe
to the body ground.
5. Ohmmeter
An ohmmeter is used to check continuity or measure resis-
tance of a switch or coil. If the measuring range has been
changed, the zero point must be adjusted before measure-
ment.
V-S-13
5) Checking switches
In a circuit diagram, a switch is represented by a sym-
bol and in the idle state.
1. Normal open or normal close switch

Switches are classified into those which make the circuit
open and those which make the circuit closed when off.
V-S-14
c. Fuse Inspection
1) Checking fuses
A blade type fuse has test taps provided to allow checking
of the fuse itself without removing it from the fuse block.
The fuse is okay if the test light comes on when its one
lead is connected to the test taps (one at a time) and the
other lead is grounded.
(Change the key switch position adequately so that the
fuse circuit becomes live.)
Cautions in event of blown fuse

State of fuse blown due to overcurrent
When a fuse is blown, there are two probable causes as
follows: One is that it is blown due to flow of current
exceeding its rating. The other is that it is blown due to
repeated on/off current flowing through it. Which of the two
causes is responsible can be easily determined by visual
check as described below.
(1) Fuse blown due to current exceeding rating
The illustration shown the state of a fuse blown due to
this cause. In this case, do not replace the fuse with a
new one hastily since a current heavy enough to blow
the fuse has flowed through it. First, check the circuit for
short-circuit and check for abnormal electric parts. Only
after the correction of such shortening or parts, fuse of
the same capacity should be used as a replacement.
Never use a fuse of larger capacity than the one that
has blown, If such a fuse is used, electric parts or wir-
ings could be damaged before the fuse blows in the
event an overcurrent occurs again.
State of fuse blown due to thermal fatigue
(2) Fuse blown due to repeated current on/off
The illustration shown the state of a fuse blown due to
repeated current on/off. Normally, this type of problem
occurs after fairly long period of use and hence is less
frequent than the above type. In this case, you may sim-
ply replace with a new fuse of the same capacity.
V-S-15
d. Harness Check
1) Check connections for looseness, rust and stains.
2) Check terminals and wires for corrosion by battery elec-
trolyte, etc.
3) Check terminals and wires for open circuit or impending
open circuit.
4) Check wire insulation and coating for damage, cracks
and degrading.
5) Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6) Check grounding parts to verify that there is complete
continuity between attaching bolt(s) and vehicle body.
7) Check for incorrect wiring.
8) Check that wirings are so clamped as to prevent contact
with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, pipe, etc.).
9) Check that wirings are clamped firmly to secure enough
clearance from the fan pulley, fan belt and other rotating
or moving parts.
10) Check that the wirings between the fixed parts such as
the vehicle body and the vibrating parts such as the
engine are made with adequate allowance for vibrations.
e. Battery Check
When checking or servicing does not require power from the
on vehicle battery, be sure to disconnect the cable from the
battery (-) terminal. This is to prevent problems that could be
caused by shorting of the circuit. Disconnect the (-) terminal
first and reconnect it last.
Caution
1. Before connecting or disconnecting the negative cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of semicon-
ductor parts being damaged.)
V-S-16
f. Measuring Instruments and Special Tools

Use the following testers and special tools to carry out the inspections safely and quickly.
• Hioki Digital Hi-Tester (3256-01)
Feature: Frequency (Hz) measurement possible
• Special tools
Use these tools if the test leads are not easily inserted or fixed in the couplers or connectors.
Product name: Ranger Harness 2 Product name: Tester Lead Set
V-S-17
V-S-18
D. WIRE HARNESS INSTALLATION

a. Precautions in Clamping the Electrical Cabling
1) Insert the band clips into the mating holes to
(1) clamp the wire harness.
2) Clamp the wire harness tightly.
* Make sure the wire harness does not stretch
out of the slit of the corrugated tube.
* Clamp the cord at the corrugated section.
(2)
(1) Wire harness

(2) Clamp here

No contact and possible Keep the unprotected sections free of any contact. Vibrations
S contact with nearby parts ↓
Cover come-off
↓
Short-circuit, fire
Understanding of routing Do not clamp together with the fuel hose. Short-circuit
S ↓
Connect the couplers, terminals, etc. tightly enough. Not to Flammable
come off by slight pull. ↓
Fire
↓
Vibrations
↓
Come-off, no continuity
Clamping of wire harness Make sure the clamps are applied as specified. Poor clamping
S in position * Anchor type: Hook up the clamp tight enough. ↓
* Screw type: Screw in the clamp deep enough. Vibrations
* Insertion type: Insert the clamp until it locks. ↓
Short-circuit, fire
Tight clamping of wire har- Make sure the clamps and connectors are tightly hooked into Poor clamping
S ness position. ↓
Vibrations
↓
Short-circuit, fire
V-S-19
(1)
(3)
(2)
(6)
(4)
(5)
(7)
(1) Fix the wire harness of slow-blow fuse battery in the opening of fan shroud.
(2) Fix the connector from the fuel tank to the bracket (coupler).
(3) Bracket (coupler)
(4) Fuel tank
(5) Retainer (fuel tank)
(6) Hydraulic tank
(7) Main wire harness
V-S-20
b. Harness Layout, Overview
V-S-21
c. Engine's Back
(1)
(2)
(1)
(3)
(4)
(1) Apply the clamp here.

(2) Battery cable (positive) and dozer cable
Pass the anti-theft unit cable through the opening of
vertical rib.
(3) Anti-theft unit cable
(4) Insert the battery cable (positive) from the machine (2)
front. (1) Slow-blow fuse
(2) Engine safety stop fuse

