Kubota KX101-3a, Workshop Manual

Page 1: ...WORKSHOP MANUAL KUBOTA EXCAVATOR KX91 3S D 101 3D Code No 97899 61260 KX121 3S D 161 3S D Minor change Chapter U35S U35 3S D U45 3S D...

Page 2: ...Record of Revisions Symbol Date Main Revised Points Corrective Measures Person in charge 1 2 3 4...

Page 3: ...e II 109 F Electrical system II 114 This WSM minor change edition has been compiled to explain the main contents of the minor change such as new service port system new auto idle system some hydraulic...

Page 4: ...WSM Minor Change I Sales Engineering Section I Sales Engineering Section A Quick feature chart I 2 B Feature discriptions I 4 C New innovations I 6 D Specifications Super series KTC KCL KTA version I...

Page 5: ...4 Engine neutral start 5 Travel lock 6 Master key compatible immo bilizer option Better maneuverability 1 Service port local control wrist rest type 2 Travel bi speed button dozer lever 3 Independent...

Page 6: ...y KX91 3S KX161 3S Thumb bracket adopted North America Service port knob control Digital navigation system adopted North America Australia Europe Greater engine output KX161 3S New immobilizer system...

Page 7: ...bucket and house swing Perfectly matched speed power and cylinder timing deliver extraordi nary responsiveness even with the slightest oper ator movements or in the toughest conditions The KX121 3 and...

Page 8: ...so make more detailed periodic mainte nance hassle free as well Wide opening side and rear covers as well as centrally located components give you quick and easy access for the servicing of vital area...

Page 9: ...ed from the floor sim ple forefinger activation as well as convenient thumb operation of the hydraulic breaker is possible SHORT STROKE OPERATING LEVER The new operating levers require less effort and...

Page 10: ...system Travel Speed Low mph km h 1 9 3 1 1 9 3 0 1 7 2 7 1 6 2 5 High mph km h 2 9 4 8 2 9 4 6 3 1 5 0 2 9 4 6 Max traction force lbs kgf 5600 2540 6098 2766 9697 4398 12861 5833 Tumbler distance ft...

Page 11: ...t in mm 4 9 1440 5 3 1603 5 6 1665 6 5 1955 H Min tail turning radius ft in mm 4 4 1310 33 5 850 4 3 1300 3 7 1090 U35S KX91 3S KX121 3S KX161 3S LIFT POINT HEIGHT ft LIFTING CAPACITY OVER FRONT BLADE...

Page 12: ...S P valve start point setting II 34 g Manual feeling setting II 40 h Panel display operation flow chart II 42 i Proportional control solenoid valve S P valve II 51 j Other controls II 55 k Troubleshoo...

Page 13: ...5 3S KX121 3S KX161 3S U45 3S KX91 3D KX101 3D U35 3D KX121 3D KX161 3D U45 3D 8 Digital panel 4 Arm with thumb bracket option Finger control ser vice port 3 Breaker switch 7 Two speed switch 6 Fuel w...

Page 14: ...main modified parts No 1 Knob switch No 6 Fuel water separator No 7 Two speed switch No 9 Anti theft system EU version No 8 Digital meter panel AI version No 5 Accumulator in pilot line No 8 Digital...

Page 15: ...alarm Canopy light Arm rest Wrist rest Wrist rest m m Wrist rest TPSS Engines type D1503 M m m m m m m Third line valve Specs KX121 3S KX121 3D KX161 3S KX161 3D U45 3S U45 3D KTC KCL KTA EU KTC KCL...

Page 16: ...m m SAE90 API GL 4 Track roller cc gal 70 0 018 m m SAE30 CD Upper roller cc gal 60 0 016 m m SAE30 CD Front idler cc gal 80 0 02 m m SAE30 CD Fuel tank L gal 46 5 12 30 m 40 6 10 6 Unit KX121 3S KX1...

Page 17: ...wivel speed L rpm 9 r 0 9 9 4 r 0 9 2 R rpm 9 r 0 9 9 4 r 0 9 3 Travel speed Lubber F1 km h 3 0 r 0 3 3 1 r 0 3 mph 1 86 r 0 19 1 93 r 0 19 4 Lubber F2 km h 4 6 r 0 5 4 8 r 0 5 mph 2 86 r 0 31 2 98 r...

Page 18: ...y mm 1230 r 37 965 r 29 inch 48 4 r 1 5 38 0 r 1 1 18 Cabin mm 1125 r 34 inch 44 3 r 1 3 19 Mini turning radius Conopy mm 2065 r 62 1940 r 116 inch 81 3 r 2 4 76 4 r 4 6 20 Cabin mm 2190 r 66 inch 86...

Page 19: ...kN 27 1 26 0 lbs 6098 5853 2 F2 kgf 1546 1485 kN 15 2 14 6 lbs 3408 3274 3 1 Travel straight ness F1 mm 600 10m distance inch 23 62 2 F2 mm 600 inch 23 62 3 Dozer F1 mm 600 Dozer up down 10m dis tanc...

Page 20: ...mm 2800 2920 r 292 inch 110 24 114 96 r 11 50 2 Cabine mm 3215 r 322 inch 126 57 r 12 68 3 Max dump height radius Canopy mm 2621 r 157 2790 r 167 at bucket pin inch 103 19 r 6 18 109 84 r 6 57 4 Cabin...

