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Kubota KX040-4 Excavator Workshop Repair Manual

Kubota KX040-4 Excavator Workshop Repair Manual

$33.00

🚜 Equipment
Brand	Kubota
Type	Excavator
Model	KX040-4
📄 Documents
Type	Repair Manual
Publication	RY921-21760
Language	English
Format	PDF
No of Pages	450

The Kubota KX040-4 Mini Excavator is a versatile and powerful compact machine engineered for efficiency, operator comfort, and reliable performance in demanding applications such as construction, utilities, and landscaping. Equipped with a Kubota D1803-CR-TE4 turbocharged diesel engine delivering 40.4 gross horsepower (38.9 net hp), the KX040-4 provides ample power while meeting Tier 4 Final emissions standards. With an operating weight of approximately 9,480 lbs and a maximum digging depth of 11.3 ft, this model is designed to deliver strong breakout forces and smooth hydraulic operation for tough excavation tasks.

The KX040-4 features a spacious cab with climate control options, ROPS/TOPS-certified safety structures, and ergonomic controls for operator comfort and productivity. Its hydraulic system provides 24.4 GPM auxiliary flow, supporting a wide range of attachments, while bucket breakout forces of 9,535 lbs and arm forces of 4,112 lbs ensure strong digging and lifting capability. The variable angle boom and blade options enhance versatility, while compact dimensions allow access to tighter workspaces without compromising stability. Fuel and hydraulic tank capacities of 17 gallons each provide extended run times between refueling and servicing.

The workshop repair manual offers comprehensive coverage of the KX040-4, including machine body servicing, engine specifications, hydraulic circuits, control valves, pumps, travel and swivel motors, and electrical system troubleshooting. It also includes torque specifications, lubrication intervals, hydraulic/electrical schematics, and detailed disassembly and reassembly instructions. With full diagnostic and maintenance coverage, this manual ensures technicians and operators can maintain factory performance and extend the machine’s service life.

Key Highlights

Kubota D1803-CR-TE4 turbocharged diesel engine, 40.4 gross hp / 38.9 net hp
Operating weight ~9,480 lbs with canopy
Maximum digging depth: 11.3 ft (3.0 m)
Bucket breakout force: 9,535 lbs; Arm breakout force: 4,112 lbs
Auxiliary hydraulic flow: 24.4 GPM for efficient attachment operation
Fuel and hydraulic tank capacity: 17 gallons each
Travel speeds: 1.8 mph (low) / 3.1 mph (high)
Cab features ROPS/TOPS certification, ergonomic controls, and optional A/C
Manual coverage: machine body, hydraulics, engine, electrical, cab, and servicing
Includes wiring diagrams, hydraulic schematics, torque values, and lubrication charts

