Kubota KX61-3 KX71-3 Excavator Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kubota KX61-3 KX71-3 Excavator Workshop Manual – PDF DOWNLOAD
Safety precautions for servicing, disassembly and reassembly
Safety precautions for servicing
Most accidents during servicing arise from carelessness. Please remember that Safety involves both the
welfare of the employees and improved work efficiency.
Safety precautions for Disassembly and reassembly
Machines must be disassembled and assembled efficiently and safely.
It is very important to thoroughly understand the construction and function of the machine, to make all
appropriate preparations, and start operations according to the specified working procedures.
a. Safety measures before starting
work
(1)Work clothes
1. Wear specified work cap and clothed.
(Under no circumstances may workers
wear undershirts only.)
Cuffs must be kept buttoned, and any tears
must be mended.)
2. Wear safety shoes.
3. Do not wear cotton gloves when working
on the internal section of engine, reduction
gears or hydrauric units for repair or others,
or when using a hammer. Wear leather
gloves, however, when hoisting wires.
(2) Inspecting equipment and tools
1. Prepare equipment (cranes, fork lifts, tool,
etc.) required for servicing and inspect for
any problems before starting work.
2. Hammer heads (metal parts) must be firmly
secured to their handles.
3. Check hosting tools (wire ropes, hoisting
chains, etc.) before use.
(3) Keep workshop in order
1. Secure appropriate space needed for
disassembly to the job.
2. Secure a clean, safe place for arranging
disassembled parts.
3. Store volatile substances (gasoline, light
oil, thinner, oily articles, etc.) in appropriate
containers at selected locations to prevent
fire hazards
TABLE OF CONTENTS:
Kubota KX61-3 KX71-3 Excavator Workshop Manual – PDF DOWNLOAD
WSM_KX61-3_71-3_Service……………………………………………………………………. 1
CONTENTS……………………………………………………………………………… 3
I General…………………………………………………………………………….. 5
A. Body and engine identification marks………………………………………………. 7
(1)Machine serial number & plate…………………………………………………. 7
(2) Engine serial number………………………………………………………… 7
B. Safety precautions for servicing, disassembly and reassembly…………………………. 8
Safety precautions for servicing…………………………………………………. 8
Safety precautions for Disassembly and reassembly………………………………….. 8
a. Safety measures before starting work……………………………………….. 8
(1) Work clothes………………………………………………………… 8
(2) Inspecting equipment and tools………………………………………… 8
(3) Keep workshop in order……………………………………………….. 8
b. Safety measures during work……………………………………………….. 8
(1) Protectors………………………………………………………….. 8
(2) Team work…………………………………………………………… 8
(3) Disassembly and assembly……………………………………………… 8
(4) Cranes……………………………………………………………… 8
(5) Others……………………………………………………………… 8
c. Preparation for disassembly……………………………………………….. 9
(1) Cleaning……………………………………………………………. 9
(2) Acceptance inspection………………………………………………… 9
(3) Equipment and tools………………………………………………….. 9
d. Precautions for disassembly and reassembly………………………………….. 9
(1) Disassembly…………………………………………………………. 9
(2) Reassembly………………………………………………………….. 9
C. IMPORTANT SAFETY PROCESS AND CRITICAL FUNCTIONAL PROCESS…………………………….. 10
a. Essential Adhesives………………………………………………………….. 10
b. Important Safety Process …………………………………………………….. 10
c. Important Critical Functional Process …………………………………………. 10
D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING………………………………………. 10
a Operate the Machine and check for Unusual Noise and Vibrations…………………….. 10
b Make Sure the Safety decals and Wireharness Clamps are in their Specified Positions….. 10
c With the Machine Front in a Specified Posture, Check the Amount of Hydraulic Oil…….. 10
E. SERVICING FUNDAMENTALS…………………………………………………………… 11
a. Items for Servicing………………………………………………………….. 11
b. O-ring, Oil seal, Circlip and Roll Pin…………………………………………. 13
c. Piping……………………………………………………………………… 15
(1) General precautions……………………………………………………… 15
(2) Hydraulic hose………………………………………………………….. 15
(3) Precautions in tightening the bolts and nuts……………………………….. 15
(4) Hose screw……………………………………………………………… 16
Metric Size Hose……………………………………………………………. 16
(5) Joint bodies……………………………………………………………. 16
(6) Tightening torque table for hose clamp (Screw type)…………………………. 17
(7) Nuts for piping…………………………………………………………. 17
(8) Tightening torque of bolts and nuts……………………………………….. 18
(9) Types and materials of bolts and nuts……………………………………… 18
(10) Washer-equipped elbow…………………………………………………… 19
