Kubota V Manual KX36 KX41 3V [PDF]

Zitiervorschau

W ORKSHOP MANUAL

KUBOTA EXCAVATOR

KX36-3 KX41-3S, KX41-3V Mechanism Chapter

C ode N o.97899-60810

Record of Revisions Symbol

Date

Main Revised Points & Corrective Measures

Person-in-charge

1

2

3

4

EU - version machine models : KX36-3, KX41-3S, KX41-3V KTC, KCL, KTA version machine model : KX41-3V

CONTENTS I General II Machine Body III Electrical system IV Hydraulic System V Engine

I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2 a. b. c. d. e. f.

Sales feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2 Difference between KX36-3 and KX41-3 . . . . . . . . . . . . . . . . . . . . . . I-2 Quick chart for selling points : KX41-3V . . . . . . . . . . . . . . . . . . . . . . . I-3 Comparison to competitors;EU - version . . . . . . . . . . . . . . . . . . . . . . I-4 New engineering feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5 Compornents compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7

I-1

I. General a. Sales feature Product concept : Comfort in conpact (1) Grade up the basic performance; Digging, filling back and lifting capacity (2) Grade up product feature to differentiate competitor; Digital meter, upper boom cylinder, hose protection Workability

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

b. Difference between KX36-3 and KX41-3 Differentiation

KX36-3

KX41-3

No1.

Engine

D782 (13 PS)

D902 (16PS)

No2.

Bucket digging forth

1276 kgf

1591 kgf

No3.

Working area (Arm length)

950 mm

1100 mm

No4.

New digital meter

Not equipped

Equipped

No5.

Variable track specification

Not adopted

Adopted

No6.

Travel speed

One speed

Two speed

No7.

Straight travel

Not equipped

Equipped

No8.

Seat grade

Standard seat

High back seat

No9.

Roof window of the cabin

Not equipped

Equipped

I-2

Remark Bucket cylinder is different

Fixed track is same parts KX41-3S, V : EU - version only

I-3

Aux. Hydraulic hoses are routed inside of arm.

Boom cylinder is installed over upside of boom

Increased bucket pin diameter Pin diameter : 30mm

Short stroke operating lever and wrist rest

c. Quick chart for selling points : KX41-3V

Best matching of displacement hydraulic pump and Kubota new diesel engine D902, 17.0HP 2300rpm

on the dozer lever

High speed travel switch

Separated boom swing pedal and auxiliary hydraulic pedal

Digital panel with new navigation system

d. Comparison to competitors;EU - version 1.5 t class Sales features(Sample:EU - version) Bucket digging forth (kgf) Variable pump adoption Workability

Maintenance ability

Boom and SP simultaneous operation Maximum digging depth priority (mm) High level stability Boom cylinder over boom

KUBOTA KUBOTA KX41-3V KX41-2αV

Bobcat 322D

VOLVO EC15B

TAKEUCHI KOMATSU YANMAR TB016 PC12 B15-3

1591

1270

1546

1541

1336

1350

1525

2382

2336

2197

2300

2375

2180

2150

Hoses arranged inner boom Bucket hose/SP hose inner Arm

(bucket)

Divided blade hoses Operator comfort

Much easier access into cabin

(485)

(390)

(420)

(460)

(400)

(450)

(345)

Cabin width expansion

(915)

(845)

(850)

(860)

(902)

(880)

(960)

New digital meter adoption Straight travel adoption Operativity

Smoother operation Wrist-controled lever Engine starting check

Safety

Travel lock system

Others (for KX36-3)

ROPS/FOPS standard equipment Tumbler distance extension (mm) Shoes width extension (mm)

1.3 t class Sales features(Sample:EU - version) Bucket digging forth (kgf) Variable pump adoption Workability

Maintenance ability

Boom and SP simultaneous operation Maximum digging depth priority (mm) High level stability Boom cylinder over boom

KUBOTA KX36-3

KUBOTA KX36-2α

JCB 8015

VOLVO EC13

1276

1245

1122

1122

2230

2170 2102 2010

Hoses arranged inner boom Bucket hose/SP hose inner Arm

(bucket)

Operator comfort

Much easier access into cabin Cabin width expansion New digital meter adoption

(bucket)

-

Divided blade hoses (440)

(390)

(550)

-

Straight travel adoption Operativity

-

Smoother operation Wrist-controled lever

-

Engine starting check Safety

Travel lock system

Others (for KX36-3)

ROPS/FOPS standard equipment Tumbler distance extension (mm) Shoes width extension (mm)

1090 230

1010 200

I-4

1008 230

1085 200

e. New engineering feature 1. Hydraulic system 1) New hydraulic circuit with downsized cylinder valve (1) New Hydraulic Circuit Despite the downsizing of the cylinder valve (with an overall length reduced to 335 mm from 368.5 mm), the construction of the interflow circuit for the upward and downward movement of the boom along with the employment of the pump flow unload valve interlocked with an unload lever ensures the smooth operability and stability of the hydraulic system. (a) Boom Upward and Downward Interflow When boom upward and downward pilot signal is input, the inflow section will be switched and the flow of pump number 3 will be guided to the boom section. The total flow of pump number 1 and number 3 will drive the boom cylinder, thus increasing the operation speed of the boom. (b) Unload Section When the safety lever beside the operator's seat is set to the unload position, the spool of the unload section will be switched and the hydraulic oil in pump number 1 and number 2 will flow directly to the tank circuit, thus ensuring safety and protecting the operator from improper control. 2) Flow characteristic simulation for operability improvement (2) Flow Characteristic Simulation To ensure the smooth operability, a fine adjustment to the cylinder valve spool is essential. The flow characteristics of the spool vary with the combination of the squeezed areas of three types of passages. Therefore, a computer simulation was conducted to grasp the flow characteristics, a prototype was manufactured, and a fine adjustment based on the feeling results of operability on an actual model was made to achieve comfortable operability.

I-5

2. Improvement in user-friendliness and operator's range of vision (1) Optimum positioning of levers and other attachments The optimum positioning of the respective levers, pedal, meter, and key was considered in a 3D (CATIA) simulation.

3. Electronic System 1) Digital Navigation System (1) Information-intensive Display The dot-type LCD provides a variety of alarms as well as normal display items supporting 11 languages. Furthermore, the display incorporates a service tester and other versatile functions for improvement in ease of use. (2) Integration of Functions The integration of functions implemented at the time of the development of the KX91-3, 101-3 Construction Machine has been further developed to include a variety of control functions into a meter for a great decrease in the number of parts along with an increase in functional performance and a reduction in cost. The meter incorporates an auto release, auto glow, finger control service port, auto idling, and two-speed selection functions.

I-6

f. Compornents compatibility Parent

100% compatible

Location

Under carriage

Upper frame

Front attachment

high compatible

low compatible

KX36-3 (EU)

S

V

KX41-3V (US)

9 stacks

Ten stacks

Ten stacks

Ten stacks

Main components 1

Track frame

2

Track roller, idler

3

Blade

4

Travel motor

5

Track shoe

6

Swivel bearing

7

Seat

8

Swivel frame

9

Hydraulic Pump

10

Control valve

11

Engine

12

Bonnet

13

Control box, cover, step

14

Cab

15

Electric parts

16

Control device

17

Swing bracket

18

Boom

19

Arm

KX41-3(EU)

Original design

I-7

I-8

II.Machine Body. . . . . . . . . . . . . . . . . . . . . . . II-2 a. Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2 b. Main component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-6

II-1

II.Machine Body a. Quality Specifications No

Specificatios Items

Q1

Main Speed JIS A8404 1

Total length(Transport)

2 1

Unit

Total width Machine size

3

Total height(Canopy)

4

Total height(Cabin)

1

Machine weight (Canopy)

2

Machine weight(Cabin)

KX36-3 EU

KX41-3S

mm

3670 ± 73

3665 ± 73

inch

144.5 ± 2.9

mm

990 ± 10

inch

KX41-3V EU KX41-3V US

←

←

144.3 ± 2.9

←

←

990 ± 10

1300/994 ± 13

←

39.0 ± 0.4

39.0 ± 0.4

51.2/39.1 ± 0.5

←

mm

2283 ± 23

←

←

←

inch

89.9 ± 0.9

←

←

←

mm

2283 ± 23

←

←

inch

89.9 ± 0.9

←

←

kg

1440 ± 29

1450 ± 29

1595 ± 32

←

lbs

3174.6 ± 63.9

3197 ± 63.9

3516.337 ± 70.5

←

1540 ± 31

1550 ± 31

kg

3395.1 ± 68.3 3417.13 ± 68.3

lbs

Remarks

Fuel tank

1705 ± 34 3759 ± 75.0

kPa 2

3

Weight

Ground contact press. (Canopy)

psi kgf/cm2 kPa

Ground contact press. (Cabin)

4

psi kgf/cm2

1

Swivel speed

2

3

3

rpm

F1

F2

Performance Travel speed

4

R1

5

R2

2

4

←

←

km/h

2.2 ± 0.2

2.4 ± 0.2

2.2 ± 0.2

2.3 ± 0.2

mph

1.37 ± 0.12

1.49 ± 0.12

1.37 ± 0.12

1.43 ± 0.12

4.3 ± 0.4

4 ± 0.4

4.1 ± 0.4 2.55 ± 0.25

km/h mph

2.67 ± 0.25

2.49 ± 0.25

km/h

2.2 ± 0.2

2.4 ± 0.2

2.2 ± 0.2

2.3 ± 0.2

mph

1.37 ± 0.12

1.49 ± 0.12

1.37 ± 0.12

1.43 ± 0.12

4.3 ± 0.4

4 ± 0.4

4.1 ± 0.4 2.55 ± 0.25

km/h

2.67 ± 0.25

2.49 ± 0.25

30
> >

> > >

Compression ratio

41.8 = 4.26 = 30.8 =

49.9 = 5.10 = 36.8 =

Max. torque

N™m kgf™m ft™lbf

Dimensions:L x W x H

mm in.

449 x 402 x 538 17.7 x 15.8 x 21.2

473 x 402 x 546 18.6 x 15.8 x 21.5

Dri weight

kg lbs

64 141

72 159

Valve clearance

mm in.

0.145-0.185 0.0057-0.0073

0.145-0.185 0.0057-0.0073

1-2-3

1-2-3

E-TVCS

E-TVCS

Firing sequence Combustion chamber Compression pressure (A)/(B)

Mpa kgf/cm2 psi

Fan belt

2.84-3.24 29-33 412-469 RPF2325

Fuel consumption ratio

g/kWh g/Psh lbs/Hph

286 210 0.47

286 210 0.47

Fuel consumption

l/h gal/h

3.2 0.85

4.1 1.08

Max.speed without load

rpm

2650 > =

2650 > =

Speed with 2 pumps relief

rpm

2300 =

Speed with idling

rpm

1200--1300

1200--1300

Engine oil pressure with rated engine rpm

kPa kgf/cm2 psi

196-441 2.0-4.5 28.4-64.0

196-441 2.0-4.5 28.4-64.0

Injection pressure

MPa kgf/cm2 psi

13.7 140 1991

>

Pressurized radiator(0.088Mpa, 0.9kgf/cm2), water pump

Cooling system Engine oil consumption ratio

52.6 5.36 38.8

g/kWh g/Psh lbs/Hph

0.95 0.7 0.0016

V-3

Engine electric components Machine model

KX36-3 EU

KX41-3 EU

KX41-3 US

Engine Model

D782-BH-3

D902-BH

D902-EBH

Fuel injection pump type

Bosch M Dtype m ini-pump

Nozzle type Injection pressure

DN4PD62 mini-nozzle Mpa kgf/cm2 psi

Dynomo

12V480W

Manufacturer P/N Regulator adjusting voltage

13.7 140 1991

V

100211-4730

100211-1670

14.2-14.8

14.2-14.8

12V1.2KW

12V1.4KW

228000-0951

228000-0991

1.5

1.5

Battery type Nominal capacity of 5hrs rating

Ah

Specific gravity of electrolite Starter motor Manufacturer P/N Glow plug

Ω

V-4

b. Performance curve KX36-3; D782-BH-3 Net value;

D1546

V-5

KX41-3S, KX41-3V; D902-EBH(-BH) Net value;

D1545

V-6

c. Function & structure of coil commander 1. Circuit diagram Hold (Red) Pull (white) Pull coil

Hold coil

Timer circuit FE Transistor Gnd (Black) Coil commander

Solenoid (pull in type)

2. Function Under some condition, such as low temp, large current flows to pull coil and may cause to cut the coil. Coil commander is to regulate the current flow to pull coil by controlling the current time according to the temperature Temperature vs Current Time

V-7

3. Inspeetion & troubleshooting 1) Check the continuity of hold coil. 2) Check pull in coil function after wiring 12V to red and while terminal and ground to black color terminal. Then engine solenoid functions and pull in the plunger head. Photo : pull in condition

Photo : hold condition

V-8

KUBOTA Corporation CONSTRUCTION MACHINERY DIVISION 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN

EDITOR: CONSTRUCTION MACHINERY MANUFACTURING DEPT. SERVICE SECTION HIRAKATA PLANT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN PHONE :+81-72-840-1195 FAX :+81-72-890-2886

K U B O TA C orporation

P rinted in Japan 0403.C M C .e.10

C ode N o.97899-60810

WORKSHOP MANUAL

KUBOTA EXCAVATOR

KX36-3 KX41-3S, KX41-3V Service Chapter

Code No.97899-60860

Record of Revisions Symbol

Date

Main Revised Points & Corrective Measures

Person-in-charge

1

2

3

4

EU - version machine models : KX36-3, KX41-3S, KX41-3V KTC, KCL, KTA version machine model : KX41-3V (PP - version, Pan-Pacific - version)

CONTENTS I General II Machine Body III Engine IV Hydraulic System V Electrical system

I. General A.Body and engine identification marks . . . . . . . . . . . . . . . . I-S-3 B.Safety precautions for servicing, disassembly and reassembly. . . . I-S-4 a. b. c. d.

Safety measures before starting work. . . . . . . . . . . . . . . . . . . . . . . I-S-4 Safety measures during work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-4 Preparation for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5 Precautions for disassembly and reassembly. . . . . . . . . . . . . . . . . I-S-5

C.Important Safety process and critical functional process . . . I-S-6 a. Essential Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6 b. Important Safety Process .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6 c. Important Critical Functional Process . . . . . . . . . . . . . . . . . . . . . . I-S-6

D.Important inspection items after reassembling . . . . . . . . . I-S-6 a. Operate the Machine and check for Unusual Noise and Vibrations.I-S-6 b. Make Sure the Safety decals and Wireharness Clamps are in their Specified Positions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6 c. With the Machine Front in a Specified Posture, Check the Amount of Hydrauric Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6 d. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-7

E.Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12 a. PP (KTC, KCL, KTA) - version . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12 b. Hydraulic Oil Check for machines with Hydraulic Breakers . . . . . I-S-14 c. EU version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-15

F. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-16 a. b. c. d.

Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-16 Machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-17 Lever stroke and operating force . . . . . . . . . . . . . . . . . . . . . . . . . I-S-19 Dimensions of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-20

Note : PP - version = Pan Pacific - version = KTC, KCL, KTA - version

I-S-1

I-S-2

A.Body and engine identification marks If trouble should occur during use, or if servicing is necessary, contact the dealer who handles the machine. At that time please inform the machine model and engine type and serial numbers.

KTC, KCL, KTA version

2-47, Shikitsuhigasi 1-Chome, Naniwa-ku, Osaka, 556-8601 JAPAN MODEL SERIAL No. ENGINE No. PRODUCT IDENTIFICATION NUMBER

1 2 3 4

No. 1 2 3 4

Items

Contents ; Example

Machine model Serial No. Engine No. PRODUCT IDENTIFICATION No.

KX41-3V 20001 >JKUK1613CO1H20001
2300 rpm

ditto

17

Load rpm with 2 pumps

> 2300 rpm

ditto

18

Load rpm with 3 pumps

> 2300 rpm

ditto

19

Engine stop - with 3 pumps load

kein Stopp

20

Idle speed

21

Accumulator - function checkedauf Funktion überprüfen

22

P1 load pressure ( bucket )

23

P2 load pressure ( arm )

24

P3 load pressure ( dozer )

25

Primary pressure ( P 4 )

26

( control force ) lever boom up

( measurement )

( handhold-middle )

bar

1200 - 1350 rpm

ditto

> 3 min

ditto

bar

a1 216 -5

+10

a2 216 -5

+10

a3 206 -5

bar

39 -0

a2 206 -5

bar

a2 201 -5 +A3/B5

39 -0 "

+10

a1 206 -5

0,8 - 1,80 kg down

+10 +10 +10

+A3/B5

27

"

0,8 - 1,80 kg

ditto

28

" lever arml crowd/dump

0,8 - 1,80 kg

ditto

29

"

0,8 - 1,80 kg

ditto

lever bucket dump / crowd

30

"

rotation lever ( lh / rh )

0,8 - 1,80 kg

ditto

31

"

lever dozer up / down

1,6 - 2,6 kg

ditto

32

"

speed lever lh / rh

1,4 - 2,4 kg

ditto ditto

33

Speed lever idle-max

4,0 - 6,0 kg

34

Speed lever max - idle

3,0 - 5,0 kg

35

Ratched lever (top/down) Canopy rh.

bar

ditto

1,0 - 5,0 3,0 - 7,0

1,0 - 3,0 2,4 - 4,4

36

cushion time boom up ( 50 °C )

0,4 - 1,3 s.

0,4 - 1,3 s.

37

Speed boom up (until cushion)

2,3 - 2,9 s.

2,0 - 2,6 s.

2,8 - 3,4 s.

2,7 - 3,3 s.

2,8 - 3,4 s.

3,1 - 3,7 s.

38

"

39

"

arm crowd

"

arm dump

40

down ( ground )

1,9 - 2,5 s.

2,1 - 2,7 s.

41

( Speed. ) bucket crowd

2,1 - 2,7 s.

2,5 - 3,1 s.

42

( Speed ) bucket dump

1,6 - 2,2 s.

1,7 - 2,3 s.

43

Swivel speed ( 3 rotations ) lh / rh

17,8 - 21.8 s.

17,8 - 21,8 s.

44

Starting speed swivel

1,9 - 2,3 s.

1,9 - 2,3 s.

I-S-29

Nr.

Inspection

KX36-3

KX41-3S, V

45

Speed swing lh ( until the stopper )

4,4- 5,0 s.

4,3- 4,9 s.

46

Speed swing rh

3,7 - 4,3 s.

3,6 - 4,2 s.

47

Speed dozer ( full stroke ) up

1,0 - 1,6 s.

1,0 - 1,6 s.

1,4 - 2,0 s.

1,4 - 2,0 s.

15 - 18 s.

ditto

---------

8,1-9,9s.

48

"

( full stroke ) down

49

1.speed rubber crawler

50

2. speed rubber crawler 4,0kh/h ± 0,4 (10m)

51

straight travel1. speed ( forwards / backwards ) ( 10 m )

< 600 mm

ditto

52

straight travel 1. speed with dozer

< 600 mm

ditto

53

Impermeability boomcyl. ( 10 min ) 0,035 m3 63 kg

< 15 mm

ditto

< 10 mm

ditto

54 55

2,2 ± 0,2 km/h (10 m)

"

( 10 min ) armcyl. 50 ± 5 °C

"

( 10 min ) bucketcyl.

56

Dozercyl. ( machine up dozer front )

57

Clearancel of the mounting Nut -> Front parts

58

Parallelism of the crawler ( front / rear )

59

Crawler tension ( rubber / steel )

60

Distance roller guides / joint ( lh/rh ) iron

61 62

< 4 mm

ditto

< 13 mm

ditto

< 1 mm

ditto

< 10 mm

ditto

10 - 15 mm

ditto

> 2 mm

ditto

Offset crawler edge / dozer edge

± 10 mm

ditto

crawler shoe width /

230 mm /

ditto

63

Arm-break at dump 1500 rpm/63 kg/72kg

no / 0 mm

ditto

64

Incline of the dozers at the ground

< 10mm

ditto

65

vertical reference line of the machineat the front part

< 10mm

ditto

66

clearance sideward from the end of the bucket

< 73 mm

53 - 73 mm

67

Distance Boom / Bucket-teeth

68

clearance bonnet / arch

5-10 / h2 mm

69

Distance - weight / protector

4-10 / h3 mm

ditto

70

Distance fan / radiator

38 ± 10 mm

ditto

71

Distance fan / protector

> 10 mm

ditto

72

Distance between muffler pipe and weight hole

> 20 mm

middle

73

Tension of fan belt

7-13 mm / 5 kg

ditto

74

Routing of breather and suction cooling hoses

no kink

ditto

75

Collision / Twist of fuel piping

no

ditto

76

Collision electrical wiring

no

ditto

77

Cooling fluid anti-freeze

62

+34 -16

- 40

mm

±5

°C

+34

167 -16 mm ditto

ditto

78

Hyd. oil qty: boom down / Arm crowd

79

Bucket close / dozer at ground

80

Travel motor

81

Tightening torque travel motor

82

Sealing of track rollers and idlers

83

Cross routing R / J ~ travel and dozer hoses

no

ditto

84

Mounting of control box (looseness)

i.O.

ditto

85

Fuse (reserve) 1x15A, 1x10A, 1x5A, 1x20A

ok

86

Battery fluid qty / density

87

Battery mounting (grease at terminals)

88

Noise at operator's ear (canopy 4P)

89

Noise at operator's ear (cabin)

0,25 l

Tank 14,5l ± 0,7

ditto

Glas 1/2 - 3/4

ditto

filler plug

ditto

60,8 - 70,6 Nm

ditto

i.O.

ditto

> 1,26 kg /

ditto dm3

i.O. < 78 dB 78

I-S-30

+2 dB

ditto ditto ditto < 78 dB

II.Machine Body A.Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3 a. Pin, bush and shim installation . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3 b. Instruction to press in the bushing . . . . . . . . . . . . . . . . . . . . . . . . II-S-8 c. Greasing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-13

B.Upper Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-16 a. b. c. d. e. f. g. h.

Swivel bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelarator lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dozer lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing & SP pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control valve links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit switch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II-S-16 II-S-17 II-S-19 II-S-21 II-S-23 II-S-25 II-S-26 II-S-27

C.Undercarrige . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-28 a. Track tension device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-28 b. Track Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-30

II-S-1

II-S-2

A.Front attachment a. Pin, bush and shim installation (1) Swing cylinder, swing bracket, boom 51

52

50

53

43 42 41 72 71

40

70 60

61 62

21 22

20

23 24

Swing bracket - swivel frame Code No. RG1386645 RG1386639 RG1386638 RG1384113 0117361204 0257250120

Q’ty 2 2 2 2 2 2

Part Pin Bush Bush Bush Bolt Nut

No. 10 11 12 13 14 15

12

Remarks I50 506037 506028 506040

13 35 34 11 30

10

32

14 15

Swing bracket - boom cylinder Code No. RG1386664 RG1386659 RG1386637 0117361080 0257450100

Q’ty 1 1 1 1 1

Part Pin Bush Bush Bolt Nut

No.

Remarks

20 I35 21 354332 22 354348 23 24

31

Code No.

Q’ty

Part

No.

RG1386656 RG1386646 RB2376657 RB2376658 0117361204 0257450100 0661115010E

1 2 1 1 1 1 1

Pin Bush Bush Bush Bolt Nut Grease nipple

30 31 32 33 34 35 36

Remarks I35 354535 354344 354344

Code No. RG1386746 0113361020 691816644 RG2012179

Q’ty 1 1 1 1

Part Pin Bolt Spacer Washer

No.

Q’ty

RG1386744 RG1386745 0113361016 0541100825

1 1 1 1

Code No.

Remarks

40 I30 41 42 43

Part Pin Key plate Bolt Spring pin

No.

Remarks

50 I30 51 52 53

Boom - boom cylinder Q’ty

RG1386664 0117361080 0257450100

Swing bracket - Swing cylinder

36

Swing bracket - Swing cylinder Code No.

Swing bracket - boom

33

1 2 1

Part

No.

Remarks

60 I35 61 62

Pin Bolt Nut

Boom - arm cylinder Code No.

Q’ty

RG1386654 0117361080 0257450100

II-S-3

1 2 1

Part Pin Bolt Nut

No.

Remarks

70 I30 71 72

(2) Arm, bucket link

114 111

125 124 123

90

121

92 91

100

126 122

102 101

110 120 112113

83 82

133 132

81

130

131

134 80

142 145 144 143

146 140 141 Arm - bucket

Boom - arm Code No.

Q’ty

Part

RG1386663 687216652 0117361080 0257450100 0661115010E

1 2 1 1 1

Pin Bush Bolt Nut Grease nipple

No.

Remarks

80 I30 81 303835 82 83 84

Arm - arm cylinder Code No. RG1386665 0117361065 0257450100

Q’ty 1 1 1

Part

No.

Remarks

90 I30 91 92

Pin Bolt Nut

Arm - bucket cylinder Code No. RG1386665 0117361065 0257450100

Q’ty 1 1 1

Part

No.

Remarks

100 I30 101 102

Pin Bolt Nut

Code No.

Q’ty

Part

No.

Remarks

RG1386676 694216691 694216652 RG0386674 RA1116733 RB1376733 0113361225 0401560120 694416692 0661115010E

1 1 2 2 2 2 1 1 1 1

Pin Pin Bush Bush Dust seal Dust seal Bolt Plain washer Spacer Grease nipple

120 120 121 121 122 122 123 124 125 126

I30 KX41-3 I25 KX36-3 303835 KX41-3 303835 KX36-3 KX41-3 KX36-3

Bucket link1 - link2, 3 Code No.

Q’ty

Part

RG1386677 RG1386678 0117361080 0211860100 0661115010E

1 2 1 2 1

Pin Bush Bolt Nut Grease nipple

No.

Remarks

130 I30 131 303840 132 133 134

Bucket link1 - bucket

Arm - bucket link2, 3 Code No.

Q’ty

Part

RG1386675 694216652 0117361080 0211860100 0661115010E

1 2 1 2 1

Pin Bush Bolt Nut Grease nipple

No.

Remarks

110 I30 111 303835 112 113 114

Code No.

Q’ty

Part

No.

Remarks

RG1386676 694216691 694216652 RG0386674 RA1116733 RB1376733 0113361225 0401560120 694416692 0661115010E

1 1 2 2 2 2 1 1 1 1

Pin Pin Bush Bush Dust seal Dust seal Bolt Plain washer Spacer Grease nipple

140 140 141 141 142 142 143 144 145 146

I30 KX41-3 I25 KX36-3 303835 KX41-3 303835 KX36-3 KX41-3 KX36-3

II-S-4

84

(3) Blade, blade cylinder and truck cylinder

153 152 151 150 154

170

171172173 181182

160

180

163 162 161

191 192 190

Truck frame - truck cylinder

Truck frame - blade Code No. RG1088905 0113361020 RG2016686 RG2012179 0661625010

Q’ty 2 2 2 2 2

Part Pin Bolt Collar Washer Grease nipple

No.

Remarks

150 I30 151 152 153 154

Code No.

Q’ty 1 1 1 1

Part Pin Bolt Collar Washer

Q’ty 2 2 2

No.

Remarks

160 I30 161 162 163

Q’ty

RG1387747 0552551000 RG1088948

Blade - blade cylinder Code No. RG1387446 0113361020 RG2016686 RG2012179

Q’ty 1 1 1 1

Part Pin Bolt Collar Washer

No.

Part

No.

Remarks

Pin 180 I30 Bolt (Stopper) 181 Washer 182

Blade - extention blade Code No.

Truck frame - blade cylinder RG1387446 0113361020 RG2016686 RG2012179

Code No. RG1088812 691912129 0451260120E

Remarks

170 I30 171 172 173

II-S-5

2 2 2

Part Pin Split pin Pin

No.

Remarks

190 I25 191 192

154 153 152 151 150

160 161162163

Truck frame - blade Code No. RG1088905 0113361020 RG2016686 RG2012179 0661625010

Q’ty

Part

2 2 2 2 2

Pin Bolt Collar Washer Grease nipple

No.

Remarks

150 I30 151 152 153 154

Truck frame - blade cylinder Code No. RG1387446 0113361020 RG2016686 RG2012179

Q’ty 1 1 1 1

Part Pin Bolt Collar Washer

No.

Remarks

160 I30 161 162 163

II-S-6

(4) Clearance adjustment (1)

(6)

(7)

(2)

(8)

(3) (9)

(4)

(5) (1) 68721-6697 Shim (0.5, 60-31) SPCC 68051-6633 Shim (1.0, 60-31) SPCC Selective use 68051-6634 Shim (1.6, 60-31) SPCC * Insert a number of shims according to the clearance on the swing cyl bottom side. (2) 68741-6686 Shim (1.0, 60-36) SPCC Selective use 68741-6687 Shim (1.6, 60-36) SPCC

}

(3) RG138-6644 Thrust collar (2.3, 92-51) SK5M * Refer to the mounting method of thrust collar. (4) RG138-6644 Thrust collar (2.3, 92-51) SK5M RG138-6648 Thrust collar (2.0, 92-51) SK5M Selective use RG138-6649 Thrust collar (2.5, 92-51) SK5M * Refer to the mounting method of thrust collar.

}

1. Front Play * Pin on fulcrum Thrust direction Clearance

0.6 mm max. * If the play exceeds 0.6 mm, add some shims and make adjustments. (Use the shims shown in the illustration.)

2. Vertical clearance between swivel frame and swing bracket.

+ 0.3 ~ +1.3 mm

3. Use the shim and thrust collar selectively with each part. 4. Installation of thrust collar

Apply grease on both surface.