Page 21: ...ar 24 5 r 24 5 24 5 psi 2944 r 71 2987 4 P4 kgf cm2 40 3 0 MPa 3 9 0 3 0 bar 3 9 0 03 0 psi 569 43 0 2 1 Cylinder oil sealing capacity Boom 50r5qC 122r41qF mm 6 20 Arm extend bucket inch 0 24 0 79 2 9...

Page 22: ...L kgf 1 2 r 1 0 1 2 r 0 5 N 11 77 r 9 81 11 77 r 4 90 lbs 2 6 r 2 2 2 6 r 1 1 9 Dozer lever up kgf 2 0 r 0 5 Up down N 19 61 r 4 90 lbs 4 4 r 1 1 10 down kgf 2 0 r 0 5 N 19 61 r 4 90 lbs 4 4 r 1 1 11...

Page 23: ...ch 4 33 r 0 39 4 extend mm 110 r 10 inch 4 33 r 0 39 5 Bucket lever stroke crowd mm 85 r 10 inch 3 35 r 0 39 6 Bucket lever stroke extend mm 85 r 10 inch 3 35 r 0 39 7 Swivel swing lever stroke R mm 8...

Page 24: ...Side dozer up kgf 276 N 2706 64 lbs 608 5 4 Front dozer up kgf 294 N 2883 16 lbs 648 2 5 Standard arm static limited load Bucket load to tip fully Side kgf 430 393 N 4216 86 3854 01 lbs 948 0 866 4 6...

Page 25: ...5 r 0 2 mph 1 86 r 0 19 1 55 r 0 12 4 Lubber F2 km h 5 0 r 5 4 6 r 0 5 mph 3 11 r 3 11 2 86 r 0 31 5 Iron F1 km h 2 9 r 0 3 2 3 r 0 2 mph 1 80 r 0 19 1 43 r 0 12 6 Iron F2 km h 4 7 r 0 5 4 2 r 0 4 mp...

Page 26: ...19 Front attach ment Mini turning radius Conopy mm 2060 r 62 2420 r 73 inch 81 1 r 2 4 95 3 r 2 9 20 Cabin mm 2060 r 62 2420 r 73 inch 81 1 r 2 4 95 3 r 2 9 21 Mini turning radius Left swing Conopy mm...

Page 27: ...0 2 40 0 lbs 6792 9001 2 F2 kgf 1455 1972 kN 14 3 19 3 lbs 3208 4348 3 1 Travel straight ness F1 mm 600 10m distance inch 23 62 2 F2 mm 600 inch 23 62 3 Dozer F1 mm 600 Dozer up down 10m dis tance inc...

Page 28: ...r41q F inch 0 0 7 1 Max digging height radius Canopy mm 2825 r 282 3640 r 364 inch 111 22 r 11 10 143 31 r 14 33 2 Cabine mm 2825 r 282 3640 r 364 inch 111 22 r 11 10 143 31 r 14 33 3 Max dump height...

Page 29: ...r psi 4 P4 kgf cm2 40 r 5 1 MPa 3 9 r 5 0 bar 3 9 r 5 0 psi 569 r 73 2 1 Cylinder oil sealing capacity Boom 50r5qC 122r41qF mm 20 Arm extend bucket inch 0 79 2 95r5qC 203r41qF mm 20 inch 0 79 3 Arm 50...

Page 30: ...r 1 1 11 Travel lever L Forward kgf 1 2 r 0 5 1 5 r 0 5 N 11 77 r 4 90 14 71 r 4 90 lbs 2 6 r 1 1 3 3 r 1 1 12 Back kgf 1 2 r 0 5 1 5 r 0 5 N 11 77 r 4 90 14 71 r 4 90 lbs 2 6 r 1 1 3 3 r 1 1 13 R Fo...

Page 31: ...h 2 83 r 0 39 2 down mm 72 r 10 inch 2 83 r 0 39 3 Arm lever stroke crowd mm 72 r 10 inch 2 83 r 0 39 4 extend mm 72 r 10 inch 2 83 r 0 39 5 Bucket lever stroke crowd mm 72 r 10 inch 2 83 r 0 39 6 Buc...

Page 32: ...ip fully Side kgf N lbs 6 Front kgf N lbs 2 1 Standard arm Dynamic opera tion load limit Bucket load to 10 degrees tipping Side dozer up kgf Arm extend bucketcrowd oil temp 50r5qC 122r41qF N lbs 2 Fro...

Page 33: ...imum control feeling adjustments can be made for maneuvering various attachments efficiently 4 Safe attachment handling is ensured through fool proof control When a thumb and tilt bucket attached the...

Page 34: ...cure safety priority 2 Control layout Controller Knob position signal Right proportional control valve output Input signal Out put Breaker mode select signal CPU Left proportional control valve output...

Page 35: ...3 Service port system components Meter panel Breaker switch Knob switch Main key ON o start Safety lever lock switch Panel Work S P Input Output CPU EEPROM Proportional solenoid valve Main control va...

Page 36: ...II Service Engineering Section Cylinder bottom thumb crowd PWM current Pilot pump P p PWM current Cylinder rod thumb release Thumb cylinder Main controle valve service port section Main pump P 2 c Hyd...