Table of Content

📙 Table of Contents

Kx040-4

KX040-4
- CONTENTS
- TO THE READER
- I INFORMATION
  - INFORMATION
    - 1. SAFETY FIRST
    - 2. IN THE INTEREST OF WORK SAFETY
      - [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS:
        (1) Precautions Before Working on the Mini-Excavator
        (2) Precautions Before Working on the Equipment
    - 3. LABELS DISPLAYED TO PROMOTE WORK SAFETY
      - [1] LOCATIONS
      - [2] LABEL MAINTENANCE
    - 4. MAIN SPECIFICATIONS
    - 5. DIMENSIONS
- G GENERAL
  - GENERAL
    - 1. CHECKING EXCAVATOR IDENTIFICATION
    - 2. ENGINE IDENTIFICATION
      - [1] MODEL NAME AND SERIAL NUMBER
      - [2] E4B ENGINE
      - [3] CYLINDER NUMBER
    - 3. MUFFLER FULL ASSEMBLY IDENTIFICATION
      - [1] PART NUMBER AND SERIAL NUMBER
    - 4. GENERAL PRECAUTIONS
    - 5. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING
      - [1] WIRING
      - [2] FUSES
      - [3] CONNECTOR
      - [4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER
    - 6. TIGHTENING TORQUES
      - [1] TORQUES FOR GENERAL USE NUTS AND BOLTS
      - [2] TORQUE FOR HYDRAULIC HOSE FITTINGS
        (1) Torque for Hydraulic Hose Fittings
        (2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings (Straight Threads)
      - [3] HOSE CLAMP SCREW TORQUE
    - 7. OIL AND WATER CAPACITY TABLE
    - 8. MAINTENANCE INTERVALS
- 1 MACHINE BODY
  - SERVICING
    - 1. FRONT
      - [1] BOOM ASSEMBLY/DISASSEMBLY
      - [2] TABLE OF DIMENSIONS
        (1) Arm
        (2) Blade
    - 2. SWIVEL FRAME
      - [1] WEIGHT ASSEMBLY/DISASSEMBLY
      - [2] CANOPY ASSEMBLY/DISASSEMBLY
      - [3] CABIN REMOVAL AND MOUNTING
      - [4] FUEL TANK ASSEMBLY/DISASSEMBLY
      - [5] HYDRAULIC OIL TANK ASSEMBLY/DISASSEMBLY
      - [6] ASSEMBLY/DISASSEMBLY OF ENGINE RELATED COMPONENTS
        (1) DPF Muffler
        (2) Engine
      - [7] ASSEMBLING OPERATING LEVERS
        (1) Travel Lever
        (2) Blade Lever
        (3) Limit Switch
    - 3. TRACK FRAME
      - [1] SWIVEL BEARING ASSEMBLY/DISASSEMBLY
      - [2] TRACK
        (1) Assembly/Disassembly of the Rubber Track
      - [3] FRONT IDLER
        (1) Assembly/Disassembly of Front Idler
        (2) Disassembly and Assembly
      - [4] GREASE CYLINDER
        (1) Assembly/Disassembly of the Grease Cylinder
        (2) Components
      - [5] TENSIONER
        (1) Tensioner Assembly/Disassembly
        (2) Components
      - [6] TRACK ROLLERS
        (1) Track Roller Assembly/Disassembly
        (2) Disassembly and Assembly
      - [7] CARRIER ROLLERS
        (1) Carrier Roller Assembly/Disassembly
        (2) Components
      - [8] TABLE OF DIMENSIONS
        (1) Rubber Track
        (2) Steel Track
        (3) Idler Sprocket
        (4) Carrier Rollers and Track Rollers
    - 4. MEASURING MACHINE PERFORMANCE
      - [1] MEASURING FRONT PERFORMANCE
        (1) Measuring Swivel Gear Backlash
        (2) Measuring Swivel Bearing Play
    - 5. SWIVEL GEAR BACKLASH PERFORMANCE
- 2 ENGINE
  - GENERAL
    - 1. SPECIFICATIONS
    - 2. DIMENSIONS
    - 3. PERFORMANCE CURVES
- 3 HYDRAULIC SYSTEM
  - MECHANISM
    - 1. HYDRAULIC CIRCUIT DIAGRAM
      - [1] HYDRAULIC CIRCUIT DIAGRAM (KX040-4 STANDARD SPECIFICATIONS (AUX1)
      - [2] HYDRAULIC CIRCUIT DIAGRAM (KX040-4 STANDARD SPECIFICATIONS (AUX1, AUX2)
      - [3] HYDRAULIC CIRCUIT DIAGRAM (KX040-4 ANGLE SPECIFICATIONS (AUX1, AUX2)
    - 2. PUMP
      - [1] SPECIFICATIONS
      - [2] FUNCTION AND STRUCTURE
        (1) Operating Principles
        (2) Horsepower Control
        (3) Flow Control (LS Control)
        (4) Gain Control
        (5) Standby Flow Amount