(5) RG246-6762 Shim (0.5, 70-36) SPCC (6) 68741-6686 Shim (1.0, 60-36) SPCC 68741-6687 Shim (1.6, 60-36) SPCC (7) 68741-6686 Shim (1.0, 60-36) SPCC 68741-6687 Shim (1.6, 60-36) SPCC (8) 68741-6686 Shim (1.0, 60-36) SPCC 68741-6687 Shim (1.6, 60-36) SPCC (9) 68741-6686 Shim (1.0, 60-36) SPCC 68741-6687 Shim (1.6, 60-36) SPCC

} Selective use } Selective use } Selective use } Selective use

II-S-7

Apply grease

b. Instruction to press in the bushing (1) Bush installation steps Part where bushing and dust seal are inserted. 1. Bushing insertion (Completed assembly with bushing press-fit is excluded.) 2. Bushing insertion dimension

1) If no dust seals are used, check that the bushing does not protrude from either side. 2) Maintain room for a dust seal on each side if it is used. (Only the dimension management of the press-fit direction can be enough.)

3. Dust seal mounting direction

Mount as shown in the illustration.

4. Bushing insertion direction

Insert the bushing from the 15° chamfer side.

(2)

(2) (2) (1)

(1)

(1) Both bushing and dust seal (2) Only bushings

Insert the bushing by using an appropriate steel plate. * Do not directly hit the bushing.

(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

5

5

3

15

15

Bush direction

C 0. 5

Bush direction

II-S-8

Dust seal

C 0. 5

3

Dust seal

(3) Installation of thrust collar on the swing bracket

Thrust collar

1. Install the thrust collar, with its grooved face downward, on top of the swivel frame. 2. Select and install a 0.5 or 1.0 mm(0.02 ~ 0.04”) thick shim to have the clearance smaller than 0.5 mm(0.02”). Thrust collar 090 : 2.3 mm 095 : 2.3, 2.0, 2.5 selective Shim 200 : 0.5, 1.0, 1.6 selective

II-S-9

(4) Swing bracket pin & bush. (1)

(1) Attention to the bush driving direction (align the holes). Make sure later that the shaft goes through smoothly. (2) Keep flush with the end face. (3) Keep the collar upward. (4) Attention to the bush driving direction (align the holes). Make sure later that the shaft goes through smoothly.

(2) 

 (3)

(4)



(2)

Bush Dust seal Collar

(3)

Specifications, New pin and bushing [ Unit : mm] Model Pin outer dia. Pin material

KX008-3, U10-3

KX36-3, KX41-3S, V

U20-3, U25-3

o 35 --0.05 0.08

o 50 --0.05 0.08

o 60 --0.05 0.08

S45C-D, S43C-D

m

m

Bush inner dia.

35

Bush outer dia.

43 +0.09 +0.06

60 +0.09 +0.06

72 +0.09 +0.06

STKM16A S43C S45C

m

m

Bush material

+0.07 +0.04

Thrust washer, shims thickness

60 +0.07 +0.04

Thrust collar : 2.0, 2.3, 2.5 Shim : 0.5, 1.0, 1.6

Swing bracket material Test pin, to go through smoothly

50

+0.07 +0.04

m

FCD500-7 -

Thrust collar : 2.8, 3.2 Shim : 0.5, 1.0, 1.6

o 49.95

pin : High frequency induction surface hardening/ Effective hardened depth : 2 ~ 4mm Surface hardness : 52 ~ 59 HRC Diameter value is for single part before installation.

II-S-10

-

Remarks

(5) Measuring the swing bracket looseness Set a dial gauge as shown below and note the height of the pointer. Lift the machine front until the swing bracket tilts to maximum frontward. Now set the dial gauge reading to zero. Next move the boom and arm until the swing bracket tilts to maximum backward. Now take the dial gauge reading. There is no specifications yet. This measuring data is just for your reference. Swing bracket looseness measuring procedure photos

II-S-11

(6) Service tip to ease customer complain Front slaggishness caused by pin-bushing worn-out largely depends on the following facters. 1. Maintenance: 2. 3. 4. 5.

6.

Daily maintenance, frequent applying of grease to renew, proper type of grease. Attachment installed: Weight of front attachment more than expected affects the excessive wear of pin and bushing. 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. Job site and strage: Dust, sand, moisture, salt or chemical acid accelerate the surface abrasive and corrosion. Total operation hours: Operating hour is the basic factor to evaluate the wear. Bushing wearcurve is basically depended on the operation hours. And varies one by one according to the ratio of oparating condition, attachment weight, application and maintenance level mentioned-above. Service limit: Allowable service limit to all pins and bushings is 1.0mm wear from the new diameter size.

II-S-12

c. Greasing points 1) Keep applying grease until it comes out of the circumference at the other end surface of each rotating part. 2) Apply grease to the end surfaces of all the rotating parts and their related shims.

A-type: Straight type (06611-15010)

B-type: 67°C (06616-25010)

C-type: 90°C (06616-35010)

(3)

(2)

(1)

(4)

(5)

(5) (3)

(4)

(5)

(8)

(5)

(5)

(6) (5) (6) (6) (5) (7) (1) View from the front

(5) A - type (Boss - greasing)

(2) Swing cylinder, bottom

(6) A - type (Pin - greasing)

(3) Swivel bearing, ball

(7) B - type (Boss - greasing)

(4) Swivel bearing, teeth

(8) C - type (Boss - greasing)

II-S-13

(5)

(7)

(7)

(5) A - type (Boss - greasing)

(7)

(7) B - type (Boss - greasing)

II-S-14

1

4 5

3

2

4

6

Q’ty (1) Frame (Truck, center)

1

(2) Frame (Truck, L)

1

(3) Frame (Truck, R)

1

(4) Bolt, stopper

4

(5) Spring washer (6) Apply grease on all surfaces of truck frame L & R as shown by hatching lines.

4

II-S-15

1. Stopper and bolt tightening torque.

77.2 ~ 90.2 N·m (7.9 ~ 9.2 kgf·m) * Screw tightening agent applied (LockTight 271)

2. Coupling truck frames left and right and truck frame center.

Apply grease to the right and left circumferences of the track frames.

B.Upper Structure a. Swivel bearing (1) 3 1

(2) Upper angle 10 Front

(5) Ｓ

2

(6)

A Swing Ball Teeth

Direction of adapter (swing cylinder) (view right side og machine)

(4) (3)

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

1. Innerring soft zone: S mark. • Set “S” mark at its right position. 2. Outer-ring soft zone: Ball inlet • This soft zone should be at its left sode. 3. Align the grease nipple hole of the swivel frame with the nipple on the bearing. A 4. Swivel Bearing Tightening • Apply Locktite #271 on the bolts. • Tightening torque: 103 ~ 117.7 N·m 10.5 ~ 12 kgf·m 75.9 ~ 86.8 ft·lbs • Apply grease to the entire surface of the bearing teeth uniformly. • Mounting bolts: Truck frame side, 01138-51230, 18 pcs Swivel frame side, 01138-51230, 19 pcs

II-S-16

b. Travel lever (2) (3)

(6)

(1)

(4)

1. Adjustments of lever to neutral position Mounting direction and angle

Mount the levers as shown in the illustration.

Improper position p Improper control

2. Travel lever rotation

The levers must return to the neutral position promptly after operation.

Improper return p Improper action

3. Travel lever adjustments 1) Forward/ Backward tolerance of left and right levers 2) Clearance of left and right levers

(5)

o 5 mm (max.) (0.2 in)

Levers not aligned p Contact between levers Improper action

o 5 ~ 25 mm (EU) 5 ~ 14 mm (KTC) (0.2 ~ 0.55 in)

4. Grip mounting Mounting direction and angle

Mount the grips securely. The grips must be in backward/forward directions.

5. Check items after mounting

The valve spool must operate full stroke. The valve spool must operate smoothly.

Improper assembly p Grips rotate Improper action p Increase in required operational power

Adjust the traveling lever as shown below table. No.

Items

Dimensions

(1)

Gap between left and right lever to longitudinal direction.

(2)

Clearance between left and right lever.

(3)

Distance beween bracket front end and newtral position center of Traveling lever grip.

(4)

Travel lever, L

(5)

Travel lever, R

(6)

Grip

Remarks

under 5 mm under 0.2 in 15 ~ 25 mm(EU), 5 ~ 14 mm(KTC) 0.43 ~ 0.67 in(EU), 0.2 ~ 0.55 in 180 mm 7.09 in

(7) Check points after assembly : Control valve spool should smoothly shift to full stroke.

II-S-17

Reference valve

(8) Apply grease on bearing, DU - bushing. Rotating parts should function smoothly. EU - type (5) Lever (Traveling, left)

1

(6) Lever (Traveling, left 3) 1 (7) Pin, spring

2

(8) Lever (Traveling, right) 1 (9) Bearing, needle

2

(10) Bolt

4 (MB 7T)

(11) Nut

4 (MB 4T)

(12) Shaft, traveling (13) Washer, plain 









 





(28) Bearing, ball

 



(29) Bush

PP - type (1) Clearance:



0.3 mm or less

(2) Bolt @ torque: 23.5 ~ 27 N·m 2.4 ~ 2.8 kgf·m







  



  

(11) 









II-S-18

c. Accelarator lever 1. idle speed : 1250 ± 50 rpm KX36-3, 41-3S, V Adjust it by stopper bolt. 2. Max. speed setting : Check if the accel lever link plate contacts to stopper bolt. 3. Lever stroke 99 mm (3.9”) Acceleration

8 7

Deceleration 55 5 mm (2.17 0.2 in)

D ) value in) (Ref. 0.59 ( m m 15

D- D

(Ref. value) 15 mm(0.59 in)

4 6

D

5

Plate

Accel cable

1")

m 9m

(3.1

Acceleration

Idle

Deceleration

7

x

Ma

60 5 mm (2.36 0.2 in) 3 2 1

) value (Ref. (0.98 in) m 25 m

(1) Cable, accel

1

(2) Washer, olain

1

(3) Splint

1

(4) Pin

1

(5) Pin, snap

1

(6) Washer, plain

1

(7) Support, accel

1

(8) Bolt, w sems

2 (MB 7T)

Plate

Accel cable

II-S-19

(Ref. value) 13 mm(0.51 in)

4. Apply grease on DU - bush. 5. Install spring, shim and plate and tighten with washer and bolt. accel lever should slide smoothly.

8 3 2

6 5

7

10

9

12 11

(2) Lever, accel

1

(3) Bush

1

(5) Grip, lever

1

(6) Splint

1

(7) Plate

1

(8) Pin, Shim

1

(9) Washer, spring lock

1

(10) Hex, box

2 M10 x 1.25 7T

(11) Hex, box

2 M10 x 1.25 7T

(12) Nut

2 M10 x 1.25 7T

Accel cable route

(1) Go through the arch guide (2) Go through the slit

(1)

(3)

II-S-20

(2)

(3) Accel cable

d. Dozer lever (6)

1. Outer part of the cable shouldn’t be bent. Straight length : 200 mm (7.78”) or more. 2. Allowable cable radius : R = 150 mm (5.91”) or more. 3. Cable shouldn’t be twisted when fixing 4. Check points after installation Control valve spool should shift smoothly at full stroke.

1 2

(7)

4)

(144.

3

4 5

4 5

(1) Glip

1

(2) Screw, pan hed

2

(3) Cable (blade)

1

(4) Washer, plain

2

(5) Pin, snap

2

(6) Dozer lever shouldn’t contact with upper cover at its full stroke. (7) Cover (R, upper)

II-S-21

13 14 15

(15)

(15)

17 16

(15)

5)

(1

(13) Assy, lever (Blade)

1

(14) Lever (blade)

1

(15) Bush

2

(16) Washer, plain

1

(17) Pin, snap

1

(8) Apply grease on DU - bush. (9) Stopper bolt setting length should be as showen in Fig. l = 15 mm (0.59”)

Dozer Cable route

(1)

(2)

(3)

(1) Go above the horn harness (2) Go inside the frame

(4)

(3) Dozer cable (4) Go through the Groove (5) Inside : Fuel hose

(2)

(6) Outside : Cable

(5) (6)

II-S-22

e. Swing & SP pedal (1) Pedal adjustment To be symmetrical right and left (Horizontal at the center) Right-and-left: Swing

(3) Tightening torque of link ball : 17.7 ~ 20.6 N·m (1.8 ~ 2.1 kgf·m) 13.0 ~ 15.2 ft·lbs

(2) Pedal operation Both spools of service port and swing port to move over their entire strokes smoothly. Each pedal should return to its newtral position smoothly.

19 20 21 22 269.5

(1)

(2)

‫ޓ‬

(3)

(4)

(5) (1) Link rod

(19) Lever (swing)

1

(2) Pedal upper face should be horizontal at neutral.

(20) Bush

2

(3) Pedal

(21) Washer, plain

1

(4) Washer and snap pin

(22) Pin, snup

1

(5) Lever and bush

II-S-23

(2)

(2) Pedal upper face should be horizontal at neutral.

24 25 26 27

II-S-24

(24) Lever (sp pedal)

1

(25) Bush

2

(26) Washer, plain

1

(27) Snup pin

1

f. Control valve links (1) Installation of each link Each link should rotate smoothly.

(3) Tightening torque of control valve mounting bolt (2). Apply screw - lock agent. 23.5 ~ 27.5 N·m (2.4 ~ 2.8 kgf·m) 17.4 ~ 20.3 ft·lbs

(2) Installation of DU-bush and shaft Apply grease.

2

4 5

3

1

5 6

3

13

14 15

(1) Bolt

4 M12 x 1.25 7T

(10) Link (plate2)

1

(2) Bolt

3 M8 7T

(11) Pin, joint

1 Dozer

(3) Link

2

(12) Snap pin

1

(4) Pin, joint

2

(13) Link (plate2)

1

(5) Snap pin

4

(6) Pin, joint

2

Traveling

(7) Link (plate1)

1

(8) Pin, joint

1 Swing

(9) Snap pin

1

10

(14) Pin, joint

1 Service port

(15) Snap pin

1

II-S-25

11 12

7

8 9

g. Limit switch installation (1) Limit switch performance Limit switch setup Limit switch to perform as specified * Apply screw loctite (Three Bond TB1401B). No gap at points (A), (B) and (C) with limit switch activated (2) Tension spring fitting on the unload lever (left) Hook tip of the spring (to hook on the unload lever) to face the machine's outside.

(3) Squeeze of the seat support rubber 2 1 ~ 2 mm (0.04 ~ 0.08 in) (4) DU-bush Apply grease. (5) Safety lock switch tightening torque: 3.9 ~ 4.9 N·m 0.4 ~ 0.5 kgf·m) 2.9 ~ 3.6 ft·lbs

(Unload lever LH) (1)

(2)

(3)

A

(5)

(4)

(Unload lever LH) (3) (2)

(6)

(1) Lock lever, (L), bush (2) Safety lock switch (3) Spring (4) Trim 1 (Seat support rubber 2) (5) Hook tip of the spring to outerward

B

(6) Lock lever, (R)

II-S-26

h. Seat belt 1

2

4

(1) Seat belt assy

1

(2) Bolt

2

(3) Bracket

1

(4) Bolt

2

(5) Meet to the corner

II-S-27

3

(5)

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

2

3

1 (5) (4)

(1) Sddy idler 2 (2) Assy cylinder, left 1 Track (left) Assy cylinder, Right (3) Nipple, grease cylinder 1 Track (Right) (4) Overlap area (5) In case of rubber track, seam mark (f) should be positioned at the upper center as shown in Fig.

II-S-28

(3)

1

2 (4)

(3) A - part

(4) Mating surface of backup ring

II-S-29

(2) Grease cylinder installation 1. Apply grease on dust seal, O - ring 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 6. Apply grease and adjust the rubber track sag distance. 7. Rubber track sag distance : 10 ~ 15 mm (0.39 ~ 0.59 inch) 8. Precaution : Rotate track for 5 to 6 times and measure the distance with “f“ mark at top position.

b. Track Roller

2 3

4

1

(1) Assy roller, truck

6

(2) Bush

12 M12 x 1.25 x L30

(3) Washer

12

(4) Plain washer

12

1. Remove the stuck oil and paint on the track roller and track frame for mounting track roller. 2. Tightening torque for mounting track roller. 103 ~ 117.7 N·m 10.5 ~ 12 kgf·m 75.9 ~ 86.8 ft·lbf Apply threebond #1305 on the femail thread. 3. Seating face clearance of track frame and track roller should be 1.5 mm (0.06 inch) or less. 4. Center line dislocation to tamber line should be ± 2 mm (0.08 inch) or less (Idler should be placed at the center of gap.)

II-S-30

III.Engine A.Engine accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3 a. b c. d. e. f. g. h.

Engine mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-4 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-6 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-10 Pump coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-12 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-13 Fuel tank cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-14 Fuel hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-15

B.Engine WSM : D902 -E . . . . . . . . . . . . . . . . . . . . . . . . . III-S-17 C.Engine WSM : D782 -B . . . . . . . . . . . . . . . . . . . . . . . . III-S-119

III-S-1

III-S-2

A.Engine accessories a. Engine mount (1) Shock absorber installation Install as shown in Fig. 1. R part should be down to swivel frame side. 2. Tighten to torque from swivel frame side. 3. Tighten to torque at engine side. Nut : 02118 - 60100 Tightening torque : 39.2 ~ 45.1 N·m (4.0 ~ 4.6 kgf·m) 28.9 ~ 33.3 ft·lbs Apply screw locktite agent.(Locktite 271)

(1)

(2)

(3)

(4) (5)

(6)

D

(7)

(9)

(8) III-S-3

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Cover Shock absorber R part Engin bracket, front Shock absorber Engin bracket, rear Harness Temp sensor Joint

b Air cleaner P/N=6C060-99411 Filtering area: 0.45m2, nominal, 10P El element paper: Clean efficiency: 99% (JIS 8 class) P/N=T0270-93221 Filtering area: 135cm2 250mesh (1)Outer element (2)Inner element (safety element) (3)Case (4)Dust cover (5)Clamps

(2)

(12)

(6)

(8)

(4)

(10)

(13)

(1)

(11)

(9)

(3)

(7)

(1) Element, 2nd filter (2) Pipe (3) Plate (4) Tube (5) Clip (6) Seal (7) Element (8) End cap (9) End cap (10)Protector (11)Inner tube (12)Gasket (13)Clip

III-S-4

9

10

8

6

7

1 2

(11)

(11)

5

3

4

(1) Assy cleaner, air (2) Band, air cleaner (3) House, inlet (4) House, clamp (5) House, clamp (6) House, inlet (7) House, clamp (8) Band, pipe (9) House, inlet (10)Band, pipe (11)Hose inlet should be vertical.

III-S-5

c. Radiator (1) Stretch of fan out of fan shroud Part (A) Refer to the Fig. Fan to stretch uniformly out of its shroud

(3) Bracket fitting on the radiator cushion Rubber catch to hook on tightly

(2) Clearance between fan and fan shroud Part (B) 10mm, 0.39 inch or more to be ensured

A (1)

B

50

(1)

(20)

(1)

(1)

(1) 10 mm (0.39”) or more.

III-S-6

5

13

6

11

4

2

3

1

22

20

9

7

8

21

22

15 17

14

12

16

10

18

(1) Assy radiator

1

19

(2) Shroud, fan

1

(3) Trim (1150)

1

(4) Bolt

4 M6 x 1 4T

(5) Cover, fan

1

(6) Bolt

2 M6 x 1 4T

(7) Bracket : oil cooler

1

(8) Bolt

4 M6 x 1 4T

(9) Oil cooler

1

(10) Bolt

4 M6 x 1 4T

13

III-S-7

(11) Hose (upper)

1

(12) Hose (bottom)

1 For canopy

(13) Hose clamp

3

(14) Hose clamp

1

(15) Hose (drain, radiator)

1

(16) Hose clamp

2

(17) Adapter (drain)

1

(18) Washer, seal

1

(19) Plug

1

(20) Stay (L, radiator)

1

(21) Stay (R, radiator)

1

(22) Bolt

2 M6 x 1 4T

5

3

4

6

(10)

7

2

(8)

(9)

1

(1) Bolt

2 M10 x 1.25 7T

(2) Assy tank, reserve

1

(3) Bracket, radiator

1

(4) Bolt

3 M10 x 1.25 7T

(5) Cushion, radiator

2

(6) Shroud, fan

1

(7) Cover, fan

1

(8) Swivel frame (9) Hose on drain side Pass through the crena of the weight. (10) Pass between the cover (fan) and shroud (Fan)

III-S-8

(4)Thermostat P/N=19434-73011 Applied model= Preformance:

Identify with black marking ink on the shaded spot.

8mm Mark the valve opening temperature here.

Mark the manufacturing date here.

Lift

Mark the manufacturer logo here. 71°C Approx. 10°C

(8) (6)

(5)

Valve opening temp.

(1)

(1)Seat (2)Body (3)Valve (4)Spring (5)Stopper (6)Shaft (7)Pellet (8)Adjust pin

(3) (2) (4) (7)

III-S-9

85°C

Full lift temp.

d. Muffler (1) Clamping the muffler pipe Tightening torque : 3.9 ~ 5.9 N·m (0.4 ~ 0.6 kgf·m) 2.9 ~ 4.3 ft·lbs

(3) Assembling order * Temporarily tighten the bolts (A), (B) and (C). No gaps at the tightened faces (a, b and c) * (A): First to tighten up * (B): Second to tighten up * (C): Third to tighten up * (D): Fourth to tighten up

(2) Ensuring the clearance between muffler pipe outlet and weight hole (1) Clearance to be over 15 mm(0.59 inch) (2) Tail pipe (3) Weight (4) Tail pipe not to stretch out of the weight end (2)

Tightening torque : (A)(B) : 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) 35.4 ~ 41.2 ft·lbs Tightening torque : (C) : 3.9 ~ 5.9 N·m (0.4 ~ 0.6 kgf·m) 2.9 ~ 4.3 ft·lbs

(1)

(3)

(4)

C

3 1

6

2 4 5

14

11 10 9 8 7

12 B

13

2 A

13

3

(234)

(11)

(1) Gasket, muffler na

1 (424)

(8) Bolt

2 M8 7T

(2) Flange (muffler)

1

(9) Plain washer

4

(3) Bolt

3 M8 7T

(10) Spring washer

2

(4) Nut

3 4T

(11) Nut

2 M8 7T

(5) Spring washer

3

(12) Bracket, muffler

1

(6) Muffler

1

(13) Bolt

5 M10 x 1.25 7T

(7) Band pipe muffler

2

(14) Pipe, muffler

1

III-S-10

(3) Applying the thermal insulators (1, muffler) (RB237-4247U) and, (2, muffler) (RB237-4248U), (3, muffler) (RB237-4249U) Apply the thermal insulator (2, 3 muffler) on both sides of the muffler first and then another thermal insulator (1, muffler). Finally bind the muffler's both ends with the wires (07811-10984).

2

4

1 (6) 262 (17.5)

(204)

5

3

(1) Insulation (1, muffler)

1

(2) Insulation (2, muffler)

1

(3) Insulation (3, muffler)

1

(4) Muffler

1 (424)

(5) Wire

2

(6) Wire fix direction

III-S-11

e. Pump coupling (1) Apply grease on spline section Proper amount to be applied (No overflow allowed) No grease to be stuck on the rubber Wipe off grease immediately as required.

(1)

(2) Tighten coupling bolts (01138-61016)

A (2)

Tightening torque : 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) Apply screw lock agent.

(3)

(4)

(1) (2) (3) (4)

Pump housing Coupring Bolt Apply grease on the spline area.

III-S-12

010

Housing, pump

020

Bolt

030

Bolt

050

Pin, Straight

070

Coupling

080

Assy pump, Piston

090

Bolt

f. Fuel tank (1) Fuel sensor assembly

KX41-3S, V : RB237-5114U KX36-3 : RB137-5114U Tightening torque : 3 ~ 4 N·m (0.3 ~ 0.4 kgf·m)

(2) Fuel tank Push the tank foward machine rear direction and fix to tight.

3

(11)

6

4

(10)

5 2

7

1

9

8 (12)

(1) Fuel tank (2) Fuel sensor

KX41-3

(2) Fuel sensor

KX36-3

(3) Flange bolt : M5 x 14

M5

(4) Tank retainer (5) Cushion (6) Bolt

M8 7T

(7) Tank stay (8) Cushion (9) Bolt (10) Front (11) Rear (12) Pushing direction

III-S-13

M10 x 1.25 7T

g. Fuel tank cushion (1) Cushion application Push and stick the cushion in place. * Clean up the surface cushion applying the cushion.

(1)

(45)

(2)

(4) (3)



(7)

(6)

(5) (1) Align the hole centers and paste the cushion in the longitudinal direction of the equipment. (2) Align the edge of the cushion with the inner edge of the equipment. (3) See Fig.1. (4) Align the edge of the cushion with the rear edge. (5) Align the hole centers and paste the cushion in the longitudinal direction of the equipment. (6) Align the edge of the cushion with the upper edge of the vertical rib of the swivel frame. (7) Align the edge of the cushion with the outer edge of the equipment.

III-S-14

Fig.1

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

* mark

RG008-5198U

# mark

RG008-5199U

(9) (7)

(10) (6)

(8)

(2) (11)

(13)

(4) (5)

(12)

(3)

(14)

(1) Joint to fuel tank L = 675, 26.6” (I 4) (Protection tube 580 mm, 22.8”) (2) Engin to joint L = 150, 5.9” (I 4) (3) Joint to engin L = 260, 10.2” (I 4) (4) Joint to joint L = 90 (I 8) (5) Pump to joint L = 100, 3.9” (6) Fuel tank to filter L = 1150, 45.3 (Protection tube 1050 mm, 41.3”) (7) Filter to pump L = 250, 9.8”

(8) Fuel tank (9) Fuel filter assy (10) T - joint (11) Fuel return (Engin) (12) Pipe joint (T - 9) (13) Fuel pump (14) Rotate 90 degrees and mount the joint so that the left and right directions will be cross shaped.

III-S-15

III-S-16

B.Engine WSM : D902 -E To the best Service Personnels of Kubota Construction Machinery Dealers. This engine WSM contains and covers Engine model D902 - E As for D782 - B, only pages that contain different data and contents were added from page III-S-119.

TO THE READER This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of Z602-E and D902-E. It is divided into two parts, "Mechanism" and "Servicing". B Mechanism Information on the construction and function are included. This part should be understood before proceeding with troubleshooting, disassembling and servicing. Refer to Diesel Engine Mechanism Workshop Manual (Code No. 97897-01872) for the one which has not been described to this workshop manual. B Servicing The heading "General" includes general precautions, check and maintenance and special tools. Other section, there are troubleshooting, servicing specification lists, checking and adjusting, disassembling and assembling, and servicing which cover procedures, precautions, factory specifications and allowable limits. All information illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes in all information at any time without notice. July 2003

KUBOTA Corporation 2003 0000003172E

III-S-17

Z602-E · D902-E, WSM

SAFETY INSTRUCTIONS

This symbol, the industry's "Safety Alert Symbol" is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.

A Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

A Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

A Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. A Indicates that equipment or property damage could result if instructions are not followed. A Gives helpful information. 0000001386E

BEFORE SERVICING AND REPAIRING A Read all instructions and safety instructions in this manual and on your engine safety decals. A Clean the work area and engine. A Park the machine on a firm and level ground. A Allow the engine to cool before proceeding. A Stop the engine, and remove the key A Disconnect the battery negative cable 0000001387E

SAFETY STARTING A Do not start the engine by shorting across starter terminals or bypassing the safety start switch. A Unauthorized modifications to the engine may impair the function and / or safety and affect engine life. 0000001388E

III-S-18

Z602-E · D902-E, WSM

SAFETY INSTRUCTIONS

SAFETY WORKING A Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. A Wear close fitting clothing and safety equipment appropriate to the job. A Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended. A When servicing is performed together by two or more persons, take care to perform all work safely. A Do not touch the rotating or hot parts while the engine is running. A Never remove the radiator cap while the engine is running, or immediately after stopping. Otherwise, hot water will spout out from radiator. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen the cap to first stop to relieve pressure before removing completely. A Escaping fluid (fuel or hydraulic oil) under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or fuel lines. Tighten all connections before applying pressure. A Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. 0000001389E

AVOID FIRES A Fuel is extremely flammable and explosive under certain conditions. Do not smoke or allow flames or sparks in your working area. A To avoid sparks from an accidental short circuit, always disconnect the battery negative cable first and connect it last. A Battery gas can explode. Keep sparks and open flame away from the top of battery, especially when charging the battery. A Make sure that no fuel has been spilled on the engine. 0000001390E

III-S-19

Z602-E · D902-E, WSM

SAFETY INSTRUCTIONS

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

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

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

PREPARE FOR EMERGENCIES A Keep a first aid kit and fire extinguisher handy at all times. A Keep emergency numbers for doctors, ambulance service, hospital and fire department near your telephone. 0000001394E

III-S-20

Z602-E · D902-E, WSM

SPECIFICATIONS

SPECIFICATIONS Model Number of Cylinders Type

Z602-E

D902-E

2

3 Vertical, water-cooled, 4-cycle IDI diesel engine

Bore x Stroke

mm (in.)

72 x 73.6 (2.83 x 2.90)

Total Displacement

(cu.in.)

599 (36.55)

898 (54.80)

SAE Net Continuous kW/ (HP/

(rpm) (rpm))

8.8 / 3200 (11.8 / 3200)

13.4 / 3200 (18.0 / 3200)

SAE Net Intermittent kW/ (HP/

(rpm) (rpm))

10.1 / 3200 (13.5 / 3200)

15.4 / 3200 (20.6 / 3200)

Maximum Bare Speed

(

Minimum Bare Idling Speed (

(rpm))

3450 900 to 1000

(rpm))

Combustion Chamber

Spherical Type (E-TVCS)

Fuel Injection Pump

Bosch MD Type mini pump

Governor

Centrifugal ball mechanical governor

Direction of Rotation

Counter-clockwise (viewed from flywheel side)

Injection Nozzle

Bosch throttle type

Injection Timing

0.30 to 0.33 rad (17 to 19 ) before T.D.C.