Page 37: ...e meter panel to call the service mode 2 Knob control Shift the knob to L or R direction to call two way PTO operation 3 Breaker operation Press the back button of the knob to call the breaker mode 1...

Page 38: ...ed while in the service mode Press the breaker switch on the back of the knob to activate the breaker The main pump fully feeds the fluid to the breaker If the thumb is attached in place the main pump...

Page 39: ...ghts up Is breaker switch ON Is knob switch shifted Breaker starts Thumb cylinder While breaker is working 1 Press breaker switch on again 2 Move the knob switch 3 Raise the safety lock lever 4 Main k...

Page 40: ...function Non effective Up 4 Safety lock lever Down 5 Warning lamp buzzer 5 6 sec 1 Service port switch Service port switch S P sw in the middle bottom on the meter panel controls the service port func...

Page 41: ...o release the breaker operation Just for reference the knob does not tilt for over 0 2 second under usual lever control conditions 6 Breaker operation Note When the safety lock lever is up position al...

Page 42: ...the three parameters 1 Current PWM current provided from the panel controller 2 Pressure Secondary pilot pressure delivered from S P solenoid valve 3 Flow Oil flow amount supplied to the thumb cylinde...

Page 43: ...reprogrammed the thumb may get activated even in neutral or slowly move even at the right end The meter memory keeps the following data in the EEPROM addresses 1023 u 8 8184 then 5 V But actual data v...

Page 44: ...The knob switch has a temperature compensated Hall element incorporated The Hall element con sists of a magnet and a coil as shown below A kind of sensor this switch has the tilt angle which changes...

Page 45: ...feeling 5 At the 500mA level however there could be fluctuations due to the control valve proportional control valve hoses and other factors The meter keeps the initial map and performs as well but th...

Page 46: ...sure level changes at a certain point This pressure level is detected and put into memory Note 450 mA and 950 mA are default values before setting in the factory Actual value may differ model by model...

Page 47: ...The start point setting works as follows When a component of the service port system line has been replaced the component with its slightly different individual behavior pattern may deli cately affec...

Page 48: ...ss the selector switch Do this for the right and left movements of the knob Does control start when the start point has been reached Pilot secondary pressure signal PWM current S P section Main hydrau...

Page 49: ...PWM current by adding the difference ai or by subtracting the difference bi to machine A and B respectively Start point set up is to test the difference ai bi and input their data to the controller So...

Page 50: ...t the thumb cylinder starts moving at a preset knob position an input at maximum rpm This cylinder behavior occurs at any engine speed Precisely speaking controller s out put current is the same at a...

Page 51: ...t and left fine adjustment values are put to addresses 62 and 63 respectively in the mem ory These values will become zero when the starting point setting of a model has been made When address 62 is s...

Page 52: ...current duty map at the current of 500 mA and the oil flowing current The proportional control valve however is rather unstable in its temperature characteristics tem perature vs resistance Such cont...

Page 53: ...ft end o S P knob neutral o Finish Key off p Set up S P valve o Down the safety lever o S P actuator middle o Engine max o S P port moves right Push selector sw o S P port moves left Push selector sw...

Page 54: ...isplay o 2 Push the display selector switch long then language to be selected comes on the display KTC and KTA version display only English KCL indicates English or French for selec tion EU version ha...

Page 55: ...art o 6 Push the display selector switch long then the display moves to Set up machine p 7 Push the display selector switch short then the display moves to Set up overheat warning Skip this menu p 8 P...

Page 56: ...tialization press the display selector switch long This initializa tion procedure will be illus trated in another pages 10 Push the display selector switch short the display indi cates Set up S P valv...

Page 57: ...up the safety lock lever moves to the display of S P knob right end p 4 Push the display selector switch short then the display shows S P knob left end p 5 Push the display selector switch short then...

Page 58: ...ay shows as Set up S P valve Safety precaution Engine is running p 2 Shift down the safety lock lever down to control the ser vice port attachment p 3 Get the S P actuator to the middle point of the f...

Page 59: ...icates the cylin der to extend left indi cates to retract p 6 After being pushed in the above automatically the dis play moves over S P port moves left Therefore push the display selector switch at th...

Page 60: ...ructed in page you re required to reach the display shows as Set up S P feeling adjust Safety precaution Engine is running p p 2 Shift down the safety lock lever down to control the ser vice port atta...

Page 61: ...rk lamp switch left end button If it starts moving too slow get it fast by pressing the service port switch middle button Digit number indicates the feeling level of slow or fast Pressing the display...

Page 62: ...modulation current supplied from the micro computer controller incorporated in the meter panel Valve spool function is basically the reducing valve same as the hydraulic pilot control valve nor mally...

Page 63: ...II 52 WSM Minor Change II Service Engineering Section 2 Structure and function Hydraulic symbols Solenoid magnetic force Spring load Pressure applied A P P A T Fp Pa A Fsol Fsp2...

Page 64: ...pilot pressure from the pilot pump controlled by the unload relief valve Pa Secondary pilot pressure to control the main control valve spool Balance of forces The balance of forces for the valve spool...

Page 65: ...Fsp1 Fsol Fsol Fsp1 Fsp2 Pa 3 0 2 0 1 0 20 15 10 5 0 0 5 1 1 5 Current A Solenoid force N Pa MPa A T Actuator to tank P A Pump to actuator Suction prevention against interference Opening area symmetr...