    - 3. CONTROL VALVES
      - [1] SPECIFICATIONS
      - [2] FUNCTION AND STRUCTURE
        (1) Unload Valve Section
        (2) Spool Section Operation
        (3) Arm Regenerative Function
        (4) Travel Section Operation
        (5) Blade Section Operation
        (6) Anti-Drift Function
        (7) Signal Circuit
    - 4. SWIVEL MOTOR
      - [1] SPECIFICATIONS
      - [2] FUNCTION AND STRUCTURE
        (1) Operating Principles
        (2) Make Up Circuit
        (3) Shockless Valves
        (4) Parking Brake
    - 5. TRAVEL MOTOR
      - [1] SPECIFICATIONS
      - [2] FUNCTION AND STRUCTURE
        (1) Operating Principles
        (2) Counterbalance Valve
        (3) Anti-Cavitation Valve
        (4) Auto-Decelerator Function
        (5) Parking Brake
        (6) Decelerator
    - 6. HYDRAULIC CYLINDER
      - [1] SPECIFICATIONS
      - [2] FUNCTION AND STRUCTURE
        (1) Operating Principles
    - 7. PILOT VALVE
      - [1] CONTROL PILOT VALVES
        (1) Specifications
        (2) Function and Structure
      - [2] TRAVEL PILOT VALVE
        (1) Specifications
        (2) Function and Structure
      - [3] SWING PILOT VALVE
        (1) Specifications
        (2) Function and Structure
      - [4] BLADE PILOT VALVES
        (1) Specifications
        (2) Function and Structure
    - 8. SOLENOID VALVE
      - [1] UNLOAD VALVE
        (1) Specifications
        (2) Function and Structure
      - [2] AUX SOLENOID VALVE
        (1) Specifications
        (2) Function and Structure
      - [3] ANGLE SOLENOID VALVE
        (1) Specifications
      - [4] EP MODE SOLENOID VALVE
        (1) Specifications
  - SERVICING
    - 1. PUMP
      - [1] PUMP DISASSEMBLY / ASSEMBLY
    - 2. CONTROL VALVE
      - [1] REMOVAL AND INSTALLATION OF THE CONTROL VALVE
    - 3. SWIVEL MOTOR
      - [1] REMOVAL AND INSTALLATION OF THE SWIVEL MOTOR
      - [2] SWIVEL MOTOR ASSEMBLY AND DISASSEMBLY
        (1) Disassembly
        (2) Assembly
    - 4. SWIVEL JOINT
      - [1] REMOVAL AND INSTALLATION OF THE SWIVEL JOINT
      - [2] SWIVEL JOINT DISASSEMBLY / ASSEMBLY PROCEDURES
        (1) Disassembly Procedures
        (2) Assembly Procedures
    - 5. TRAVEL MOTOR
      - [1] REMOVAL AND INSTALLATION OF THE TRAVEL MOTOR
      - [2] TRAVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES
        (1) Disassembly
        (2) Assembly
      - [3] SPECIAL TOOLS
    - 6. HYDRAULIC CYLINDER
      - [1] TIGHTENING TORQUE
    - 7. PILOT VALVE (CONTROL)
      - [1] CONTROL PILOT VALVES
        (1) Disassembly
        (2) Assembly
        (3) Special Tools
      - [2] TRAVEL PILOT VALVE
        (1) Disassembly
        (2) Assembly
      - [3] SWING PILOT VALVE
        (1) Disassembly
        (2) Assembly
      - [4] BLADE PILOT VALVES
        (1) Disassembly
        (2) Assembly
    - 8. SOLENOID VALVE
      - [1] UNLOAD VALVE
      - [2] AUX/ANGLE SOLENOID VALVE
      - [3] EP MODE SOLENOID VALVE
    - 9. ROUTING OF HYDRAULIC HOSES
      - [1] TYPES OF HYDRAULIC HOSES
      - [2] HIGH-PRESSURE HOSES
        (1) Deliver Hose Routing
        (2) Front Hose Routing
        (3) Travel, Swivel, Blade, Swing and Angle Hose Routing
        (4) Swivel and Rotary Joint Hose Routing
        (5) Undercarriage Hose Routing
        (6) Hose Routing Inside the Track Frame
      - [3] LOW-PRESSURE HOSES
        (1) Suction Pipe and Hose Routing
        (2) Drain Hose Routing
      - [4] PILOT HOSES
        (1) Port P Hose Routing (1/2)
        (2) Port P Hose Routing (2/2)
        (3) Port T Hose Routing
        (4) Pilot Valve Hose Routing (1/2)
        (5) Pilot Valve Hose Routing (2/2)