Firing Order

1-2

Injection Pressure

1-2-3 13.73 MPa (140

, 1991 psi)

Compression Ratio

24 : 1

Lubricating System

Forced lubrication by pump

Cooling System

Pressurized radiator, forced circulation with water pump

Starting System

Cell starter (with glow plug)

Starting Motor Recommended Battery Capacity (5 Hr capacity)

12 V, 1.0 kW

12 V, 1.2 kW

12 V, 36AH, equivalent

12 V, 52AH, equivalent

Charging Alternator

12 V, 480 W

Fuel

Diesel Fuel No.2-D Class CF lubricating oil as per API classification is recommended. If this class of lubricating oil is not available, preferably use Class CD or CE lubricating oil. For details on recommended lubricating oils, see page S-16, 20.

Lubricating Oil Lubricating Oil Capacity Weight (Dry) BB spec.

kg (lbs)

2.5 L (2.64 U.S.qts)

3.7 L (3.91 U.S.qts)

57.0 (125.7)

72.0 (158.7)

A Specifications are subject to change without notice. A The battery capacity is indicated in 5-hour ratio. 0000003173E

III-S-21

Z602-E · D902-E, WSM

PERFORMANCE CURVES

PERFORMANCE CURVES B Z602-E

(1)

Brake Horsepower

(6)

Net Intermittent Torque

(11)

Net Intermittent B.S.F.C.

(15)

Gross B.H.P.

(2)

Engine Speed

(7)

Net Continuous Torque

(12)

Gross Torque

(16)

Overload B.H.P.

(3)

B.S.F.C.

(8)

Gross Intermittent B.H.P.

(13)

Overload Torque

(17)

Continuous B.H.P.

(4)

Torque

(9)

Net Intermittent B.H.P.

(14)

Continuous Torque

(18)

Overload B.S.F.C.

(5)

Gross Intermittent Torque

(10)

Net Continuous B.H.P. 0000003174E

III-S-22

Z602-E · D902-E, WSM

PERFORMANCE CURVES

B D902-E

(1)

Brake Horsepower

(6)

Net Intermittent Torque

(11)

Net Intermittent B.S.F.C.

(15)

Gross B.H.P.

(2)

Engine Speed

(7)

Net Continuous Torque

(12)

Gross Torque

(16)

Overload B.H.P.

(3)

B.S.F.C.

(8)

Gross Intermittent B.H.P.

(13)

Overload Torque

(17)

Continuous B.H.P.

(4)

Torque

(9)

Net Intermittent B.H.P.

(14)

Continuous Torque

(18)

Overload B.S.F.C.

(5)

Gross Intermittent Torque

(10)

Net Continuous B.H.P. 0000003301E

III-S-23

Z602-E · D902-E, WSM

DIMENSIONS

DIMENSIONS B Z602-E

0000003175E

III-S-24

Z602-E · D902-E, WSM

DIMENSIONS

B D902-E

0000003176E

III-S-25

CONTENTS 1. ENGINE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-27 [1] HALF-FLOATING HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . .III-S-27 [2] PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-28 [3] OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-28

2. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-29 [1] COOLING FIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-29

III-S-26

Z602-E · D902-E, WSM

ENGINE

1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0.5 mm or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head. (1)

Cylinder Head Cover

[a]

Z602-E

(2)

Rubber Packing

[b]

D902-E 0000003177E

III-S-27

Z602-E · D902-E, WSM

ENGINE

[2] PISTON Piston's skirt is coated with molybdenum isulfide , which reduces the piston slap noise and thus the entire operating noise. Molybdenum disulfide (MoS ) The molybdenum disulfide serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil. (1)

Molybdenum Disulfide 0000001272E

[3] OIL PAN The oil pan is expanded under the gear case. Therefore, the height of the engine can be lowered more than so far while securing a necessary amount of oil. (1)

Gear Case

[a]

Z602-E

(2)

Oil Pan

[b]

D902-E

(3)

Crank Case 0000003178E

III-S-28

Z602-E · D902-E, WSM

ENGINE

2. COOLING SYSTEM [1] COOLING FIN The cooling fin is set up around the oil passage in the gear case. Therefore, the temperature of oil is decreased by the wind generated by the cooling fan. (1)

Cooling Fin

[a]

Z602-E

[b]

D902-E 0000003302E

III-S-29

CONTENTS 1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-32 [1] ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-32 (1) Model Name and Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . III-S-32 (2) Cylinder Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-33

[2] GENERAL PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-34 [3] TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-35 (1) Tightening torques for special use screws, bolts and nuts . . . . . . . . . . III-S-35 (2) Tightening torques for general use screws, bolts and nuts . . . . . . . . . . III-S-36

[4] TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-37 [5] SERVICING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . .III-S-40 [6] MAINTENANCE CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-46 [7] CHECK AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-48 (1) (2) (3) (4) (5) (6) (7)

Daily Check Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-48 Check Points of Every 50 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-50 Check Points of Every 100 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-51 Check Points of Every 200 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-52 Check Points of Every 400 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-53 Check Points of Every 500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-54 Check Points of Every Year or Every Sixth Cleanings of Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-55 (8) Check Points of Every 800 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-56 (9) Check Points of Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-57 (10) Check Points of Every 3000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-57 (11) Check Points of Every 2 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-57

[8] SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-58

2. ENGINE BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-64 [1] CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-64 [2] DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . .III-S-65 (1) (2) (3) (4) (5) (6)

Draining Coolant and Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head, Valves and Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear, Camshaft and Fuel Camshaft . . . . . . . . . . . . . . . . . . . . . Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

III-S-65 III-S-66 III-S-66 III-S-73 III-S-76 III-S-78

[3] SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-S-81 (1) Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-81 (2) Timing Gear, Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-87 (3) Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-89 III-S-30

(4) Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-93 (5) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-97

3. LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . III-S-99 [1] CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-99 [2] SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-99

4. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-101 [1] CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . III-S-101 [2] DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . III-S-103

5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-104 [1] CHECKING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . III-S-104 (1) Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-104 (2) Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-107

6. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . III-S-109 [1] CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-109 (1) Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-109 (2) Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-109 (3) Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-110

[2] DISASSEMBLING AND ASSEMBLING . . . . . . . . . . . . . . . . . . III-S-110 (1) Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-110 (2) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-111

[3] SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-113 (1) Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-113 (2) Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-S-116

III-S-31

Z602-E · D902-E, WSM

ENGINE

1. GENERAL [1] ENGINE IDENTIFICATION (1) Model Name and Engine Serial Number When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced. B Engine Serial Number The engine serial number is an identified number for the engine. It is marked after the engine model number. It indicates month and year of manufacture as follows. A Year of manufacture Alphabet or Number

Year

Alphabet or Number

Year

1

2001

F

2015

2

2002

G

2016

3

2003

H

2017

4

2004

J

2018

5

2005

K

2019

6

2006

L

2020

7

2007

M

2021

8

2008

N

2022

9

2009

P

2023

A

2010

R

2024

B

2011

S

2025

C

2012

T

2026

D

2013

V

2027

E

2014

A:

Engine Model Name and

[a]

Z602-E

Serial Number

[b]

D902-E 0000003179E

III-S-32

Z602-E · D902-E, WSM

ENGINE

A Month of manufacture Engine Serial Number Month 0001 ~ 9999

10000 ~

January

A0001 ~ A9999

B10000 ~

February

C0001 ~ C9999

D10000 ~

March

E0001 ~ E9999

F10000 ~

April

G0001 ~ G9999

H10000 ~

May

J0001 ~ J9999

K10000 ~

June

L0001 ~ L9999

M10000 ~

July

N0001 ~ N9999

P10000 ~

August

Q0001 ~ Q9999

R10000 ~

September

S0001 ~ S9999

T10000 ~

October

U0001 ~ U9999

V10000 ~

November

W0001 ~ W9999

X10000 ~

December

Y0001 ~ Y9999

Z10000 ~

e.g. Z602-3A0001 "3" indicates 2003 and "A" indicates January. So, 3A indicates that the engine was manufactured on January, 2003. 0000001298E

(2) Cylinder Number The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2 and No.3 starting from the gear case side. 0000003180E

III-S-33

Z602-E · D902-E, WSM

ENGINE

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

Grease

(A)

External Snap Ring

(2)

Force

(B)

Internal Snap Ring

(3)

Place the Sharp Edge against the Direction of Force 0000001277E

III-S-34

Z602-E · D902-E, WSM

ENGINE

[3] TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque. 0000001286E

(1) Tightening torques for special use screws, bolts and nuts

A For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. A The letter "M" in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads. The pitch is the nominal distance in mm between two threads. Item

Size x Pitch

ft-lbs

*Cylinder head cover screw

M6 x 1

6.86 to 11.3

0.7 to 1.15

5.1 to 8.3

Injection pipe retaining nut

M12 x 1.5

24.5 to 34.3

2.5 to 3.5

18.1 to 25.3

Overflow pipe retaining nut

M12 x 1.5

19.6 to 24.5

2.0 to 2.5

14.5 to 18.1

Nozzle holder assembly

M20 x 1.5

49.0 to 68.6

5.0 to 7.0

36.2 to 50.6

Glow plug

M8 x 1

7.85 to 14.7

0.8 to 1.5

5.8 to 10.8

*Rocker arm bracket screw

M6 x 1

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3

*Cylinder head screw

M8 x 1.25

37.3 to 42.2

3.8 to 4.3

27.5 to 31.1

*Fan drive pulley screw

M12 x 1.5

98.1 to 107.9

10.0 to 11.0

72.3 to 79.6

M6 x 1

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3

*Connecting rod screw

M7 x 0.75

26.5 to 30.4

2.7 to 3.1

19.5 to 22.4

*Flywheel screw

M10 x 1.25

53.9 to 58.8

5.5 to 6.0

39.8 to 43.4

Bearing case cover mounting screw

M6 x 1

9.8 to 11.3

1.00 to 1.15

7.2 to 8.3

*Main bearing case screw 2

M7 x 1

26.5 to 30.4

2.7 to 3.1

19.5 to 22.4

*Main bearing case screw 1

M6 x 1

12.7 to 15.7

1.3 to 1.6

9.4 to 11.6

-

34.3 to 39.2

3.5 to 4.0

25.3 to 28.9

PT 1/8

14.7 to 19.6

1.5 to 2.0

10.8 to 14.5

-

5.9 to 11.8

0.6 to 1.2

4.3 to 8.7

*Idle gear shaft mounting screw

Nozzle holder Oil pressure switch Starter (C terminal nut)

0000001287E

III-S-35

Z602-E · D902-E, WSM

ENGINE

(2) Tightening torques for general use screws, bolts and nuts When the tightening torques are not specified, tighten the screws, bolts and nuts according to the table below. Standard Screw and Bolt

Grade Nominal Diameter

Special Screw and Bolt

ft-lbs

Unit

ft-lbs

M6

7.9 to 9.3

0.80 to 0.95

5.8 to 6.9

9.8 to 11.3

1.00 to 1.15

7.23 to 8.32

M8

17.7 to 20.6

1.8 to 2.1

13.0 to 15.2

23.5 to 27.5

2.4 to 2.8

17.4 to 20.3

M10

39.2 to 45.1

4.0 to 4.6

28.9 to 33.3

48.1 to 55.9

4.9 to 5.7

35.4 to 41.2

M12

62.8 to 72.6

6.4 to 7.4

46.3 to 53.5

77.5 to 90.2

7.9 to 9.2

57.1 to 66.5

Screw and bolt material grades are shown by numbers punched on the screw and bolt heads. Prior to tightening, be sure to check out the numbers as shown below. Punched number

Screw and bolt material grade

None or 4

Standard screw and bolt SS41, S20C

7

Special screw and bolt S43C, S48C (Refined) 0000001288E

III-S-36

Z602-E · D902-E, WSM

ENGINE

[4] TROUBLE SHOOTING Symptom

Probable Cause

Engine Does Not Start A No fuel

Solution

Reference Page

Replenish fuel

A Air in the fuel system

Bleed

A Water in the fuel system

Change fuel and repair or replace fuel system

A Fuel hose clogged

Clean

A Fuel filter clogged

Change

A Excessively high viscosity of fuel or engine oil Use specified fuel or engine oil at low temperature A Fuel with low cetane number

III-S-50

III-S-53 III-S-51

Use specified fuel

A Fuel leak due to loose injection pipe retaining Tighten retaining nut nut

III-S-67

A Incorrect injection timing

Adjust

III-S-104

A Fuel camshaft worn

Replace

III-S-75

A Injection nozzle clogged

Repair or replace

III-S-107,108

A Injection pump malfunctioning

Replace

III-S-73

A Seizure of crankshaft, camshaft, piston, Repair or replace cylinder or bearing

(Starter Does Not Run)

Engine Revolution Is Not Smooth

A Compression leak from cylinder

Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

III-S-64

A Improper valve timing

Correct or replace timing gear

III-S-74

A Piston ring and cylinder worn

Replace

III-S-77, 91, 97, 98

A Excessive valve clearance

Adjust

III-S-56

A Battery discharged

Charge

A Starter malfunctioning

Repair or replace

A Wiring disconnected

Connect

A Fuel filter clogged or dirty

Replace

III-S-53

A Air cleaner clogged

Clean or replace

III-S-51

III-S-110

A Fuel leak due to loose injection pipe retaining Tighten retaining nut nut

III-S-67

A Injection pump malfunctioning

Replace

III-S-73

A Incorrect nozzle injection pressure

Adjust

III-S-107,108

A Injection nozzle stuck or clogged

Repair or replace

III-S-68,108,109

A Governor malfunctioning

Repair

III-S-75

III-S-37

Z602-E · D902-E, WSM

ENGINE

Symptom Either White or Blue Exhaust Gas Is Observed

Either Black or Dark Gray Exhaust Gas Is Observed

Deficient Output

Excessive Lubricant Oil Consumption

Fuel Mixed into Lubricant Oil

Water Mixed into Lubricant Oil

Probable Cause

Solution

Reference Page

A Excessive engine oil

Reduce to specified level

III-S-48

A Piston ring and cylinder worn or stuck

Repair or replace

III-S-77, 91, 97, 98

A Incorrect injection timing

Adjust

III-S-104

A Deficient compression

Adjust top clearance

III-S-65

A Overload

Reduce the load

A Low grade fuel used

Use specified fuel

A Fuel filter clogged

Replace

III-S-53

A Air cleaner clogged

Clean or replace

III-S-51

A Deficient nozzle injection

Repair or replace nozzle

III-S-68,107, 108

A Incorrect injection timing

Adjust

III-S-104

A Engine's moving parts seem to be seizing

Repair or replace

A Uneven fuel injection

Replace injection pump

III-S-73

A Deficient nozzle injection

Repair or replace nozzle

III-S-68, 107, 108

A Compression leak

Replace head gasket, III-S-64 tighten cylinder head screw, glow plug and nozzle holder

A Piston ring's gap facing the same direction

Shift ring gap direction

III-S-76

A Oil ring worn or stuck

Replace

III-S-77, 91

A Piston ring groove worn

Replace piston

III-S-77, 91

A Valve stem and valve guide worn

Replace

III-S-71, 82

A Oil leaking due to defective seals or packing

Replace

A Injection pump's plunger worn

Replace injection pump

III-S-73

A Deficient nozzle injection

Repair or replace nozzle

III-S-68, 107, 108

A Injection pump broken

Replace

III-S-73

A Head gasket defective

Replace

III-S-70

A Cylinder block or cylinder head flawed

Replace

III-S-38

Z602-E · D902-E, WSM

Symptom Low Oil Pressure

High Oil Pressure

Engine Overheated

ENGINE

Probable Cause

Solution

Reference Page

A Engine oil insufficient

Replenish

III-S-48

A Oil strainer clogged

Clean

III-S-72

A Oil filter cartridge clogged

Replace

III-S-53

A Relief valve stuck with dirt

Clean

A Relief valve spring weaken or broken

Replace

A Excessive oil clearance of crankshaft bearing

Replace

III-S-80, 95 to 97

A Excessive oil clearance of crankpin bearing

Replace

III-S-77, 94

A Excessive oil clearance of rocker arm

Replace

III-S-85

A Oil passage clogged

Clean

A Different type of oil

Use specified type of oil

III-S-51

A Oil pump defective

Repair or replace

III-S-75,99,100

A Different type of oil

Use specified type of oil

III-S-51

A Relief valve defective

Replace

A Engine oil insufficient

Replenish

III-S-48

A Fan belt broken or tensioned improperly

Replace or adjust

III-S-55, 101

A Coolant insufficient

Replenish

III-S-49

A Radiator net and radiator fin clogged with dust Clean A Inside of radiator corroded

Clean or replace

III-S-54

A Coolant flow route corroded

Clean or replace

III-S-52

A Radiator cap defective

Replace

III-S-102

A Radiator hose damaged

Replace

III-S-52

A Overload running

Reduce the load

A Head gasket defective

Replace

III-S-70

A Incorrect injection timing

Adjust

III-S-104

A Unsuitable fuel used

Use specified fuel 0000003183E

III-S-39

Z602-E · D902-E, WSM

ENGINE

[5] SERVICING SPECIFICATIONS ENGINE BODY Item

Factory Specification

Valve Clearance (Cold)

0.145 to 0.185 mm 0.00571 to 0.00728 in.

Compression Pressure

3.53 to 4.02 MPa 36.0 to 41.0 512 to 583 psi Variance Among Cylinder

Top Clearance Cylinder Head Surface

10 % or less

Flatness

0.05 mm 0.0020 in. -0.10 to 0.10 mm -0.0039 to 0.0039 in.

0.30 mm 0.0118 in.

Clearance

0.030 to 0.057 mm 0.00118 to 0.00224 in.

0.10 mm 0.0039 in.

Valve Stem (O.D.)

5.968 to 5.980 mm 0.23496 to 0.23543 in.

Valve Guide (I.D.)

6.010 to 6.025 mm 0.23661 to 0.23720 in.

Valve Face

Angle

0.785 rad 45

Valve Seat

Angle

0.785 rad 45

Width

2.12 mm 0.0835 in.

Valve Spring

2.55 MPa 26.0 370 psi

0.50 to 0.70 mm 0.0197 to 0.0276 in.

Valve Recessing (Intake and Exhaust) Valve Stem to Valve Guide

Allowable Limit

Free Length

31.3 to 31.8 mm 1.232 to 1.252 in.

Tilt

28.4 mm 1.118 in. 1.2 mm 0.047 in.

Setting Load / Setting Length

64.7 N / 27.0 mm 6.6 kgf / 27.0 mm 14.6 lbs / 1.063 in.

54.9 N / 27.0 mm 5.6 kgf / 27.0 mm 12.3 lbs / 1.063 in. 0000001278E

III-S-40

Z602-E · D902-E, WSM

ENGINE

ENGINE BODY (Continued) Item Rocker Arm Shaft to Rocker Arm

Factory Specification

Allowable Limit

Oil Clearance

0.016 to 0.045 mm 0.00063 to 0.00177 in.

0.15 mm 0.0059 in.

Rocker Arm Shaft (O.D.)

10.473 to 10.484 mm 0.41232 to 0.41276 in.

Rocker Arm (I.D.)

10.500 to 10.518 mm 0.41339 to 0.41410 in.

Push Rod

Alignment

Tappet to Tappet Guide Bore

Oil Clearance

0.016 to 0.052 mm 0.00063 to 0.00205 in.

Tappet (O.D.)

17.966 to 17.984 mm 0.70732 to 0.70803 in.

Tappet Guide Bore (I.D.)

18.000 to 18.018 mm 0.70866 to 0.70937 in.

Crank Gear to Idle Gear (Backlash)

0.043 to 0.124 mm 0.00169 to 0.00488 in.

0.15 mm 0.0059 in.

Idle Gear to Cam Gear (Backlash)

0.047 to 0.123 mm 0.00185 to 0.00484 in.

0.15 mm 0.0059 in.

Idle Gear to Injection Pump Gear (Backlash)

0.046 to 0.124 mm 0.00181 to 0.00488 in.

0.15 mm 0.0059 in.

Crank Gear to Oil Pump Drive Gear (Backlash)

0.041 to 0.123 mm 0.00161 to 0.00484 in.

0.15 mm 0.0059 in.

Timing Gear

0.25 mm 0.0098 in. 0.10 mm 0.0039 in.

Idle Gear

Side Clearance

0.20 to 0.51 mm 0.0079 to 0.0201 in.

0.80 mm 0.0315 in.

Camshaft

Side Clearance

0.15 to 0.31 mm 0.0059 to 0.0122 in.

0.5 mm 0.0197 in.

Alignment Cam Height (Intake and Exhaust) Camshaft Journal to Cylinder Block Bore

0.01 mm 0.0004 in. 26.88 mm 1.0583 in.

26.83 mm 1.0563 in.

Oil Clearance

0.050 to 0.091 mm 0.00197 to 0.00358 in.

0.15 mm 0.0059 in.

Camshaft Journal (O.D.)

32.934 to 32.950 mm 1.29661 to 1.29724 in.

Cylinder Block Bore (I.D.)

33.000 to 33.025 mm 1.29921 to 1.30020 in. 0000001279E

III-S-41

Z602-E · D902-E, WSM

ENGINE

ENGINE BODY (Continued) Item

Factory Specification

Allowable Limit

Oil Clearance

0.020 to 0.084 mm 0.00079 to 0.00331 in.

0.10 mm 0.0039 in.

Idle Gear Shaft (O.D.)

19.967 to 19.980 mm 0.78610 to 0.78661 in.

Idle Gear Bushing (I.D.)

20.000 to 20.051 mm 0.78740 to 0.78941 in.

Piston Pin Bore

I.D.

20.000 to 20.013 mm 0.78740 to 0.78791 in.

20.05 mm 0.7894 in.

Piston Pin to Small End Bushing

Oil Clearance

0.014 to 0.038 mm 0.00055 to 0.00150 in.

0.10 mm 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.

Oil Clearance

0.015 to 0.075 mm 0.00059 to 0.00295 in.

Small End Bushing (I.D.)

20.026 to 20.077 mm 0.78845 to 0.79043 in.

Idle Gear Shaft to Idle Gear Bushing

Piston Pin to Small End Bushing (Spare Parts)

Piston Ring Gap

Piston Ring to Piston Ring Groove

0.15 mm 0.0059 in.

Top Ring

0.20 to 0.35 mm 0.0079 to 0.0138 in.

1.25 mm 0.0492 in.

Second Ring

0.35 to 0.50 mm 0.0138 to 0.0197 in.

1.25 mm 0.0492 in.

Oil Ring

0.20 to 0.35 mm 0.0079 to 0.0138 in.

1.25 mm 0.0492 in.

Second Ring (Clearance)

0.090 to 0.120 mm 0.00354 to 0.00472 in.

0.15 mm 0.0059 in.

Oil Ring (Clearance)

0.04 to 0.08 mm 0.0016 to 0.0031 in.

0.15 mm 0.0059 in.

Connecting Rod

Alignment

0.05 mm 0.0020 in.

Crankshaft

Side Clearance Alignment

0.15 to 0.31 mm 0.0059 to 0.0122 in.

0.50 mm 0.0197 in. 0.02 mm 0.0008 in. 0000001280E

III-S-42

Z602-E · D902-E, WSM

ENGINE

ENGINE BODY (Continued) Item

Factory Specification

Allowable Limit

Oil Clearance

0.020 to 0.051 mm 0.00079 to 0.00201 in.

0.15 mm 0.0059 in.

Crankpin (O.D.)

33.959 to 33.975 mm 1.33697 to 1.33760 in.

Crankpin Bearing (I.D.)

33.995 to 34.010 mm 1.33893 to 1.33898 in.

Oil Clearance

0.034 to 0.106 mm 0.00134 to 0.00417 in.

Crankshaft Journal (O.D.)

43.934 to 43.950 mm 1.72968 to 1.73031 in.

Crankshaft Bearing 1 (I.D.)

43.984 to 44.040 mm 1.73165 to 1.73386 in.

Oil Clearance

0.028 to 0.059 mm 0.00110 to 0.00232 in.

Crankshaft Journal (O.D.)

43.934 to 43.950 mm 1.72968 to 1.73031 in.

Crankshaft Bearing 2 (I.D.)

43.978 to 43.993 mm 1.73142 to 1.73201 in.

Oil Clearance

0.028 to 0.059 mm 0.00110 to 0.00232 in.

Crankshaft Journal (O.D.)

43.934 to 43.950 mm 1.72968 to 1.73031 in.

Crankshaft Bearing 3 (I.D.)

43.978 to 43.993 mm 1.73142 to 1.73201 in.

Cylinder Liner [Standard]

I.D.

72.000 to 72.019 mm 2.83464 to 2.83539 in.

72.169 mm 2.84129 in.

Cylinder Liner [Oversize : 0.25 mm (0.0098 in.)]

I.D.

72.500 to 72.519 mm 2.85433 to 2.85507 in.

72.669 mm 2.86098 in.

Crankpin to Crankpin Bearing

Crankshaft Journal to Crankshaft Bearing 1

Crankshaft Journal to Crankshaft Bearing 2 (Flywheel Side)

Crankshaft Journal to Crankshaft Bearing 3 (Intermediate)

0.20 mm 0.0079 in.

0.20 mm 0.0079 in.

0.20 mm 0.0079 in.

0000001281E

III-S-43

Z602-E · D902-E, WSM

ENGINE

LUBRICATING SYSTEM Item Engine Oil Pressure

Factory Specification At Idle Speed

More than 49 kPa 0.5 7 psi

At Rated Speed

196 to 441 kPa 2.0 to 4.5 28 to 64 psi

Inner Rotor to Outer Rotor

Clearance

0.03 to 0.14 mm 0.0012 to 0.0055 in.

Outer Rotor to Pump Body

Clearance

0.07 to 0.15 mm 0.0028 to 0.0059 in.

Inner Rotor to Cover

Clearance

0.075 to 0.135 mm 0.00295 to 0.00531 in.

Allowable Limit

147 kPa 1.5 21 psi

0000001282E

COOLING SYSTEM Item

Factory Specification

Fan Belt

Tension

Thermostat

Valve Opening Temperature (At Beginning)

Allowable Limit

7.0 to 9.0 mm / 98 N 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbs)

Valve Opening Temperature (Opened Completely)

69.5 to 72.5 157.1 to 162.5 85 185

Radiator Cap

Pressure Falling Time

10 seconds or more 88 59 kPa 0.9 0.6 13 9 psi

Radiator

Weak Leakage Test Pressure

No leaks at specified pressure 157 kPa 1.6 23 psi 0000001283E

III-S-44

Z602-E · D902-E, WSM

ENGINE

FUEL SYSTEM Item

Factory Specification

Injection Pump

Injection Timing

Pump Element

Fuel Tightness

Delivery Valve

Fuel Tightness

10 seconds 13.73 12.75 MPa 140 130 1991 1849 psi

Fuel Injection Nozzle

Injection Pressure

13.73 to 14.71 MPa 140 to 150 1991 to 2134 psi

Valve Seat Tightness

Allowable Limit

0.30 to 0.33 rad (17 to 19 ) before T.D.C. 13.73 MPa 140 1991 psi 5 seconds 13.73 12.75 MPa 140 130 1991 1849 psi

When the pressure is 12.75 MPa (130 , 1849 psi), the valve seat must be fuel tightness 0000001284E

ELECTRICAL SYSTEM Item

Factory Specification

Allowable Limit

Glow Plug

Resistance

Starter

Commutator (O.D.)

30.0 mm 1.181 in.

29.0 mm 1.142 in.

Difference of O.D.'s

Less than 0.02 mm 0.0008 in.

0.05 mm 0.0020 in.

Mica Undercut

0.50 to 0.80 mm 0.0197 to 0.0315 in.

0.20 mm 0.0079 in.

Brush Length

14.0 mm 0.551 in.

9.0 mm 0.354 in.

Alternator

Approx. 0.9

Stator Resistance

Less than 1.0

Rotor Resistance

2.9

Slip Ring O.D.

14.4 mm 0.5669 in.

14.0 mm 0.5512 in.

Brush Length

10.0 mm 0.3937 in.

1.5 mm 0.0591 in. 0000001285E

III-S-45

Z602-E · D902-E, WSM

ENGINE

[6] MAINTENANCE CHECK LIST To maintain long-lasting and safe engine performance, make it a rule to carry out regular inspections by following the table below. The lubricating oil change intervals listed in the table below are for Classes CF, CE and CD lubricating oils of API classification with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition. Service Interval Item

Initial 50 hrs

Every 50 hrs

Every 100 hrs

Every 200 hrs

Every 400 hrs

Every 500 hrs

Every 1 year

Every 800 hrs

Every 1500 hrs

Every 3000 hrs

Every 2 years

Reference page

Checking fuel hose and clamp bands

III-S-50

Changing engine oil

III-S-51

Replacing oil filter cartridge

III-S-53

Checking fan belt tension and damage

III-S-51

Cleaning air cleaner element

III-S-51

Cleaning fuel filter

III-S-52

Checking radiator hoses and hose clamp bands

III-S-52

Checking intake air line

III-S-52

Replacing fuel filter

III-S-53

Cleaning fuel tank inside

III-S-54

Cleaning water jacket and radiator interior

III-S-54

Replacing fan belt

III-S-55

*Replacing air cleaner element

III-S-55

Checking valve clearance

III-S-56

**Checking fuel injection nozzle condition

III-S-57

Checking injection pump

III-S-57

Replacing intake air line

III-S-57

Replacing radiator hoses and clamp bands

III-S-57

Replacing fuel hoses and clamp bands

III-S-57

Changing radiator coolant (L.L.C.)