Page 66: ...a 3 Fool proof control When the service port sensor reads below 0 25 V or over 4 75 V for 0 2 second Nothing displayed however out of the service mode 4 Idle up control The idling speed increases by 1...

Page 67: ...alve S P section 4 Knob switch initial setting error Knob switch initial setting 5 S P valve pressure is quite low in one side Test the S P valve pressure c Service port attachment moves slower than s...

Page 68: ...II 57 WSM Minor Change II Service Engineering Section...

Page 69: ...3S D U45 3D 1 Moter swash plate Light weight type 2 Hi Low piston Shape change 3 Thrust plate Shape change 4 Sun gear Snap ring removed 5 Ring nut Casting iron to steel iron 6 Reduction gear case drai...

Page 70: ...ring Section b Hydraulic pump KX161 3s KX161 3D 1 Pump installation KX161 3S D U45 3D 1 Adapter tightening torque P port G3 4 117 6 127 4N m 12 0 13 0kgf m PPS PLS CH port G1 4 24 5 29 4N m 2 5 3 0kgf...

Page 71: ...II 59 WSM Minor Change II Service Engineering Section 2 Piston pump KX161 3S PP KX161 3D EU U45 3D EU KTA 63 7 21...

Page 72: ...II 60 WSM Minor Change II Service Engineering Section 7 7 1 1 72548...

Page 73: ...qC Short time use 20 90qC Drive system Input shaft Direct drive No radial load General spec All efficiency Typical value 79 VG46 50 qC 2200 rpm 13 7 MPa Control method Power constant control Load sens...

Page 74: ...II 62 WSM Minor Change II Service Engineering Section...

Page 75: ...II 63 WSM Minor Change II Service Engineering Section c Control valve 1 PP version KX161 3S...

Page 76: ...II 64 WSM Minor Change II Service Engineering Section 2 EU KTA version KX161 3D S...

Page 77: ...II 65 WSM Minor Change II Service Engineering Section 3 Third line version EU KTA KX161 3D S...

Page 78: ...ump Orifice diameter 0 8 Orifice diameter 0 7 Section B B Section B B Compensation pulse signal Orifice diameter 0 7 To pump Hose volume H350 Orifice diameter 1 0 Tightening torque 5 1 N m Orifice dia...

Page 79: ...II 67 WSM Minor Change II Service Engineering Section Spool ID marking on the surface 5 Other section shuttle plate change...

Page 80: ...f cm2 1 0 1MPa 145 1 4 psi 5 Media Mineral oil 6 Allowable pressure ratio Max pressure charging pressure Under 8 1 Example When charging pressure is set 10 bar should set max pressure under 80 bar fo...

Page 81: ...re Maker Hydro control As for EU version accumulator structure and specifications almost all remains same as before 2 2 Specifications 1 Max oil flow 16 l min 4 23 Us gal 2 Rated voltage and output 12...

Page 82: ...II 70 WSM Minor Change II Service Engineering Section 3 Accumulator installation KX91 3S U35S U35 3S KTA 1 Bolt tightening torque 48 1 55 9N m 4 9 5 7kgf m...

Page 83: ...II 71 WSM Minor Change II Service Engineering Section...

Page 84: ...72 WSM Minor Change II Service Engineering Section 4 Accumulator installation KX121 3S 161 3S 1 Bolt tightening torque 48 1 55 9N m 4 9 5 7kgf m 2 Adapter G3 8 tightening torque 37 2 42 1N m 3 8 4 3kg...

Page 85: ...II 73 WSM Minor Change II Service Engineering Section e Hydraulic system line 1 Pilot control line PP version KX161 3S KX121 3S is almost same except control valve...

Page 86: ...II 74 WSM Minor Change II Service Engineering Section 2 Pilot control line EU version KX161 3D...

Page 87: ...II 75 WSM Minor Change II Service Engineering Section 3 Pilot delivery line KX161 3S...

Page 88: ...ineering Section 4 Pilot filter Kubota Japan make is almost same among KX91 3S to KX161 3S 1 Bolt tightening torque 9 8 11 3 N m 1 0 1 15 kgf m 2 Adapter tightening torque G3 8 37 2 42 1 N m 3 8 4 3 k...

Page 89: ...II 77 WSM Minor Change II Service Engineering Section 5 Pilot control line KX91 3S U35S U35 3S KTA...

Page 90: ...II 78 WSM Minor Change II Service Engineering Section 6 Delivery hose KX91 3S U35S U35 3S KTA...

Page 91: ...II 79 WSM Minor Change II Service Engineering Section...

Page 92: ...II 80 WSM Minor Change II Service Engineering Section 7 Rotary joint hoses KX91 3S U35S U35 3S KTA...

Page 93: ...ice Engineering Section 1 Adapter tightening torque G1 4 Pipe joint L G1 4 G1 4 RC601 6372 24 5 29 4 N m 2 5 3 0 kgf m G3 8 Pipe joint L G3 8 G3 8 RP201 6181 Pipe joint T F2 F3 RC411 6384 49 1 53 9 N...

Page 94: ...II 82 WSM Minor Change II Service Engineering Section f Service port S P solenoid valve 1 S P valve Adapter tightening torqueG1 4 25 0 30 0 N m 2 5 3 0 kgf m...

