Kubota KX040-4 User manual

OPERATOR'S MANUAL
1BAAAADAP0600
1BAAAADAP1010
English (U.S.A./CANADA)
Code No. RD158-8121-3
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0
4
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PRINTED IN JAPAN © KUBOTA Corporation 2012 READ AND SAVE THIS MANUAL
MODEL 040-4

KX040-4
AR . E . 4 - 4 . 3 . AK
LIST OF ABBREVIATION
Abbreviations Description
American Petroleum Institute
American Society for Testing and Materials, USA
Committee for European Construction Equipment
German Institute for Standards, Federal Republic of Germany
European Standard
Occupational Safety and Health Administration
Falling Object Protective Structures
"Front" means the front view towards the boom and dozer
High speed
International Standardization Organization
Japanese Industrial Standard
Volume (Liter)
Liter per minute
Low speed
Military Standards
Revolutions Per Minute
Roll-Over Protective Structures
Society of Automotive Engineers, USA
Two Pattern Selection System
Auto Idle
Common Rail System
Diesel Particulate Filter
Diesel Oxidation Catalyst
Pressure Limiter
Swirl Control Valve
Air Flow Sensor
Exhaust Gas Re-circulation
Positive Crankcase Ventilation
Mass Air Flow
API
ASTM
CECE
DIN
EN
OSHA
FOPS
FRONT
Hi
ISO
JIS
L
L/min
Lo
MIL
rpm
ROPS
SAE
TPSS
AI
CRS
DPF
DOC
P/L
SCV
AFS
EGR
PCV
MAF
California Proposition 65
WARNING
Engine exhaust, some of its constituents,
certain vehicle components and fluids,
contain or emit chemicals known to the
State of California to cause cancer and birth
defects or other reproductive harm.

GENERAL SYMBOLS
The instruments and operation elements have been marked with a series of symbols in order to simplify the operation of
excavator. These symbols are listed below with the respective descriptions.
Safety alert Symbol
Warning lamp ''Fuel level too low''
System lamp
Warning lamp ''Engine Oil pressure''
Warning lamp ''Battery charge''
Warning lamp ''Auto Idle (AI) Lamp''
Indicator lamp ''Glow''
Working light switch
Horn
Wiper/Washer switch
Diesel
Hydraulic fluid
Gear oil
Grease
Fast
Slow
Excavator - Overhead movement toward the front
Excavator - Overhead movement toward the rear
Boom up
Boom down
Arm up
Arm crowd
Bucket crowd
Bucket dump
Boom swing (left)
Boom swing (Right)
Dozer raise
Dozer lower
Operation direction of control lever
Operation direction of control lever
Read operator's manual
Engine stop control lamp
DPF Standby / Regeneration
Engine Rev up
Inhibit DPF Regeneration
Eco mode (Energy saving mode)

FOREWORD
3
SAFETY FIRST
IMPORTANT :
NOTE :
3DANGER :
3WARNING :
3CAUTION :
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
Indicates that equipment or property damage could result if
instructions are not followed.
Gives helpful information.
You are now the proud owner of a KUBOTA Excavator. This excavator is a product
of KUBOTA quality engineering and manufacturing. It is made of fine materials and
under a rigid quality control system. It will give you long, satisfactory service. To
obtain the best use of your excavator, please read this manual carefully. It will help
you become familiar with the operation of the excavator and contains many helpful
hints about excavator maintenance. It is KUBOTA's policy to utilize as quickly as
possible every advance in our research. The immediate use of new techniques in
the manufacture of products may cause some small parts of this manual to be
outdated. KUBOTA distributors and dealers will have the most up-to-date
information. Please do not hesitate to consult with them.
Please note that there may be some differences between your actual machine and
the illustration in the 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 assemble or use this unit.