Tightening of cable fixingTightening torque Too high torque
S nut to self-starting motor5.9 ~ 11.8 N·m ↓
(0.6 ~ 1.2 kgf·m) Damaged contact, engine start
(4.34 ~ 8.68 ft·lbf) failure
Starter switch Adjust the starter switch groove to the projection of cover (right, Wrong setup direction
S (RC411-5346Δ) top). ↓
Key return failure
Tightening torque of nut ↓
4.0 ~ 5.0 N·m Motor burn-out
(0.4 ~ 0.5 kgf·m) ↓
(2.89 ~ 3.62 ft·lbf) Too high torque
↓
Damage
↓
Key return failure
↓
Too low torque
↓
Come-off
Checking of starter auto- Connect the starter switch to the start position to start the Malfunction
S matic release performance engine. Make sure the starter gets turned off immediately. ↓
Key return failure
Starter seizure
V-S-22
(1)
(1)
(2) (2)
(3)
(4)
(5)
(6)
(7) (1) Insert at the front.
(2) Battery cable (positive)
(1) Straight upward (5) Fixed in the lower opening Dozer cable
(2) Bolt (VT, M8) (bolt) The wire harness for the anti-theft unit passes through the
(3) Cable (body ground) (6) Straight downward vertical rib.
(4) Straight upward (7) Battery cable (positive)
(1)
(2)
(2)
(1)
(3)
(1) Key setting connector (1) Oil Switch

(2) Slow-blow fuse (2) Insert into the guide clips.
(3) Ensure a clearance of over 5 mm with the inside connector.
(1) Power cord to go into the upper opening

(2) Power cable (positive) to pass behind the arch
(3) Negative cord to go into the lower opening
(4) Negative terminal to face just sideways toward the
machine front
V-S-23
(1)
45°
(2) (3) (5)
(4)
(8) (9)
(10) (11)
(1) T1066-30372
Bolt (VT, M8)
(2) Finally make sure this part faces toward the back of the machine.
(3) RA221-5322Δ
Battery cable (positive)
To face just downward
(4) 01135-61020
Bolt
To face just downward and be fixed in the lower hole
(5) RA221-5324Δ
Cable (body ground)
(6) Wire harness
(7) Slow-blow fuse
(8) Groove
(9) Cover (right, top)
RA231-4475Δ
(10) Projection
(11) Starter switch
RC461-5396Δ
V-S-24
d. Engine's Top
(1) Bi-speed: Insert into the right hole. (1)
Connect the yellow wire harness (white-marked) and
the wire harness (white-marked) below the unload
valve.
(2) Hook the wire harness.
(3) Unload: Insert into the left hole.
Connect the green wire harness and the wire harness
located above.
(1) Couple with ESS.

(2) Water temperature sensor
(3) To alternator and starter
(1) Connect the stop solenoid.

(2) Tighten the glow terminal facing rightward.
(3) Insert the clip.
(4) Tighten the stay (harness 1, boom 3) (RP821-6738Δ)
to the water flange with the new bolt (01123-60830).
(2) (3)
(1)
(3)
(2)
(1) Fuel pump
(2) Ground
(3) Unload (4)
Left-hand hole
Green wire harness
Upper solenoid
(4) Dual-speed
Right-hand hole
Yellow wire harness
Lower solenoid
(1)
(1) Glow plug
Pass below the guide.
V-S-25
e. Cabling the Unload and Horn Switch

(1) Fix the two spots from inside.
(2) Pass behind the round bar.
(3) Clamp the two spots.
(4) Insert the clip in the swivel
frame.
(1) (5) Pass behind the pilot hose (at
the oil cooler side).
(2)
(3) (5)
(4)
(1)
(2)
(1) Switch (limit)

(2) Connector
(1) Cabling the horn switch at (1) (3)

the right of the console
(2) With the cables clamped, (2) (4)
move the lever in all direc-
tions to make sure there is
a clearance of one finger
around.
(3) Fix the main harness con-
nector and cabling clamp
tightly with the bracket. (5)
(4) Clamp (143L)
(5) Crimp with a crimping tool.
(6) Clamp (112L, 2-3.2T) (6)
(1) Clamp at the spot just out

of the hole.
(2) Clamp and fix to the 5.5 (1)
hole.
(2)
V-S-26
Fitting of the control devices (limit switch)

No. Item Points to remember
1 Performance of the limit Make sure the limit switch functions as specified. Malfunction
switch Countersunk machine screw ↓
Fitting of the limit switch (03056-50520) Unload malfunction
3.9 ~ 4.9 N·m
(0.4 ~ 0.5 kgf·m)
Apply screw adhesive.
No gap allowed at Point (A) with the limit switch locked Limit switch overloaded
↓
Poor durability
2 DU bushing bearing Apply grease. Greasing failure
↓
Rotating resistance too high
Too much grease

↓
Poor appearance
1 A
10
3
4 5

1 Switch (limit) 1
Countersunk machine screw 2 M5
2 Tension spring 1
3 Lever (lock, 2) 1
4 Switch (limit) 1
5 Pedal (acceleration) 1
(6) Unload lever

(7) Dual-speed pedal (for Japan-destined machines only)
V-S-27
f. Routing the Front Electrical Cables

(3)
Routing of the Pass the wire har- Caught by the hose
wire harness at ness below the ↓
the swing bracket boom support pin. Broken wire, difficulty
when replacing
(2)
(1)
(4)
(6)
(1) With the connector connected, store the wire harness in the corrugated section.
(2) Cord clamp 34260-29381
Tighten the cord clamp together with the working light lock bolt.
(3) Cord band 55311-41261
Secure the wire harness to the member on the boom's side.
(4) Pass the wire harness through the opening first and then the boss-side plate. (5)
(5) Pass below the boom pin.
(6) Fix the anchor clamp to the fixture.
4 2 1 3
No. Part Name Q’ty Remarks (7)

1 Lamp 1
(working light)
2 Guard 1 Blue No. 19:
(light) Japan and China
Guard 1 Red No. 1:
(light) Europe, USA and Australia
3 Bolt 1 7T
4 Nut 1
(7) Place the light with its lighting face in parallel with the boom bottom plate.
V-S-28
g. High-speed Switch, Horn

(1)
(6)
(5)
(5) Insert
(2) (1) ECU (anti-theft) (6) RD411-5347
(2) Connect to the wire harness of Switch (Limit)
anti-theft unit.
(3) (3) Pass between the counterweight
and battery mount.
(4) (4)
(1)
(4)
(2)
(3)
(1) 36919-8262Δ
Collar
(2) 01125-60816
Bolt
(3) RD809-5371Δ
Horn assembly (111DB)
010 Battery 1 (4) Insert the clamp into position.
020 Label (battery) 1
025 Rubber pad (fuel tank) 1
030 Plate (battery) 1
040 Bolt 3
045 Trim (plate, auxiliary) 1
050 Cushion (fuel tank, 3) 3
060 Retainer (battery) 1
070 Cushion (rubber 2) 2
080 Bolt (hook) 1
090 Plain washer 2
100 Nut 4
105 Spring washer 2
110 Battery cable (positive) 1
(1) 36919-8262Δ
120 Battery cable (negative) 1 Collar
130 Bolt (VT, M8) 1 (2) 01125-60816
Bolt
140 Cable (body ground) 1 (3) RD809-5371Δ
150 Bolt (VT, M8) 1 Horn assembly (111DB)
160 Bolt 1
V-S-29
h. Electrical Cabling (Engine Room, Fuel Sensor)

Engine room front top
(1) Secure tightly through the M6 hole of the engine bracket.