        (6) Pilot Valve Hose Routing (Control Valves)
        (7) Pilot Valve Hose Routing (Around the Driver’s Seat)
    - 10. MEASURING HYDRAULIC DEVICE PERFORMANCE
      - [1] PISTON PUMP AIR BLEEDING PROCEDURE
      - [2] RELEASE OF PRESSURE IN THE HYDRAULIC SYSTEM
      - [3] MANUAL BOOM LOWERING PROCEDURE
      - [4] MEASURING THE FLOW RATE
        (1) Measuring Main Pump Flow
        (2) Measuring the AUX Proportional Limit
        (3) Measuring AUX Discharge Flow
      - [5] MEASURING PRESSURE
        (1) Measuring the Main Relief Valve Pressure
        (2) Measuring Pilot Secondary Pressure
        (3) Measuring EP Proportional Solenoid Pressure
        (4) Measuring the Overload Relief Valve Pressure
        (5) Pressure Measuring Kit
        (6) Measuring Swivel Relief Pressure
        (7) Adjusting the LS Control Differential Pressure Adjusting Spring
      - [6] MEASURING SWIVEL PERFORMANCE
        (1) Measuring Swivel Motor Drain Volume
        (2) Measuring Swivel Block Performance
        (3) Measuring Swivel Speed
      - [7] MEASURING TRAVEL PERFORMANCE
        (1) Measuring Travel Motor Drain Volume
        (2) Measuring Travel Block Performance
        (3) Measuring Travel Speed
        (4) Measuring Travel Drift
      - [8] MEASURING CYLINDER SPEED
        (1) Measuring Hydraulic Cylinder Operating Time
        (2) Measuring Hydraulic Cylinder Drift
        (3) Measuring Swing Cylinder Deviation
    - 11. HYDRAULIC DEVICE PERFORMANCE STANDARDS
      - [1] FLOW RATE
        (1) Main Pump Discharge Flow Rate Data (Measured Values)
        (2) Flow Rate Data for AUX Proportional Control (Measured Values)
        (3) AUX Discharge Flow Rate Data (Measured Values)
      - [2] RELIEF PRESSURE (MEASURED VALUES)
      - [3] SWIVEL PERFORMANCE
      - [4] TRAVEL PERFORMANCE
      - [5] CYLINDER SPEED
    - 12. TROUBLESHOOTING
      - [1] TROUBLESHOOTING ALL ACTUATORS
      - [2] TROUBLESHOOTING FRONT SYSTEMS
      - [3] TRAVEL SYSTEM TROUBLESHOOTING
      - [4] SWIVEL SYSTEM TROUBLESHOOTING
- 4 ELECTRICAL SYSTEM
  - SERVICING
    - 1. ELECTRICAL DEVICE LAYOUT AND WIRING CIRCUIT
      - [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING
      - [2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS
    - 2. METER PANEL OPERATION
      - [1] NAMES AND FUNCTIONS OF METERS
      - [2] USER SETTINGS MODE
        (1) Log Record
        (2) Periodic Check
        (3) Set Clock
        (4) Set AUX Flow Ctrl
        (5) Various Settings
        (6) Language Setting
      - [3] SERVICE DEALER SETTING
        (1) Crane Mode
        (2) Arm Control Mode (Only on Japan Spec.)
      - [4] SERVICE/DEALER MODE
        (1) Diagnosis
        (2) Setting
      - [5] SETTINGS WHEN REPLACING ELECTRONIC DEVICES
        (1) When Replacing the Meter or Main ECU
        (2) When the Battery is Removed
      - [6] TABLE OF METER PANEL MESSAGES AND ERROR HISTORY LIST
        (1) Red Warning Lamp Lit
        (2) Yellow Warning Lamp Lit
        (3) Other Screens
        (4) PM Clog Level and the State of the Machine
        (5) Table of Engine System Error Numbers
    - 3. INSPECTIONS
      - [1] POWER AND GROUND
      - [2] STARTING AND STOPPING DEVICE
      - [3] RELAY LAYOUT
    - 4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION)
    - 5. METHODS FOR DIAGNOSING ERRORS
      - [1] GUIDE TO DIAGNOSING ERRORS
      - [2] ERROR DIAGNOSIS PROCEDURE
      - [3] TESTING WITH A CIRCUIT TESTER
    - 6. TROUBLESHOOTING (METER PANEL VERSION)
      - [1] MACHINE RELATED SYSTEM
        (1) Engine Oil Pressure Errors
        (2) Charging System Errors
        (3) Fuel Sensor Errors