III-S-57

* Or, every sixth cleanings of air cleaner element. **Maintenance interval as per EPA instructions. 0000003184E

III-S-46

Z602-E · D902-E, WSM

ENGINE

A When changing or inspecting, be sure to level and stop the engine. A Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a lowsulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals. A Lubricating oil recommended when a low-sulfur or high-sulfur fuel is employed. Fuel Low sulfur (0.5 % )

High sulfur

CF

O

O

CF-4

O

X

CG-4

O

X

Lubricating oil class

O : Recommendable

Remarks

TBN

10

X : Not recommendable 0000001294E

III-S-47

Z602-E · D902-E, WSM

ENGINE

[7] CHECK AND MAINTENANCE (1) Daily Check Points Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again. Check to see that the oil level lies between the two notches. 3. If the level is too low, add new oil to the specified level. A When using an oil of different maker or viscosity from the previous, drain old oil. Never mix two different types of oil. A Be sure to inspect the engine, locating it on a horizontal place. If placed on gradients, accurately, oil quantity may not be measured. A Be sure to keep the oil level between upper and lower limits of the dipstick. Too much oil may cause a drop in output or excessive blow-by gas. On the closed breather type engine in which mist is sucked through port, too much oil may caused oil hammer. While too little oil, may seize the engine's rotating and sliding parts. (The closed breather is an option.) (1)

Dipstick 0000003437E

III-S-48

Z602-E · D902-E, WSM

ENGINE

Checking and Replenish Coolant 1. Without recovery tank ; Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) ; Check to see that the coolant level lies between FULL (A) and LOW (B). 2. If coolant level is too low, check the reason for decreasing coolant. (Case 1) If coolant is decreasing by evaporation, replenish only fresh, soft water. (Case 2) If coolant is decreasing by leak, replenish coolant of the same manufacture and type in the specified mixture ratio (fresh, soft water and L.L.C.). If the coolant brand cannot be identified, drain out all of the remaining coolant and refill with a totally new brand of coolant mix. A Do not remove the radiator cap until coolant temperature is below its boiling point. Then loosen the cap slightly to relieve any excess pressure before removing the cap completely. A During filling the coolant, air must be vented from the engine coolant passages. The air vents by jiggling the radiator upper and lower hoses. A Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak out and the engine could overheat. A Do not use an antifreeze and scale inhibitor at the same time. A Never mix the different type or brand of L.L.C.. (1)

Radiator Cap

(A)

FULL

(2)

Recovery Tank

(B)

LOW 0000001296E

III-S-49

Z602-E · D902-E, WSM

ENGINE

(2) Check Points of Every 50 Hours Checking Fuel Hose and Clamp Bands 1. If the clamp (1) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (2) is made of rubber and ages regardless of the period service. Change the fuel hose together with the clamp every two years. 3. However, if the fuel hose and clamp are found to be damaged or deteriorate earlier than two years, then change or remedy. 4. After the fuel hose and the clamp have been changed, bleed the fuel system. A Stop the engine when attempting the check and change prescribed above. (When bleeding fuel system) 1. Fill the tank with fuel and open the cock (4). 2. Loosen the air vent plug (3) of the fuel filter a few turns. 3. Screw back the plug when bubbles do not come up any more. 4. Open the air vent cock (5) on top of the fuel injection pump. 5. If equipped electrical fuel feed pump, turn the key to AC position and pump the fuel up for 10 to 15 seconds. If equipped mechanical fuel feed pump, set the stop lever on stop position and crank the engine for 10 to 15 seconds. 6. Close securely the air vent cock after air bleeding. A Always keep the air vent cock on the fuel injection pump closed except when air is vented, or it may cause the engine to stop. (1)

Clamp

[A]

Cartridge Type

(2)

Fuel Hose

[B]

Element Type

(3)

Air Vent Plug

(4)

Fuel Cock

(5)

Air Vent Cock 0000001297E

III-S-50

Z602-E · D902-E, WSM

ENGINE

(3) Check Points of Every 100 Hours Changing Engine Oil

A 1. 2. 3.

Be sure to stop engine before changing engine oil. Start and warm up the engine for approx. 5 minutes. Place an oil pan underneath the engine. To drain the used oil, remove the drain plug (1) at the bottom of the engine and drain the oil completely. 4. Screw the drain plug (1). 5. Fill new oil up to upper line on the dipstick (2). A When using an oil of different maker or viscosity from the previous one, remove all of the old oil. A Never mix two different types of oil. A Engine oil should have properties of API classification CD/CE/CF/CF-4/CG-4. A Use the proper SAE Engine Oil according to ambient temperature. Above 25

(77

0

(32

to 25

Below 0

(32

SAE30 or SAE10W-30 SAE10W-40

) to 77

SAE20 or SAE10W-30 SAE10W-40

)

SAE10W or SAE10W-30 SAE10W-40

)

Model

Z602-E

Oil pan depth Engine oil capacity

(1)

Drain Plug

D902-E 101 mm (3.98 in.)

2.5 L 2.64 U.S.qts

3.7 L 3.91 U.S.qts (2)

Dipstick 0000003303E

Checking Fan Belt Tension and Damage See page III-S-101. 0000003185E

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

III-S-51

Z602-E · D902-E, WSM

ENGINE

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

Cock Body

(4)

Filter Element

(2)

Air Vent Plug

(5)

Filter Cup

(3)

Fuel Cock

(6)

Retaining Ring 0000001302E

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

Upper Hose

(2)

Lower Hose 0000001303E

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

Intake Air Hose

(2)

Clamp 0000001304E

III-S-52

Z602-E · D902-E, WSM

ENGINE

Replacing Oil Filter Cartridge

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

Engine Oil Filter Cartridge 0000001305E

(5) Check Points of Every 400 Hours Replacing Fuel Filter Cartridge (Cartridge Type) Water and dust in fuel are collected in the filter cartridge. So, change the filter cartridge every 400 hours service. 1. Remove the used filter cartridge with filter wrench. 2. Apply a thin film of fuel to the surface of new filter cartridge gasket before screwing on. 3. Then tighten enough by hand. 4. Loosen the air vent plug to let the air out. 5. Start engine and check for fuel leakage. (1)

Fuel Filter Cartridge 0000001306E

Replacing Fuel Filter Element (Element Type) 1. Close the fuel cock (3). 2. Unscrew the retaining ring (6) and remove the cup (5), and rinse the inside with kerosene. 3. Replace the filter element (4). 4. Reassemble the fuel filter, keeping out dust and dirt. 5. Bleed the fuel system. (1)

Cock Body

(4)

Filter Element

(2)

Air Vent Plug

(5)

Filter Cup

(3)

Fuel Cock

(6)

Retaining Ring 0000001307E

III-S-53

Z602-E · D902-E, WSM

ENGINE

(6) Check Points of Every 500 Hours Cleaning Fuel Tank Inside 0000001308E

Cleaning Water Jacket and Radiator Interior

A Do not remove the radiator cap when the engine is hot. Then loosen cap slightly to the stop to relieve any excess pressure before removing cap completely. 1. Stop the engine and let cool down. 2. To drain the coolant, open the radiator drain plug (2) and remove the radiator cap (1). Then radiator cap (1) must be removed to completely drain the coolant. And open the drain cock (3). 3. After all coolant is drained, close the drain plug. 4. Fill with clean water and cooling system cleaner. 5. Follow directions of the cleaner instruction. 6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the port. Install the radiator cap (1) securely. 7. Fill with coolant up to "FULL" (A) mark on the recovery tank (4). 8. Start and operate the engine for few minutes. 9. Stop the engine and let cool. Check coolant level of radiator and recovery tank (4) and add coolant if necessary. A Do not start engine without coolant. A Use clean, fresh, soft water and anti-freeze to fill the radiator and recovery tank. A When the anti-freeze is mixed with fresh, soft water, the anti-freeze mixing ratio must be less than 50 %. A Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat. (1)

Radiator Cap

A:

Full

(2)

Drain Plug

B:

Low

(3)

Drain Cock

(4)

Recovery Tank 0000001309E

III-S-54

Z602-E · D902-E, WSM

ENGINE

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. Deflection (A)

(1)

7.0 to 9.0 mm / 98 N or 10 kgf 0.28 to 0.35 in. / 98 N or 22 lbs

Factory spec.

Fan Belt

(A)

Deflection 0000001310E

(7) Check Points of Every Year or Every Sixth Cleanings of Air Cleaner Element Replacing Air Cleaner Element See page III-S-51. 0000003438E

III-S-55

Z602-E · D902-E, WSM

ENGINE

(8) Check Points of Every 800 Hours Checking Valve Clearance A The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover (1) and the glow plugs. 2. Align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No. 1 piston comes to the compression top dead center. 3. Check the following valve clearance marked with " " using a thickness gauge. 4. If the clearance is not within the factory specifications, adjust with the adjusting screw. 5. Then turn the flywheel 6.28 rad (360 ), and align the "1TC" mark (2) on the flywheel and alignment mark (3) on the rear end plate so that the No.1 piston comes to the overlap position. 6. Check the following valve clearance marked with " " using a thickness gauge Engine model valve arrangement Adjustable cylinder location of piston

Z602-E

D902-E

Intake valve

Exhaust valve

-

-

Intake valve

Exhaust 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. 7. If the clearance is not within the factory specifications, adjust with the adjusting screw. Intake and exhaust valve clearance (Cold)

0.145 to 0.185 mm 0.00571 to 0.00728 in.

Factory spec.

A The sequence of cylinder numbers is given as No.1, No.2 and No.3 starting from the gear case side. A After adjusting the valve clearance, secure the adjusting screw with the lock nut. (1)

Cylinder Head Cover

A:

Gear Case Side

(2)

"1TC" Mark

[a]

Z602-E

(3)

Alignment Mark

[b]

D902-E 0000003187E

III-S-56

Z602-E · D902-E, WSM

ENGINE

(9) Check Points of Every 1500 Hours Checking Fuel Injection Nozzle Condition See page III-S-107, 108. 0000003188E

(10)Check Points of Every 3000 Hours Checking Injection Pump See page III-S-104, 105, 106. 0000003189E

(11)Check Points of Every 2 Years Replacing Intake Air Line See page III-S-52. 0000003190E

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

Replacing Fuel Hoses and Clamp Bands See page III-S-50. 0000003192E

Changing Radiator Coolant (L.L.C.) See page III-S-49, 54. 0000003193E

III-S-57

Z602-E · D902-E, WSM

ENGINE

[8] SPECIAL TOOLS Special Use Puller Set Code No : 07916-09032 Application : Use exclusively for pulling out bearing, gears and other parts with ease. 0000000677E

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

Piston Ring Tool Code No : 07909-32121 Application : Use exclusively for removing or installing the piston ring with ease. 0000000679E

Diesel Engine Compression Tester Code No : 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application : Use to measure diesel engine compression and diagnostics of need for major overhaul. (1)

Gauge

(7)

(2)

L Joint

(8)

Adaptor F Adaptor G

(3)

Adaptor A

(9)

Adaptor H

(4)

Adaptor B

(10)

Adaptor I

(5)

Adaptor C

(11)

Adaptor J

(6)

Adaptor E 0000000680E

III-S-58

Z602-E · D902-E, WSM

ENGINE

Diesel Engine Compression Tester (for Glow Plug) Code No : 07909-39081 (Assembly) 07909-31301 (L) 07909-31291 (K) 07909-31311 (M) Application : Use to measure diesel engine compression and diagnostics of need for major overhaul. (1)

Gauge

(4)

Adaptor L

(2)

L Joint

(5)

Adaptor M

(3)

Adaptor K 0000001398E

Oil Pressure Tester Code No : 07916-32032 Application : Use to measure lubricating oil pressure. (1)

Gauge

(5)

Adaptor 2

(2)

Cable

(6)

Adaptor 3

(3)

Threaded Joint

(7)

Adaptor 4

(4)

Adaptor 1

(8)

Adaptor 5 0000000681E

Valve Seat Cutter Code No : 07909-33102 Application : Use to reseat valves. Angle : 0.785 rad (45 ) 0.262 rad (15 ) Diameter : 28.6 mm (1.126 in.) 38.0 mm (1.496 in.) 31.6 mm (1.244 in.) 41.3 mm (1.626 in.) 35.0 mm (1.378 in.) 50.8 mm (2.000 in.) 0000000682E

Radiator Tester Code No : 07909-31551 Application : Use to check of radiator cap pressure, and leaks from cooling system. Remarks : Adaptor (1) BANZAI Code No. RCT-2A-30S. 0000000815E

III-S-59

Z602-E · D902-E, WSM

ENGINE

Connecting Rod Alignment Tool Code No : 07909-31661 Application : Use to check the connecting rod alignment. Applicable : Connecting rod big end I.D. range 30 to 75 mm (1.18 to 2.95 in.) dia. Connecting rod length 65 to 300 mm (2.56 to 11.81 in.) 0000000684

Nozzle Tester Code No : 07909-31361 Application : Use to check the fuel injection pressure and spray pattern of nozzle. Measuring : 0 to 50 MPa range (0 to 500 , 0 to 7000 psi) 0000000685E

Plastigage Code No : 07909-30241 Application : Use to check the oil clearance between crankshaft and bearing, etc.. Measuring : Green.....0.025 to 0.076 mm (0.001 to 0.003 in.) range Red.........0.051 to 0.152 mm (0.002 to 0.006 in.) Blue.........0.102 to 0.229 mm (0.004 to 0.009 in.) 0000000686E

Red Check Code No : 07909-31371 Application : Use to check cracks on cylinder head, cylinder block, etc.. 0000000687E

III-S-60

Z602-E · D902-E, WSM

ENGINE

Injection Pump Pressure Tester Application : Use to check fuel tightness of injection pumps. A

Pressure gauge full scale : More than 29.4 MPa (300 psi)

B

Copper gasket

C

Flange (Material : Steel)

D

Hex. nut 27 mm (1.06 in.) across the plat

E

Retaining nut

F

PF 1/2

G

5 mm (0.20 in.)

H

17 mm dia. (0.67 in.dia.)

I

8 mm dia. (0.31 in.dia.)

J

1.0 mm (0.039 in.)

K

17 mm dia. (0.67 in.dia.)

L

6.10 to 6.20 mm dia. (0.2402 to 0.2441 in.dia.)

M

8 mm (0.31 in.)

N

4 mm (0.16 in.)

O

11.97 to11.99 mm dia. (0.4713 to 0.4721 in.dia.)

P

PF 1/2

Q

23 mm (0.91 in.)

R

17 mm (0.67 in.)

S

4 mm (0.16 in.)

T

12.00 to 12.02 mm dia. (0.4724 to 0.4732 in.dia.)

U

100 mm (3.94 in.)

V

M12 x P1.5

a

Adhesive application

b

Fillet welding on the enter circumference

, 4267

0000001341E

III-S-61

Z602-E · D902-E, WSM

ENGINE

Valve Guide Replacing Tool Application : Use to press out and press fit the valve guide. A

20 mm dia. (0.79 in. dia.)

B

9.96 to 9.98 mm dia. (0.3921 to 0.3929 in.dia.)

C

5.5 to 5.7 mm dia. (0.2165 to 0.2244 in.dia.)

D

200 mm (7.87 in.)

E

80 mm (3.15 in.)

F

40 mm (1.58 in.)

G

15 mm (0.59 in.)

H

5 mm (0.197 in.)

I

6.0 to 6.1 mm dia. (0.236 to 0.240 in.dia.)

J

18 mm dia. (0.71 in.dia.)

K

10.6 to 10.7 mm dia. (0.417 to 0.421 in.dia.)

L

7 mm (0.276 in.)

C1

Chamfer 1.0 mm (0.039 in.)

C2

Chamfer 2.0 mm (0.079 in.)

C0.3

Chamfer 0.3 mm (0.012 in.) 0000000816E

Bushing Replacing Tools Application : Use to press out and to press fit the bushing. 1. For small end bushing A

145 mm (5.71 in.)

B

20 mm (0.79 in.)

C

100 mm (3.94 in.)

D

19.90 to 19.95 mm (0.7835 to 0.7854 in.)

E

21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

F

25 mm (0.98 in.)

a

6.3

(250

.)

b

6.3

(250

.)

2. For idle gear bushing A

150 mm (5.91 in.)

B

20 mm (0.79 in.)

C

100 mm (3.94 in.)

D

19.90 to 19.95 mm (0.7835 to 0.7854 in.)

E

21.90 to 21.95 mm dia. (0.8622 to 0.8642 in. dia.)

F

25 mm (0.98 in.)

a

6.3

(250

.)

b

6.3

(250

.) 0000003194E

III-S-62

Z602-E · D902-E, WSM

ENGINE

Flywheel Stopper Application : Use to loosen and tighten the flywheel screw. A

200 mm (7.87 in.)

B

20 mm (0.79 in.)

C

30 mm (1.18 in.)

D

8 mm (0.31 in.)

E

10 mm dia. (0.39 in. dia.) 0000000818E

Crankshaft Bearing 1 Replacing Tool Application : Use to press out and press fit the crankshaft bearing 1. [Press Out] A

135 mm (5.31 in.)

B

72 mm (2.83 in.)

C

40 mm radius (1.57 in. radius)

D

10 mm (0.39 in.)

E

22 mm (0.87 in.)

F

20 mm dia. (0.79 in. dia.)

G

47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)

H

43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

[Press Fit] A

130 mm (5.12 in.)

B

72 mm (2.83 in.)

C

40 mm radius (1.57 in. radius)

D

9 mm (0.35 in.)

E

24 mm (0.95 in.)

F

20 mm dia. (0.79 in. dia.)

G

68 mm dia. (2.68 in. dia.)

H

43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.) 0000000819E

III-S-63

Z602-E · D902-E, WSM

ENGINE

2. ENGINE BODY [1] CHECKING AND ADJUSTING Compression Pressure 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Remove the air cleaner, the muffler, the head cover and all glow plugs. 4. Set a compression tester (Code No. 07909-30208) with the adaptor (Adaptor K, code No. 07909-291) to the glow plug hole. 5. After making sure that the stop lever is set at the stop position (non-injection), run the engine with the starter and measure the compression pressure. 6. Repeat steps 4 and 5 for each cylinder. 7. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the glow plug hole and measure the compression pressure again. 8. If the compression pressure is still less than the allowable limit, check the top clearance, valve clearance and cylinder head. 9. If the compression pressure increases after applying oil, check the cylinder wall and piston rings. A Check the compression pressure with the specified valve clearance. A Always use a fully charged battery for performing this test. A Variances in cylinder compression values should be under 10 %. Factory spec.

3.53 to 4.02 MPa 36 to 41 512 to 583 psi

Allowable limit

2.55 MPa 26 370 psi

Compression pressure

0000001289E

III-S-64

Z602-E · D902-E, WSM

ENGINE

Top Clearance 1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.). 2. Move the piston up, and stick a strip of fuse [1.5 mm dia. (0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports. 3. Lower the piston, and install the cylinder head and tighten the cylinder head screws to the specified torque. 4. Turn the flywheel until the piston exceeds its top dead center. 5. Remove the cylinder head, and measure the thickness of the squeezed fuses. 6. If the measurement is not within the factory specifications, check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing. A After checking the top clearance, be sure to assemble the cylinder head with a new cylinder head gasket. Top clearance

Tightening torque

(1)

Factory spec.

Cylinder head screw

0.50 to 0.70 mm 0.0197 to 0.0276 in. 37.3 to 42.2 3.8 to 4.3 27.5 to 31.1 ft-lbs

Fuse 0000000844E

[2] DISASSEMBLING AND ASSEMBLING (1) Draining Coolant and Engine Oil Draining Coolant

A Never remove radiator cap while operating or immediately after stopping. Otherwise, hot water will spout out from the radiator. Wait for more than ten minutes to cool the radiator, before opening the cap. 1. Prepare a bucket. Open the coolant drain cock. (1)

Coolant Drain Cock 0000001290E

III-S-65

Z602-E · D902-E, WSM

ENGINE

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

Drain Plug

(2)

Dipstick

(3)

Oil Inlet Plug

0000001291E

(2) External Components Alternator, Starter and Others 1. Remove the air cleaner and muffler. 2. Remove the engine stop solenoid (1). 3. Remove the cooling fan (2), fan pulley and fan belt (3). 4. Remove the alternator. 5. Remove the starter. (When reassembling) A Check to see that there are no cracks on the belt surface. A Keep the engine stop lever (5) to touch the stopper (4). Tighten the engine stop solenoid mounting screw (6) so that there be no gap between the engine stop lever and the engine stop solenoid plunger (7). A After reassembling the fan belt, be sure to adjust the fan belt tension. A Do not confuse the direction of the fan. (1)

Engine Stop Solenoid

(2)

Cooling Fan

(3)

Fan Belt

(4)

Stopper

(5)

Engine Stop Lever

(6)

Engine Stop Solenoid Mounting Screw

(7)

Plunger

A:

0 mm (0 in.) 0000003304E

III-S-66

Z602-E · D902-E, WSM

ENGINE

(3) Cylinder Head, Valves and Oil Pan Cylinder Head Cover 1. Remove the head cover screws (1). 2. Remove the cylinder head cover (2). (When reassembling) A Check to see if the cylinder head cover gasket is not defective. Tightening torque

6.86 to 11.3 0.7 to 1.15 5.1 to 8.3 ft-lbs

Cylinder head cover screw

(1)

Head Cover Screws

[a]

Z602-E

(2)

Cylinder Head Cover

[b]

D902-E 0000003305E

Injection Pipes 1. Loosen the screws on the pipe clamp (1). 2. Detach the injection pipes (2). (When reassembling) A Sent compressed air into the pipes to blow out dust. Then, reassemble the pipes in the reverse order. Tightening torque

Injection pipe retaining nut

24.5 to 34.3 2.5 to 3.5 18.1 to 25.3 ft-lbs

(1)

Pipe Clamp

[a]

Z602-E

(2)

Injection Pipe

[b]

D902-E 0000003195E

III-S-67

Z602-E · D902-E, WSM

ENGINE

Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (1). 2. Remove the nozzle holder assemblies (2). 3. Remove the copper gasket (5) and the heat seal (6). 4. Remove the lead (3) from the glow plugs (4). 5. Remove the glow plugs (4). (When reassembling) A Replace the copper gasket and heat seal with new one.

Tightening torque

Overflow pipe retaining nut

19.6 to 24.5 2.0 to 2.5 14.5 to 18.1 ft-lbs

Nozzle holder assembly

49.0 to 68.6 5.0 to 7.0 36.2 to 50.6 ft-lbs

Glow plug

7.85 to 14.7 0.8 to 1.5 5.8 to 10.8 ft-lbs

(1)

Overflow Pipe

[a]

Z602-E

(2)

Nozzle Holder Assembly

[b]

D902-E

(3)

Lead

(4)

Glow Plug

(5)

Copper Gasket

(6)

Heat Seal 0000003196E

III-S-68

Z602-E · D902-E, WSM

ENGINE

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

Rocker arm bracket screw

9.8 to 11.3 1.00 to 1.15 7.2 to 8.3 ft-lbs

(1)

Rocker Arm Bracket screws

[a]

Z602-E

(2)

Rocker Arm Assembly

[b]

D902-E

(3)

Push Rod

(4)

Tappet 0000003197E

III-S-69

Z602-E · D902-E, WSM

ENGINE

Cylinder Head 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of (n or j) to (a). 3. Lift up the cylinder head to detach. 4. Remove the cylinder head gasket and O-ring (3). (When reassembling) A Replace the cylinder head gasket with a new one. A Securely fit the O-ring (3) to the pipe pin. A Tighten the cylinder head screws after applying sufficient oil. A Tighten the cylinder head screws in order of (a) to (n or j). A Tighten them uniformly, or the head may deform in the long run. A Retighten the cylinder head screws after running the engine for 30 minutes. Tightening torque

Cylinder head screw

A:

37.3 to 42.2 3.8 to 4.3 27.5 to 31.1 ft-lbs

(1)

Pipe Clamp

(2)

Water Return Pipe

(n or j) to (a): To Loosen

Gear Case Side

(3)

O-ring

(a) to (n or j): To Tighten [a]

Z602-E

[b]

D902-E 0000003198E

III-S-70

Z602-E · D902-E, WSM

ENGINE

Tappets 1. Remove the tappets (1) from the crankcase. (When reassembling) A Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets. A Before installing the tappets, apply engine oil thinly around them. A Do not change the combination of tappet and tappet guide. (1)

Tappet 0000001324E

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

Valve Spring Replacer

(5)

(2)

Valve Cap

(6)

Valve Spring Valve Stem Seal

(3)

Valve Spring Collet

(7)

Valve

(4)

Valve Spring Retainer 0000001325E

III-S-71

Z602-E · D902-E, WSM

ENGINE

Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (1). 2. Remove the oil pan (2) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3). (When reassembling) A After cleaning the oil strainer, check to see that the filter mesh in clean, and install it. A Visually check the O-ring (4), apply engine oil, and install it. A Securely fit the O-ring to the oil strainer. A To avoid uneven tightening, tighten oil pan mounting screws in diagonal order from the center. For Z602-E A Using the hole (5) numbered "2", install the oil strainer by mounting screw. For D902-E A Using the hole (6) numbered "3", install the oil strainer by mounting screw. A Scrape off the old adhesive completely. Wipe the sealing surface clean. Now apply new adhesive 3 to 5 mm (0.12 to 0.20 in.) thick all over the contact surface. Apply the adhesive also on the center of the flange as well as on the inner wall of each screw hole. A Cut the nozzle of the "liquid gasket" (Three Bond 1207D or equivalent) container at its second notch. Apply "liquid gasket" about 5 mm (0.20 in.) thick. Within 20 minutes after the application of fluid sealant, reassemble the components. Wait then for about 30 minutes, and pour oil in the crankcase. (1)

Oil Pan Mounting Screw

[a]

Z602-E

(2)

Oil Pan

[b]

D902-E

(3)

Oil Strainer

(4)

O-ring

(5)

Hole Numbered "2"

(6)

Hole Numbered "3" 0000003199E

III-S-72

Z602-E · D902-E, WSM

ENGINE

(4) Timing Gear, Camshaft and Fuel Camshaft Injection Pump, Fuel Feed Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (1). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the governor spring (4). 3. Disconnect the governor spring (4) and remove the speed control plate (2). 4. Remove the fuel feed pump (3). (When reassembling) A Hook the governor spring (4) to the governor lever (5) first and install the speed control plate (2). A Be sure to place the copper washers underneath two screws (6). (Two screws (6) in the upper of the speed control plate (2).) A Position the slot (7) on the fork lever just under the slot (8) on the crankcase. A Insert the injection pump (1) so that the control rod (10) should be pushed by the idling adjusting spring (9) at its end and the pin (11) on the rod engages with the slot (7) on the fork lever (as shown in the photo). A The sealant is applied to both sides of the soft metal gasket shim. The liquid gasket is not required for assembling. A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 ) A In disassembling and replacing, be sure to use the same number of new gasket shims with the same thickness. (1)

Injection Pump

(7)

Slot (Fork Lever Side)

(2)

Speed Control Plate

(8)

Slot (Crankcase Side)

(3)

Fuel Feed Pump

(9)

Idling Adjusting Spring

(4)

Governor Spring

(10)

Control Rod

(5)

Governor Lever

(11)

Pin

(6)

Screw and Copper Washer 0000001327E

Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) A Install the pulley to the crankshaft, aligning the mark (1) on them. A Apply engine oil to the fan drive pulley retaining screws. And tighten them. Tightening torque

(1)

Fan drive pulley screw

98.1 to 107.9 10.0 to 11.0 72.3 to 79.6 ft-lbs

Alignment Mark 0000001328E

III-S-73

Z602-E · D902-E, WSM

ENGINE

Gear Case 1. Disconnect the start spring (2) from the fork lever 1 (3). 2. Remove the screw (1) of inside the gear case and outside screws. 3. Remove the gear case (4). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the gear case gasket. A Be sure to set three O-rings inside the gear case. (1)

Screw (Inside)

(3)

Fork Lever 1

(2)

Start Spring

(4)

Gear Case 0000001329E

Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5). (When reassembling) A Apply engine oil to the idle gear shaft mounting screw (4). And tighten them. A Install the idle gear, aligning the mark (6) on the gears referring to the photo. Tightening torque

Idle gear shaft mounting screw

(1)

Idle Gear

(2)

Idle Gear Collar

(3)

External Snap Ring

(4)

9.8 to 11.3 1.00 to 1.15 7.2 to 8.3 ft-lbs

Idle Gear Shaft Mounting Screw

(5)

Idle Gear Shaft

(6)

Alignment Mark 0000001330E

III-S-74

Z602-E · D902-E, WSM

ENGINE

Camshaft 1. Remove the camshaft mounting screws (1) and draw out the camshaft with gear (2) on it. (When reassembling) A When install the camshaft, apply engine oil to the camshaft journals. A Apply engine oil to the camshaft mounting screws. And tighten them. (1)

Camshaft Mounting Screw

(2)

Camshaft Gear 0000001331E

Fuel Camshaft 1. Remove the retaining plate (1). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (3) and fuel camshaft (2) with the governor fork assembly. (When reassembling) A Hook the governor spring (7) to the fork lever 2 (6) as shown in the figure before installing the fork lever assembly to the crankcase. (1)

Retaining Plate

(5)

Fork Lever 1

(2)

Fuel Camshaft

(6)

Fork Lever 2

(3)

Injection Pump Gear

(7)

Governor Spring

(4)

Governor Sleeve

(8)

Fork Lever Holder Mounting Screw 0000001332E

Oil Pump and Crankshaft Gear 1. Remove the oil pump gear (6). 2. Remove the oil pump (5). 3. Remove the collar (4), O-ring (3) and crankshaft oil slinger (2). (When reassembling) A Install the collar (4) after aligning the marks on the gear. (See the photo at "Idle Gear".). (1)

Crankshaft Gear

(4)

Crankshaft Collar

(2)

Crankshaft Oil Slinger

(5)

Oil Pump

(3)

O-ring

(6)

Oil Pump Gear 0000001333E

III-S-75

Z602-E · D902-E, WSM

ENGINE

(5) Piston and Connecting Rod Connecting Rod 1. Remove the connecting rod caps (1) using a bihexagonal 8 mm socket. (When reassembling) A Align the marks (a) with each other. (Face the marks toward the injection pump.) A Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque. If the connecting rod screw won't be screwed in smoothly, clean the threads. If the connecting rod screw is still hard to screw in, replace it. Tightening torque

(1)

Connecting rod screw

Connecting Rod Cap

(a)