(2) Connect with the main wire harness.
(3) RA231-5333Δ
Wire harness (rotating sensor)
(4) RC418-5345Δ
Socket assembly
V-S-30
i. Electrical Cabling route (Unload, Horn)

Destined for Japan and China only
(4)
(6) (10)
(7)
(8)
(5)
(9)
(JAPAN)
(1) Secure a two points from inside.

(2) Unload switch
(3) Connector
(4) Pass through the notch.
(5) Pass the branch line on this side.
(6) Horn switch cabling at the right-hand console
(7) Clamp the cable and move the lever in all directions.
Then ensure a clearance as wide as one finger.
(8) 200 mm long up to the clamp
(9) Crimp the terminals with a crimping tool.
(10) RC411-5304Δ
Clamp (143L)
(EU-version) (EU-version)
V-S-31
j. Electrical Cabling (Horn and Dual-speed Wire Harnesses in Right-hand Console)
(3)
(2)
(1) Pass through the arch's notch.

(2) Insert the clamp into position.
(3) Pass behind the acceleration cable.
(1)
V-S-32
E. MAIN COMPONENTS MAINTENANCE

a. Checking the Fuses
(1) Check points Fig. 1
Check the slow-blow fuse (50A) for continuity. (Fig. 1)
Check also the fuse (10A) for continuity. (Fig. 2)
7777772#
Fig. 2
(1)
(1) Fuse box
7777772#
b. Checking the Battery

(1) Check points
Voltage 12 V
Capacity (5 hr.) 36 Ah
Weight (with fluid) 12.5 kg (27.6 lbs)
Electrolyte amount 3.2 L (0.85 us gal.)
Specific gravity 1.28 ± 0.01 (20°C)
Start the engine.

Bring the circuit tester probes to the battery's positive
and negative terminals.
Reading over 10.5 V: Battery normal Fig. 8
Reading below 10.5 V: Charge or replace the battery.
Fig. 3
7777772#
V-S-33
c. Checking the Horn

(1) Measuring the horn terminal voltage (Fig. 41)
Fig. 41
* Key switch: ON (1)
* Horn switch: ON
12 V: Normal. Check the horn itself.
Other than 12 V: Check for continuity and the
horn switch itself.
(1) Horn switch

(2) Checking the horn switch (Fig. 42) Fig. 42
* Turn on and off the horn switch to make sure the
tester pointer swings accordingly.
Swing: Normal
No swing: Defective
(3) Checking the horn (Fig. 43)

* Apply 12V voltage between the horn terminals to Fig. 43
make sure the horn sounds.
Sound: Normal
No sound: Defective
(4) Checking for continuity

* Disconnect the coupler.
* Key switch: OFF
(1) Check for continuity between the horn coupler and the harness coupler.
(2) Check for continuity between the horn switch coupler and the 10A fuse box.
V-S-34
d. Checking the Glow Relay

(1) Checking the glow relay performance (Fig. 13) (1)
(1) Keep your hand in slight touch with the glow
relay.
(2) Key switch: ON
(3) Make sure the glow relay clicks as specified.
Click: Normal. Check the glow plug voltage.
No click: Measure the voltage and check for
continuity. Check also the glow relay (Fig. 17)
(2) Measuring the glow relay coupler voltage (Fig. 14)

* Disconnect the glow relay coupler CN17.
* Key switch: ON
* Measure the voltage between the coupler CN17
[1] and [2], as well as between the coupler CN17
[3] and [4].
12 V at both (1) and (2): Glow relay defective
Other than 12 V: Wire harness broken (1) Glow relay
(3) Checking the glow relay (Fig. 17) Fig. 13

(1) Measure the resistance of the glow relay
alone.
Specification 52-80 Ω
Actual reading About 78 Ω
* Apply 12V voltage between (1) and (2) of the

glow relay and make sure there is continuity
between (3) and (4).
Continuity: Normal
No continuity: Defective Fig. 14
(4) Measuring the meter coupler voltage

* Disconnect the meter coupler.
* Key switch: ON
pins (7) and (17). (2)
12 V: Meter defective
Other than 12 V: Wire harness broken. Check
for continuity.
(3)
(2) Glow relay

(3) Glow plug
Fig. 17
V-S-35
e. Glow Plug
(1) Function of the glow plug (7)
This plug is of two-material QGS (Quick Glow Sys-
tem) type. It features quick temperature rise, self-
control function and high durability. (5)
The Super Glow plug has a heating element and a (1)
(3) (8)
heating-cum-resisting element built in a sheathing
tube. These elements are connected in series.
(9)
The lower temperature the heating element is, the
lower resistance it shows, and vice versa. (2)
(6)
Because a sufficient current flows initially through
the heating element, the element quickly gets (4)
heated and its resistance becomes higher. This (10)
means that the flowing current will get smaller to
prevent the heating element from overheat. (1) Heating-cum-resisting (6) Current (A)
The glowing point is located 2-3 mm around the tip element (7) Super Glow plug
to keep the projection into the combustion cham- (2) Heating element (8) Conventional quick-heat
(3) Sheathing tube glow plug
ber relatively short. (4) Insulating powder (9) Glow plug current
(5) Glow plug temperature (10) Power-on time (sec.)
(1) Unload lever (°C)
(2) Bi-speed pedal (for Japanese market only)
(2) Checking the resistance