      - [2] FRONT-END SYSTEMS
        (1) Lever Lock System Errors
        (2) Travel 2-Speed System Error
        (3) Angle System Errors
      - [3] AUTO IDLING (AI) SYSTEM
        (1) AI System Errors
        (2) Testing the AI Pressure Switch
        (3) Testing the AI Switch
      - [4] ANTI-THEFT (AT) SYSTEM
        (1) Anti-Theft System Errors
      - [5] POWER SUPPLY SYSTEM
        (1) Over Voltage
        (2) 5 V Short System Error
      - [6] COMMUNICATION SYSTEM
        (1) CAN Communication Errors
      - [7] MULTIPURPOSE SWITCH
        (1) Multipurpose Switch Control System Errors
      - [8] AUX SYSTEM
        (1) AUX1 / AUX2 (Thumb) System Errors
      - [9] ECO MODE SYSTEM
        (1) EP System Errors
- 5 CABIN
  - MECHANISM
    - 1. AIR CONDITIONING SYSTEM
      - [1] STRUCTURE
      - [2] HOW THE MECHANISMS OF THE SYSTEM WORK
      - [3] COMPRESSOR
      - [4] AIR CONDITIONING UNIT
      - [5] CONDENSER
      - [6] RECEIVER
      - [7] PRESSURE SWITCH
      - [8] ELECTRICAL SYSTEM
        (1) Electrical Circuits
        (2) Relays
        (3) Blower Switch
    - 2. WIPER
      - [1] WIPER SWITCH
      - [2] WIPER
      - [3] WIPER MOTOR
  - SERVICING
    - 1. TROUBLESHOOTING
    - 2. MAINTENANCE AND SERVICE RELATED SPECIFICATIONS
    - 3. TORQUE
    - 4. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM
      - [1] USE OF SERVICE TOOLS
        (1) Manifold Gauge Set
        (2) Refrigerant Charging Hoses
        (3) Vacuum Pump Adapter
        (4) Electric Gas Leak Tester
        (5) Canister Tap Valve
        (6) T-Joint
        (7) R134a Refrigerant Collection/Recycling Device
    - 5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM
      - [1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE
      - [2] COLLECTION, VACUUMING AND CHARGING
        (1) Collecting Refrigerant
        (2) Vacuuming Out the System
        (3) Charging from the High-Pressure Side
        (4) Charging from the Low-Pressure Side
        (5) Inspections and Troubleshooting
    - 6. INSPECTION AND DISASSEMBLY
      - [1] CHECKS AND ADJUSTMENTS
        (1) Compressor
        (2) Relays
        (3) Blower Motor
        (5) Blower Switch
        (6) Servo Motor (for Temp Control)
        (7) Pressure Switch
      - [2] DISASSEMBLY AND ASSEMBLY
        (1) Connecting / Disconnecting AC Hoses
        (2) Mounting and Removing the Compressor
        (3) Diagram of AC Hoses
        (4) Mounting and Removal of the Condenser and Receiver
    - 7. WINDOW WASHER
      - [1] WIPER SWITCH
      - [2] WIPER MOTOR
      - [3] WASHER MOTOR
    - 8. REMOVAL AND INSTALLATION OF GLASS
      - [1] PREPARATION
      - [2] REMOVING GLASS
      - [3] INSTALLING GLASS
      - [4] GLASS TRIM TYPE
      - [5] HOW TO REPLACE THE GLASS OF THE RIGHT-SIDE WINDOW
    - 9. FRONT WINDOW
      - [1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP)
      - [2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP)
- ELECTRICAL CIRCUIT DIAGRAM
- CONNECTOR CHART

Specification

Specification	Kubota KX040-4 Mini Excavator
Engine Model & Type	Kubota D1803-CR-TE4, 3-cyl turbocharged diesel, Tier 4 Final
Gross / Net Power	40.4 hp gross / 38.9 hp net @ 2200 rpm
Operating Weight	~9,480 lb (4,300 kg), canopy
Digging Depth	~11.3 ft (3 m)
Bucket Breakout Force	9,535 lb (4,325 kg)
Arm Breakout Force	4,112 lb (1,865 kg)
Auxiliary Hydraulic Flow	24.4 GPM (92.4 L/min)
Travel Speed	Low: 1.8 mph (2.9 km/h); High: 3.1 mph (5.0 km/h)
Fuel Capacity	17 gal (64 L)
Hydraulic System Fluid Capacity	17.2 gal (65 L)

Buyer Questions & Answers

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