26.5 to 30.4 2.7 to 3.1 19.5 to 22.4 ft-lbs Mark 0000003200E

Piston 1. Turn the flywheel and bring the piston to top dead center. 2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the grip of a hammer. 3. Draw out the other piston in the same method as above. (When reassembling) A Before inserting the piston into the cylinder, apply enough engine oil to the piston. A When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump. A Do not change the combination of cylinder and piston. Make sure of the position of each piston by marking. For example, mark "1" on the No.1 piston. A When installing the piston into the cylinder, place the gaps of all the piston rings as shown in the figure. A Carefully insert the piston using a piston ring compressor (1). Otherwise, their chrome-plated section may be scratched, causing trouble inside the cylinder. (1)

Piston Ring Compressor

(a)

0.785 rad (45 )

(A)

Top Ring Gap

(b)

0.785 rad (45 )

(B)

Second Ring Gap

(c)

1.57 rad (90 )

(C)

Oil Ring Gap

(D)

Piston Pin Hole 0000001335E

III-S-76

Z602-E · D902-E, WSM

ENGINE

Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool (Code No. 07909-32121). 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) A When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston. A When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11). A Apply engine oil to the piston pin. A When installing the connecting rod to the piston, immerse the piston in 80 (176 ) oil for 10 to 15 minutes and insert the piston pin to the piston. A When installing the connecting rod to the piston, align the mark (8) on the connecting rod to the fan-shaped concave (9). A Mark the same number on the connecting rod and the piston so as not to change the combination. (1)

Top Ring

(2)

Second Ring

(9) (10)

Fan-Shaped Concave Expander Joint

(3)

Oil Ring

(11)

Oil Ring Gap

(4)

Piston Pin Snap Ring

(12)

Manufacturer's Mark

(5)

Piston

(6)

Connecting Rod

(7)

Piston Pin

(8)

Mark 0000003201E

III-S-77

Z602-E · D902-E, WSM

ENGINE

(6) Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (See page III-S-63.) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) A Align the "1TC" mark (a) on the outer surface of the flywheel horizontally with the alignment mark (b) on the rear end plate. Now fit the flywheel in position. A Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw. Tightening torque

53.9 to 58.8 5.5 to 6.0 39.8 to 43.4 ft-lbs

Flywheel screw

(1)

Flywheel Screw

(a)

1TC Mark

(2)

Flywheel

(b)

Alignment Mark 0000003202E

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

(1) (2)

Bearing case cover mounting screw

9.8 to 11.3 1.00 to 1.15 7.2 to 8.3 ft-lbs

Bearing Case Cover Mounting

(5)

Oil Seal

Screw (Inside)

(6)

Bearing Case Cover

Bearing Case Cover Mounting Screw (Outside)

(a)

Top Mark "UP"

(3)

Bearing Case Gasket

(b)

Upside

(4)

Bearing Case Cover Gasket 0000001337E

III-S-78

Z602-E · D902-E, WSM

ENGINE

Crankshaft Assembly For Z602-E 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the cylinder to the horizontal directions (Right or Left). Then draw out all the crankshaft, holding the crankpins to the horizontal directions. For D902-E 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the third cylinder to the bottom dead center. Then draw out the crankshaft until the crankpin of the second cylinder comes to the center of the third cylinder. 3. Turn the crankshaft by 2.09 rad (120 ) counterclockwise to set the crankpin of the second cylinder to the bottom dead center. Draw out the crankshaft until the crankpin of the first cylinder comes to the center of the third cylinder. 4. Repeat the above steps to draw out all the crankshaft. (When reassembling) A Clean the oil passage of the crankshaft with compressed air. A Install the crankshaft assembly, aligning the screw hole of main bearing case screw 2 with the screw hole of crankcase. A When tightening the main bearing case 2, apply oil to the main bearing case screw 2 (1) and screw by hand before tightening the specific torque. If not smooth to screw by hand, align the screw holes between the crankcase and the main bearing case. Tightening torque

(1)

Main bearing case screw 2

Main Bearing Case Screw 2

A:

26.5 to 30.4 2.7 to 3.1 19.5 to 22.4 ft-lbs Cut place for removing and installing the crankshaft

[a]

Z602-E

[b]

D902-E 0000003203E

III-S-79

Z602-E · D902-E, WSM

ENGINE

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

Main bearing case screw 1

12.7 to 15.7 1.3 to 1.6 9.4 to 11.6 ft-lbs

(1)

Main Bearing Case Assembly 1

(a)

Alignment Number

(2)

Main Bearing Case Assembly 2

(b)

Marking (1 or 2)

(3)

Main Bearing Case Assembly

(c)

Oil Groove

(4)

Crankshaft Bearing 3 (Upper, with oil groove)

(5) (6)

Crankshaft Bearing 3 (Lower) Crankshaft Bearing 2 (Upper, with oil groove)

(7)

Crankshaft Bearing 2 (Lower)

(8)

Thrust Bearing

(9)

Main Bearing Case Screw 1 0000003204E

III-S-80

Z602-E · D902-E, WSM

ENGINE

[3] SERVICING (1) Cylinder Head and Valves Cylinder Head Surface Flatness 1. Clean the cylinder head surface. 2. Place a straightedge on the cylinder head's four sides and two diagonals as shown in the figure. 3. Measure the clearance with a thickness gauge. 4. If the measurement exceeds the allowable limit, correct it with a surface grinder. A Do not place the straightedge on the combustion chamber. A Be sure to check the valve recessing after correcting. Cylinder head surface flatness

0.05 mm 0.0020 in.

Allowable limit

0000001342E

Cylinder Head Flaw 1. Prepare an air spray red check (Code No. 07909-31371). 2. Clean the surface of the cylinder head with the detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying. 4. Wash away the red permeative liquid on the cylinder head surface with the detergent (2). 5. Spray the cylinder head surface with the white developer (3). 6. If flawed, it can be identified as red marks. (1)

Red Permetive Liquid

(2)

Detergent

(3)

White Developer

0000000875E

III-S-81

Z602-E · D902-E, WSM

ENGINE

Valve Recessing 1. Clean the cylinder head surface, valve face and valve seat. 2. Insert the valve into the valve guide. 3. Measure the valve recessing with a depth gauge. 4. If the measurement exceeds the allowable limit, replace the valve. 5. If it still exceeds the allowable limit after replacing the valve, correct the valve seat face of the cylinder head with a valve seat cutter (Code No. 07909-33102) or valve seat grinder. 6. Then, correct the cylinder head surface with a surface grinder, or replace the cylinder head. Factory spec.

0.10 (protrusion) to 0.10 (recessing) mm 0.0039 (protrusion) to 0.0039 (recessing) in.

Allowable limit

0.30 (recessing) mm 0.0118 (recessing) in.

Valve recessing (Intake and Exhaust)

(1)

Cylinder Head Surface

(A)

Recessing

(B)

Protrusion 0000001343E

Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance. 4. If the clearance exceeds the allowable limit, replace the valves. If it still exceeds the allowable limit, replace the valve guide. Clearance between valve stem and valve guide

Factory spec.

0.030 to 0.057 mm 0.00118 to 0.00224 in.

Allowable limit

0.10 mm 0.0039 in.

Valve stem O.D.

Factory spec.

5.968 to 5.980 mm 0.23496 to 0.23543 in.

Valve guide I.D.

Factory spec.

6.010 to 6.025 mm 0.23661 to 0.23720 in. 0000000877E

III-S-82

Z602-E · D902-E, WSM

ENGINE

Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page S-62.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them. 2. Press in a new valve guide using a valve guide replacing tool. 3. Ream precisely the I.D. of the valve guide to the specified dimension. Valve guide I.D. (Intake and Exhaust)

6.010 to 6.025 mm 0.2366 to 0.2372 in.

Factory spec.

A Do not hit the valve guide with a hammer during replacement. (A)

When removing

(B)

When installing 0000003205E

Valve Seating 1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact. 2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows. 3. If the valve contact does not comply with the reference value, replace the valve or correct the contact of valve seating. Valve seat width

(1)

Correct

(2)

Incorrect

2.12 mm 0.0835 in.

Factory spec.

(3)

Incorrect

0000000879E

III-S-83

Z602-E · D902-E, WSM

ENGINE

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

0.785 rad 45

Factory spec.

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

(1)

0.785 rad 45

Factory spec.

Valve Seat Cutter

(a)

Identical Dimensions

(A)

Check Contact

(b)

Valve Seat Width

(B)

Correct Seat Width

(c)

0.262 rad (15 )

(C)

Correct Seat Surface

(d)

0.785 rad (45 )

(D)

Check Contact 0000003400E

Valve Lapping 1. Apply compound evenly to the valve lapping surface. 2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver. 3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil. 4. Apply prussian blue to the contact surface to check the seated rate. If it is less than 70 %, repeat valve lapping again. A When valve lapping is performed, be sure to check the valve recessing and adjust the valve clearance after assembling the valve. 0000001345E

III-S-84

Z602-E · D902-E, WSM

ENGINE

Free Length and Tilt of Valve Spring 1. Measure the free length (A) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring. 3. Check to see if the entire side is in contact with the square. Rotate the valve spring and measure the maximum tilt (B). If the measurement exceeds the allowable limit, replace it. 4. Check the entire surface of the valve spring for scratches. If there is any defect, replace it. Factory spec.

31.3 to 31.8 mm 1.232 to 1.252 in.

Allowable limit

28.4 mm 1.118 in.

Allowable limit

1.2 mm 0.047 in.

Free length (A)

Tilt (B)

(A)

Free Length

(B)

Tilt 0000003633E

Valve Spring Setting Load 1. Place the valve spring on a tester and compress it to the same length it is actually compressed in the engine. 2. Read the compression load on the gauge. 3. If the measurement is less than the allowable limit, replace it. Factory spec.

64.7 N / 27.0 mm 6.6 kgf / 27.0 mm 14.6 lbs / 1.063 in.

Allowable limit

54.9 N / 27.0 mm 5.6 kgf / 27.0 mm 12.3 lbs / 1.063 in.

Setting load / Setting length

0000000883E

Oil Clearance between Rocker Arm and Rocker Arm Shaft 1. Measure the rocker arm shaft O.D. with an outside micrometer. 2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again. If it still exceeds the allowable limit, replace also the rocker arm shaft. Oil clearance between rocker arm and rocker arm shaft

Factory spec.

0.016 to 0.045 mm 0.00063 to 0.00177 in.

Allowable limit

0.15 mm 0.0059 in.

Rocker arm shaft O.D.

Factory spec.

10.473 to 10.484 mm 0.41232 to 0.41276 in.

Rocker arm I.D.

Factory spec.

10.500 to 10.518 mm 0.41339 to 0.41410 in. 0000000884E

III-S-85

Z602-E · D902-E, WSM

ENGINE

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. Push rod alignment

Allowable limit

0.25 mm 0.0098 in. 0000000885E

Oil Clearance between Tappet and Tappet Guide Bore 1. Measure the tappet O.D. with an outside micrometer. 2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit or the tappet is damaged, replace the tappet. Oil clearance between tappet and tappet guide bore

Factory spec.

0.016 to 0.052 mm 0.00063 to 0.00205 in.

Allowable limit

0.10 mm 0.0039 in.

Tappet O.D.

Factory spec.

17.966 to 17.984 mm 0.70732 to 0.70803 in.

Tappet guide bore I.D.

Factory spec.

18.000 to 18.018 mm 0.70866 to 0.70937 in. 0000001346E

III-S-86

Z602-E · D902-E, WSM

ENGINE

(2) Timing Gear, Camshaft Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear. 4. If the oil clearance isn't proper, replace the gear. Factory spec.

0.043 to 0.124 mm 0.00169 to 0.00488 in.

Allowable limit

0.15 mm 0.0059 in.

Factory spec.

0.047 to 0.123 mm 0.00185 to 0.00484 in.

Allowable limit

0.15 mm 0.0059 in.

Backlash between idle gear and injection pump gear

Factory spec.

0.046 to 0.124 mm 0.00181 to 0.00488 in.

Allowable limit

0.15 mm 0.0059 in.

Backlash between oil pump drive gear and crank gear

Factory spec.

0.041 to 0.123 mm 0.00161 to 0.00484 in.

Allowable limit

0.15 mm 0.0059 in.

Backlash between idle gear and crank gear

Backlash between idle gear and cam gear

0000001347E

Idle Gear Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the idle gear collar. Factory spec.

0.20 to 0.51 mm 0.0079 to 0.0201 in.

Allowable limit

0.80 mm 0.0315 in.

Idle gear side clearance

0000001348E

Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. Measure the side clearance by moving the cam gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper. Factory spec.

0.15 to 0.31 mm 0.0059 to 0.0122 in.

Allowable limit

0.50 mm 0.0197 in.

Camshaft side clearance

0000001349E

III-S-87

Z602-E · D902-E, WSM

ENGINE

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. 4. If the measurement exceeds the allowable limit, replace the camshaft. Camshaft alignment

Allowable limit

0.01 mm 0.0004 in. 0000000891E

Cam Height 1. Measure the height of the cam at its highest point with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. Factory spec.

26.88 mm 1.0583 in.

Allowable limit

26.83 mm 1.0563 in.

Cam height of intake and exhaust

0000000892E

Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft. Factory spec.

0.050 to 0.091 mm 0.00197 to 0.00358 in.

Allowable limit

0.15 mm 0.0059 in.

Camshaft journal O.D.

Factory spec.

32.934 to 32.950 mm 1.29661 to 1.29724 in.

Camshaft bearing I.D. (Cylinder block bore I.D.)

Factory spec.

33.000 to 33.025 mm 1.29921 to 1.30020 in.

Oil clearance of camshaft journal

0000001350E

III-S-88

Z602-E · D902-E, WSM

ENGINE

Oil Clearance between Idle Gear Shaft and Idle Gear Bushing 1. Measure the idle gear shaft O.D. with an outside micrometer. 2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the bushing. 4. If it still exceeds the allowable limit, replace the idle gear shaft. Oil clearance between idle gear shaft and idle gear bushing

Factory spec.

0.020 to 0.084 mm 0.00079 to 0.00331 in.

Allowable limit

0.10 mm 0.0039 in.

Idle gear shaft O.D.

Factory spec.

19.967 to 19.980 mm 0.78610 to 0.78661 in.

Idle gear bushing I.D.

Factory spec.

20.000 to 20.051 mm 0.78740 to 0.78941 in. 0000001351E

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

When removing

(B)

When installing 0000003206E

(3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston. Factory spec.

20.000 to 20.013 mm 0.78740 to 0.78791 in.

Allowable limit

20.05 mm 0.7894 in.

Piston pin bore I.D.

0000000897E

III-S-89

Z602-E · D902-E, WSM

ENGINE

Oil Clearance between Piston Pin and Small End Bushing 1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer. 2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the piston pin. Oil clearance between piston pin and small end bushing

Factory spec.

0.014 to 0.038 mm 0.00055 to 0.00150 in.

Allowable limit

0.10 mm 0.0039 in.

Piston pin O.D.

Factory spec.

20.002 to 20.011 mm 0.78748 to 0.78783 in.

Small end bushing I.D.

Factory spec.

20.025 to 20.040 mm 0.78839 to 0.78897 in. 0000000898E

Replacing Small End Bushing (When removing) 1. Press out the used bushing using a small end bushing replacing tool. (See page III-S-62.) (When installing) 1. Clean a new small end bushing and bore, and apply engine oil to them. 2. Insert a new bushing onto the tool and press-fit it with a press so that the seam (1) of bushing positions as shown in the figure, until it is flush with the connecting rod. 3. Drill a hole to the bushing with aligning the oil hole (2) of connecting rod. (Refer to the figure.) A Be sure to chamfer the oil hole circumference with an oil stone. Oil clearance between piston pin and small end bushing (Spare parts)

Small end bushing I.D. (Spare parts)

Factory spec.

0.015 to 0.075 mm 0.00059 to 0.00295 in.

Allowable limit

0.15 mm 0.0059 in.

Factory spec.

20.026 to 20.077 mm 0.78845 to 0.79043 in.

(1)

Seam

(A)

When removing

(2)

Oil Hole

(B)

When installing

(a)

0.785 rad (45 ) 0000003207E

III-S-90

Z602-E · D902-E, WSM

ENGINE

Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring. Factory spec.

0.20 to 0.35 mm 0.0079 to 0.0138 in.

Allowable limit

1.25 mm 0.0492 in.

Factory spec.

0.35 to 0.50 mm 0.0138 to 0.0197 in.

Allowable limit

1.25 mm 0.0492 in.

Factory spec.

0.20 to 0.35 mm 0.0079 to 0.0138 in.

Allowable limit

1.25 mm 0.0492 in.

Top ring

Piston ring gap

Second ring

Oil ring

0000000900E

Clearance between Piston Ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a thickness gauge. 3. If the clearance exceeds the allowable limit, replace the piston ring. 4. If the clearance still exceeds the allowable limit with new ring, replace the piston. Second ring Clearance between piston ring and piston ring groove

Factory spec.

0.090 to 0.120 mm 0.00354 to 0.00472 in.

Allowable limit

0.15 mm 0.0059 in.

Factory spec.

0.04 to 0.08 mm 0.0016 to 0.0031 in.

Allowable limit

0.15 mm 0.0059 in.

Oil ring

0000000901E

III-S-91

Z602-E · D902-E, WSM

ENGINE

Connecting Rod Alignment 1. Remove the crankpin bearing, and install the connecting rod cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661). 4. Put a gauge over the piston pin, and move it against the face plate. 5. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate. 6. If the measurement exceeds the allowable limit, replace the connecting rod. Space between gauge pin face plate

Allowable limit

0.05 mm 0.0020 in. 0000001381E

III-S-92

Z602-E · D902-E, WSM

ENGINE

(4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings. 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. Factory spec.

0.15 to 0.31 mm 0.0059 to 0.0122 in.

Allowable limit

0.50 mm 0.0197 in.

Crankshaft side clearance

(Reference) A Oversize thrust bearing Oversize

Bearing

Code Number

Marking

0.2 mm 0.008 in.

Thrust bearing 1 02

15261-23950

020 OS

Thrust bearing 2 02

15261-23970

020 OS

0.4 mm 0.016 in.

Thrust bearing 1 04

15261-23960

040 OS

Thrust bearing 2 04

15261-23980

040 OS

A Oversize dimensions of crankshaft journal Oversize

0.2 mm 0.008 in.

0.4 mm 0.016 in.

Dimension A

23.40 to 23.45 mm 0.9134 to 0.9154 in.

23.80 to 23.85 mm 0.9213 to 0.9232 in.

Dimension B

46.1 to 46.3 mm 1.815 to 1.823 in.

46.3 to 46.5 mm 1.823 to 1.831 in.

Dimension C

1.8 to 2.2 mm radius 0.071 to 0.087 in. radius

1.8 to 2.2 mm radius 0.071 to 0.087 in. radius (0.8-S)

The crankshaft journal must be fine-finished to higher than 0000001353E

Crankshaft Alignment 1. Support the crankshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the crankshaft alignment. 4. If the measurement exceeds the allowable limit, replace the crankshaft. Crankshaft alignment

Allowable limit

0.02 mm 0.0008 in. 0000000905E

III-S-93

Z602-E · D902-E, WSM

ENGINE

Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again. 4. Measure the amount of the flattening with the scale, and get the oil clearance. 5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing. 6. If the same size bearing is useless because of the crankpin wear, replace it with an undersize one referring to the table and figure. A Never insert the plastigage into the crankpin oil hole. A Be sure not to move the crankshaft while the connecting rod screws are tightened. Oil clearance between crankpin and crankpin bearing

Factory spec.

0.020 to 0.051 mm 0.00079 to 0.00201 in.

Allowable limit

0.15 mm 0.0059 in.

Crankpin O.D.

Factory spec.

33.959 to 33.975 mm 1.33697 to 1.33760 in.

Crankpin bearing I.D.

Factory spec.

33.995 to 34.010 mm 1.33893 to 1.33898 in.

(Reference) A Undersize crankpin bearing Undersize

Bearing

Code Number

Marking

0.2 mm 0.008 in.

Crankpin bearing 02

15861-22970

020 US

0.4 mm 0.016 in.

Crankpin bearing 04

15861-22980

040 US

A Undersize dimensions of crankpin Undersize

0.2 mm 0.008 in.

0.4 mm 0.016 in.

Dimension A

2.3 to 2.7 mm radius 0.091 to 0.106 in. radius

2.3 to 2.7 mm radius 0.091 to 0.106 in. radius

Dimension B

4 mm dia. 0.16 in. dia.

4 mm dia. 0.16 in. dia.

Dimension C

33.759 to 33.775 mm dia. 1.32910 to 1.32973 in. dia.

33.559 to 33.575 mm dia. 1.32112 to 1.32185 in. dia. (0.8-S)

The crankpin must be fine-finished to higher than 0000000906E

III-S-94

Z602-E · D902-E, WSM

ENGINE

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. 3. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 1. 4. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure. Oil clearance between crankshaft journal and crankshaft bearing 1

Factory spec.

0.034 to 0.106 mm 0.00134 to 0.00417 in.

Allowable limit

0.20 mm 0.0079 in.

Crankshaft journal O.D.

Factory spec.

43.934 to 43.950 mm 1.72968 to 1.73031 in.

Crankshaft bearing 1 I.D.

Factory spec.

43.984 to 44.040 mm 1.73165 to 1.73386 in.

(Reference) A Undersize crankshaft bearing 1 Undersize

Bearing

Code Number

Marking

0.2 mm 0.008 in.

Crankshaft bearing 1 02

1G460-23910

020 US

0.4 mm 0.016 in.

Crankshaft bearing 1 04

1G460-23920

040 US

A Undersize dimensions of crankshaft journal Undersize

0.2 mm 0.008 in.

0.4 mm 0.016 in.

Dimension A

1.8 to 2.2 mm radius 0.071 to 0.087 in. radius

1.8 to 2.2 mm radius 0.071 to 0.087 in. radius

Dimension B

4 mm dia. 0.16 in. dia.

4 mm dia. 0.16 in. dia.

Dimension C

43.734 to 43.750 mm dia. 1.72181 to 1.72244 in. dia.

43.534 to 43.550 mm dia. 1.71394 to 1.7147 in. dia. (0.8-S)

The crankpin must be fine-finished to higher than 0000001354E

III-S-95

Z602-E · D902-E, WSM

ENGINE

Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (See page III-S-63.) (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them. 2. Using a crankshaft bearing 1 replacing tool, press in a new bearing 1 (2) so that its seam (1) directs toward the exhaust manifold side. (See figure.) Dimension (A)

0.0 to 0.3 mm 0.0 to 0.0118 in.

Factory spec.

(1)

Seam

(3)

Cylinder Block

(2)

Crankshaft Bearing 1

(a)

0.366 rad (21 ) 0000003208E

Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigage (Code No. 07909-30241) on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again. 3. Measure the amount of the flattening with the scale, and get the oil clearance. 4. If the oil clearance exceeds the allowable limit, replace the crankshaft bearing 2 (crankshaft bearing 3). 5. If the same size bearing is useless because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure. A Be sure not to move the crankshaft while the bearing case screws are tightened. Factory spec.

0.028 to 0.059 mm 0.00110 to 0.00232 in.

Allowable limit

0.20 mm 0.0079 in.

Crankshaft journal O.D. (Flywheel side)

Factory spec.

43.934 to 43.950 mm 1.72968 to 1.73031 in.

Crankshaft bearing 2 I.D.

Factory spec.

43.978 to 43.993 mm 1.73142 to 1.73201 in.

Crankshaft journal O.D. (Intermediate)

Factory spec.

43.934 to 43.950 mm 1.72968 to 1.73031 in.

Crankshaft bearing 3 I.D.

Factory spec.

43.978 to 43.993 mm 1.73142 to 1.73201 in.

Oil clearance between crankshaft journal and crankshaft bearing 2 (Crankshaft bearing 3)

0000000909E

III-S-96

Z602-E · D902-E, WSM

ENGINE

Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) (Continued) (Reference) A Undersize crankshaft bearing 2 and 3 Undersize

Bearing

Code Number

Crankshaft bearing 2 02

15694-23930

Crankshaft bearing 2F 02

1G460-07530

Crankshaft bearing 3 02

1G460-07580

Crankshaft bearing 3F 02

1G460-07630

Crankshaft bearing 2 04

15694-23940

Crankshaft bearing 2F 04

1G460-07540

Crankshaft bearing 3 04

1G460-07590

Crankshaft bearing 3F 04

1G460-07640

Marking 020 US

0.2 mm 0.008 in.

020 US

040 US 0.4 mm 0.016 in.

040 US

A Undersize dimensions of crankshaft journal Undersize

0.2 mm 0.008 in.

0.4 mm 0.016 in.

Dimension A

1.8 to 2.2 mm radius 0.071 to 0.087 in. radius

1.8 to 2.2 mm radius 0.071 to 0.087 in. radius

Dimension B

4 mm dia. 0.16 in. dia.

4 mm dia. 0.16 in. dia.

Dimension C

43.734 to 43.750 mm dia. 1.72181 to 1.72244 in. dia.

43.534 to 43.550 mm dia. 1.71394 to 1.7147 in. dia.

Dimension D

43.734 to 43.750 mm dia. 1.72181 to 1.72244 in. dia.

43.534 to 43.550 mm dia. 1.71394 to 1.7147 in. dia. (0.8-S)

The crankpin must be fine-finished to higher than 0000000910E

(5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s. 3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension. (Refer to "Correcting Cylinder".) 4. Visually check the cylinder wall for scratches. If deep scratches are found, the cylinder should be bored. (Refer to "Correcting Cylinder".) Factory spec.

72.000 to 72.019 mm 2.83464 to 2.83539 in.

Allowable limit

72.169 mm 2.84129 in.

Cylinder I.D.

(A)

Top

(a)

Right-angled to Piston Pin

(B)

Middle

(b)

Piston Pin Direction

(C)

Bottom (Skirt) 0000001355E

III-S-97

Z602-E · D902-E, WSM

ENGINE

Correcting Cylinder 1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension. Factory spec.

72.500 to 72.519 mm 2.85433 to 2.85507 in.

Allowable limit

72.669 mm 2.86098 in.

Cylinder I.D. [Oversize]

Horn to 1.2 to 2.0 m Rmax. Finishing (0.000047 to 0.000079 in. Rmax.)

2. Replace the piston and piston rings with oversize ones. Oversize

Part Name

Code Number

Marking

0.25 mm 0.0098 in.

Piston

1G460-21900

025

Piston ring assembly

1G460-21090

025

A When the oversize cylinder is worn beyond the allowable limit, replace the cylinder block with a new one. (1)

Cylinder I.D.

(2)

Cylinder I.D. [Oversize]

[Before Correction] 0000000913E

III-S-98

Z602-E · D902-E, WSM

ENGINE

3. LUBRICATING SYSTEM [1] CHECKING Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds. 3. If the oil pressure is less than the allowable limit, check the following. A Engine oil insufficient A Oil pump defective A Oil strainer clogged A Oil filter cartridge clogged A Oil gallery clogged A Excessive oil clearance A Foreign matter in the relief valve At idle speed

Engine oil pressure

Factory spec.

More than 49 kPa 0.5 7 psi

Factory spec.

196 to 441 kPa 2.0 to 4.5 28 to 64 psi

Allowable limit

147 kPa 1.5 21 psi

At rated speed

(When reassembling) A After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque. Tightening torque

Oil pressure switch

14.7 to 19.6 1.5 to 2.0 10.8 to 14.5 ft-lbs 0000001356E

[2] SERVICING Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. Rotor lobe clearance

Factory spec.

0.03 to 0.14 mm 0.0012 to 0.0055 in. 0000000915E

III-S-99

Z602-E · D902-E, WSM

ENGINE

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 pump rotor assembly. Clearance between outer rotor and pump body

Factory spec.

0.07 to 0.15 mm 0.0028 to 0.0059 in.

0000000916E

Clearance between Rotor and Cover 1. Put a strip of plastigage (Code No. 07909-30241) onto the rotor face with grease. 2. Install the cover and tighten the screws. 3. Remove the cover carefully, and measure the amount of the flattening with the scale and get the clearance. 4. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly. Clearance between rotor and cover

Factory spec.

0.075 to 0.135 mm 0.00295 to 0.00531 in. 0000000918E

III-S-100

Z602-E · D902-E, WSM

ENGINE

4. COOLING SYSTEM [1] CHECKING AND ADJUSTING Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and the alternator pulley at specified force 98 N (10 kgf, 22 lbs). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust. Deflection (A)

7.0 to 9.0 mm 0.28 to 0.35 in.

Factory spec.

0000001384E

Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it. (A)

Good

(B)

Bad 0000000920E

Thermostat Valve Opening Temperature 1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat. 2. Heating the water gradually, read the temperature when the valve opens and leaves the string. 3. Continue heating and read the temperature when the valve opens approx. 8 mm (0.315 in.). 4. If the measurement is not within the factory specifications, replace the thermostat. Thermostat's valve opening temperature

Factory spec.

69.5 to 72.5 157.1 to 162.5

Temperature at which thermostat completely opens

Factory spec.

85 185

0000001382E

III-S-101

Z602-E · D902-E, WSM

ENGINE

A When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. 0000000922E

Radiator Cap Air Leakage 1. Set a radiator tester (1) and adaptor (2) (BANZAI Code No.: RCT-2A-30S) on the radiator cap. 2. Apply the specified pressure (88 kPa, 0.9 , 13 psi), and measure the time for the pressure to fall to 59 kPa (0.6 , 9 psi). 3. If the measurement is less than the factory specification, replace the radiator cap.

Pressure falling time

(1)

More than 10 seconds for pressure fall from 88 to 59 kPa (from 0.9 to 0.6 from 13 to 9 psi)

Factory spec.

Radiator Tester

(2)

Adaptor 0000000923E

Radiator Water Leakage 1. Pour a specified amount of water into the radiator. 2. Set a radiator tester (1) (Code No. 07909-31551) and an adaptor (2) (BANZAI Code No.: RCT-2A-30S) and raise the water pressure to the specified pressure. 3. Check the radiator for water leaks. 4. For water leak from the pinhole, repair with the radiator cement. When water leak is excessive, replace the radiator. Radiator water leakage test pressure

(1)

Radiator Tester

157 kPa 1.6 23 psi

Factory spec.