1. Disconnect the glow plug from the cylinder
head.
2. Check the resistance between the glow plugís (1) (2)
tip (terminal) and the housing.
3. If the resistance is 0 Ω, it means there is a
short-circuit. Replace the glow plug. If the
resistance is infinite, the heating coil is broken.
Replace this coil.
Glow plug Reference About 0.9 Ω
resistance value (at room temperature)
(1) Terminal (2) Housing

(3) Measuring the glow plug voltage (Fig. 15)
* Disconnect the glow plug LE terminal. Fig. 15
* Key switch: ON
* Measure the voltage between the LE terminal
and the body ground.
* The voltage is 12 V first and then becomes 0 (2)
V in 10 seconds.
12 V to 0 V: Glow plug defective
Other than 12 V: Glow controller defective.
Glow relay defective. Wire harness broken.
(3)
(2) Glow relay

(3) Glow plug
V-S-36
f. Unload Safety Switch

(1) Points to remember in reassembling
Limit switch performance See if the switch functions as specified. Poor performance
↓
Fitting of limit switch Countersunk screw (03056-50520)
3.9 ~ 4.9 N·m (0.4 ~ 0.5 kgf·m) ( ~ ft·lbf)
Apply thread adhesive Poor unloading
With the limit switch side locked, no gap is allowed at Part (A). Overloaded limit switch
↓
Poor durability
DU bushing bearing Apply grease. No greasing
↓
Greater turning resistance
Too much grease
↓
Poor appearance
1 Switch (limit) 1 (6)

Countersunk screw 2 M5
2 Tension spring
3 Lever (lock, 2)
4 Switch (limit)
5 Pedal (acceleration)
6 Bi-speed switch
7 Bi-speed solenoid valve
* The limit switch component parts are
not supplied as parts.
(7)
V-S-37
2) Unload limit switch
(18)
(17)
(13) (16)
(15)
(14)
(19)
(22)
(21)
(20)
ITEM DRW. No. PART NAME Q’TY MATERIAL DIMENSION SEUFACE TEXT REMARKS
1 KE1-401 Plunger 1 SWRM8 φ5 KFZa8-3K
2 P-56 Plain washer 1 SPCC t1 MFZa8-3B
3 RC411-53961 Boot 1 B 510-01 BLACK
KE1-701
4 P-31 Contactor 1 C1100P 10.5
5 KE1-101 Body 1 ZDC Chromate (black)
6 KE2-021A Terminal block complete 1 PM-EE
7 KE1-301 Packing 1 10.5
8 CE77-601 Cord 1 AV 0.5
9 R-P5 O-ring 1 P5
10 YG3-501 Action spring 1 SWPA φ 0.45
11 YE23-201 Roller 1 POM Natural
12 S-58 Spring 1 SWPA φ 0.8 KFZa8-3B
(1) * Stroke
(2) Not to stretch out of the mounting face
(3) Apply silicone resin.
(4) Crimp. (4 spots)
(5) PVC tube, black
(6) Sumitomo 6195-0006 (dark gray)
Water-proof connector M
(7) Mounting face
(8) Surface treated
(9) Crimp. (all around)
(10) Internal details
V-S-38
g. Hi-Low Travel Switch

Green-colored hi-low switch for EU and PP-version
(1) With the cover in place, the wire

harness must not come out of
the bottom.
(2) To be secured here.
(3) Apply the clamp here.
(4) Pass behind the acceleration
cable.
010 Assy lever, blade 090 Shaft, blade

020 Bush 100 Bolt
030 Washer, plain 110 Pin, joint
040 Pin, snap 120 Pin, snap
050 Seal, blade lever 130 Link, plate
060 Grip 140 Cable, blade
062 Button, switch green 150 Bracket, blade cable
064 Screw, pan-head 160 Bolt
066 Clamp 170 Washer, plain
070 Assy link, blade 180 Pin, snap
080 Bush
(1) Note: Japan and south Korea - version have a pedal

for Hi - Low speed change.
(1) Hi-Low pedal
V-S-39
h. Checking the Solenoid Valve

(1) Specifications
Rated voltage DC 12 V
Power consumption 14.4 W
Manufacturer Nishina Industrial Co., Ltd.
(1)
(8)
(9)
(2)
(10)
(3)
(4) (11)
(5) (12)
(6) (13)
(7) (14)
(15)
(16)
(17)
(18)
(1) Circuit diagram (6) Tab contactor (13) Plate

(2) Apply the cable tie (white) to the (7) Rubber plug (14) Tab contactor
right. (8) Positive cord: Red (15) Rubber plug
Cut off excess cable tie. (9) Negative cord: Red (16) Protective tube
(on Solenoid A only) (10) View Y (17) Length
(3) Amplifier Mark II, bipolar (on both Solenoids A and B) (18) Furukawa Beamex
(4) Housing (11) Amplifier Mark II, bipolar
(5) Plate (12) Housing
(2) Checking procedure
1. Make sure the lever lock coupler and lever lock
switch coupler are tight in position. (Fig. 33)
* The bi-speed coupler is yellow-striped (below
the valve).
* The lever lock coupler is blue-striped (above the
valve).
2. Reposition the lever lock coupler (Fig. 34)
* Replace the lever lock coupler with the bi-speed
coupler.
* Start the engine.
* Lower the unload lever.
* Step on the bi-speed pedal and see if the attach-
ment moves as specified.
Attachment motion: Solenoid valve defective.
Lever lock switch defective.
No attachment motion: Wire broken. Lever lock
switch defective.
V-S-40
3. Make sure voltages are applied at the lever lock

solenoid coupler and lever lock switch coupler. Fig. 35
* Disconnect the couplers.
* Key switch: ON, Unload lever: DOWN
(1) Measure the voltage between the solenoid
valve coupler CN12 [1] and [2].
valve coupler CN12 [2] and the body ground.
(3) Measure the voltage between the left lever lock
coupler CN11 [1] and [2]. (1)
(4) Measure the voltage between the left lever lock
coupler CN12 [2] and the body ground.
12 V: (1) and (3) normal. Check the solenoid
valve.
Other than 12 V: Check for continuity ((2) and
(4)). Check the lever lock switch.
(2)
(1) Left lever lock switch (2) Lever lock solenoid valve
4. Checking for continuity (Fig. 36)
Disconnect the couplers in advance. Fig. 36
(1) Check for continuity between the solenoid
(2) Check for continuity between the solenoid
valve coupler CN12 [1] and CN11 [1].
(3) Check for continuity between the left lever lock
coupler CN11 [2] and the 5A fuse.
(1)
(2)
(1) Left lever lock switch (2) Lever lock solenoid valve
5. Checking the solenoid valve (Fig. 37)
(1) Coil resistance Fig. 37
Specification: 6-15 Ω
* The figure at right shows measurement with
digital meters.
(Note that the positive and negative sides must
be reversed with analog meters.)
(2) Coil insulation resistance
Specification: Over 1 MΩ
V-S-41
6. Checking the lever lock switch (Fig. 38)