F. Maintenance intervals……………………………………………………………. 20
a. Maintenance intervals chart:EU – version……………………………………….. 20
b. Maintenance interval chart : PP – version………………………………………. 21
c. Hydraulic Oil Check for machines with Hydraulic Breakers…………………………. 23
d. Periodic replacement of important parts………………………………………… 24
II. Machine body………………………………………………………………………. 25
A. Specifications………………………………………………………………….. 27
a. Machine weight………………………………………………………………. 27
b. Machine specifications……………………………………………………….. 28
[1] Major specifications…………………………………………………….. 28
[2] Main dimensions…………………………………………………………. 29
c. Lever stroke and operating force………………………………………………. 30
d. Dimensions of parts………………………………………………………….. 31
[1] Front pins Service limit of pin dia. : -1.0 mm (-0.04 in.)…………………… 31
[2] Bucket link Service limit of front bushing : +1.0 mm (+0.04 in.)……………… 32
[3] Bucket dimensions……………………………………………………….. 33
[4] Bucket installation relevant dimensions……………………………………. 34
e. Undercarriage specifications………………………………………………….. 35
[1] Rubber crawler………………………………………………………….. 35
[2] Steel crawler…………………………………………………………… 35
[3] Track roller, idler, sprocket…………………………………………….. 36
[4] Dozer………………………………………………………………….. 37
f. Parts weight………………………………………………………………… 38
g. Water and oil quantity……………………………………………………….. 40
B. Front attachment………………………………………………………………… 41
a. Parts designation……………………………………………………………. 41
b. Exchange of bucket (Kubota Japan Bucket)……………………………………….. 43
c. Exchange of bucket teeth and side cutters [JPN bucket version]……………………. 44
d. Installing direction of dust seal……………………………………………… 45
e. Installation of thrust collar on the swing bracket………………………………. 45
f. Installation of pin and bush………………………………………………….. 46
[1] Pin bush……………………………………………………………….. 46
[2] Pin, bush………………………………………………………………. 47
g. Grease nipple……………………………………………………………….. 49
h. Upper structure……………………………………………………………… 50
(1) Lever and pedal…………………………………………………………. 50
[1] Travel lever………………………………………………………… 50
[2] Acceleration lever…………………………………………………… 52
[3] Dozer lever…………………………………………………………. 54
[4] Swing pedal…………………………………………………………. 56
[5] Service port pedal…………………………………………………… 58
[6] Control valve and linkage…………………………………………….. 60
[7] Pilot lever…………………………………………………………. 61
i. Counterweight……………………………………………………………….. 62
Counterweight assembly view………………………………………………….. 62
C. Cab canopy installation………………………………………………………….. 63
a. Installing the cabin or canopy………………………………………………… 63
[1] Dismounting of cab………………………………………………………. 63
[2] Installing the cabin…………………………………………………….. 65
[3] Canopy installation……………………………………………………… 69
[4] Heater setup……………………………………………………………. 70
[5] Defroster setup…………………………………………………………. 71
[6] Thermal insulation and sound absorber……………………………………… 72
[7] Seat and seat belt………………………………………………………. 78
[8] Cab window replacement procedure………………………………………….. 79
D. Under carriage………………………………………………………………….. 83
a. Swivel bearing………………………………………………………………. 83
b. Grease tube…………………………………………………………………. 83
c. Track tension device…………………………………………………………. 84
d. Upper roller and track roller…………………………………………………. 86
e. Crawler replacement and tension adjustment……………………………………… 90
III. Engine…………………………………………………………………………… 93
A. Specifications………………………………………………………………….. 95
a. Main specifications………………………………………………………….. 95
B. Engine accessories;Disassembly and reassembly………………………………………. 96
a. Radiator fan………………………………………………………………… 96
b. Radiator……………………………………………………………………. 97
c. Electrical parts……………………………………………………………..100
d. Engine mount…………………………………………………………………101
e. Air cleaner………………………………………………………………….103
f. Muffler……………………………………………………………………..104
g. Pump coupling………………………………………………………………..106
h. Fuel tank……………………………………………………………………107
i. Fuel hoses…………………………………………………………………..109
C. Engine dismounting & remounting……………………………………………………111
D. Engine WSM (Mechanism section)…………………………………………………….117
A. Feature……………………………………………………………………..119
B. Engine body………………………………………………………………….120
[1] Cylinder block…………………………………………………………..120
[2] Cylinder head……………………………………………………………120
[3] Crankshaft………………………………………………………………121
[4] Piston and piston rings…………………………………………………..121
[5] Connecting rod…………………………………………………………..122
[6] Rocker arm………………………………………………………………122
[7] Camshaft………………………………………………………………..122
[8] Fuel camshaft……………………………………………………………123
[9] Flywheel………………………………………………………………..123
C. Lubricating system……………………………………………………………124
[1] General…………………………………………………………………124