(2)

Adaptor 0000001383E

III-S-102

Z602-E · D902-E, WSM

ENGINE

[2] DISASSEMBLING AND ASSEMBLING Thermostat Assembly 1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2). 2. Remove the thermostat assembly (4). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3). (1) (2)

Thermostat Cover Mounting

(3)

Thermostat Cover Gasket

Screw

(4)

Thermostat Assembly

Thermostat Cover 0000001357E

Water Pump Assembly 1. Loosen the alternator mounting screws, and remove the fan belt. 2. Remove the fan and fan pulley. 3. Remove the water pump assembly from the gear case cover. 4. Remove the water pump flange (1). 5. Press out the water pump shaft (2) with the impeller (6) on it. 6. Remove the impeller from the water pump shaft. 7. Remove the mechanical seal (5). (When reassembling) A Apply a liquid gasket (Three Bond 1215 or equivalent) to the both sides of gasket (4). A Replace the mechanical seal with new one. (1)

Water Pump Flange

(4)

(2)

Water Pump Shaft

(5)

Water Pump Gasket Mechanical Seal

(3)

Water Pump Body

(6)

Impeller 0000001358E

III-S-103

Z602-E · D902-E, WSM

ENGINE

5. FUEL SYSTEM [1] CHECKING AND ADJUSTING (1) Injection Pump Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder. 4. Continue to turn the flywheel slowly, and stop it as soon as the fuel level at the tip of the delivery valve holder begins to increase. 5. Check to see if the timing angle lines on the flywheel is aligned with the alignment mark (2). 6. If the injection timing is out of adjustment, readjust the timing with shims. Injection timing

0.30 to 0.33 rad (17 to 19 ) before T.D.C.

Factory spec.

A The sealant is applied to both sides of the shim (soft metal gasket shim). The liquid gasket is not required for assembling. A Shims are available in thickness of 0.20 mm (0.0079 in.), 0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments. A Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 ). A In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness. A Refer to figure below to check the thickness of the shims. (1)

Timing Line

(2)

Alignment Mark

(3)

Shim (Soft Metal Gasket Shim)

(4)

Two-holes: 0.20 mm (0.0079 in.)

(5)

One-hole: 0.25 mm (0.0098 in.)

(6)

Without hole: 0.30 mm (0.0118 in.) 0000001359E

III-S-104

Z602-E · D902-E, WSM

ENGINE

Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2). (Refer to the photo.) 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. Fuel tightness of pump element

13.73 MPa 140 1991 psi

Allowable limit

A Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubota-authorized pump service shop. (1)

Injection Nozzle

(2)

Injection Pump Pressure Tester

(3)

Protection Cover for Jetted Fuel

0000001360E

III-S-105

Z602-E · D902-E, WSM

ENGINE

Fuel Tightness of Delivery Valve 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Set a pressure tester to the fuel injection pump. 4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2). 5. Run the starter to increase the pressure. 6. Stop the starter when the fuel jets from the injection nozzle. After that, turn the flywheel by the hand and raise the pressure to approx. 13.73 MPa (140 , 1991 psi). 7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from 140 to 130 , from 1991 to 1849 psi). 8. Measure the time needed to decrease the pressure from 13.73 to 12.75 MPa (from 140 to 130 , from 1991 to 1849 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. Factory spec.

10 seconds 13.73 12.75 MPa 140 130 1991 1849 psi

Allowable limit

5 seconds 13.73 12.75 MPa 140 130 1991 1849 psi

Fuel tightness of delivery valve

A Never try to disassemble the injection pump assembly. For repairs, you are strongly requested to contact a Kubota-authorized pump service shop. (1)

Injection Nozzle

(2)

Injection Pump Pressure Tester

(3)

Protection Cover for Jetted Fuel

0000001361E

III-S-106

Z602-E · D902-E, WSM

ENGINE

(2) Injection Nozzle

A Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. A If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused. 0000000932E

Nozzle Spraying Condition 1. Set the injection nozzle to a nozzle tester (Code No. 0790931361), and check the nozzle spraying condition. 2. If the spraying condition is defective, replace the nozzle piece. (a)

Good

(b)

Bad 0000000933E

Fuel Injection Pressure 1. Set the injection nozzle to a nozzle tester (Code No. 0790931361). 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. Fuel injection pressure

Factory spec.

13.73 to 14.71 MPa 140 to 150 1991 to 2134 psi

(Reference) A Pressure variation with 0.01 mm (0.0004 in.) difference of adjusting washer thickness. Approx. 235 kPa (2.4 , 34 psi) (1)

Adjusting Washer 0000000934E

III-S-107

Z602-E · D902-E, WSM

ENGINE

Valve Seat Tightness 1. Set the injection nozzle to a nozzle tester (Code No. 0790931361). 2. Raise the fuel pressure, and keep at 12.75 MPa (130 , 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece. Valve seat tightness

No fuel leak at 12.75 MPa 130 1849 psi

Factory spec.

0000000935E

Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and take out parts inside. (When reassembling) A Assemble the nozzle in clean fuel oil. A Install the push rod (4), noting its direction. A After assembling the nozzle, be sure to adjust the fuel injection pressure.

Tightening torque

Nozzle holder

34.3 to 39.2 3.5 to 4.0 25.3 to 28.9 ft-lbs

Overflow pipe nut

19.6 to 24.5 2.0 to 2.5 14.5 to 18.1 ft-lbs

Nozzle holder assembly

49.0 to 68.6 5.0 to 7.0 36.2 to 50.6 ft-lbs

(1)

Nozzle Holder

(5)

Distance Piece

(2)

Adjusting Washer

(6)

Nozzle Piece

(3)

Nozzle Spring

(7)

Nozzle Retaining Nut

(4)

Push Rod 0000000936E

III-S-108

Z602-E · D902-E, WSM

ENGINE

6. ELECTRICAL SYSTEM [1] CHECKING (1) Starter Motor Test

A Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable and the leads from the starter. 3. Remove the starter from the engine. 4. Disconnect the connecting lead (2) from the starter C terminal (1). 5. Connect a jumper lead from the connecting lead (2) to the battery positive terminal post. 6. Connect a jumper lead momentarily between the starter motor housing and the battery negative terminal post. 7. If the motor does not run, check the motor. (1)

C Terminal

(2)

Connecting Lead 0000001148E

Magnet Switch Test (Pull-in, Holding Coils) A Preparate a 6 V battery for the test, and each test should be carried out for 3 to 5 seconds. 1) Checking Pull-in Coil 1. Connect jumper lead from the battery's negative terminal post to the C terminal. 2. The plunger should be attracted strongly when a jumper lead is connected from the battery positive terminal to the S terminal. 2) Checking Holding Coil 1. Connect jumper leads from the battery's negative terminal post to the body and the battery's positive terminal post to the S terminal. 2. Push the plunger in by hand and release it. Then, the plunger should remain being attracted. 0000001149E

(2) Glow Plug Glow Plug Continuity 1. Disconnect the lead from the glow plugs. 2. Measure the resistance with an ohmmeter between the glow plug terminal and the chassis. 3. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited. 4. If the factory specification is not indicated, the glow plug is faulty. Glow plug resistance

Factory spec.

Approx. 0.9 0000001152E

III-S-109

Z602-E · D902-E, WSM

ENGINE

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

Battery (12 V) 0000001163E

[2] DISASSEMBLING AND ASSEMBLING (1) Starter (1)

Magnetic Switch Mounting Nut

(2)

Housing

(3)

Magnetic Switch

(4)

C Terminal Nut

(5)

Shaft Assembly

(6)

Drive Lever

(7)

Overrunning Clutch

(8)

Connecting Lead

(9)

1. 2. 3. 4. 5. 6. 7.

Mounting Screw

(10)

Armature

(11)

Yoke

(12)

Brush Holder

(13)

Rear End Frame

(14)

Through Bolt

Unscrew the C terminal nut (4), and disconnect the connecting lead (8). Unscrew the magnetic switch mounting nuts (1), and remove the magnetic switch (3) from the housing (2). Unscrew the through bolts (14) and mounting screw (9), and remove the rear end frame (13). Remove the brush from the brush holder while holding the spring up. Remove the brush holder (12). Draw out the armature (10) and yoke (11) from the housing. Draw out the shaft assembly (5) with the drive lever (6) and overrunning clutch (7) from the housing.

(When reassembling) Tightening torque

C Terminal Nut

5.9 to 11.8 0.6 to 1.2 4.3 to 8.7 ft-lbs 0000001167E

III-S-110

Z602-E · D902-E, WSM

ENGINE

(2) Alternator Pulley 1. Secure the hexagonal end of the pulley shaft with a doubleended ratchet wrench as shown in the figure, loosen the pulley nut with a socket wrench and remove it. (When reassembling) Tightening torque

Pulley nut

58.3 to 78.9 5.95 to 8.05 43.0 to 58.2 ft-lbs 0000001364E

Rear End Cover 1. Unscrew the three rear end cover screws and the B terminal nut, and remove the rear end cover. 0000001365E

Brush Holder 1. Unscrew the two screws holding the brush holder, and remove the brush holder (1). (1)

Brush Holder 0000001366E

IC Regulator 1. Unscrew the three screws holding the IC regulator, and remove IC regulator (1). (1)

IC Regulator 0000001367E

III-S-111

Z602-E · D902-E, WSM

ENGINE

Rectifier 1. Remove the four screws holding the rectifier and the stator lead wires. 2. Remove the rectifier (1). (1)

Rectifier 0000001368E

Rear End Frame 1. Unscrew the two nuts and two screws holding the drive end frame and the rear end frame. 2. Remove the rear end frame (1). (1)

Rear End Frame 0000001369E

Rotor 1. Press out the rotor (1) from drive end frame (3). A Take special care not to drop the rotor and not to damage the slip ring or fan, etc. (1)

Rotor

(2)

Block

(3)

Drive End Frame

0000001370E

Retainer Plate 1. Unscrew the four screws holding the retainer plate, and remove the retainer plate (1). (1)

Retainer Plate 0000001371E

III-S-112

Z602-E · D902-E, WSM

ENGINE

Bearing on Drive End Side 1. Press out the bearing from drive end frame (3) with a press and jig (1). (1)

Jig

(2)

Block

(3)

Drive End Frame

0000001372E

Bearing at Slip Ring Side 1. Lightly secure the rotor (1) with a vise to prevent damage, and remove the bearing (2) with a puller (3). (1)

Rotor

(2)

Bearing

(3)

Puller

0000001373E

[3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any defect, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction. 4. If the pinion slips or does not rotate in the both directions, replace the overrunning clutch assembly. 0000001168E

III-S-113

Z602-E · D902-E, WSM

ENGINE

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

30.0 mm 1.181 in.

Allowable limit

29.0 mm 1.142 in.

Factory spec.

Less than 0.02 mm 0.0008 in.

Allowable limit

0.05 mm 0.0020 in.

Factory spec.

0.50 to 0.80 mm 0.0197 to 0.0315 in.

Allowable limit

0.20 mm 0.0079 in.

Commutator O.D.

Difference of O.D.'s

Mica undercut

(1)

Segment

(a)

Correct

(2)

Undercut

(b)

incorrect

(3)

Mica 0000001169E

Brush Wear 1. If the contact face of the brush is dirty or dusty, clean it with emery paper. 2. Measure the brush length (A) with vernier calipers. 3. If the length is less than the allowable limit, replace the yoke assembly and brush holder. Factory spec.

14.0 mm 0.551 in.

Allowable limit

9.0 mm 0.354 in.

Brush length (A)

0000001170E

III-S-114

Z602-E · D902-E, WSM

ENGINE

Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. 0000001171E

Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter. 4. If it does not conduct, replace the armature. 0000001172E

Field Coil 1. Check the continuity across the lead (1) and brush (2) with an ohmmeter. 2. If it does not conduct, replace the yoke assembly. 3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter. 4. If it conducts, replace the yoke assembly. (1)

Lead

(2)

Brush

(3)

Yoke

0000001173E

III-S-115

Z602-E · D902-E, WSM

ENGINE

(2) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. 0000001374E

Stator 1. Measure the resistance across each lead of the stator coil with an ohmmeter. 2. If the measurement is not within factory specification, replace it. 3. Check the continuity across each stator coil lead and core with an ohmmeter. 4. If infinity is not indicated, replace it. Stator resistance

Factory spec.

Less than 1 0000001375E

Rotor 1. Measure the resistance across the slip rings. 2. If the resistance is not the factory specification, replace it. 3. Check the continuity across the slip ring and core with an ohmmeter. 4. If continuous, replace it. Rotor resistance

Factory spec.

2.9 0000001376E

Slip Ring 1. Check the slip ring for score. 2. If scored, correct with an sand paper or on a lathe. Factory spec.

14.4 mm 0.5669 in.

Allowable limit

14 mm 0.5512 in.

Slip ring O.D.

0000001377E

III-S-116

Brush Wear 1. Check the length of the brush, if the length is shorter than the allowable limit, replace it. 2. Make sure that the brush moves smoothly. 3. If the brush is defective, replace it Factory spec.

10.0 mm 0.3937 in.

Allowable limit

1.5 mm 0.0591 in.

Brush length

0000001378E

Rectifier 1. Check the continuity across each diode of rectifier with an ohmmeter. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction. 0000001379E

IC Regulator 1. Check the continuity across the "B" terminal and the "F" terminal of IC regulator with an ohmmeter. 2. The IC regulator is normal if the conducts in one direction and does not conduct in the reverse direction. B:

"B" Terminal

F:

"F" Terminal 0000001380E

III-S-117

III-S-118

C.Engine WSM : D782 -B Fllowing pages cover Engine model D782 -B. But only pages that contain different data and contents from engin WSM of D902 - E were selected. Except the following pages, data and contents are identical to engin WSM of D902 - E.

III-S-119

III-S-120

III-S-121

III-S-122

III-S-123

III-S-124

III-S-125

III-S-126

III-S-127

III-S-128

III-S-129

III-S-130

III-S-131

III-S-132

III-S-133

III-S-134

III-S-135

III-S-136

III-S-137

III-S-138

III-S-139

III-S-140

III-S-141

III-S-142

III-S-143

III-S-144

III-S-145

III-S-146

III-S-147

III-S-148

III-S-149

III-S-150

III-S-151

III-S-152

III-S-153

III-S-154

IV.Hydraulic system

A.Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-3 a. b. c. d. e. f. g.

Common circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-3 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-6 Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-9 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-10 Swivel performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-11 Traveling performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-13 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-15

B.Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-19 a. b. c. d. e. f. g. h. i. j.

Testing Instruments & special tools . . . . . . . . . . . . . . . . . . . . . . IV-S-19 Pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-21 Pressure measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-22 Drain measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-30 Measurement of block performance . . . . . . . . . . . . . . . . . . . . . . IV-S-32 Operating speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-34 Straight travel performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-36 Cylinder natural fall amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-37 Control and Traveling lever operating force . . . . . . . . . . . . . . . . IV-S-37 Lever stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-37

C.Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-38 a. b. c. d. e. g. h.

Pump specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-38 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-40 Swivel performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-42 Traveling performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-42 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-44 Motor oil drain amount test sample . . . . . . . . . . . . . . . . . . . . . . . IV-S-46 Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-47

D.Disassembling and reassembling . . . . . . . . . . . . . . . . .IV-S-57 a. b. c. c. d. d. e. f. g. h.

Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-57 Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-68 Pilot valve (PP version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-112 Pilot valve (EU version). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-135 Swivel motor (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-146 Swivel motor (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . . . IV-S-159 Rotary Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-161 Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-176 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-194 Unload valve (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-203 IV-S-1

h. i. i. j.

Unload valve (KX36-3 EU, KX41-3 EU). . . . . . . . . . . . . . . . . . IV-S-206 Change valve (Dozer, Track)(KX41-3 PP). . . . . . . . . . . . . . . . IV-S-207 Change valve (Dozer, Track) (KX36-3 EU, KX41-3 EU) . . . . . IV-S-211 TPSS valve (TPSS = Two patern selection system) (PP Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-212 k. Oil tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-215 l. Delivery hose (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-216 m. Return hose (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-217 n. Table of hoses (KX41-3 PP) . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-218 O. Pilot Hose (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . . . . . IV-S-223 P. Delivery Travel, Swivel, Blade, Swing Hose (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-225 Q. Suction, Return Hose (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . IV-S-227 R. Table of Hoses (KX36-3 EU, KX41-3 EU) . . . . . . . . . . . . . . . . IV-S-230

IV-S-2

A.Troubleshooting a. Common circuit Engine System Engine not starts

Starter not rotates normally

Check electrical components

Starter rotates but engine not starts

Check engine components Check electrical components

Engine starts but not normally

Engine not stops Irregular engine revolution White or blue engine exhaust Black or dark gray engine exhaust

Check engine components

Insufficient output 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 system not starts

Slow and weak hydraulic pressure equipment

Excessive natural drop of hydraulic system, hydraulic system not stop, excessive oil flow

Temperature of operating oil tank rises

Whole hydraulic pressure system not operates

Check hydraulic components

Boom, arm, bucket, swing, or dozer cylinder not operates

Check hydraulic components

Swivel not operates

Check swivel components

Traveling not operates

Check traveling components

Abnormal top speed engine revolution

Check engine components

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 boom, arm, bucket, or dozer cylinder natural drop

Check hydraulic components

Swivel not stops or excessive flow occurs

Check swivel components

Travelling motion not stops or runs away on slopes

Check traveling components

Engine system error; cooling water, oil, or combustion system

Check engine components

Improper attachment of heat insulator on engine bonnet

Check heat insulator and cover mounting conditions

Operator's traveling control is not normal

Give proper traveling control instructions

Attachment not satisfies recommended operating range

Check specifications of attachment and machine

Oil not of recommended quality or in recommended quantity

Hydraulic pressure system error

IV-S-4

Use recommended oil

Check hydraulic components

Abnormal sound while in operation

Loosened mounting bolts or nuts for cover and other parts around source of abnormal sound

Check cover and other parts mounting conditions

Tube, hose, or other parts around source of abnormal sound in contact with other parts

Check tube or hose mounting conditions

Generation of abnormal sound from pins or bushings

Check pin or bushing wear or seizing

Generation of abnormal sound from hydraulic system

Check hydraulic components

Generation of abnormal sound from engine system

Check engine components

Generation of abnormal sound from undercarriage

Check crawler, idler, or truck roller mounting conditions

IV-S-5

b. Hydraulics Reference page

Failure

Probable cause

Remedy

Whole hydraulic pressure system not operates Slow speed and weak power.

1) The quantity of hydraulic oil in the tank is insufficient or the hydraulic oil is of poor quality.

Supply or replace the hydraulic oil.

2) The suction line (suction filter) is clogged.

Check the suction line or replace the suction filter.

3) The pump mounting coupling is in improper condition.

Repair or replace the pump coupling.

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, or swivel does not operate. Slow speed and weak power.

1) The hydraulic pressure pilot line filter is blocked.

Clean or replace the pilot filter.

2) The change valve is in improper condition.

Disassemble or change valve.

3) The seizing of or damage to the internal parts of the pilot pump.

Replace the pilot pump.

The boom, bucket, or traveling LH does not operate. Slow speed and weak power.

1) The main relief valve (P1) is not at the specified pressure.

Check and adjust the main relief valve (P1).

2) The seizing of or damage to the internal parts of the P1 or P2 pump system if the arm, service port, or traveling RH does not operate.

Repair or replace the pump.

1) The main relief valve (P2) is not at the specified pressure.

Check and adjust the main relief valve (P2).

2) The seizing of or damage to the internal parts of the P1 or P2 pump system if the boom, bucket, or traveling LH does not operate.

Repair or replace the pump.

The swing, dozer, or swivel does not operate. Slow speed and weak power.

1) The main relief valve (P3) is not at the specified pressure.

Check and adjust the main relief valve (P3).

2) The seizing of or damage to the internal parts of the P3 pump system.

Repair or replace the pump.

The boom or arm does not operate. Slow speed and weak power.

1) The operation or adjustment of the TPSS link is improper.

Check and adjust the link.

2) The TPSS valve is in improper operation.

Disassemble the replace the seal.

Only the boom does not operate. Slow speed and weak power.

1) The overload relief valve of the boom is not at the specified pressure.

Check and repair the overload relief valve.

2) The spools of the control valve boom section is in improper operation.

Check and repair the spools.

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.

1) The overload relief valve of the arm is not at the specified pressure.

Check and repair the overload relief valve.

2) The spools of the control valve arm section is in improper operation.

Check and repair the spools.

3) The pilot valve is in improper condition.

Measure the secondary pressure and check the pilot valve.

4) Damage to the packing of the arm cylinder rod.

Disassemble the cylinder and replace the seal.

The arm, service port, or traveling RH does not operate. Slow speed and weak power.

Only the arm does not operate. Slow speed and weak power.

IV-S-6

replace

valve

the

and

Reference page

Failure

Probable cause

Remedy

Only the bucket does not operate. Slow speed and weak power.

1) The overload relief valve of the bucket is not at the specified pressure.

Check and repair the overload relief valve.

2) The spools of the control valve bucket section is in improper operation.

Check and repair the spools.

3) The pilot valve is in improper condition.

Measure the secondary pressure and check the pilot valve.

4) Damage to the packing of the bucket cylinder rod.

Disassemble the cylinder and replace the seal.

1) Improper adjustments to the swing pedal and link.

Check and adjust the pedal and link.

2) The spools of the control valve swing section is in improper operation.

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.

1) Improper adjustments to the dozer lever and cable.

Check and adjust the lever and cable.

2) The spools of the control valve dozer section is in improper operation.

Check and repair the spools.

3) Damage to the packing of the dozer cylinder or tracking cylinder rod.

Disassemble the cylinder and replace the seal.

4) The operation or adjustment of the link of the change valve (dozer and truck) is improper.

Check and adjust the link.

5) The change valve (dozer and truck) is in improper operation.

Disassemble the replace the seal.

1) Improper adjustments to the service port pedal and link.

Check and adjust the pedal and link.

2) The spools of the control valve service port section is in improper operation.

Check and repair the spools.

1) The overload relief valve is not at the specified pressure.

Check and repair the overload relief valve.

2) Damage to the spool or spring of the control valve.

Check and repair the spool or the spring.

3) Damage to the packing of the boom cylinder rod.

Disassemble the cylinder and replace the seal.

1) Improper adjustments to the link system of the swing pedal.

Check and adjust the link.

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 control valve.

Check and repair the spools.

4) Damage to the swing cylinder rod.

Disassemble the cylinder and replace the seal.

1) Damage to the spool or spring of the control valve.

Check and repair the spools.

2) The change valve (dozer and truck) is in improper operation.

Disassemble the replace the seal.

3) Damage to the packing of the dozer cylinder rod.

Disassemble the cylinder and replace the seal.

Only the swing does not operate. Slow speed and weak power.

Only the dozer or leg expansion and contraction function does not operate. Slow speed and weak power.

Only the service port does not operate. Slow speed and weak power. The natural drop of the boom, arm or bucket cylinder is excessive.

The swing cylinder returned to the neutral position moves.

Natural drop of the dozer cylinder is excessive.

IV-S-7

valve

valve

and

and

Failure

Probable cause

Remedy

The temperature of the operating oil tank rises.

1) Hot air overflows due to damage to the division plate around the oil cooler.

Check 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 filter.

4) The low-pressure line is clogged with a foreign matter.

Check the low-pressure line.

IV-S-8

Reference page

c. Pump Problem

Cause

Correction

1) Engine rpm higher than specified. 1. The engine gets overloaded. 2) Pressure higher than specified. 3) Pump internal parts seized or damaged.

1) Readjust as specified. 2) Readjust as specified. 3) Repair or replace the pump.

2. The pump flowrate drops extremely with too low discharge pressure.

1) Engine rpm too low. 2) Pump coupling defective. 3) Pump internal parts seized or damaged.

1) Readjust the rpm. 2) Repair or replace the pump coupling. 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. 2) Clean or replace the suction strainer. 3) Correct the suction pipe. 4) Repair or replace the attached pump. 5) Replace the piston assembly. 6) Mount correctly. 7) Replace the coupling.

3. Unusual noise or unusual vibrations occur (cavitation phenomenon).

2) 3) 4) 5) 6) 7)

Suction strainer clogged. Suction pipe clogged or throttled. Attached pump in trouble (if provided). Piston shoe poorly crimped. Pump loosely mounted. Coupling defective.

1) O-ring or sheet packing defective. 4. There is oil leak. 2) Oil leak from oil seal edge.

IV-S-9

1) Replace the O-ring or sheet packing (install as specified). 2) Replace or repair the oil seal or shaft.

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.

Incoming flowrate too low.

Check the pump discharge rate, the motor rpm, and the valves for oil leak.

Motor failure Dust, degraded hydraulic oil, cavitation, Run the motor alone and get it under a pressure of 30 kgf/cm2 (2.9 to run 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.

Rpm not as Low viscosity and internal leak for oil designed temperature or other reason. Wrong turning direction

Oil leak

Unusual noise

Ensure the specified viscosity ranges.

Internal parts worn out.

Replace worn-out parts.

Wrong pipe connections.

Reverse the pipe connections.

Poor valve timing due to wrong disassembling/reassembling procedures.

Disassemble and reassemble again for good valve timing.

Oil seal scratched or worn.

Replace the oil seal. Repair or replace if the shaft seal contact surface is scratched or worn.

Loose bolt or plug, resulting in oil leak (at joints) from O-ring.

Tighten the bolt and plug to their specified torques. See also if the Oring is damaged. Replace the O-ring as required.

O-ring scratched or damaged.

Replace the O-ring.

Dust or dent on the O-ring contact face.

Check for hit marks, burr, etc. Correct the surface with #600 or so sandpaper. Replace the O-ring. Clean up and reassemble.

Cracked port, damaged screw. Inappropriate joint.

Replace the housing. Use an appropriate joint and tighten it to the specified torque.

Shaft poorly fitted.

Center the shaft exactly.

Air left in the circuit or motor.

Let out the air completely. Fill the motor with oil and keep it running under no load until there is no air bubbles in the tank.

Pump's cavitation.

Unclog the suction filter.

Air mixed in the suction pipe line.

Apply oil or grease to each connection and carefully listen to the noise there. If the noise is less, retighten the joint there.

Unusual Cooler in trouble. temperature Motor seized. rise

Repair the cooler. 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. Failure 1. The swivel does not turn left or right.

2. One of the two sides does not work.

3. The power is low. The speed is low.

Probable cause

Remedy

1) The spooling of the pilot valve is improper.

Check the operation of the valve, and disassemble and clean the valve.

2) The spool stick of the control valve operates improperly.

Check the operation of the valve, 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 disassemble, 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.

1) The spooling of the pilot valve is improper.

Check the operation of the valve, and disassemble and clean the valve.

2) The spool stick of the control valve operates improperly.

Check the operation of the valve, 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 disassemble, 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.

1) The spooling of the pilot valve is improper.

Check the operation of the valve, and disassemble and clean the valve.

2) The spool stick of the control valve operates improperly.

Check the operation of the valve, 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 disassemble, 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.

IV-S-11

Reference page

Failure 4. The swivel does not stop with the position set to neutral. An excessive flow.

5. Excessive shock with the swivel comes to a stop. No inching is possible.

6. The swivel wobbles when the swivel is pressed by hand.

Probable cause

Remedy

1) The spooling of the pilot valve is improper.

Check the operation of the valve, and disassemble and clean the valve.

2) The spool stick of the control valve operates improperly.

Check the operation of the valve, and disassemble and clean the valve.

3) Relief valve pressure is improper.

Measure the pressure, and disassemble, clean, and adjust the valve.

4) Excessive motor drain.

Measure the drain.

1) The spooling of the pilot valve is improper.

Check the operation of the valve, and disassemble and clean the valve.

2) The spool stick of the control valve operates improperly.

Check the operation of the valve, and disassemble and clean the valve.

3) Relief valve pressure is improper.

Measure the pressure, and disassemble, clean, and adjust the valve.

4) Excessive motor drain.

Measure the drain.

1) The spool of the control valve operates improperly.

Check the operation of the valve, and disassemble and clean the valve.

2) Relief valve pressure is improper.

Measure the pressure, and disassemble, clean, and adjust the valve.

3) Excessive motor drain.

Measure the drain.

IV-S-12

Reference page

f. Traveling performance Check in advance that only the traveling components are in improper condition. Failure Machine does not run.

Slow traveling speed. Low traveling power.

Skewing (Only in traveling control)

Probable cause

Remedy

1. Sticking or dropping of the traveling lever of the link system.

Adjust and replace the link system.

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 valve.

Disassemble, clean, and replace the counter balance valve.

5) Excessive motor drain.

Measure the drain quantity, disassemble, and replace the motor.

6) Internal damage to the motor.

Disassemble and replace the motor.

1) The link system of the traveling lever is in improper operation.

Adjust the link system.

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 improper.

Disassemble, clean, and replace the counter balance valve.

5) Excessive motor drain.

Measure the drain quantity, disassemble, 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 communicating valve and clean the filter.

1) The left and right traveling levers of the link system are not in uniformed operation.

Adjust the link system.

2) The left and right control valves are not in uniformed spool operation.

Disassemble, clean, and replace 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 valve.

Disassemble, clean, and replace the counter balance valve.

5) The difference between the left and right in motor drain quantity is great.

Measure the drain quantity, disassemble, and replace the motor.

6) Internal damage to the motor on one side.

Disassemble and replace the motor.

Reference page

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 running. Machine runs away on slopes.

1) Improper returning or sticking of the link system of the traveling lever.

Adjust the link system.

2) Improper returning or sticking of the spool of the control valve.

Disassemble, clean, and replace the control valve.

3) Improper returning or sticking of the spool of the counter balance valve.

Disassemble, clean, and replace the counter balance valve.

IV-S-13

Reference page

Failure

Probable cause

Remedy

The traveling speed range does not change.

1) The spool of the change valve is in improper operation.

Disassemble, and clean replace the change valve.