Key switch: OFF
Move the unload lever of the left control lever to
turn on and off the lever lock switch. Make sure
the tester pointer swings accordingly.
Swing: Normal
No swing: Defective
* For the bi-speed switch, use the acceleration
pedal.
7. Make sure voltages are applied at the bi-speed

solenoid coupler and bi-speed switch coupler. Fig. 39
* Disconnect the couplers.
* Key switch: ON
valve coupler CN13 [1] and [2].
(3) Measure the voltage between the bi-speed
(1)
switch coupler CN15 [1] and [2].
(4) Measure the voltage between the bi-speed
switch coupler CN15 [2] and the body ground.
(2)
(1) Bi-speed switch
(2) Bi-speed solenoid valve
8. Checking for continuity (Fig. 40)

Fig. 40
Disconnect the couplers in advance.
(1) Check for continuity between CN13 [2] and the
body ground.
(2) Check for continuity between CN13 [1] and
CN15 [1].
(3) Check for continuity between CN15 [2] and the
5A fuse.
(1)
(1) Bi-speed switch (2)

(2) Bi-speed solenoid valve
V-S-42
i. Checking the Fuel Pump

(1) Specifications
(1)
(2)
(3)
(4)
(5)
(1) Yazaki part codes

Connector: 7122-2820-30 (black)
Terminal: 7114-2630-02 (surface treatment: Sn-plated)
(2) AEX 1.25fB (black)
(3) AEX 1.25fB(red)
(4) Vinyl tube (white), outer dia. 6
(6) (5) Manufacturing date stamped here (Example: 1C06)
(6) Simplified code stamped here (B28)
1. Rated voltage: DC 12 V
2. Operating voltage range: DC 8.5-16.5 V
3. Maximum operating current: Below 1.5 A
4. Discharge rate: Above 400 cm3/min when open
5. Cut-off pressure (discharge pressure + suction pressure):
Average total pressure below 37.3 kPa
6. Suction pressure (when dry): Below -4.9 kPa
7. Air-tightness: Apply 98-kPa pneumatic pressure
from the suction port and discharge port for 15 sec-
onds, and make sure there is no air leak.
8. Operating temperature range: -30°C to +70°C
V-S-43
(2) Measuring the fuel pump coupler voltage (Fig. 9)

* Disconnect the fuel pump coupler CN24. (1)
Fig. 9
* Key switch: ON
* Measure the voltage between the coupler CN24 [1]
and [2].
12 V: Fuel pump defective
Other than 12 V: Check for continuity. (Fig. 10)
(2)
(1) Fuse box

(2) Fuel pump
(3) Checking for continuity (Fig. 10)

* Key switch: OFF (1)
* Disconnect the coupler in advance. Fig. 10
(1) Check for continuity between the fuel pump cou-
pler CN24 [2] and the body ground.
(2) Check for continuity between the fuel pump cou-
pler CN24 [1] and the 10A fuse.
(2)
(1) Fuse box

(2) Fuel pump
V-S-44
j. Checking the Fuel Sensor
(1) Checking the appearance

1. Make sure the relay coupler CN23 of the fuel sen-
sor is connected in position. (Fig. 29)
2. Measuring the fuel sensor coupler voltage (Fig. 30)

* Disconnect the coupler CN23. Fig. 30
* Key switch: ON
12 V: Normal. Check the sensor.
Other than 12 V: Check the voltage in (2).
(1) Measure the voltage between the sensor cou-
pler CN23 [1] and [3].
(2) Measure the voltage between the sensor cou-
pler CN23 [3] and the body ground.
3. Checking for continuity (Fig. 31) Fig. 31

* Key switch: OFF
* Disconnect the meter coupler CN1.
(1) Check for continuity between the sensor cou-
pler CN23 [1] and the meter coupler CN11 [11].
(2) Check for continuity between the sensor cou-
pler CN23 [2] and the meter coupler CN1 [14].
V-S-45
4. Checking the fuel sensor (Fig. 32)

* Disconnect the fuel sensor from the fuel tank
and check the sensor for defects. Fig. 32
* Apply the positive test lead to the coupler CN23
[3] terminal.
* Apply the negative test lead to the plated portion
to measure the resistance.
Setup location Fuel tank

Rated voltage DC 12V
Operating voltage DC 10 - 16V
Applied specifications Float position FULL 1/2 EMPTY
Resistance (Ω) 3 **32.5 110
Allowable difference (Ω) ±2 **±5 ±5
To be measured with constant 40 mA current.
Circuit diagram
1
2
3
4
5
(1) (Black)
(2) Unit
(3) (Blue)
(4) Thermistor
(5) (Red)
7777772#
V-S-46
k. Engine Stop Solenoid and Coil Commander

(1) Function
Turn the key to ON position, and the engine stop sole-
noid gets excited, attracting the plunger.
(2) Measuring the engine stop solenoid voltage

(Fig. 11)
* Disconnect the engine stop solenoid coupler
CN36.
[1] (or [2]) and the body ground.
12 V: Stop solenoid defective
Other than 12 V: Check for continuity. (Fig. 12)
(3) Checking for continuity (Fig. 12)
* Key switch: OFF
* Disconnect the coupler for checking.
* Check for continuity between the solenoid cou-
pler CN36 [1] (or [2]:) and the coupler CN457 [3].
(4) Checking the performance

Fig. 11
1. Disconnect the stop solenoid from the engine.
2. Apply DC 12V between the connector CN36 [1]
and [2] of stop solenoid to see if the plunger is
attracted.
3. If not, replace the stop solenoid with new one.
(1)
(1) Engine stop solenoid
V-S-47
l. Checking the Water Temperature Gauge