[2] Oil pump………………………………………………………………..125
[3] Relief valve…………………………………………………………….125
[4] Oil filter cartridge……………………………………………………..126
[5] Oil pressure switch………………………………………………………126
D. Cooling system……………………………………………………………….127
[1] General…………………………………………………………………127
[2] Water pump………………………………………………………………127
[3] Thermostat………………………………………………………………128
[4] Radiator (not included in the basic engine)…………………………………128
[5] Radiator cap…………………………………………………………….129
E. Intake / exhaust system……………………………………………………….130
[1] Air cleaner (not included in the basic engine)………………………………130
[2] Muffler (not included in the basic engine)………………………………….130
F. Fuel system………………………………………………………………….131
[1] General…………………………………………………………………131
[2] Injection pump…………………………………………………………..131
[3] Injection nozzle…………………………………………………………134
[4] Fuel filter (not included in the basic model)……………………………….134
[5] Governor………………………………………………………………..135
[6] Automatic advance timer (not included in the basic model)…………………….137
G. Electrical system…………………………………………………………….139
[1] Charging system………………………………………………………….139
D. Engine WSM (Service section)………………………………………………………141
A. General……………………………………………………………………..143
[1] Engine identification…………………………………………………….143
[2] General precaution……………………………………………………….144
[3] Tightening torques……………………………………………………….145
[4] Troubleshooting………………………………………………………….146
[5] Servicing specifications………………………………………………….149
[6] Maintenance check list……………………………………………………158
[7] Check and maintenance…………………………………………………….159
B. Engine body………………………………………………………………….172
CHECKING AND ADJUSTING……………………………………………………….172
DISASSEMBLING AND ASSEMBLING………………………………………………….173
[1] Draining water and oil……………………………………………………174
[2] External components………………………………………………………174
[3] Cylinder head and valves………………………………………………….175
[4] Gear case……………………………………………………………….177
[5] Piston and connecting rod…………………………………………………183
[6] Flywheel and crankshaft…………………………………………………..186
SERVICING…………………………………………………………………..188
[1] Cylinder head……………………………………………………………188
[2] Timing gear and camshaft………………………………………………….193
[3] Piston and connecting rod…………………………………………………195
[4] Crankshaft………………………………………………………………198
[5] Cylinder………………………………………………………………..204
C. Lubricating system……………………………………………………………206
CHECKING……………………………………………………………………206
SERVICING…………………………………………………………………..206
[1] Oil pump………………………………………………………………..206
D. Cooling system……………………………………………………………….208
CHECKING……………………………………………………………………208
[1] Fan belt………………………………………………………………..208
[2] Radiator………………………………………………………………..208
DISASSEMBLING AND ASSEMBLING………………………………………………….209
E. Fuel system………………………………………………………………….211
CHECKING AND ADJUSTING……………………………………………………….211
[1] Injection pump…………………………………………………………..211
[2] Injection nozzle…………………………………………………………213
DISASSEMBLING AND ASSEMBLING………………………………………………….214
[1] Injection pump…………………………………………………………..214
[2] Injection nozzle…………………………………………………………215
F. Electrical system…………………………………………………………….216
CHECKING……………………………………………………………………216
[1] Starter…………………………………………………………………216
[2] Glow plug……………………………………………………………….217
DISASSEMBLING AND ASSEMBLING………………………………………………….217
[1] Starter…………………………………………………………………217
[2] Alternator………………………………………………………………218
SERVICING…………………………………………………………………..221
[1] Starter…………………………………………………………………221
[2] Alternator………………………………………………………………223
IV. Hydraulic System……………………………………………………………………227
A. Troubleshooting………………………………………………………………….229
a. Common Circuit……………………………………………………………….229
b. Hydraulic system……………………………………………………………..231
c. Pump………………………………………………………………………..233
d. Motor……………………………………………………………………….234
e. Swivel performance……………………………………………………………235
f. Traveling performance…………………………………………………………241
B. Specifications…………………………………………………………………..245
a. Pump………………………………………………………………………..245
[1] Specifications…………………………………………………………..245
b. Control valve………………………………………………………………..246
[1] Relief valve (bench data)…………………………………………………247
[2] Main relief valve (at the measurement port on the machine)……………………247
[3] Overload relief valve (bench data)…………………………………………248
[4] Overload ralief valve (at the measurement port on the machine)………………..248
c. Swivel performance……………………………………………………………249
d. Traveling performance…………………………………………………………250
e. Cylinder…………………………………………………………………….251
[1] Speed…………………………………………………………………..251
[2] Natural fall…………………………………………………………….251
[3] Specifications and dimensions……………………………………………..252