Page 95: ...II 83 WSM Minor Change II Service Engineering Section 2 S P valve...

Page 96: ...II 84 WSM Minor Change II Service Engineering Section 3 Heat up circuit...

Page 97: ...ring R The return oil from the motor flows through the variable orifice of the spool and port P2 and back into the tank When the return oil passes via the spool s variable ori fice a back pressure occ...

Page 98: ...at low level When the free piston has completely moved the relief valve gets activated at a speci fied pressure The M2 port pressure is thus raised in two stages which eases possible violent jolts Fig...

Page 99: ...rresponding to the opening area The counterbalance spool s return time is determined by the spring force and the orifice opening The stronger the spring force and the larger the orifice opening the qu...

Page 100: ...dition is almost equivalent or a little better than the previous type FIg 6 New Type High speed Fig 7 New type Low speed Fig 8 Previous type High speed Fig 9 Previous type Low speed Time sec Pressure...

Page 101: ...plicable for automatic dual speed setting 5 Dual speed piston Shoeless configuration with modified surface treatment 50 Sun gear Snap ring eliminated 15 Ring nut Change in material 10 Holder Surface t...

Page 102: ...Change II Service Engineering Section Dual speed piston with shoe Excess padding eliminated according to the main piston shoe locus Main piston shoe locus Dual speed piston shoeless 2 Swash plate and...

Page 103: ...rsion 97 6 U35 3S KTA version U35S KCL version 98 7 U35 3D EU version 99 8 KX121 3S KTC KCL version 100 9 KX121 3S KTA version 101 10 KX121 3D EU version 102 11 KX161 3S KTC KCL KTA version 103 12 KX1...

Page 104: ...II 92 WSM Minor Change II Service Engineering Section...

Page 105: ...II 93 WSM Minor Change II Service Engineering Section 1 KX91 3S KTC version...

Page 106: ...II 94 WSM Minor Change II Service Engineering Section 2 KX91 3S KCL KTA version...

Page 107: ...II 95 WSM Minor Change II Service Engineering Section 3 KX91 3D EU version...

Page 108: ...II 96 WSM Minor Change II Service Engineering Section 4 KX101 3D EU version...

Page 109: ...II 97 WSM Minor Change II Service Engineering Section 5 U35S KTC version...

Page 110: ...II 98 WSM Minor Change II Service Engineering Section 6 U35 3S KTA version U35S KCL version...

Page 111: ...II 99 WSM Minor Change II Service Engineering Section 7 U35 3D EU version...

Page 112: ...II 100 WSM Minor Change II Service Engineering Section 8 KX121 3S KTC KCL version...

Page 113: ...II 101 WSM Minor Change II Service Engineering Section 9 KX121 3S KTA version...

Page 114: ...II 102 WSM Minor Change II Service Engineering Section 10 KX121 3D EU version...

Page 115: ...II 103 WSM Minor Change II Service Engineering Section 11 KX161 3S KTC KCL KTA version...

Page 116: ...II 104 WSM Minor Change II Service Engineering Section 12 KX161 3D EU version...

Page 117: ...II 105 WSM Minor Change II Service Engineering Section 13 U45 3S KTA version...

Page 118: ...II 106 WSM Minor Change II Service Engineering Section 14 U45 3D EU version...

Page 119: ...YDOYH DVV 6ZLQJ F OLQGHU 6 3 VROHQRLG YDOYH KHFN YDOYH 5RWDU MRLQW 7UDYHO ORFN F OLQGHU 6ZLYHO PRWRU 7366 YDOYH 7 7 7UDYHO PRWRU 5 2LO FRROHU 8 YHUVLRQ 0DLQ SXPS GUDXOLF RLO WDQN FFXPXODWRU KDQJH YDOY...

Page 120: ...F OLQGHU 6 3 VROHQRLG YDOYH RQWURO YDOYH DVV 6XFWLRQ ILOWHU 5HWXUQ ILOWHU GUDXOLF RLO WDQN 7UDFN UROOHU KDQJH YDOYH 7 7 2LO FRROHU FFXPXODWRU 7UDYHO PRWRU 5 6ZLYHO PRWRU 3LORW YDOYH 5 3LORW YDOYH 7UDY...

Page 121: ...que gross N m 163 5 kgf m 16 7 ft lbf 120 6 Dimensions L u W u H mm 705 u 511 u 700 in 27 8 u 20 1 u 27 6 Dri weight kg 180 lbs 396 8 Valve clearance mm 0 18 0 22 in 0 0071 0 0087 Firing sequence 1 3...

Page 122: ...zle type DNOPD mini nozzle Injection pressure Mpa 13 7 14 7 kgf cm2 140 150 psi 1991 2133 Dynomo 12V A540W Manufacturer P N 101211 3781 Regulator adjusting voltage V 14 15 Battery type 90D26R Nominal...

Page 123: ...II 111 WSM Minor Change II Service Engineering Section c Engine performance curve QFGN 8 5 5 TQUU KPVGTOKVVGPV 2 0GV KPVGTOKVVGPV 2 6T TQUU KPVGTOKVVGPV 2 2 0GV KPVGTOKVVGPV 2 DG...

Page 124: ...II 112 WSM Minor Change II Service Engineering Section QFGN 8 5 6T 25 DG...

Page 125: ...II 113 WSM Minor Change II Service Engineering Section...