1) Measuring the water temperature gauge coupler volt- (2)
age (Fig. 26)
* Disconnect the water temperature gauge coupler.
* Key switch: ON
12 V at water temperature gauge coupler CN32 [1]:
Normal
Other than 12 V: Check for continuity.
2 Checking for continuity (Fig. 27)

* Key switch: OFF
(1) Check for continuity between the water temperature
gauge coupler CN32 [1] and the auto glow controller
coupler CN300 [2].
(2) Check for continuity between the meter coupler CN1 [7] Fig. 26
and the glow relay CN17 [3].
(1)
(3) Checking the water temperature gauge
Performance Values in ( ) for reference. (2)
With 7V, 55Ω gauge
Temperature
Resistance Current (3)
(50°C) +25.0
(153.9 -20.0 Ω) (33.5±1.6mA)
80°C 51.9 +4.9
-4.4 Ω (65.5 +2.8
-2.9 mA)
100°C 27.4 +1.9
Ω
-1.4 (85.0 +1.2
-2.0 mA)
(1) Glow relay (2) Water temperature sensor
(120°C) (161 ±1.2Ω) (98.5±1.6mA)
* Make measurements with the coupler in place.
Fig. 27
Checking for continuity
1. Put a temperature gauge and the thermal switch in water
as shown below.
2. Heat the water and see at what temperature the switch
turns on.
3. Let the water cool down and see at what temperature the
switch turns off. (1)
4. If the thermal switch fails to turn on and off, replace it with
new one.
Continuity between OFF →ON Reference 115 ±3 °C
terminal and body ON →OFF value (2)
108 °C
(3)
(1) Glow relay (2) Water temperature sensor
V-S-48
m.Oil Switch
(1) Checking for continuity
1. Disconnect the cable from the oil switch terminal.
2. Check for continuity between the terminal and the
body. (1)
3. Start the engine and check for the same continuity
as above.
4. If not as specified, replace the oil switch with new
one.
Hydraulic pressure
below 4.9 kPa (0.5 0Ω
Between kgf/cm2) 7.1 psi Reference
terminal
Hydraulic pressure value
and body
above 4.9 kPa (0.5 ∞Ω
(1) Oil switch
kgf/cm2) 7.1 psi
(2) Measuring the engine oil pressure (Fig. 24) Fig. 24

Measure the engine oil pressure.
Idling 0.4 MPa (4 kgf/cm2) 56.9 psi
MAX 0.6 MPa (6 kgf/cm2) 85.3 psi
* Oil switch operating pressure
7777772#
(1)
(2)
(3)
(1) (Stop)
(2) (Start)
(3) Pressure
V-S-49
(3) Checking the oil switch coupler
1. See if the oil switch coupler CN28 [1] is connected

Fig. 21
in position. (Fig. 21)
2. Measuring the voltage at oil switch coupler CN28

[1] (Fig. 22) Fig. 22
* Disconnect the oil switch coupler CN28 [1]
* Key switch: ON
(1) Measure the voltage at oil switch coupler CN28
[1].
12 V: Normal. Measure the engine oil pressure.
Other than 12 V: Check for continuity.
(2) Connect the oil switch coupler CN28 [1] to the
body ground.
(1)
Oil switch lamp
ON: Oil switch defective
OFF: Wire harness broken. Check for con-
tinuity.
(1) Oil switch

3. Checking for continuity (Fig. 23) Fig. 23
* Key switch: OFF
Check for continuity between the oil switch
coupler CN28 [1] and the meter coupler CN1
[2].
(1)
(1) Oil switch
V-S-50
n. Relay
(1)Location
(6)
4 Relay applications
A: Lever lock relay
A B: ESS relay
5 C: Starter relay
3 B D: T horn relay
F C Relays boxed above to be des-
G D tined for Japan and Europe only
2 H E: Cabin relay
E
F: Horn relay
G: Light relay
H: Automatic release relay
1
(7)
Details below only for anti-theft type only
(12)
(9)
(6) T1060-3371Δ (10)

Relay (glow)
(7) T1060-3372Δ
Relay (starter)
(8) Machine front (8)
(11)
No. Part Code Part Name Q’ty PP EU (9) RC461-9315Δ

Antenna (anti-theft)
1 RA231-4475Δ Cover (right, top) 1 (10) RC461-5396Δ
RA231-4475Δ Meter assembly (JP) 1 Starter switch
RA231-4475Δ Meter assembly 1 (11) 01205-60612
2 Bolt
RA231-4475Δ Meter assembly (US) 1 (12) Note:Pass the antenna (anti-theft) cable first
RA231-4475Δ Meter assembly (EU) 1 and then install the starter switch.
RA231-4475Δ Cap (switch) 1
3
RA231-4475Δ Switch (beacon) 1
RA231-4475Δ Cap (switch) 1
4
RA231-4475Δ Lamp (HI) 1
RA231-4475Δ Antenna (anti-theft) 1
5
RA231-4475Δ Cover (starter switch) 1
PP: KTC, KCL, KTA
010 Auto release controller

020 Auto glow controller
030 Relay, glow
040 Relay
050 Relay
060 Assy horn
V-S-51
o. Installation of Canopy Light for KTA

(1) Canopy area
(1) (8)
(9)
(10)
(2)
(3) (11)
(12)
(14)
(15)
(13)
(4) (5) (16)
(17)
(18)
(6)
(7)
(1) Insert from behind.