CONTENTS
SAFE OPERATION............................................................................................ -1
DEALER SERVICE...................................................................................................... 1
TECHNICAL DATA...................................................................................................... 2
DESCRIPTION OF MACHINE PARTS........................................................................ 3
INSTRUMENT PANEL AND CONTROL ELEMENTS................................................. 4
CHECKS BEFORE START......................................................................................... 6
DAILY CHECKS....................................................................................................... 6
CHECKING THE DEVICES..................................................................................... 6
Starter Switch ...................................................................................................................6
Display Selector Switch....................................................................................................7
LCD Display for Normal Operation...................................................................................7
Warning Lamp ................................................................................................................10
LCD Display for Warning................................................................................................10
Setting the Clock.............................................................................................................12
Reordering the year/month/day and Changing the AM/PM System to the 24-hour One13
Log Record.....................................................................................................................14
Periodic Check................................................................................................................15
If All the Check Points are not Displayed at a Glance on a Single Screen.....................15
When the Check-up is Completed..................................................................................17
Horn Switch ....................................................................................................................17
Light Switch ....................................................................................................................17
AUX Port Flow Rate Limit Switch ...................................................................................17
Auto Idle Switch..............................................................................................................18
Throttle Potentiometer....................................................................................................18
Travel Speed Switch.......................................................................................................18
Inhibit Diesel Particulate Filter (DPF) Regeneration Switch ...........................................19
ECO MODE............................................................................................................ 20
CAB TYPE MACHINES ......................................................................................... 20
Wiper/Washer Switch .....................................................................................................20
Interior Lamp...................................................................................................................20
Heater Switch .................................................................................................................21
Beacon Light Switch.......................................................................................................21
Opening/Closing of CAB Door........................................................................................21
Opening/Closing of Front CAB Window..........................................................................22
Opening/Closing of Side CAB Window...........................................................................22
Emergency Hammer.......................................................................................................22
AIR CONDITIONER............................................................................................... 23
Air Flow...........................................................................................................................23
Air Control Vent ..............................................................................................................23
Control Panel..................................................................................................................24
Operation........................................................................................................................24
HANDLING THE SAFETY DEVICES..................................................................... 24
Pilot Control Lock Lever..................................................................................................24
OPERATION OF THE ENGINE................................................................................. 25

CONTENTS
STARTING THE ENGINE...................................................................................... 25
STARTING THE ENGINE UNDER COLD CONDITIONS...................................... 26
STARTING WITH AN AUXILIARY BATTERY ....................................................... 27
Observe Following Guidelines when Starting with an Auxiliary Battery..........................27
CHECK POINTS AFTER STARTING THE ENGINE............................................. 27
STOPPING THE ENGINE...................................................................................... 28
Engine Stop Button.........................................................................................................28
Precautions in case of Overheat.....................................................................................28
EXCAVATOR OPERATION ...................................................................................... 29
RUNNING-IN OF THE NEW EXCAVATOR........................................................... 29
Do not Work with Full Engine Rpm's or Full Loads during the First 50 Working Hours..29
Oil Change in the Run-in Stage......................................................................................29
Adjusting the Operator's Seat.........................................................................................29
Seat Belt.........................................................................................................................30
STARTING............................................................................................................. 30
Pilot Control Lock Lever..................................................................................................30
DRIVING................................................................................................................ 31
Drive Levers(Right,Left)..................................................................................................32
TURNS................................................................................................................... 32
Pivot Turn .......................................................................................................................32
Spin Turn........................................................................................................................33
UP AND DOWNHILL DRIVING.............................................................................. 34
PARKING ON A SLOPE........................................................................................ 34
OPERATION OF THE DOZER.............................................................................. 34
TWO PATTERN SELECTION SYSTEM(TPSS).................................................... 35
Pattern Change...............................................................................................................35
OPERATION OF THE BOOM................................................................................ 36
OPERATION OF THE ARM................................................................................... 36
OPERATION OF THE BUCKET............................................................................ 37
UNIT SWING AND BOOM SWING OPERATION.................................................. 37
Unit Swing Operation......................................................................................................37
Boom Swing Operation...................................................................................................37
AUXILIARY PORT OPERATION........................................................................... 38
Selecting the Action Modes............................................................................................38
AUX Port Handling Procedure........................................................................................39
Setting the Maximum Flow Volume................................................................................41
HOW TO RELEASE PRESSURE TRAPPED IN THE HYDRAULIC SYSTEM...... 46
ANGLE BLADE OPERATION................................................................................ 47
1-way or 2-way CIRCUIT SELECTION VALVE OPERATION............................... 48
BOOM LOWERING VALVE................................................................................... 49
AUTO IDLE (AI) OPERATION............................................................................... 49
ANTI-THEFT DEVICE (for KCL only)..................................................................... 50
Anti-Theft Device............................................................................................................50
IMPORTANT INFORMATION ON EXCAVATOR OPERATION............................ 53
TRANSPORTING THE EXCAVATOR ON A VEHICLE............................................. 54
LIFTING OF THE EXCAVATOR................................................................................ 56
MAINTENANCE......................................................................................................... 58
MAINTENANCE INTERVALS................................................................................ 58