Page 126: ...Outline of Kubota ICS Intelligent Control System II 118 c Operating Mode II 121 d Service mode menues II 124 e New auto idling AI control system II 144 f Main component s function II 159 g Failure Di...

Page 127: ...Oil pressure see fig 4 on the right hand side Charge see fig 5 on the right hand side Overvoltage Overheating 2 Inspection time instruction function SERVICE HOURS appears whenever the time has come fo...

Page 128: ...eference LCD Display Examples of New Meter Fig 1 Normal screen Key switch ON Only the glowing moment Normal screen with the tachometer selected Normal screen with the hourmeter selected Fig 2 Language...

Page 129: ...nual Yes delete method auto 3 Anti theft system Yes sample date not fixed No 4 AI Auto idle function Yes Yes 5 Engine overheat warning Yes No 6 Starter motor auto release function Yes Yes 7 Glowplug a...

Page 130: ...II 118 WSM Minor Change II Service Engineering Section b Outline of Kubota ICS Intelligent Control System...

Page 131: ...II 119 WSM Minor Change II Service Engineering Section...

Page 132: ...II 120 WSM Minor Change II Service Engineering Section...

Page 133: ...ows three types of information 1 Key switch ON 2 Normal display hour meter 3 Normal display tachometer When in trouble LCD shows warning and failure indications as shown below In the following list it...

Page 134: ...cates the warning ofaccel sensor line break or shortage data009 The letter on the LCD indicates the warning of governor sensor line break or shortage data010 The letter on the LCD indicates the warnin...

Page 135: ...ing indications 1 Lift up the lock lever to start engine 2 At key on position 3 In case oil sw and charge lines broken 4 Fuel shortage 5 Battery charge warning 6 Engine oil pressure warning 7 Lift dow...

Page 136: ...tional attachment and control system and also diagnose machine trouble Display indication items are listed in page II 140 and II 141 from data number 023 085 Following pages include 1 Service mode flo...

Page 137: ...t As explained above the system is designed to support 11 languages and the language selection screen will appear first See fig The selection screen of the 11 languages is written in each of the langu...

Page 138: ...revolution under the same condition for 60 seconds Battery Battery Voltage The battery voltage is input into the meter through two diodes Therefore the voltage displayed is added with 1 4 V in conside...

Page 139: ...ust once the next failure point can be viewed If there is no failure No fail record will be displayed See the Section of Fail Safe for failures in detail Fig 3 Fail record dump 3 4 Deletion of Fail Re...

Page 140: ...try of manufacturer European specifications and North American specifications are distinguished If AI optional specifications are provided the selection of AI as an optional item will appear as well F...

Page 141: ...mode set up Chinese version only Simple mode settings can be made by selecting Set up Engine start Set up machine and Simple mode While in simple mode the output will be turned OFF when the fail safe...

Page 142: ...the engine revolution is 800 rpm or over While in harness check mode the following items can be checked Items in parentheses are error criteria Lever lock switch OFF When lever is down Fuel sensor Rea...

Page 143: ...l Fail Record 3 10 EEPROM read The data of the EEPROM can be checked by selecting Other menu Other menu and EEPROM read See Fig 7 Ten items are displayed on each page in hexadecimal and 13 pages will...

Page 144: ...Manual are considered a message will be dis played at 50 hour intervals which is not so meaningful In view of the foregoing important items e g items related to the engine oil operating oil air filter...

Page 145: ...atically returns to service hour meter with new service hours 3 14 Servive hour meter delete A deletion method of the service hour meter can be set by selecting Other menu Other menu and Service warni...

Page 146: ...rature of the glow plug will drop Therefore the actual glow will be kept turned ON for 2 seconds after the glow icon disappears This will make a response time lag between the display and glow time thu...

Page 147: ...the start position the glow relay will be turned OFF 2 If the battery is discharged while the key turned ON In case operator left the key ON and when the bat tery voltage is close to the level of tri...

Page 148: ...Service Engineering Section 3 FYI For your information water V temp C 0 33 140 0 409 130 0 504 120 0 634 110 0 795 100 1 90 1 26 80 1 58 70 1 96 60 2 4 50 2 86 40 3 36 30 3 77 20 4 15 10 4 44 0 4 66...

Page 149: ...l flow 2 The travel mechanism will start in low gear to ensure safety when the key is turned ON 3 With consideration of the change of the operator with the key kept turned ON the frame mechanism will...

Page 150: ...eration of the power supply voltage The fuel shortage alarm will be displayed when the quantity of remaining fuel is between approximately 5 and 10 liters the range of which however varies with the mo...

Page 151: ...e displayed at once 4 The alarm displayed will be canceled if the alarm cancel voltage 0 719 V or below is detected 649 times or more i e a minimum of 90 of the total after the sensor signal is sample...

Page 152: ...in the tank is not much the buzzer will be heard at long intervals When the quantity approaches the full tank level the intermittent buzzer continues at shorter intervals When the tank is full the buz...

Page 153: ...ature unless the revolution rises approxi mately 800 rpm Therefore the start of the engine is judged at 1 000 rpm The judgment of the release of the starter has been raised by 200 rpm As for the other...

Page 154: ...temp sensor voltage Fuel V indicates fuel sensor voltage data045 AI SW indicates on or off condition of AI switch Press indicates AI pressure switch condition Motor A means current amount flowing to...