(2) View A
(3) Wire harness (light, 4P canopy) (RC418-5338Δ)
(4) Front right side
(5) Front left side
(6) Machine front
(7) Pass through the nut’s hole to outside.
(8) View A
(9) Insert from outside.
(10) Pass above the bar.
(11) From the post (left top), pass the wire harness
through the large hole first and then into the
small hole.
(12) Light assembly view (common for left and
right)
(13) Bolt (01123-60816)
(14) Bracket (lamp) (RC418-9451Δ)
(15) Work light (T0270-7530Δ)
(16) Nut (02014-60060)
(17) Plain washer (04013-60060)
(18) Bolt (01023-60660)
V-S-52
(2) Swivel frame area, KTA-version

(1)
(6)
(7) (8)
(9)
(2)
(10)
(3)
(11)
(12)
(4)
(5)
(1) Wire harness (light power) (RC418-5339Δ)
(2) Clamp with the main wire harness (2 locations).
(3) To canopy
(4) Pass between the T3 hose and the control valve.
(5) Wire harness (light, 4P canopy) (RC418-5338Δ)
(6) Connector
(7) Without canopy light
(8) With canopy light
(9) Wire harness (main)
(10) Wire harness (light power)
(11) Disconnect the connector and reconnect it as shown at left.
(12) Wire harness (light, 4P canopy)
V-S-53
(3) Control stand area

(1)
(1) Switch
(2) Relay
(3) Cover (right) inside
(4) Relay, starter
(T1060-3372Δ)
(5) Work light switch
‚e
‚d
(36919-5422Δ)
(6) Wire harness (light power)
(RA228-5339Δ)
(2) (7) Pass inside of the accelera-
tion cable.
(8) Double-speed wire harness
(3) and clamp
(9) Right side of the machine
(4) (5) (10)Tank top
(11)Clamp
(12)Pass above the fuel hose and
clamp to the return pipe.
(6)
(7)
(8)
(9)
(10)
(12)
(11)
V-S-54
F. ANTI-THEFT SYSTEM
a. Outline
Anti-theft system is now only introduced to EU and Japanese markets.
The structure and function of Anti-theft System of U17-3α are identical with those of KX41-3.
You're requested to refer to the following Code Number of Anti-theft System WSM.
Anti-theft System WSM: Code No. 97899-61431
Note: Meter panel doesn't show the model name of U17-3α. You're requested to follow the same menu flow with KX41-3.
When needed the machine set up after replacing the meter panel, you're also supposed to follow to KX41-3.
(3) (1) Meter panel
(2) Antenna
(3) Key switch cover
(2)
(1)
(7) (4) Red key
(4) (5) Black key
(5) (6)
(7) Yellow instruction guide
(6)
Model name
V-S-55
b. Anti-theft system
The excavator is equipped with an anti-theft system that restricts the engine to be started using a registered
key only. If a registered key gets lost or stolen, you can invalidate it. This will prevent the engine from being
started with this key, thus protecting the vehicle against theft.
The vehicle comes with two different types of key:

Black (individual) key
• This key is used to start the engine.
• The engine can be started by inserting the key and turning it

to the START position.
• To be able to start the engine with a black key, it must be

registered using the red key.
The engine can be started only with a key that was registered for the particular vehicle.
The scope of delivery includes two black keys, among them a spare key. The two black keys
have already been registered. Up to four keys can be registered.
Red key (for registering)
• ,IRQHRIWKHEODFNNH\VLVORVWDQRWKHUEODFNNH\FDQEHUHJLVWHUHGXVLQJWKHUHGNH\SDJH
(Next page).
• 7KHHQJLQHFDQQRWEHVWDUWHGZLWKWKHUHGNH\
The key system
• ,IDUHJLVWHUHGNH\LVORVWWKHVHFRQGDQGQHZEODFNNH\PXVWEHUHUHJLVWHUHG7KLVSURFHGXUHORFNVWKH
ORVWRUVWROHQEODFNNH\ZKLFKFDQQRORQJHUEHXVHGWRVWDUWWKHHQJLQH
• ,IWKHUHGNH\LVORVWWKHEODFNNH\VFDQQRORQJHUEHUHUHJLVWHUHG%HVXUHWRNHHSWKHUHGNH\LQDVHFXUH
ORFDWLRQ VXFK DV D VDIH LQ WKH RIILFH 1HYHU OHDYH WKH NH\ LQVLGH WKH PDFKLQH ,I LW VKRXOG JHW ORVW
QHYHUWKHOHVVSOHDVHFRQWDFW\RXUDXWKRULVHGGHDOHULPPHGLDWHO\
• 'R QRW XVH VHYHUDO RI WKHVH NH\V LQ D EXQFK 7KLV FRXOG OHDG WR HOHFWULFDO LQWHUIHULQJ IUHTXHQFLHV ZKLFK
PLJKWSUHYHQWWKHPRWRUIURPVWDUWLQJ
• $IWHUUHFHLYLQJWKHVHWRINH\VVHSDUDWHWKHPIURPHDFKRWKHU$OZD\VPDNHVXUHWKHNH\VDUHQRWSDUWRI
D EXQFK ,I RQH RI WKH EODFN NH\V IRU H[DPSOH LV LQVHUWHG LQWR WKH VWDUWHU VZLWFK WKH UHG NH\ PLJKW EH
GHWHFWHGE\WKHHOHFWURQLFV\VWHP7KLVPLJKWOHDGWRDIDLOXUHRIWKHHOHFWURQLFV\VWHP
• 0HVVDJHVLQWKHGLVSOD\FDQEHVKRZQLQODQJXDJHV
<RXU.8%27$GHDOHUFDQDVVLVW\RXLQ\RXUODQJXDJHVHOHFWLRQ
V-S-56
• If you erroneously attempt to register a black key that has

already been registered, the display will show the "Already
registered" message. This means that registration can not
be done.
• If you attempt to register a fifth black key, the display will

show the "Can't register any more" message. This means
that the registration can not be done.
Registering a black key for the machine
Register a black key only under the following conditions:

Make sure that there are no persons within the excavator's working area. It is essential to warn
persons in the vicinity of the excavator by briefly blowing the horn.
Make sure that all operational controls are in neutral position.
Starting the excavator is only allowed when the operator is sitting on the driver's seat.
Do not allow the engine to run indoors, unless the room is equipped with an exhaust gas
extraction system or otherwise well ventilated. The exhaust gas contains carbon monoxide, a
colourless, odourless, and lethal gas.
V-S-57
,QVHUWUHGNH\LQWRWKHVWDUWHUVZLWFK
Do not turn the key at this point. If the key is in the

RUN position, turn it back to the STOP position.
3UHVVWKHGLVSOD\VHOHFWRUVZLWFK
7KH GLVSOD\ VKRZV WKH 5HJLVWHU PRGH SXOO RXW UHG NH\
PHVVDJH
3XOORXWWKHUHGNH\
7KHGLVSOD\VKRZVWKH5HJLVWHUPRGHLQVHUWNH\PHVVDJH
,QVHUWEODFNNH\LQWRWKHVWDUWHUVZLWFK
Do not turn the key at this point. If the key is in the