2) The high/low speed change spool in the travel motor is in improper operation.

Disassemble, and clean or 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 broken.

Check and replace the harnesses.

IV-S-14

or

g. Electrical components (1) Engine components Failure

Probable cause

1. The starter does not rotate.

1) Check that the slow-blow fuse or fuse has not burnt out.

Check and replace the fuse.

2) Check that the battery terminals are not loosened.

Tighten the terminals.

3) Check that the minimum voltage between the battery terminals (positive and negative) is 10.5 V at the start position.

Charge or replace the battery.

4) Exchange the auto-release relay and light relay.

Check and replace the fuse.

5) Check that the starter M terminal is not loosened.

Tighten the terminals.

6) Check that the starter 50 terminal is at 9 V or over at the start position.

Repair or replace the terminal.

7) Check whether the key switch is in normal condition.

Check and replace the fuse.

1) Check that the fuel overflows to the tank with the key switch turned ON.

Visual check.

2) Touch the fuel pump by hand and check that the pump operates with the key switch turned ON.

Replace.

3) Check that the fuel pump fuse has not burnt out.

Replace.

4) Check that voltage is applied to the fuel pump coupler 1 and fuel pump coupler 2.

Repair or replace the terminal.

5) Check that the engine starts with the stop solenoid dismounted.

Repair or replace the terminal.

6) Check that voltage is applied to the engine stop solenoid coupler with the key turned ON.

Repair or replace the terminal.

2. The starter rotates but the engine does not start.

3. The engine does not start smoothly at low temperatures.

Remedy

1) Check that the battery voltage is normal.

Charge or replace the battery.

2) Check that the glow relay fuse has not burnt out.

Replace.

3) Touch the glow relay by hand and check that the glow relay operates.

Replace.

4) Check that the voltage is applied to the glow relay coupler.

Repair or replace the terminal.

5) Check that the voltage is applied to the glow plug.

Repair or replace the terminal.

6) Check that the glow plug is in normal condition.

Replace.

7)Check the glow relay.

Replace.

IV-S-15

Remarks

(2) Panel components (with key switch turned ON) Failure

Probable cause

1. The glow symbol does not appear on the panel.

1) Touch the glow relay by hand and check that the glow relay operates.

Replace.

2) Check that the coupler on the panel side is not disconnected.

Repair or replace the terminal.

3) Check the voltage of the coupler on the panel side.

Replace.

2. The charge symbol does not appear on the panel.

3. The oil symbol does not appear on the panel.

4. The remaining fuel does not appear on the panel.

Remedy

4) Check that the lamp has not burnt out.

Replace.

1) Check that the fuse has not burnt out.

Replace.

2) Check that the alternator coupler is not disconnected.

Repair or replace the terminal.

3) Check that the coupler on the panel side is not disconnected.

Repair or replace the terminal.

4) Check that the lamp has not burnt out.

Replace.

1) Check that the fuse has not burnt out.

Replace.

2) Check that the oil switch coupler is not disconnected.

Repair or replace the terminal

3) Check that voltage is applied to the oil switch coupler.

Repair or replace the terminal

4) Check that the symbol appears when the harness terminal of the oil switch is removed and grounded to the body.

Replace the terminal

5) Measure the pressure of the engine oil.

Repair the terminal

1) Check that the fuse has not burnt out.

Replace.

2) Check that the charge and oil symbols appear on the panel. Lit : Normal Not lit : Abnormal

Repair or replace the terminal

3) Ground the harness terminal of the fuel sensor to the body. Lit : Normal Not lit : Harness wire disconnection

Repair or replace the terminal

IV-S-16

Reference page

(3) Panel components (with engine started) Failure 1. The charge symbol does not appear on the panel.

2. The oil symbol does not appear on the panel.

3. The water temperature symbol does not appear on the panel.

Probable cause

Remedy

1) Check that the 60-A fuse has not burned out.

Replace.

2) Check that the alternator B terminal or the coupler is not disconnected.

Repair or replace the terminal.

3) Check that the alternator is in normal condition.

Repair or replace the terminal.

1) Check that the specified quantity of the oil is provided.

Replenish.

2) Check that the oil switch coupler is not disconnected.

Repair or replace the terminal.

3) Check that voltage is applied to the oil switch coupler.

Replace.

4) Measure the pressure of the engine oil.

Replace the terminal

1) Check that the fuse has not burnt out.

Replace.

2) Check that the water temperature sensor coupler is not disconnected.

Repair or replace the terminal.

3) Check that the coupler on the panel side is not disconnected.

Repair or replace the terminal.

4) Check that voltage is applied to the water temperature coupler.

Replace the terminal

5) Check that the water temperature sensor is in normal condition.

Replace the terminal

4. The remaining fuel does not appear on the panel.

1) Check that the quantity of fuel is sufficient. 2) Check that the fuel sensor is in normal condition.

Replace.

5. The remaining fuel display on the panel does not move.

1) Check that the fuse has not burnt out.

Replace.

2) Check that fuel sensor coupler is not disconnected.

Repair or replace the terminal.

3) Check that the coupler on the panel side is not disconnected.

Repair or replace the terminal.

4) Check that voltage is applied to the fuel pump coupler .

Replace the terminal

5) Check that the fuel sensor is in normal condition.

In addition to the above, refer to the check points described in the "Explanation of New Panel".

IV-S-17

Reference page

(4) Others Failure 1. The front attachment does not operate with the lock lever released.

2. The traveling speed does not change with the high speed panel pressed.

3. The horn does not sound with the horn switch pressed.

4. The work light is not lit when the work light switch pressed.

Probable cause

Remedy

1) Check that the fuse has not burnt out.

Replace.

2.)Check that the lever lock solenoid and switch coupler are not disconnected.

Repair or replace the terminal.

3) Exchange the coupler with the solenoid coupler for the second gear.

Repair or replace the terminal.

4) Check that voltage is applied to the lever lock solenoid coupler and switch coupler.

Repair or replace the terminal.

5) Check the electromagnetic valve.

Repair or replace the terminal.

6) Check that the lever lock switch is in normal condition.

Replace.

1) Check that the fuse has not burnt out.

Replace.

2) Check that the solenoid coupler for the high speed and switch coupler are not disconnected.

Replace.

3) Exchange the coupler with the lever lock solenoid coupler.

Repair or replace the terminal.

4) Check that voltage is applied to the solenoid valve coupler for the high speed and switch coupler.

Replace.

5) Check the electromagnetic valve in the change valve.

Replace.

6) Check that the high speed switch is in normal condition.

Replace.

1) Check that the fuse has not burnt out.

Replace.

2) Check that the harness from the grip (horn switch) is not disconnected.

Repair or replace the terminal.

3) Check that the horn coupler and grip (horn switch) coupler are not disconnected.

Repair or replace the terminal.

4) Check that voltage is applied to the horn terminal.

Replace.

5) Check that the horn switch is in normal condition.

Replace.

6) Check that the horn is in normal condition.

Replace.

1) Check that the fuse has not burnt out.

Replace.

2) Check that the work light terminal and switch coupler are not disconnected.

Repair or replace the terminal.

3) Check that voltage is applied to the work light terminal.

Replace.

4) Exchange the work light relay and break-off relay.

Replace.

5) Check that the lamp has not burnt out.

IV-S-18

Reference page

B.Testing a. Testing Instruments & special tools 1) Gauges and special tools for pressure testing 1. Pressure hose 2. Pressure gauge; 2.94 MPa, 30kgf/cm2, 427 psi For Secondary pilot pressure test. 3. Pressure gauge; 5.88 MPa, 60kgf/cm2, 853psi For primary pilot pressure test. 4. Pressure gauge; 64.3 MPa, 350kgf/cm2, 4978psi For main relief pressure and overload relief pressure test. 5. Pipe joint (S, F2 - F2) code No.: 69181-63191 6. Pressure test plug; PT 1/8 7. Allen wrench; M5 8. Plug; PT 1/8 Code No.: 68311-13381 9. Wrench; Size 17 - 19 mm

IV-S-19

2) Flow meter and special tools for flow testing (5)

(4) (3)

(2) (1)

(1) (2) (3) (4) (5) (6)

Flow meter; Flowtech Inc. make Loading handle Male-female joint 1” × 1” joint 1” × 1/2” Hose 1/2” O-ring

(3) (4) (5)

Drawing of (3) Male - female joint 1” × 1”

Vacuum pump FESTO VAD-1/4 9334 P

R u

IV-S-20

b. Pump flow

(1) Hydraulic oil tank (3) Tester

1) Measuring procedure 1. Connect the tester to the pump outlet. Be careful 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.

(2) Pump (4) Control valve

2) Checking the pump performance

Pump discharge side

To inspect the pump performance, apply the specified pressure to the pump discharge side. Measure the discharge rate at the specified rpm to check the volumetric efficiency. Volumetric efficiency = Discharge rate at rated load Theoretical discharge rate (calculated value)

(1)

(2)

(1) To control valve (P2) (2) To control valve (P1) (3) To control valve (P3) (4) To pilot valve

(3)

(4)

× 100(%)

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 the pump usually runs at lower rpm. Discharge rate under rated load (cc/rev) =

Discharge rate at rated load (L/min) × 1000 Pump rpm at rated load (rpm)

4. The volumetric efficiency must be satisfied to accept the pump for its performance. 5. The hydraulic oil temperature must be 50±5°C.

IV-S-21

c. Pressure measurement (1) Pilot pressure 1) Primary pressure 1. Vacuum the hydraulic system line to prevent oil from leaking out. Install the vacuum pump onto the tank cap.Set the main key on and get the safety lever down. 2. Open rear bonnet. 3. Install the pressure gauge on pilot pump delivery port. 4. Start the engine and run it at the maximum speed. 5. Leave the safety lever up or get lever down. 6. Take 2 or 3 measurements to have an exact reading. 7. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F KX36-3, KX41-3, KX41-3V 3.9 ± 0.5 MPa Reference Value

40 ± 5 kgf / cm2 569 ± 71 psi

Note : In case of engin idle speed, pressure value is slightly lower than that engine max. speed by 2 ~ 5 kgf / cm2 (0.2 ~ 0.5 MPa, 28 ~ 71 psi).

IV-S-22

2) Secondary pressure 1. Remove step. 2. Connect a joint for measurement to the arrow marked point and set pressure gauge on it. 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 ± 41 °F 8. Pilot valve is at its max. stroke and control valve spool is being fully shifted. KX36-3, KX41-3, KX41-3V 1.96 ± 0.2 MPa Reference Value at idle speed

20 ± 2 kgf / cm2 284 ± 28 psi 2.16 ± 0.3 MPa

Reference Value at max.speed

22 ± 3 kgf / cm2 313 ± 43 psi

(Boom - up)

(Arm - crowd)

IV-S-23

(2) Main relief valve 1) Measurement method 1. Set pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there. 2. Start the engine and run it at the maximum speed. 3. Get the safety lever down to activate the unload valve. 4. Get the following main relief valves activated. 5. Take 2 or 3 measurements to have their respective exact readings. 6. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F 7. Recommended testing actuators. P1 : Bucket dump P2 : Travel R (Arm) P3 : Dozer up Read the circuit diagram and take the appropriate actuators not to mix up the main relief pressure and overload relief pressure. 8. Specifications : Refer to page IV-S-41.

(P2)

2) Location of the main relief valve P1

P2

IV-S-24

P3

3) Adjustment of main relief valve. 1. Loosen the lock nut of the P1, P2 or P3 main relief valve. 2. Using a hex wrench, turn the adjusting screw to reach the specified setting. 3. Then tighten up the lock nut. Clockwise turn raises the pressure, and counterclockwise turn lowers it. Main relief valve pressure rises by approximately 30 kgf / cm2 (2.9 MPa, 427 psi) at 60 degree turns of adjusting screw. 4. Run the engine at the maximum speed. Move the levers and make sure the pressure setting. 5. Get the safety lever down to activate the unload valve. 6. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F (a1 relief valve)

(a2 relief valve)

(a3 relief valve)

IV-S-25

(3) Overload relief valve 1) Measurement method

(P1)

1. Set the pressure gauge to the coupler at P1, P2, P3 port on the pump. Or remove the plug of P1, P2, P3 port and set pressure gauge there. 2. Raise the pressure setting of the main relief valve about o.98 MPa (10 Kgf / cm2, 142 psi) over than that of the overload relief valve setting to be tested. 3. Run the engine at 1500rpm for b1, b2, b3, b4, b5. 4. Get the safety lever down to activate the unload 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. 7. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F 8. Specifications : Refer to page IV-S-41.

(Adjust a1 main relief valve)

(Adjust boom-up over load relief valve) b1 : Bucket bottom b2 : Boom rod b3: Boom bottom b4 : Arm rod b5 : Arm bottom a1 : P1 main relief valve a3 : P3 main relief valve

(b1)

(b2)

(a1)

(b5)

(a3)

IV-S-26

2) Location of overload relief valves (1)

(2)

(4)

Arm

Combination Swing Dozer A

B

Bucket

Travel

Travel Supply

SP

Boom

(3)

(5)

(1) Bucket, bottom (2) Boom, rod (3) Boom, bottom (4) Arm, bottom (5) Arm, rod

IV-S-27

Swing

3) Adjustment of overload relief valve. 1. Loosen the lock nut of the overload relief valve. Using a hex wrench, turn the adjusting screw to reach the specified setting. Then tighten up the lock nut. Clockwise turn raises the pressure, and counterclockwise turn lowers it. 2. Run the engine at the maximum speed. 3. Get the safety lever down to activate the unload valve. 4. Move the levers and make sure the pressure setting. 5. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F 6. Specifications : Refer to page IV-S-41.

(Test boom down overload pressure)

IV-S-28

(4) Swivel brake valve pressure 1) Measurement method 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. 2. Get the safety lever down to activate the unload valve. 3. Bring the bucket or arm tip end in contact with a solid block. Slowly move at toward the block. 4. With the engine at rated rpm, measure the relief pressure. 5. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F 6. Specifications : Refer to page IV-S-41.

(Swivel motor, relife valve.)

IV-S-29

d. Drain measurement (1) Traveling motor 1. Vacuum the hydraulic system line to prevent oil from leaking out. 2. Disconnect the drain hose from the travel motor and connect another hose (the pressure gauge hose will do) where the drain hose was disconnected. 3. Float the crawlers as shown as below. 4. Run the engine one minute at max. rpm with the lever in the forward position and measure the amount of hydraulic oil in the pan. 5. If the measurement exceeds the specification, determine the cause and replace the assembly. 6. Hydraulic oil temp. : 50 ± 5 °C, 122 ± 41 °F 7. Reference value : Refer to page IV-S-46. Never place your body under the crawler. (1)

(1) Drain port (2) 2nd speed pilot line (3) Main high pressure hoses

(3)

(2)

(Travel motor lock condition)

IV-S-30

(2) Swivel motor 1. Remove step. 2. Locate front attachment to traveling position. Bucket should be located 1 m above from ground. 3. Remove drain hose of the swivel motor and recieve drain oil in a suitable reservoir. 4. Swivel the machine one minute at max. engine rpm and measure amount of hydraulic oil in the reservoir.

(1)

Make sure nobody is around swivel radius area. 5. Reference value : Refer to page IV-S-46. Vacuum the hydraulic system line to prevent oil leakage while fitting hoses. (1) Vacuum pump, compression air type (2) Drain port (3) Measuring cylinder

(2)

(3)

(Swivel motor lock condition)

IV-S-31

e. Measurement of block performance (1) Swivel 1. Locate the machine on the 20 deg. slope. 2. The front position is of arm dump and bucket crowd. Keep the boom so that the boom end pin is aligned with the bucket pin. 3. Mark the outer ring of swivel bearing and truck frame. 4. Unlock the safety lock lever, and measure the one minute shifting distance between them with engine idling rpm and engin stop condition. 5. Load on the bucket should be as follows. KX36-3: 63 kg (139 lbs)-exclude bucket weight KX41-3: 72 kg (159lbs)-exclude bucket weight Reference Value

Engine idle

under 30 degrees / min

Engine stop

6. Hydraulic oil temp. : 50 ± 5°C, 122 ± 41°F.

IV-S-32

(2) Traveling 1. Park the machine on a 20deg. slope. Keep front at traveling position. 2. Put marks on the truck frame and the crawler. 3. Measure 10 minutes slip-distance without engine running. 4. Hydraulic oil temp. : 50 ± 5°C, 122 ± 41°F. KX36-3, KX41-3S, KX41-3V Reference Value

IV-S-33

300 mm/10 min 0.98 ft/10 min

f. Operating speed (1) Checking each operating speed. [Important points] 1. Measure full stroke operating time with no load on the standard bucket. 2. Make several mesurement and use average time for judgement. 3. Two different measurements are expected for the forward and backward movements as well as the right and left swivelings. Obtain their respective measurements. Do not calculate for their average. 4. Before operation, make sure nobody is around the machine.

[Measurement conditions] 1. 2. 3. 4.

Engine rpm is max.. Hydraulic temperature is 50 ± 5°C, 122 ± 41°F. Ground is flat. Measure time after several pre-operation.

(2) Boom cylinder 1. Arm and bucket cylinder shouls be most shorted position. 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 Value

Up Down

KX36-3 KX41-3S KX41-3V EU KX41-3V PP 2.3 ~ 2.9 2.0 ~ 2.6 m m 2.8 ~ 3.4 2.7 ~ 3.3 m 2.3 ~ 2.9

(3) Arm cylinder 1. Position the boom and arm as showm at left. 2. Measure the arm cylinder full stroke operating time. [sec] Reference Value

IV-S-34

Crowd Dump

KX36-3 KX41-3S KX41-3V EU KX41-3V PP 3.1 ~ 3.7 m m m 1.9 ~ 2.5 2.1 ~ 2.7 m m

(4) Bucket cylinder 1. Position the boom and arm as showm at left. 2. Measure the bucket cylinder full stroke operating time. [sec] Reference Value

Crowd Dump

KX36-3 KX41-3S KX41-3V EU KX41-3V PP 2.1 ~ 2.7 2.5 ~ 3.1 m m 1.9 ~ 2.5 1.7 ~ 2.3 m m

(5) Swing cylinder 1. Position the boom, arm and bucket as showm at left. (with the bottom of the bucket about 1 m (33 ft) above from the ground.) 2. Measure the swing cylinder full stroke operating time. (right to left and left to right) [sec] Reference Value

Left Right

KX36-3 KX41-3S KX41-3V EU KX41-3V PP 4.4 ~ 5.0 4.3 ~ 4.9 m m 3.7 ~ 4.3 3.6 ~ 4.2 m m

(6) Dozer cylinder 1. Place the bucket on the ground. Position the machine as shown at left for the dozer to make a full stroke. 2. Measure the dozer cylinder full stroke operating time. [sec] Reference Value

IV-S-35

Left Right

KX36-3 1.0 ~ 1.6 1.4 ~ 2.0

KX41-3S m m

KX41-3V EU KX41-3V PP m 1.3 ~ 1.9 m 1.7 ~ 2.3

(7) Swivel speed 1. Position the boom, arm and bucket as showm at left. 2. Measure three times rotation time. [sec/three turns] Reference Value

KX36-3 2.4.6 ~ 30.0

KX41-3S m

KX41-3V EU KX41-3V PP m m

(8) Traveling speed 1. Travel the machine untill getting max. speed. 2. After getting max. speed, measure the 10 mm (33 ft) traveling time. [sec] Reference Value

1F 2F

KX36-3 KX41-3S KX41-3V EU KX41-3V PP 2.0 ~ 2.4 2.2 ~ 2.6 2.0 ~ 2.4 2.1 ~ 2.5 3.9 ~ 4.7 3.6 ~ 4.4 3.7 ~ 4.5

g. Straight travel performance 1. Travel the machine untill getting max. speed. 2. Measure the vertical distance from the traveling line.

Reference Value

IV-S-36

Under 600 mm/10 m 1.97 ft / 32.8 ft

h. Cylinder natural fall amount 1. Locate the machine on the flat ground, and put the load the bucket. Load on the bucket should be as follows. 2. Arm cylinder must be fully retracted. Bucket cylinder must be fully extended. 3. Locate the bottom of bracket about 1 m above from the ground. Stop the engine. 4. Mark on the rod of each cylinder. 5. Measure the fall distance after 10 min. Reference Value

Refer to page IV-S-44

i. Control and Traveling lever operating force 1. Stop the engine. 2. Measure force of right and left control and traveling levers. 3. Start the engine, operate the control lever or traveling lever for a full stroke, and measure the max. operating force. 4. Make three measurements and take their average. 5. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 9°F. Reference Value

Refer to page IV-S-55

j. Lever stroke 1. Stop the engine. 2. Move each lever from neutral to full stroke end, and measure each stroke with respect to the top center of the each lever glip. 3. If any lever is loose at its neutral position, measure the stroke from each loose end. 4. Make three measurements and take their average. Reference Value

IV-S-37

Refer to page IV-S-56

C.Specifications a. Pump specifications No. Machine model

KX36-3

KX41-3S/V EU

KX41-3V PP

STD value

STD value

STD Allowance

NACHI

m

m

PVD-00B-14P5G3-4978A

PVD-00B-15P5G3-4982A

m

2300

m

m

cc/rev

7.2

7.5

m

cu.in./rev

0.44

0.46

m

cc/rev

7.2

7.5

m

cu.in./rev

0.44

0.46

m

cc/rev

4.5

m

m

cu.in./rev

0.27

m

m

cc/rev

2.7

m

m

cu.in./rev

0.16

m

m

L/min

16.6

17.3

m

USGPM

4.37

4.56

m

L/min

16.6

17.3

m

USGPM

4.37

4.56

m

L/min

10.4

m

m

USGPM

2.73

m

m

L/min

6.2

m

m

USGPM

1.64

m

m

Unit 1

Manufacturer

2

Pump type

3

Pump rated RPM

4

Theoretical dis- p1 charge amount capacity p2 p3 p4

5

Theoretical p1 delivery amount at rated rpm: p2 p3 p4

6

Actual delivery amount : p1,p2

Remarks

Load: cc/rev 15kgf/cm2 (1.47MPa) cu.in./rev (213psi)

7.30 0.40 -0.40 Recommeded limit : KV =80% 0.45 0.02 -0.02 Service limit : KV =70%

Load: cc/rev 2 50kgf/cm (4.90MPa) cu.in./rev (711psi)

6.42 0.32 -0.32 0.39 0.02 -0.02

Load: cc/rev 100kgf/cm2 (9.8MPa) cu.in./rev (1422psi)

5.30 0.27 -0.27 0.32 0.02 -0.02

Load: cc/rev 150kgf/cm2 (14.7MPa) cu.in./rev (2130psi)

4.15 0.21 -0.21 0.25 0.01 -0.01

cc/rev Load: 2 200kgf/cm (19.6MPa) cu.in./rev (2845psi)

2.64 0.13 -0.13 0.16 0.01 -0.01

IV-S-38

No. Machine model Unit 7

8

Actual delivery amount : p3

Actual delivery amount : pp

KX36-3

KX41-3S/V EU

KX41-3V PP

STD value

STD value

STD Allowance

Remarks

Load: cc/rev 2 15kgf/cm (1.47MPa) cu.in./rev (213psi)

4.30 0.20 -0.20 Recommeded limit : KV =85% 0.26 0.01 -0.01 Service limit : KV =80%

Load: cc/rev 200kgf/cm2 (19.6MPa) cu.in./rev (2845psi)

3.83 0.20 -0.20 0.23 0.01 -0.01

Load: cc/rev 2 40kgf/cm (3.92MPa) cu.in./rev (569psi)

2.50 0.20 -0.20 Recommeded limit : KV =85% 0.15 0.01 -0.01 Service limit : KV =80%

IV-S-39

b. Relief Valve (1) Bench set data No. Type of valve

Unit

KX36-3 STD

1

2

3

4

5

a1:Main relief valve of P1

a2:Main relief valve of P2

a3:Main relief valve of P3

ap:Primary pilot system pressure

MPa

8

Allowance

STD

Allowance

0.5

0.0

21.6

0.5

0.0

21.6

0.3

-0.2

kgf/cm

5

0

220

5

0

220

3

-2

Bar

206

5

0

216

5

0.0

216

3

-2.0

psi

2986

71

0

3128

71

0

3128

43

-28

MPa

20.6

0.5

0.0

21.6

0.5

0.0

21.6

0.3

-0.2

kgf/cm2

210

5

0

220

5

0

220

3

-2

Bar

206

5

0.0

216

5

0.0

216

3

-2.0

psi

2986

71

0

3128

71

0

3128

43

-28

MPa

20.1

0.5

0.0

20.6

0.5

0.0

20.6

0.3

-0.2

kgf/cm2

205

5

0

210

5

0

210

3

-2

Bar

201

5

0.0

206

5

0.0

206

3

-2.0

psi

2915

71

0

2986

71

0

2986

43

-28

MPa

3.9

0.3

-0.2

3.9

0.3

-0.2

3.9

0.3

-0.2

kgf/cm2

40

3

-2

40

3

-2

40

3

-2

Bar

39.2

2.9

-2.0

39.2

2.9

-2.0

39.2

2.9

-2.0

psi

569

43

-28

569

43

-28

569

43

-28

2.8

0.0

0.0

2.8

0.0

0.0

2.8

0.0

0.0

29

0

0

29

0

0

29

0

0

28.3

0.3

-0.2

28.3

0.3

-0.2

28.3

0.3

-0.2

410

4

-3

410

4

-3

410

4

-3

23.5

0.5

0.0

23.5

0.5

0.0

23.0

0.3

-0.2

240

5

0

240

5

0

235

3

-2

235

5

0.0

235

5

0.0

231

3

-2.0

MPa as:Secondary pilot system preskgf/cm2 sure Bar b1:Overload relief MPa valve of bucket kgf/cm2 bottom Bar

3413

71

0

3413

71

0

3342

43

-28

27.5

0.5

0.0

27.5

0.5

0.0

27.5

0.3

-0.2

280

5

0

280

5

0

280

3

-2

Bar

275

5

0.0

275

5

0.0

275

3

-2.0

psi

3982

71

0

3982

71

0

3982

43

-28

17.1

0.5

0.0

17.1

0.5

0.0

17.7

0.3

-0.2

174

5

0

174

5

0

180

3

-2

171

5

0.0

171

5

0.0

177

3

-2.0

2474

71

0

2474

71

0

2560

43

-28

23.5

0.5

0.0

23.5

0.5

0.0

23.0

0.3

-0.2

240

5

0

240

5

0

235

3

-2

b2:Overload relief MPa valve of boom rod kgf/cm2

b3:Overload relief MPa valve of boom kgf/cm2 bottom Bar psi

9

STD

Remarks

210

psi 7

Allowance

KX41-3V PP

20.6 2

psi 6

KX41-3S/V EU

MPa b4,b5:Overload relief valve of kgf/cm2 arm, rod and botBar tom psi

MPa 10 c1,:Overload relief valve of kgf/cm2 swivel motor R&L Bar psi

235

5

0.0

235

5

0.0

231

3

-2.0

3413

71

0

3413

71

0

3342

43

-28

23.5

0.5

0.0

23.5

0.5

0.0

23.0

0.3

-0.2

240

5

0

240

5

0

235

3

-2

235

5

0.0

235

5

0.0

231

3

-2.0

3413

71

0

3413

71

0

3342

43

-28

IV-S-40

at 17.4l/min (4.6USGPM)

at 17.4l/min (4.6USGPM)

at 17.4l/min (4.6USGPM)

at 5.0l/min (1.3USGPM)

at 5.0l/min (1.3USGPM)

at 5.0l/min (1.3USGPM)

at 5.0l/min (1.3USGPM)

at 5.0l/min (1.3USGPM)

(2) Machine set data (at the pump gauge port) No. Type of valve 1

2

3

4

5

Actuator

Unit

KX36-3

a3:Main relief Blade up valve of P3

ap:Primary pilot system pressure

Engine start Safety lever up

7

Allowance

STD

Allowance

20.6

1.0

-0.5

21.6

1.0

-0.5

21.6

1.0

-1.0

210

10

-5

220

10

-5

220

10

-10

Bar

206

10

-5

216

10

-5

216

10

-10

psi

2987

145

-73

3132

145

-73

3128

142

-142

MPa

20.6

1.0

-0.5

21.6

1.0

-0.5

21.6

1.0

-1.0

kgf/cm2

210

10

-5

220

10

-5

220

10

-10

Bar

206

10

-5

216

10

-5

216

10

-10

psi

2987

145

-73

3132

145

-73

3128

142

-142

MPa

20.1

1.0

-0.5

20.6

1.0

-0.5

20.6

1.0

-1.0

kgf/cm2

205

10

-5

210

10

-5

210

10

-10

Bar

201

10

-5

206

10

-5

206

10

-10

psi

2915

145

-73

2987

145

-73

2986

142

-142

MPa

3.9

0.2

0.0

3.9

0.2

0.0

4.9

0.5

-0.5

kgf/cm2

40

2

0

40

2

0

50

5

-5

Bar

39.0

2.0

0.0

39.0

2.0

0.0

49.0

4.9

-4.9

psi

566

29

0

566

29

0

711

71

-71

2.7

0.2

-0.2

28

2

-2

27.5

2.0

-2.0

398

28

-28

24.5

2.0

-2.0

250

20

-20

245

20

-20

3555

284

-284

MPa

27.5

2.0

-2.0

kgf/cm2

280

20

-20

Control lever MPa as:Secondary pilot sys- shift end kgf/cm2 tem pressure (boom,arm,bu Bar cket,swivel)

8

9

b1:Overload Bucket crowd MPa relief valve of kgf/cm2 bucket botBar tom psi b2:Overload Boom up relief valve of boom rod

b3:Overload Boom down relief valve of boom bottom

b4,b5:OverArm load relief valve of arm, rod and bottom

10 c1,:Overload Swivel relief valve of swivel motor R&L

Remarks

STD

psi 6

KX41-3V US

Allowance

a1:Main relief Bucket dump MPa valve of P1 kgf/cm2

a2:Main relief Arm valve of P2

KX41-3S/V EU

STD

Bar

275

20

-20

psi

3982

284

-284

MPa

19.6

2.0

-2.0

kgf/cm2

200

20

-20

Bar

196

20

-20

psi

2844

284

-284

25.5

2.0

-2.0

kgf/cm

260

20

-20

Bar

255

20

-20

MPa 2

psi

3697

284

-284

MPa

18.1

1.0

-1.0

kgf/cm2

185

10

-10

Bar

181

10

-10

psi

2631

142

-142

IV-S-41

at Max. speed

at Max. speed

at Max. speed

at Max. speed

at Max. speed

at 1500rpm

at 1500rpm

at 1500rpm

at 1500rpm

at Max. speed

c. Swivel performance Machine model

KX36-2

KX41-2S/V EU

KX41-2V PP

Remarks

Unit Manufacturer

SUMITOMO EATON

Model

2-200DOS-E3888

Displacement

cc/rev

195

m

m

Max.oil flow

L/min

30

m

m

Motor speed

rpm

53.3

m

m

Brake valve pressure

MPa

13.2

m

m

kgf/cm2

135

m

m

Drain amount at lock

L/min

Drain amount while rotating

L/min

Swivel speed

rpm

8.7

m

m

3 times rotation swivel speed

sec

6.9

m

m

Swivel block performance

deg.