Page 155: ...ata065 This shows LCD condition data066 This shows LCD condition data067 This indicates the service hours of the machine data068 This indicates the hours of machine set up data069 This indicates the s...

Page 156: ...ed on the engine governor The gover nor position signal is sent to the controller CPU 6 The controller CPU processes the above information and feeds a current command to the AI motor so that the engin...

Page 157: ...r lock If the lock lever is raised Engine changes to idling rotation immediately does not wait for 4 seconds Convenient at the time of gets off a machine 2 Interlocked with Anti Theft If Anti Theft is...

Page 158: ...hen the safety lock laver is liffted up engine speed gose down to idle rpm 25 3 kgf cm2 20 3 kgf cm2 ON AI controller Electric accelerator CPU OFF C7 B1 A2 A3 C5 C6 Acceleration AI pressure switch sig...

Page 159: ...bout 4 seconds the AI motor gets started to reduce the engine speed to the idling level M C7 C5 B1 C6 CPU A2 A3 Lever Pilot pressure Pressure switch Neutral Below 20 kgf cm2 ON Operation Above 25 kgf...

Page 160: ...ied to turn off the pressure switch The AI controller functions to run the AI motor so that the engine governor should reach maximum position The engine speed rises quickly to maximum rpm M C7 B1 C6 C...

Page 161: ...the battery current flows for running the AI motor in the normal direction AI SW Motor position Acceleration sensor Governor sensor Acceleration cable AI motor normal turn Error detection LCD Output N...

Page 162: ...unning the AI motor in the reverse direction AI SW Motor position Acceleration sensor Governor sensor Acceleration cable AI motor reverse turn Error detection LCD Reverse turn Reverse Motor normal Gov...

Page 163: ...ime when he turns the main key engine starts at max speed This is a kind of frightenning to the operator New function is to relieve this annoyance Function chart After the main key is off the controll...

Page 164: ...water temp sensor value If the temp value is over 30 C 86 F then CPU commands to output the preset idle PRM If the temp value is below 30 C 86 F then CPU commands to output 150 rpm higher then the pre...

Page 165: ...k Function chart Function diagram Watching the voltage condition of compressor magnet switch CPU in the controller commands the AI motor to regulate the engine idle speed If the magnet switch is ON th...

Page 166: ...rpm Therefore whenever the meter panel is replaced you re required to reset the idling RPM for AI version according to the above table In case of non AI version machine mechanical link system is ready...

Page 167: ...ter s automatic release system gear teeth 68 Fuel pump gear 0 7 0 2 mm 2 x 60 68 x t pulse convert circuit sensor chip A B N A B V This sensor is composed of a sensor and a rotor The sensor has a coil...

Page 168: ...ce 100M or more 4 Output performance 1 Case 2 Cover 3 Roter 4 Shaft 5 Resistance 6 Element termi nal 7 Connector ter minal 8 Slider 9 Wave washer 10 Return spring 11 Rubber seal 12 E ring 13 Washer 14...

Page 169: ...r Code No Sample data Accel sensor position Min Max 1 3 R1 R2 941 1 2 R1 R2 680 364 2 3 R2 R3 285 606 1 2 3 4 4 4 1 2 3 4 4 4 Accel sensor is in Min position Accel sensor is in Max position R2 is cont...

Page 170: ...the other hand the pressure in the hydraulic pilot circuit rises At 25 kgf cm2 the hydraulic pressure pushes the dia phragm as shown at left which opens the contact The microcomputer picks up the res...

Page 171: ...tomatic release control system regulates the transistor s base cur rent flow which turns on the release relay solenoid ON or OFF Engine speed Auto release relay T1 T2 KX41 3 KX61 3SS 161 3SS 1000 Nx 8...

Page 172: ...ease of the starter motor is judged before the startup revolution of the engine is reached 5 The reason why detecting engine speed is set at 1000 rpm If 800 rpm is set to detect the engine start up sp...

Page 173: ...II 161 WSM Minor Change II Service Engineering Section 3 Operational flow chart 3 1...

Page 174: ...II 162 WSM Minor Change II Service Engineering Section 3 2...

Page 175: ...nd condition of auto release relay starter relay Auto release relay Engine speed Nx Time T1 T2 Auto release relay KX61 3 KX161 3S D KX41 3 800 Nx 1000 Nx ON 801 950 1001 1150 Within 6 seconds ON After...

Page 176: ...on and off the travel hi speed switch and check the continuity and discontinuity 4 Check the continuity of the travel hi speed solenoid coil and measure its resistance 5 If there is no problem with th...

Page 177: ...ON 1 16 ON 1 14 ON 1 13 ON 1 22 ON 17 4 ON 17 3 ON 17 1 ON 17 4 ON 17 3 ON 17 2 ON 17 2 ON 17 1 Glow relay Auto release relay ON 1 21 ON 1 9 ON 1 11 ON 1 5 ON 1 6 ON 1 7 ON 13 2 ON 13 1 ON 1 8 ON 1 1...

Page 178: ...l 65 85 At 5 V normal The following conditions continue 10 s charge L and 800 rpm min 4 High voltage 4 High voltage Continu ally Red Turn key OFF AI AUX 67 87 At 5 V normal A power supply voltage of 1...