RUN position, turn it back to the STOP position.
7KHGLVSOD\VKRZVWKHEOLQNLQJ5HJLVWHUPRGHLQVHUWNH\
PHVVDJH
$IWHUDEULHIPRPHQWWKHGLVSOD\VKRZVWKH)LQLVKSXOORXW
EODFNNH\PHVVDJH7KLVPHVVDJHLQGLFDWHVWKDWWKHEODFN
NH\ZDVUHJLVWHUHGIRUWKHJLYHQYHKLFOH
2QFHWKHEODFNNH\LVSXOOHGRXWRIWKHVWDUWHUVZLWFKWKHGLVSOD\ZLOOVKRZWKH)LQLVKSXOORXWEODFNNH\
PHVVDJH
)ROORZVWHSVWRWRUHJLVWHUDVSDUHNH\8SWRIRXUEODFNNH\VFDQEHUHJLVWHUHG
7XUQWKHNH\WRWKH581SRVLWLRQWRILQLVKWKHUHJLVWUDWLRQSURFHGXUH
2QHDIWHUWKHRWKHU LQVHUW DOOUHJLVWHUHG EODFNNH\VLQWRWKHVWDUWHUVZLWFK DQGFKHFNZKHWKHUWKH HQJLQH

FDQEHVWDUWHGXVLQJWKHVHNH\V
If a registered black key is lost, the other black keyes must be re-registered. This procedure locks
the lost or stolen black key, which can no longer be used to start the engine.
V-S-58
c. Troubleshooting: Display indications

Preliminary
Display Colour Problem/Error Solution
Measure
Yellow • No fuel. -- Refill.
Engine may be
• Oil pressure too Stop the engine defective.
Red
low. immediately. Immediately contact
skilled personnel.
Check V-belt.
• Faulty battery When the V-belt is If the indicator does
Red charger circuit OK, let the engine not go out, contact
• Charging error. run until indicator skilled personnel.
goes out.
If the indicator still
comes on after the
Jump-start the
Red • Defective starter. external ignition,
engine.
contact skilled
personnel.
• Starting Lift the control
procedure with Engine does not console and repeat
Yellow
lowered control start up. the starting
console. procedure.
Run the
• Maintenance
Yellow -- maintenance
due.
procedure.
Yellow • Wrong key. -- Use correct key.
• Try starting the
Try starting the
engine with the Engine does not
-- engine with the
red key (for start.
black key.
registration).
• The key is
attached to a
Engine does not Remove the metal
-- -- metal object
start. object and retry.
(such as a key
ring).
• The key is part
Detach the proper
-- -- of a bunch of --
key and retry.
keys.
• Short circuit in
No display Working lights light Contact skilled
Red the sensor
(warning light flashes) up. personnel.
power source.
V-S-59
V-S-60
KUBOTA Corporation
CONSTRUCTION MACHINERY DIVISION
1-1-1 NAKAMIYA-OHIKE, HIRAKATA, OSAKA, JAPAN
EDITOR:
CONSTRUCTION MACHINERY DIVISION
CUSTOMER TECHNICAL SUPPORT DEPT.
HIRAKATA PLANT
1-1-1 NAKAMIYA-OHIKE, HIRAKATA, OSAKA, JAPAN
PHONE: +81-72-890-2888
FAX: +81-72-890-2886
KUBOTA Corporation Printed in Japan 0805, 0808, 0810.CMC.e.12 OSIK Code No.97899-61952

U17 3alpha

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

U17 3alpha

Încărcat de

Drepturi de autor:

Formate disponibile

WORKSHOP MANUAL

Oct. 2008 Correction of descriptions on: I. Okae

U17-3α is the model name of EU - version

II. MACHINE BODY

IV. HYDRAULIC SYSTEM

b. PP (KTC, KCL)-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-17

A. BODY AND ENGINE IDENTIFICATION MARKS

Example: S/N 10001

No. Items Contents

No. Items Contents

Name plate: Code No. RA018-57721

(1) Machine serial number

(1) Serial No.

(1) Engine serial No.

Year of manufacture Month of manufacture

B. SAFETY PRECAUTIONS FOR SERVICING, DISASSEMBLY AND REASSEMBLY

Safety precautions for disassembly and reassembly

a. Safety Measures Before Starting Work

c. Preparation for Disassembly

(2) Acceptance inspection

(3) Equipment and tools

d. Precautions for Disassembly and Reassembly

C. IMPORTANT SAFETY PROCESS AND CRITICAL FUNCTIONAL PROCESS

2. Important Safety Process S

3. Important Critical Functional Process A

D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING

Oil gauge (level)

(2) Hydraulic hose

(3) Precautions in tightening the bolts and nuts

R (Tapered thread) Steel pipe Union nut Tapered thread

(4) Hose screw Metric Size Hose

(5) Joint bodies

R (tapered thread) G (straight thread)

19.6 ~ 29.4 N·m

(6) Tightening torque table for hose clamp (Screw type)

(7) Nuts for piping

(8) Tightening torque of bolts and nuts

(9) Types and materials of bolts and nuts

(10) Washer-equipped elbow

2. Radiator hose sealant

General maintenance Elapsed hours of operation

Lubricate the swivel gear 50 h

Check, clean air filter 1.) 200 h

Grease the swivel bearing 200 h

General maintenance Elapsed hours of operation

Lubricate the swivel gear 50 h

Check, clean air filter 1.) 200 h

Grease the swivel bearing 200 h

[Servicing by skilled personnel or KUBOTA dealer]

Servicing Elapsed hours of operation *

Check/adjust V-belt tension 250 h

Grease pilot valve linkage 250 h

Replace the fuel filter 4.) 500 h

Change return filter for the 500 h

[Servicing by skilled personnel or KUBOTA dealer]

Servicing Elapsed hours of operation

Check/adjust V-belt tension 250 h

Grease pilot valve linkage 250 h

Replace the fuel filter 4.) 500 h

Change return filter for the 500 h

20 Fuel injection nozzle injection check every 1500 hrs *4 @

* 500 thru 1000 continued to the following table.

Hour meter indicator

Cleaning with compressed air