30

m

m

Capable swivel rotation angle

deg.

25

m

m

Play at the tip of bucket Brake release pressure

mm

53

m

m

inch

2.1

m

m

MPa

13.2

m

m

kgf/cm2

135

m

m

at 10.4L/min

1min. 20 degree slope

d. Traveling performance No. Machine model 1

KX36-3

Motor Displacement Low speed High speed

2

Gearbox ratio

3

Total displacement

4

Max.pressure

5

Max.flow

6

Max.drain pressure

7

8 9

10.92cm

3/rev

-

KX41-3S EU

KX41-3V EU

KX41-3V PP

12.46cm3/rev

11.36cm3/rev

0.693 cu.in

6.88cm3/rev

6.21cm3/rev

0.379 cu.in

1 : 37.22

1 : 31.8

1 : 34.2

1 : 36.96

High speed

-

396.23cm3/rev

396.23cm3/rev

419.87cm3/rev

25.62 cu.in

Low speed

406.44cm3/rev

218.78cm3/rev

235.30cm3/rev

229.52cm3/rev

14.01 cu.in

206 bar

216 bar

21.6MPa (220kgf/cm2)

3129 psi

16.6 l/min

17.3l/min

m

4.57 USGPM

Continuous

1 bar

m

m

14.5 psi

Peak

5 bar

m

m

72.5 psi

High speed

-

273 Nm at 216 bar

39.0 Nm at 216 bar

8.78 ft•lbs at 3129 psi

Low speed

35.8Nm at 206 bar

428 Nm at 216 bar

21.3 Nm at 216 bar

4.79 ft•lbs at 3129 psi

High speed

-

2515 rpm

2786 rpm

Low speed

1520 rpm

1388 rpm

1523 rpm

Max.gearbox output High speed torque (theoretical) Low speed

-

751 Nm

810 Nm

788.5 Nm

177.3 ft•lbs

1333 Nm

1361 Nm

1467 Nm

1443 Nm

324.5 ft•lbs

Max.motor output torque (theoretical)

Max.motor output speed (theoretical)

10 Max.gearbox output High speed speed (theoretical) Low speed

-

73.4 rpm

75.4 rpm

40.8 rpm

40.6 rpm

41.2 rpm

IV-S-42

No. Machine model

KX36-3

11 Counter balance spool operating pressure 12 Check valve cracking pressure 13 Hydraulic motor oil 14 Gearbox oil type

15 Gearbox oil: quantity 16 Oil temperature 17 Total weight

KX41-3S EU

KX41-3V EU

3 bar

6-7 bar

less than 0.3 bar

m

KX41-3V PP

ISO VG46

m

m

ISO VG150 E.P./ SAE 80W90 API GL5/MIL-L-2105

m

SAE-30-CD

1 l ± 10%

0.3 l ± 10%

-20 °C/+100°C

m

m

17kg ± 10%

m

m

20.13 cu.in

330 cm3

30°

m

m

1F

11.9 kN

12.2 kN

13.1 kN

12.7 kN

2855 lbw

2F

-

6.7 kN

7.2 kN

7.1 kN

1596 lbw

less than 300 mm

m

m

1F 21 Traveling Rubber/ Steel crawler 2F speed

2.2 km/h

2.4 km/h

2.2 km/h

2.3 km/h

-

4.3 km/h

4.0 km/h

4.1 km/h

22 10m traveling time

1F

16.3 sec

15.0 sec

16.3 sec

15.7 sec

2F

-

8.4 sec

9.0 sec

8.8 sec

less than 600 mm

m

m

TRASMITALKAYABA

m

m

NACHI

MAG10

MAG12V-TRB

m

PHV-120

277.18 mm

m

m

18 Climbing ability 19 Max. traction force

20 Traveling block performance

23 Straight travel performance

1,2F

m

m

m

1.43 mph 2.55 mph

less than 23.6 in

24 Drain amount at lock 1F 2F 25 Drain amount while rotating

1F 2F

26 Hi-speed change pressure 1st o 2nd 27 Manufacturer 28 Motor type 29 Sprocket, PCD

-

30

IV-S-43

m

10.91 in

e. Cylinder (1) Speed (unit : sec.) Unit

KX36-3 (A)

KX41-3S EU

KX41-3V EU

KX41-3V PP

(B)

(A)

(B)

(A)

(B)

(A)

(B)

Canopy 2.3~2.9

3.5

2.0~2.6

3.1

2.0~2.6

3.1

2.0~2.6

3.1

Cabin

2.3~2.9

3.5

2.0~2.6

3.1

2.0~2.6

3.1

-

-

Boom cylinder Down Canopy 2.8~3.4

4.1

2.7~3.3

4.0

2.7~3.3

4.0

2.3~2.9

3.5

Boom cylinder Up

2.8~3.4

4.1

2.7~3.3

4.0

2.7~3.3

4.0

-

-

Boom cylinder cushion

Cabin

0.4~1.3

1.6

0.4~1.3

1.6

0.4~1.3

1.6

0.4~1.3

1.6

Arm cylinder Crowd

3.1~3.7

4.4

3.1~3.7

4.4

3.1~3.7

4.4

3.1~3.7

4.4

Arm cylinder Dump

1.9~2.5

3.0

2.1~2.7

3.2

2.1~2.7

3.2

2.1~2.7

3.2

Bucket cylinder Crowd

2.1~2.7

3.2

2.5~3.1

3.7

2.5~3.1

3.7

2.5~3.1

3.7

Bucket cylinder Dump

1.6~2.2

2.6

1.7~2.3

2.8

1.7~2.3

2.8

1.7~2.3

2.8

Canopy 4.4~5.0

6.0

4.3~4.9

5.9

4.3~4.9

5.9

4.3~4.9

5.9

Cabin

4.4~5.0

6.0

4.3~4.9

5.9

4.3~4.9

5.9

-

-

Swing cylinder Right Canopy 3.7~4.3

Swing cylinder Left

5.2

3.6~4.2

5.0

3.6~4.2

5.0

3.6~4.2

5.0

3.7~4.3

5.2

3.6~4.2

5.0

3.6~4.2

5.0

-

-

Blade cylinder Up

1.0~1.6

1.9

1.0~1.6

1.9

1.0~1.6

1.9

1.3~1.9

2.3

Blade cylinder Down

1.4~2.0

2.4

1.4~2.0

2.4

1.4~2.0

2.4

1.7~2.3

2.8

Cabin

Truck cylinder Extend

-

-

-

-

Truck cylinder Retract

-

-

-

-

Remarks GL to Max. height (exclude cushion time) Max.height to GL

Cylinder full stroke Cylinder full stroke Cylinder full stroke

Cylinder full stroke Cylinder full stroke

(A) New machine reference value (B) Allowable limit

(2) Natural fall Unit

KX36-3 (A)

(B)

KX41-3V EU

KX41-3V US

(A)

(A)

(A)

(B)

Boom cylinder

mm

15

75

15

75

15

75

15

75

inch

0.59

3.0

0.59

3.0

0.59

3.0

0.59

3.0

Dozer cylinder

72(159)

72(159)

mm

10

50

10

50

10

50

10

50

inch

0.39

1.97

0.39

1.97

0.39

1.97

0.39

1.97

mm

4

20

4

20

4

20

4

20

inch

0.16

0.79

0.16

0.79

0.16

0.79

0.16

0.79

mm

13

65

13

65

13

65

13

65

inch

0.51

2.56

0.51

2.56

0.51

2.56

0.51

2.56

Oil temp. : 50 ± 5°C, 10 minutes

Remarks

(B)

kg(lbs)

Bucket cylinder

72 (159)

(B)

Load weight

Arm cylinder

63 (139)

KX41-3S EU

include bucket weight Boom raise, Arm extend, Bucket crowd, Bucket load: heaped capacity 10 min Engine stop

(A) New machine reference value (B) Allowable limit

IV-S-44

(3) Cylinder maintenance data

No.

Unit

Boom

Arm

Bucket

Dozer

Swing

Track

A

I.D.

mm in.

35 1.38

30 1.18

30 1.18

30 1.18

30 1.18

30 1.18

B

I.D.

mm in.

35 1.38

30 1.18

30 1.18

30 1.18

30 1.18

30 1.18

C

mm in.

45 1.77

45 1.77

45 1.77

45 1.77

35 1.38

35 1.38

D

mm in.

45 1.77

45 1.77

45 1.77

45 1.77

35 1.38

35 1.38

E

Rod O.D.

mm in.

30 1.18

35 1.38

35 1.38

30 1.18

30 1.18

30 1.18

F

Tube I.D.

mm in.

60 2.36

60 2.36

60 2.36

60 2.36

55 2.17

55 2.17

G

Tube O.D.

mm in.

70 2.76

70 2.76

70 2.76

70 2.76

65 2.56

65 2.56

mm in.

35 1.38

32 1.26

32 1.26

32 1.26

32 1.26

27.5 1.08

mm in.

765 30.11

585 23.03

529 20.83

358 14.09

610 24.02

507 19.96

mm in.

35 1.38

32 1.26

32 1.26

32 1.26

32 1.26

28 1.10

H I

Max. retraction length

J K

Stroke

mm in.

469 18.46

339.5 13.37

276.5 10.89

97 3.82

340 13.39

289 11.37

L

Port screw size

mm in.

G1/4(PF1/4)

G1/4(PF1/4)

G1/4(PF1/4)

G1/4(PF1/4)

G1/4(PF1/4)

R1/4(PT1/4)

M

Cylinder head tighting torque

N·m kgf·m ft·lbf

390 ~ 430 40 ~ 44 288 ~ 317

390 ~ 430 40 ~ 44 288 ~ 317

390 ~ 430 40 ~ 44 288 ~ 317

N·m Piston tightning kgf·m torque ft·lbf

410 ~ 450 42 ~ 46 302 ~ 332

510 ~ 550 52 ~ 56 376 ~ 406

510 ~ 550 52 ~ 56 376 ~ 406

343 ~ 392 35 ~ 40 253 ~ 289

343 ~ 392 35 ~ 40 253 ~ 289

343 ~ 392 35 ~ 40 253 ~ 289

-

M24 x 1.5

M24 x 1.5

M22 x 1.5

M22 x 1.5

M22 x 1.5

N

Piston screw size Seal kit No.

IV-S-45

215.6 ~ 235.2 215.6 ~ 235.2 137.2 ~ 156.8 22 ~ 24 22 ~ 24 14 ~ 16 159 ~ 174 159 ~ 174 102 ~ 116

Remarks

f. Service port flow amount (Test sample data : KX41-3PP) Pressure

Qs=Q2+Q3

kgf/cm2

psi No load

Engine RPM

L/min

USGPM

28.0

7.3968

2440

50

711.2

27.1

7.1591

2350

75

1066.7

26.5

7.0006

2330

100

1422.3

25.3

6.6836

2310

120

1706.8

23.4

6.1816

2300

140

1991.3

21.1

5.5741

2300

150

2133.5

20.0

5.2835

2290

160

2275.7

19.1

5.0457

2290

170

2418.0

17.7

4.6759

2290

180

2560.2

16.4

4.3324

2290

190

2702.4

15.2

4.0154

2290

200

2844.7

13.3

3.5135

2290

Note : Above data is just for your information, not the specifications.

g. Motor oil drain amount test sample (Test sample data : KX41-3PP, Serial No. 20001)

(1) Travel motor Right side

Left side

cc/min

cu.in./min

cc/min

cu.in./min

1st (40~50 kgf/cm2)

F

164

10

131

8

R

262

16

164

10

2nd (60~80 kgf/cm2)

F

787

48

606

37

R

803

49

737

45

Lock (270 kgf/cm2)

F

240

15

350

21

R

385

23

310

19

(2) Swivel motor Right Swiveling condition (70 kgf/cm Lock condition (185 kgf/cm2)

2)

Left

cc/min

cu.in./min

cc/min

cu.in./min

63

4

80

5

335

20

365

22

Note : Above data is just for your information, not the specifications.

IV-S-46

h. Quality Specifications No Q1 1

1

Specificatios Items Machine size Total length (Transport) Total width

3 4 1 2 3

KX36-3EU

KX41-3S EU

KX41-3V EU

KX41-3V PP

Remarks

Main Speed JIS A8404

2

2

Unit

Weight

mm

3670 ± 73

3665 ± 73

m

m

inch

144.5 ± 2.9

144.3 ± 2.9

m

m

mm

990 ± 10

990 ± 10

1300/994 ± 13

m

inch

39.0 ± 0.4

39.0 ± 0.4

51.2/39.1 ± 0.5

m

Total height (Canopy)

mm

2283 ± 23

m

m

m

inch

89.9 ± 0.9

m

m

m

Total height (Cabin)

mm

2283 ± 23

m

m

m

inch

89.9 ± 0.9

m

m

m

Machine weight (Canopy)

kg

1440 ± 29

1450 ± 29

1595 ± 32

m

lbs

3174.6 ± 63.9

3197 ± 63.9

3516.337 ± 70.5

m

Machine weight (Cabin)

kg

1540 ± 31

1550 ± 31

1705 ± 34

lbs

3395.1 ± 68.3 3417.13 ± 68.3

Fuel tank

3759 ± 75.0

Ground contact kPa press. (Canopy) psi kgf/cm2

4

Ground contact press. (Cabin)

kPa psi kgf/cm2

3

1 2

Performance Swivel speed Travel speed

3

F2

4

R1

5 6 4

1

F1

R2 Gradeability Rear end min. turning radius

rpm

8.7 ± 0.9

m

m

m

km/h

2.2 ± 0.2

2.4 ± 0.2

2.2 ± 0.2

2.3 ± 0.2

mph

1.37 ± 0.12

1.49 ± 0.12

1.37 ± 0.12

1.43 ± 0.12

km/h

4.3 ± 0.4

4 ± 0.4

4.1 ± 0.4

mph

2.67 ± 0.25

2.49 ± 0.25

2.55 ± 0.25

km/h

2.2 ± 0.2

2.4 ± 0.2

2.2 ± 0.2

2.3 ± 0.2

mph

1.37 ± 0.12

1.49 ± 0.12

1.37 ± 0.12

1.43 ± 0.12

km/h

4.3 ± 0.4

4 ± 0.4

4.1 ± 0.4

mph

2.67 ± 0.25

2.49 ± 0.25

2.55 ± 0.25

deg

> 30

m

m

m

mm

1070 ± 21

m

m

m

inch

42.1 ± 0.8

m

m

m

m

426 ± 8

2

Swivel frame rear ground clear- mm ance inch

423 ± 8

m

16.7 ± 0.3

m

m

16.8 ± 0.3

3

Tambler center distance

mm

1090 ± 33

m

1230 ± 37

m

inch

42.9 ± 1.3

m

48.4 ± 1.5

m

1587 ± 48

m

4

Crawler total length

mm

1445 ± 43

m

inch

56.9 ± 1.7

m

62.5 ± 1.9

m

5

Crawler total width

mm

990 ± 20

m

1300/994 ± 26

m

inch

39.0 ± 0.8

m

51.2/39.1 ± 1.0

m

m

m

m

6

Crawler shoe width

mm

230 ± 5

inch

9.1 ± 0.2

m

m

m

7

Min. ground clearance

mm

167 ± 5

158

m

m

inch

6.6 ± 0.2

6.2

m

m

IV-S-47

Rated engine RPM, K=100%

No 5

6

1

Specificatios Items

Unit

KX36-3EU

KX41-3S EU

KX41-3V EU

KX41-3V PP

D782-BH

D902-BH

D902-BH

D902-EBH

kw

9.00 ± 0.20

11.80 ± 0.30

m

m

ps

2

Engine,SAE Model name J1349 Gross Rated output DIN 70020

12.2 ± 0.3

16.0 ± 0.4

m

m

3

Rated speed

rpm

2300

m

m

m

4

Displacement

L

0.778

0.898

m

m

cc

778

898

m

m

Usgal

0.21

0.24

m

m

16.6 x 2

17.3 x 2

m

m

10.4, 6.2

10.4, 6.2

m

m

1

Hydraulic pump type

2

Pump delivery

L

4.39 x 2

4.57 x 2

m

m

2.75, 1.72

2.75, 1.72

m

m

Mpa

20.6 -0.2

21.6 -0.2

m

m

kgf/cm2

210 +3, -2

220 +3, -2

m

m

Bar

206

216

m

m

psi

2986

3128

m

m

Mpa

20.1

20.6

m

m

kgf/cm2

205

220

m

m

Bar

201

216

m

m

Usgal 3

Main relief pressure (Bench set)

p1, p2

p3

2915

3128

m

m

3.9 +0.3

m

m

m

40

m

m

m

Bar

39

m

m

m

psi

569

m

m

m

m3

0.035 ± 0.002

0.04 ± 0.002

m

m

yd3

0.046 ±

0.052 ±

m

m

m3

0.035 ± 0.002

0.04 ± 0.002

m

m

yd3

0.046 ±

0.052 ±

m

m

mm

402 ± 10

450 ± 10

m

m

inch

15.8 ± 0.4

17.7 ± 0.4

m

m

psi p4

Mpa kgf/cm2

7

1

Swivel motor type

8

1

Under carrage Travel motor type

2

Parking brake type

3

Crawler shoe type

9

1 2 3 4 5 6 7 8 9

Front attach- Bucket CECE ment heaped capacity SAE, JIS Bucket width Swing angle

L

deg

73 ± 2

73 ± 2

m

m

R

deg

50 ± 2

m

m

m

mm

3782 ± 57

3910 ± 59

m

m

inch

148.92.2

153.9 ± 2.3

m

m

Max. digging radius

Ground level Max. mm digging radius inch

3723 ± 56

3855 ± 58

m

m

146.6 ± 2.2

151.8 ± 2.3

m

m

Ground level Min. mm finish radius inch

1237 ± 25

1231 ± 25

m

m

48.7 ± 1.0

48.5 ± 1.0

m

m

Max. digging depth

mm

2227 ± 45

2370 ± 47

m

m

inch

87.7 ± 1.8

93.3 ± 1.9

m

m

IV-S-48

Remarks

Valve bench set

Without side cutter

Bucket bottom horizontal

No 9

Specificatios Items

Unit

10 Front attach- Max. vertical dig- mm ment ging depth inch 11

1742 ± 35

1835 ± 37

m

m

68.6 ± 1.4

72.2 ± 1.5

m

m

3458 ± 69

3540 ± 71

m

m

139.4 ± 2.8

m

m

mm

2366 ± 47

2455 ± 49

m

m

inch

93.1 ± 1.9

96.7 ± 1.9

m

m

mm

1439 ± 43

1550 ± 47

m

m

inch

56.7 ± 1.7

61.0 ± 1.9

m

m

Mini. turning radius mm (Left swing) inch

1147 ± 34

1245 ± 37

m

m

45.2 ± 1.3

49.0 ± 1.5

m

m

Max. dump height mm (Arm vertical) inch

14

Mini. turning radius

Off-set L amount

mm

512 ± 15

m

m

m

inch

20.2 ± 0.6

m

m

m

R

mm

323 ± 10

m

m

m

inch

12.7 ± 0.4

m

m

m

17 18

KX41-3V PP

136.1 ± 2.7

13

16

KX41-3V EU

mm

Max. dump height

15

KX41-3S EU

inch

Max. digging height

12

KX36-3EU

Max. digging force

kgf N lbw

19

10 1

Dozer

2

Optional JIS, bucket SAE range

m3

Width

mm

990 ± 5

m

1300/990 ± 5

m

inch

39.0 ± 0.2

m

51.2/39.0 ± 0.2

m

Height

mm

230 ± 5

m

231 ± 5

m

inch

9.1 ± 0.2

m

9.1 ± 0.2

m

yd3

3

Length

mm

4

Max. lift above GL mm

180 ± 9

181 ± 9

201 ± 10

m

inch

7.1 ± 0.4

7.1 ± 0.4

7.9 ± 0.4

m

inch

5

Max. below GL

mm

193 ± 10

m

205 ± 11

m

inch

7.6 ± 0.4

m

8.1 ± 0.4

m

6

Displacement capacity

m3

11 1

Water & oil

yd3

Radiator capacity L US gal

2

Reserve tank capacity

L

3

Engine crank case

L

4

Hydraulic oil Full (all amount)

L

Hydraulic oil Tank (tank amount)

L

14.5 ± 0.7

m

m

m

US gal

3.83 ± 0.18

m

m

m

5

US gal US gal US gal

IV-S-49

Remarks

No 11 6

Specificatios Items Water & oil

Gear oil Wheel motor

Unit

KX36-3EU

KX41-3S EU

KX41-3V EU

KX41-3V PP

21 ± 1.1

m

m

20 ± 1

5.55 ± 0.29

m

m

5.28 ± 0.26

mm

53 < 73

m

m

m

inch

2.1 < 2.9

m

m

m

L US gal

7

Swivel L reduction US gal case

8

Track roller

L

Front idler

L

9 10

Fuel tank

US gal US gal L US gal

Q2 1

2

Remarks

Main Specs JIS A8404 1

Bucket tooth slaggish

2

Declination of front excavator

mm

< 10

m

m

m

inch

< 0.39

m

m

m

3

Dozer's declination

mm

< 10

m

m

m

inch

< 0.39

m

m

m

1

Eccentric amount from swing center

mm

2

Distance to swing center

mm

inch inch

3

1

Distance to boom pin

mm

2

Boom pin height

mm

inch exclude grouser

inch mm

62 -16/+34

167 -16/+34

m

m

inch

2.4 -0.6/+1.3

6.6 -0.6/+1.3

m

m

26.5 ± 2.7

m

25.5 ± 2.6

m

3

Min. clearance of bucket teeth to boom cylinder protector

4

Clearance of boom cylinder to shoe

mm inch

4

1

Approach angle

deg

5

1

Crawler height

mm

357 ± 7

m

m

m

inch

14.06 ± 0.28

m

m

m

mm

358 ± 7

m

m

m

inch

14.09 ± 0.28

m

m

m

2

3 4

Max. crawler height

Clearance of swivel frame to crawler Distance to idler center Distance to sprocket center

Include grouser on the spocket

mm inch mm

From swivel centerl

inch 5

Include grouser on the spocket

mm inch

IV-S-50

No Q3 1

Specificatios Items

Unit

KX36-3EU

KX41-3S EU

KX41-3V EU

KX41-3V PP

< 2600

m

m

m

Remarks

Engine performance 1

Max. engine torque

kgf•m N•m ft•lbs

2

2

Torque rise

1

Max. engine rpm

2

% no load

rpm

1 pump relief

rpm

3

2 pump relief

rpm

> 2300

m

m

m

4

3 pump relief

sec

> 2300

m

m

m

rpm

1200.0 +150

m

m

m

3

1

Idler

4

1

Engine start time (Normal temp sec and grow)

Grow 5 sec

5

1

Cold start

Temp. -17 °C

2 6

2

sec

Number of start

1

Charge starting engine

2

Charging voltage & ampare

Q4 1

Cell start time

rpm

a1

Engine spec 12V 40A

Travelling performance 1 1

Travel motor block performance, L/R

mm

< 300

m

m

m

inch

< 11.81

m

m

m

Max. Traction force

kgf.m

2

F1

F2

1.21346 ± 0.12237 1.24405 ± 0.12237 1.335828 ± 0.13256 1.29504 ± 0.13256 K=65%

kN.m

11.90 ± 1.20

12.20 ± 1.20

13.10 ± 1.30

12.70 ± 1.30

ft.lbs

9±1

9±1

10 ± 1

9±1

0.68321 ± 0.07138 0.734196 ± 0.07138 0.724 ± 0.07138

kgf.m kN.m ft.lbs

3

1

Travel straightness

F1

2

F2

3

DozerrF1

4

1 2

DozerrR1 Track shoe Iron sag distance Rubber

6.70 ± 0.70

7.20 ± 0.70

7.10 ± 0.70

5±1

5±1

5±1

mm

< 600

m

m

m

inch

< 23.62

m

m

m

< 600

m

m

mm

< 23.62

m

m

mm

< 600

m

m

m

inch

< 23.62

m

m

m

mm

< 600

m

m

m

inch

< 23.62

m

m

m

mm

10 - 15

m

m

m

inch

0.39 - 0.59

m

m

m

inch

4

20 deg, 10 min

mm inch

IV-S-51

10m distance

Dozer up & down 10m distance

No Q5 1

2

Specificatios Items

KX36-3EU

KX41-3S EU

KX41-3V EU

KX41-3V PP

Remarks

Work performance 1

Work amount 45 deg digging & m3/h side dump yd3/h

2

Digging, 180 deg m3/h loading yd3/h

1

Cycle time

2 3

Unit

1

45 deg digging & sec side dump Digging, 180 deg sec loading

Fuel consumption

2

Calculated

L/h

Load coefficiency=60%

US gal/h Actual

L/h US gal/h

4

1

Boom lifting capacity

kgf

Front end, Arm extend bucket crowd, at tooth

kN lbw 2

3

4

Arm digging force

Bucket digging force

Dozer force

up

kgf

0.7342 > 0.69341

0.79538 > 0.7138

m

kN

7.20 > 6.80

7.80 > 7.00

m

lbw

5>5

6>5

m

5>5

0.75459 > 0.7138 Bucket tooth 7.40 > 7.00 root

kgf

1.32563 > 1.25425 1.59076 > 1.50918

m

m

kN

13.00 > 12.30

15.60 > 14.80

m

m

lbw

10 >9

12 > 11

m

m

kgf

Cutting edge down force at ground level

kN lbw down

Machine stance to JIS bucket tooth root

kgf kN lbw

5

6

1

Boom speed

sec

2.6 ± 0.3

2.3 ± 0.3

m

m

3 ± 0.3

m

2.6 ± 0.3

Oil temp. 50 ± 5°C Max. heiht to ground

2

up 2nd sec

3

down

sec

3.1 ± 0.3

crowd

sec

3.4 ± 0.3

dump

sec

2.2 ± 0.3

2.4 ± 0.3

m

m

Bucket speed

crowd

sec

2.4 ± 0.3

2.8 ± 0.3

m

m

dump

sec

1.9 ± 0.3

2 ± 0.3

m

m

Dozer speed

up

sec

1.3 ± 3

m

m

1.6 ± 0.3

Max. down to max. up

2

down

sec

1.7 ± 0.3

m

m

2 ± 0.3

Max. up to max. down

1

Swivel angle while boom raise

2

Incling performance

1

Arm speed

2 7

1

8

1

2

9

up 1st

degree

GL-Max. height, before cushioning

mm

CV spool stroke

inch

IV-S-52

No 10 1 2

Specificatios Items

Unit

KX36-3EU

KX41-3S EU

KX41-3V EU

KX41-3V PP

Arm cylinder cavitation

Remarks Oil temp. 50 ± 5°C

Arm cylinder shrink

11 1

Dozer cylinder cavitation

12 1

Bucket outer w/o side cutter width

inch

with side cutter

mm

2

mm

inch 13 1

Max. digging height radius

mm

1895 ± 190

2044 ± 204

m

m

inch

74.61 ± 7.48

80.47 ± 8.03

m

m

2

Max. dump height radius

mm

1529 ± 92

2083 ± 125

m

m

inch

60.20 ± 3.62

82.01 ± 4.92

m

m

3

Distance max. digging depth

mm

From swivel center

inch 4

Bucket bottom height at arm vertical

mm

1052 ± 32

929 ± 28

m

m

inch

41.42 ± 1.26

36.57 ± 1.10

m

m

5

Bucket wrist angle

degree

185 ± 3

186 ± 3

m

m

6

Bucket bottom angle

degree

Q6 1

at bucket pin

Bucket horizontal

Boom up, arm extend bucket crowd

Swivel, swing performance 1

Swivel torque

L

2

R

2

1

Swivel angle

3

1

Swivel block performance

4

1

Swivel slippage (Flat ground, no load)

5

1

Swivel start-up speed

6

1

Swing torque, max.

kgf•m

0.25493 > 0.21414

m

m

m

kN.m

2.50 > 2.10

m

m

m

ft•lbs

2>2

m

m

m

kgf•m

0.25493 > 0.21414

m

m

m

kN.m

2.50 > 2.10

m

m

m

ft•lbs

2>2

m

m

m

deg

> 25

m

m

m

L/R

deg

< 30

m

m

m

L/R

deg

Bucket load=JIS heaped x 1.8

90 deg swivel

deg sec

Arm extend,show /Quick

2.1± 0.2

m

m

m

0~90 deg swivel

Left kgf•m (Right) kN.m ft•lbs

7

1

Swing speed

2 8

1

2

Swing Lock

Reciprocating motion

L/R

Left

sec

4.7 ± 0.3

4.6 ± 0.3

m

m

Right

sec

4.0 ± 0.3

3.9 ± 0.3

m

m

Swivel R&L

mm