Page 179: ...en tarily Yellow Wait for 3 s Engine does not start Theft prevention specifications The wrong key is used to start the engine The specifications are presently under consideration 34 Owner tag Momen ta...

Page 180: ...ess than one hour see fig 1 Hour meter data and the number of errors 1 will be written to both addresses if an error occurs for the first time The last hour meter data will be converted into present h...

Page 181: ...shooting possible if the LCD meter is returned to the factory due to a failure after shipping The contents of addresses 65 through 103 are zero cleared with the PC before shipping Fig 2 Address and co...

Page 182: ...lenoid R break 77 5 Overheat 78 55 Meter controller error 79 54 Sensor supply short 5V 80 53 Sensor supply short 12V 81 52 Fuel sensor 82 51 Coolant sensor 83 61 AI motor retricted 84 reserve 85 3 Cha...

Page 183: ...e from the battery the self diagnostic program built into the meter will run thus making the self diagnosis of the incorporated hard ware of the meter possible with the inputs and outputs of the meter...

Page 184: ...n the illustration on the right hand side turns ON and OFF repeatedly The buzzer beeps The backlight of the meter turns ON and OFF repeatedly 4 If the following message appears in approxi mately one m...

Page 185: ...switch box as shown in the photo As a test push on of the switch to NG position and let it run the self diagnosis test Then the pre set failure number will be dis played on the LCD screen Example No...

Page 186: ...mp relay output start switch input Turn OFF the working lamp relay and make sure that the start switch is set to high level 3 Input output Working lamp relay output start switch input Turn ON the work...

Page 187: ...low level 9 Input output AUX sol positive R output compressor clutch switch input AN2_7 input Turn ON the AUX sol positive R and make sure that the compressor clutch switch is set to high level The AN...

Page 188: ...icrocomputer The microcomputer checks if the results coincide with the check sum data prepared while in normal operation i e at the time of writing the program The microcomputer will go to the next st...

Page 189: ...and checks if the data on the output side is normal Note Yazaki I O and aging and only original manufacturer s use only SW1 7 8 9 are for your test and training purpose Self diagnosis Yazaki I O Yazak...

Page 190: ...you ll be in the service mode The model name which was pre set will come to appear on the LCD screen 1 3 What do the arrows indicate p vertial to down You re required to push the selector switch for...

Page 191: ...2 AI or Non AI selection 3 AI set up Idle max speed 4 Service warning set up 5 S P knob set up 6 S P valve set up 7 Overheat warning set up 2 Replace from a canopy to a cab or vice versa 1 Idle speed...

Page 192: ...II 180 WSM Minor Change II Service Engineering Section...

Page 193: ...Engineering Section 2 Service mode flow 2 1 KTC KCL KTA Service mode flow U35S U35 3S KX91 3S S P ver 1 20 How to enter the service mode While pushing the display select switch turn the main key to ON...

Page 194: ...rvice Engineering Section 2 2 KTC KCL KTA Service mode flow KX121 3S KX161 3S U45 3S AI S P ver 1 20 How to enter the service mode While pushing the display select switch turn the main key to ON posit...

Page 195: ...Engineering Section 2 3 EU service mode KX91 3D KX101 3D KX121 3D KX161 3D U35 3D U45 3D AI S P ver 1 20 How to enter the service mode While pushing the display select switch turn the main key to ON...

Page 196: ...II 184 WSM Minor Change II Service Engineering Section...

Page 197: ...y switch Accel dial Hi low switch S P switch Horn switch Breaker lock switch Heater switch Meter panel Hi low solenoid Unload solenoid Engine pressure switch Starter motor Glow plug Fuel pump Water te...

Page 198: ...P solenoid valve Fuse box Ciger lighter PTO Safety lock switch R Control lever R Accel dial Main key switch Hi low switch Hi low solenoid Battery Unload solenoid Heater switch Meter panel Revolution s...

Page 199: ...solenoid Heater switch Meter panel Revolution sensor Engine pressure switch Fuel pump Water temp sensor Auto glow Safety lock switch R Main key switch Hi low switch Hi low solenoid Control lever R Acc...

Page 200: ...e lighter 15A Room Light 5A Blower Motor 20A Compressor 10A ON 15 1 ON 18 1 ON 55 1 ON 55 1 ON 55 1 ON 55 1 ON 55 2 ON 100 ON 100 ON 55 2 ON 18 2 ON 18 2 ON 305 1 ON 305 6 ON 305 2 ON 305 1 ON 16 4 ON...

Page 201: ...II 189 WSM Minor Change II Service Engineering Section 2 KX91 3S U35S U35 3S PP version...

Page 202: ...II 190 WSM Minor Change II Service Engineering Section 3 KX91 3D 101 3D U35 3D EU version...

Page 203: ...II 191 WSM Minor Change II Service Engineering Section 4 KX121 3S D 161 3S D U45 3S D EU and PP version...

Page 204: ...II 192 WSM Minor Change II Service Engineering Section...

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Page 206: ...IRAKATA CITY OSAKA JAPAN EDITOR CONSTRUCTION MACHINERY MANUFACTURING DEPT SERVICE ENGINEERING SECTION HIRAKATA PLANT 1 1 1 NAKAMIYA OHIKE HIRAKATA CITY OSAKA JAPAN PHONE 81 72 840 1195 FAX 81 72 840 2...