f. Motor drain amount……………………………………………………………257
[1] Swivel motor…………………………………………………………….257
[2] Travel motor…………………………………………………………….257
g. Service port performance………………………………………………………258
C. Testing…………………………………………………………………………259
a. Pump flow……………………………………………………………………259
b. Pressure measurement………………………………………………………….261
[1] Pilot pressure…………………………………………………………..261
[2] Main relief valve pressure………………………………………………..262
[3] Overload relief pressure………………………………………………….264
[4] Swivel brake pressure…………………………………………………….265
[5] Swivel brake release valve………………………………………………..266
[6] Travel two-speed selector pressure…………………………………………266
c. Drain measurement…………………………………………………………….267
[1] Travel motor…………………………………………………………….267
[2] Swivel motor…………………………………………………………….268
d. Measurement of block performance……………………………………………….269
[1] Swivel………………………………………………………………….269
[2] Travel………………………………………………………………….269
e. Operating speed………………………………………………………………270
[1] Checking procedure of each speed…………………………………………..270
f. Straight travel performance……………………………………………………272
g. Cylinder natural fall amount…………………………………………………..272
h. Control and traveling lever operating force……………………………………..272
i. Lever stroke…………………………………………………………………272
D. Disassembling and Assembling………………………………………………………273
a. Preparation………………………………………………………………….126
b. Front attachment assembly……………………………………………………..273
c. Pump………………………………………………………………………..276
[1] Pump coupling……………………………………………………………276
[2] Mounting and dismounting the pump………………………………………….134
[3]Component parts of pump……………………………………………………281
[4]Disassembling and reassembling the pump……………………………………..282
General precautions………………………………………………………….282
Reassembling precautions……………………………………………………..285
[5]Troubleshooting of pump……………………………………………………287
d. Control valve………………………………………………………………..288
[1] Dismounting……………………………………………………………..288
[2] Remounting of control valve……………………………………………….290
[3] Control valve : KBM – make………………………………………………..291
[4] Installment……………………………………………………………..299
[4] Component parts of sections,KBT – make……………………………………..300
3) Travel right section………………………………………………………301
e. Pilot valve………………………………………………………………….307
[1] Mounting and dismounting the pilot valve……………………………………307
[2] Disassembling and reassembling the pilot valve………………………………311
[3] Trouble shooting…………………………………………………………322
f. Swivel motor…………………………………………………………………323
[1] Dismounting……………………………………………………………..323
[2] Structure……………………………………………………………….325
[3] Function………………………………………………………………..326
[4] Operation Explanation…………………………………………………….327
[5] Operational Precautions…………………………………………………..332
[6] Inspection Guidelines…………………………………………………….334
[7] Swivel motor disassembling / reassembling…………………………………..337
g. Rotary joint (Swivel joint)……………………………………………………358
h. Traveling motor : KX71-3 PP version…………………………………………….362
[1] Dismounting……………………………………………………………..362
[2] List of adapter hoses…………………………………………………….364
[3] Component parts of wheel motor…………………………………………….365
[4] Disassembling and reassembling the wheel motor………………………………367
i. Cylinder…………………………………………………………………….394
j. Pilot filter…………………………………………………………………399
k. Change valve…………………………………………………………………401
l. TPSS valve, KX71-3 PP version………………………………………………….402
m. Hydraulic oil tank……………………………………………………………404
n. Hydraulic hose……………………………………………………………….407
[1] Pilot hose………………………………………………………………407
[2] High pressure hose……………………………………………………….411
[3] Low pressure hose………………………………………………………..419
V. Electrical System……………………………………………………………………425
A. Specifications…………………………………………………………………..427
B. Wireharness diagram and couplers…………………………………………………..429
a. Coupler identification : KX61-3, KX71-3…………………………………………429
b. Wireharness diagram : KX61-3, KX71-3, EU – version……………………………….430
c. Wireharness diagram : KX71-3, PP – version………………………………………431
d. Functional circuit diagram…………………………………………………….432
C. Troubleshooting & Testing…………………………………………………………433
a. Engine………………………………………………………………………433
b. Meter panel………………………………………………………………….434
c. Others………………………………………………………………………436
d. Testing……………………………………………………………………..437
D. Wire harness installation…………………………………………………………445
a. Precautions………………………………………………………………….445
b. Engine earth, starter switch…………………………………………………..446
c. Battery……………………………………………………………………..447
d. Limit switch…………………………………………………………………448
e. Wire harness route……………………………………………………………449
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S.V