CONTENTS
OPENING AND CLOSING OF COVERS............................................................... 63
Opening/Closing of the Engine Hood.............................................................................63
Opening/Closing of the Side Cover................................................................................63
Where to store the Tool..................................................................................................64
Cup Holder......................................................................................................................64
Where to store the Grease Gun......................................................................................64
Where to keep Operator's Manual..................................................................................64
DAILY CHECKS..................................................................................................... 65
Checking Coolant Level..................................................................................................65
Checking Fuel Level.......................................................................................................65
Checking Engine Oil Level..............................................................................................66
Checking Hydraulic Oil Level..........................................................................................66
Checking V-belt ..............................................................................................................67
Checking Radiator and Oil Cooler..................................................................................67
Checking Washer Liquid.................................................................................................68
Checking and Cleaning Engine and Electrical Wiring.....................................................68
Washing Whole Machine................................................................................................68
Greasing Front Attachments (without Bucket Pin and Boom Swing Fulcrum)................68
Greasing Bucket Pin.......................................................................................................69
Greasing Boom Swing Fulcrum......................................................................................69
REGULAR CHECKS AND MAINTENANCE WORK ................................................. 70
EVERY 50 SERVICE HOURS............................................................................... 70
Draining Fuel Tank .........................................................................................................70
Draining Water Separator...............................................................................................70
Checking Battery Condition............................................................................................71
Greasing Swing Bearing Teeth.......................................................................................72
EVERY 200 SERVICE HOURS............................................................................. 73
Adjusting V-belt Tension.................................................................................................73
Checking Radiator Hoses and Clamps...........................................................................74
Grease Swing Ball Bearing.............................................................................................74
Inspection and Cleaning Air Filter Element.....................................................................74
Air Filter Maintenance.....................................................................................................75
Cleaning Evacuator Valve ..............................................................................................75
Checking Diesel Particulate Filter (DPF) Muffler............................................................75
Checking Fuel Line and Intake Air Line..........................................................................76
AIR CONDITIONER............................................................................................... 76
Cleaning Air Filter...........................................................................................................76
Checking Air-Conditioner Condenser.............................................................................77
EVERY 500 SERVICE HOURS............................................................................. 77
Changing Engine Oil(Change the engine oil every 500 hours,or every 1 year in the case
that service hour is less than 500 hours)........................................................................77
Replacing Engine Oil Filter Cartridge (Replace the engine oil filter cartridge every 500
hours,or every 1 year in the case that service hour is less than 500 hours)...................78
Drive unit Oil Change(First Oil Change of the 50 hours)................................................78
Replacing Fuel Filter Cartridge.......................................................................................79
Replacing Breather Filter................................................................................................79
Replacing Fan Belt .........................................................................................................79
EVERY 1000 SERVICE HOURS........................................................................... 79
Replacing the Hydraulic Pilot Filter Element...................................................................79
Replacing Hydraulic Return Filter Element.....................................................................80
Hydraulic Oil Change (Including Replacing of the Suction Filter in the Hydraulic Tank) 80

CONTENTS
Hydraulic Oil Check with Hydraulic Hammers................................................................81
EVERY 1000 SERVICE HOURS OR ONCE A YEAR........................................... 82
Replacing Air Filter Element...........................................................................................82
EVERY 1500 SERVICE HOURS........................................................................... 82
Checking Injector Tip......................................................................................................82
Replacing Oil Separator Element and O Ring................................................................82
Checking EGR Cooler ....................................................................................................83
EVERY 2000 SERVICE HOURS........................................................................... 83
Checking the Alternator and Starter Motor.....................................................................83
EVERY 3000 SERVICE HOURS........................................................................... 83
Checking EGR System...................................................................................................83
Checking Turbocharger..................................................................................................83
Cleaning Diesel Particulate Filter (DPF).........................................................................83
ANNUAL SERVICING............................................................................................ 83
Checking Air-Conditioner Pipes and Hoses....................................................................83
Checking Exhaust Manifold (Cracks, Gas, Leakage and Mounting Screw) ...................83
Checking Intake Air Line for Air Leaks............................................................................83
Checking Boost Sensor and AFS (Air Flow Sensor) ......................................................83
Checking Condition of Diesel Particulate Filter (DPF) Muffler........................................83
Checking Diesel Particulate Filter (DPF) Differential Pressure Pipes and Hoses ..........83
Checking Diesel Particulate Filter (DPF) Exhaust Gas Temperature Sensor.................83
Checking EGR Piping for Gas Leak ...............................................................................83
BIENNIAL SERVICING.......................................................................................... 84
Replacing Air-Conditioner Pipes and Hoses...................................................................84
Replacement of Radiator Hoses and Hose Clamps.......................................................84
Changing Radiator Coolant ............................................................................................84
Replacing Fuel Hoses and Clamps ................................................................................85
Replacing Intake Air line.................................................................................................86
Replacement of Oil Separator Rubber Hose..................................................................86
Replacement of Diesel Particulate Filter (DPF) Differential Pressure Sensor Rubber
Piping (Front and Back)..................................................................................................86
Replacement of Suction pipe downstream the AFS (Air Flow Sensor)..........................86
Replacement of Boost Sensor Pressure Rubber Piping.................................................86
Replacement of EGR Cooler Hose.................................................................................86
SERVICING AS REQUIRED.................................................................................. 86
Checking Amount of Refrigerant (gas) ...........................................................................86
OTHER ADJUSTMENTS AND REPLACEMENTS.................................................... 87
PURGING OF THE FUEL SYSTEM...................................................................... 87
ADJUSTMENT OF TRACKS ................................................................................. 87
Special Information when Using Rubber Tracks.............................................................88
CHANGING THE BUCKET.................................................................................... 89
FUSES................................................................................................................... 89
Replacing Fuses.............................................................................................................89
Fuse Capacities and Circuits..........................................................................................90
Auxiliary Electric .............................................................................................................91
Slow Blow Fuse..............................................................................................................91
TROUBLESHOOTING............................................................................................... 92
OPERATION UNDER COLD WEATHER CONDITIONS .......................................... 94
PREPARATION FOR OPERATION IN COLD WEATHER.................................... 94
PROCEDURE AFTER DONE WORK.................................................................... 94

CONTENTS
LONG STORAGE...................................................................................................... 95
RECOMMENDED OILS............................................................................................. 97
APPENDICES............................................................................................................ 99
MAIN DIMENSIONS .............................................................................................. 99
LIFTING CAPACITY................................................................................................ 100
LIST OF SCREENS................................................................................................. 103
LIST OF NORMAL SCREENS............................................................................. 103
NAVIGATION LIST OF SCREENS...................................................................... 104