Kubota KX91-3 KX101-3 Excavator Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kubota KX91-3 KX101-3 Excavator Workshop Manual – PDF DOWNLOAD
Safty precautions for servicing, disassembly and reassembly
Safty precautions for servicing :
Most accidents during servicing arise from carelessness. Please remember that safty involves both the welfare
of the employees and improved work efficiency.
Safty precautions for Disassembly and reassembly
Machines must be diassembled 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. Safty 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 hydrauricunits 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 KX91-3 KX101-3 Excavator Workshop Manual – PDF DOWNLOAD
WSM_KX91_101-3………………………………………………………………………………………………… 1
CONTENTS………………………………………………………………………………………………….. 3
I. General………………………………………………………………………………………………… 5
A. Body and engine identification marks…………………………………………………………………… 7
B. Safty precautions for servicing, disassembly and reassembly………………………………………………. 8
a. Safty measures before starting work………………………………………………………………… 8
(1) Work clothes………………………………………………………………………………… 8
(2) Inspecting equipment and tools………………………………………………………………… 8
(3) Keep workshop in order……………………………………………………………………….. 8
b. Safty 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 SAFTY 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 Hydrauric 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
II. Machine body(Mechanism section)………………………………………………………………………….. 19
A. Front attachment…………………………………………………………………………………….. 21
a. Greasing points………………………………………………………………………………….. 21
b. Bucket interchangeability…………………………………………………………………………. 22
B. Swivel frame and components…………………………………………………………………………… 23
a. Accel lever (Standard-version)…………………………………………………………………….. 24
(1) Engine RPM………………………………………………………………………………….. 24
(2)Accel lever operating force……………………………………………………………………. 24
b. Auto idle-version………………………………………………………………………………… 25
(1) Accel lever side…………………………………………………………………………….. 25
(2) AI motor side……………………………………………………………………………….. 26
(3) Engine side…………………………………………………………………………………. 26
c. Accel cable……………………………………………………………………………………… 27
d. Swivel bearing…………………………………………………………………………………… 28
C. Track frame and components……………………………………………………………………………. 29
a. Tension spring pre-set length……………………………………………………………………… 29
b. Additional parts to change from rubber track to iron track……………………………………………. 29
c. Track tension adjustment………………………………………………………………………….. 30
d. Grease tension cylinder, L………………………………………………………………………… 31
e. Drive sprocket…………………………………………………………………………………… 32
f. Rubber track…………………………………………………………………………………….. 33
g. Iron track………………………………………………………………………………………. 34
II. Machine body(Service section)……………………………………………………………………………. 35
A. Specifications………………………………………………………………………………………. 37
a. Machine Weight…………………………………………………………………………………… 37
(1) KE, KDG, KUK version…………………………………………………………………………. 37
(2) KTC, KCL, KTA version………………………………………………………………………… 37
b. Machine specifications……………………………………………………………………………. 38
(1) KE, KDG, KUK version…………………………………………………………………………. 38
(2) KTC, KCL, KTA version………………………………………………………………………… 39
c. Lever stroke and operating force…………………………………………………………………… 40
d. Dimensions of Parts………………………………………………………………………………. 41
(1) Front pins………………………………………………………………………………….. 41
(2) Bucket……………………………………………………………………………………… 42
(3) Rubber crawler………………………………………………………………………………. 45
(4) Iron crawler………………………………………………………………………………… 45
(5) Track toller, idler, sprocket…………………………………………………………………. 46
(6) Dozer………………………………………………………………………………………. 47
(7) Parts weight………………………………………………………………………………… 48
(8) Quantity Water and Oil……………………………………………………………………….. 50
B. Front attachment…………………………………………………………………………………….. 51
a. Parts designation………………………………………………………………………………… 51
b. Exchange of bucket (Kubota Japan Bucket)……………………………………………………………. 54
c. Exchange of bucket teeth and side cutter……………………………………………………………. 55
d. Installing direction of dust seal………………………………………………………………….. 56
e. Installation of thrust collar on the swing bracket…………………………………………………… 56
e-1. Service tip to ease customer complain…………………………………………………………….. 57
e-2. Swing bracket pin & bush………………………………………………………………………… 58
e-3. Replacing the swing bracket support bush………………………………………………………….. 59
e-4. Measuring the swing bracket looseness…………………………………………………………….. 65
f. Installing direction of fixing pin bolts……………………………………………………………. 67
g. Front hoses and clamps……………………………………………………………………………. 68
C. Upper Structure……………………………………………………………………………………… 69
a. Swivel bearing…………………………………………………………………………………… 69
b. Traveling lever………………………………………………………………………………….. 70
d. Traveling lever adjustment………………………………………………………………………… 71
e. Traveling lever lock……………………………………………………………………………… 72
Adjusting the lever’s neutral position…………………………………………………………….. 72
f. Accelarator lever………………………………………………………………………………… 73
(1) KE, KUK, KDG version…………………………………………………………………………. 73
(2) KTC, KU, KTA version…………………………………………………………………………. 73
g. Dozer lever……………………………………………………………………………………… 74
h. Swing pedal……………………………………………………………………………………… 75
i. Auxiliary port pedal……………………………………………………………………………… 76
j. Location of links for each operation……………………………………………………………….. 77
D. Under carriage………………………………………………………………………………………. 79
a. Track tension device……………………………………………………………………………… 79
b. Crawler installation……………………………………………………………………………… 80
c. Track Roller and Upper Roller installation………………………………………………………….. 81
III. Engine(Mechanism section)………………………………………………………………………………. 83
A. Specification & features……………………………………………………………………………… 85
a. Specifications…………………………………………………………………………………… 85
b. Features………………………………………………………………………………………… 85
B. Fuel injection pump………………………………………………………………………………….. 86
a. Structure……………………………………………………………………………………….. 86
b. Precaution of removing reassembly………………………………………………………………….. 87
(1) Removing injection pump………………………………………………………………………. 87
(2) Mounting of injection pump……………………………………………………………………. 87
(3) Engine stop lever installation………………………………………………………………… 88
C. Radiator fan & coupling flange………………………………………………………………………… 91
a. Fan belt tension adjustment……………………………………………………………………….. 91
b. Alternator mounting bolt torque:…………………………………………………………………… 91
c. Temp. sensor tightning torque:…………………………………………………………………….. 91
d. Fan flange bolt tightning torque:………………………………………………………………….. 91
e. Bolt tightning torque of coupling flange……………………………………………………………. 91
f. Coupling flange………………………………………………………………………………….. 92
D. Other parts…………………………………………………………………………………………. 92
a. Fuel filter……………………………………………………………………………………… 92
b. Air filter………………………………………………………………………………………. 93
c. Thermostat………………………………………………………………………………………. 94
E. Technical Data………………………………………………………………………………………. 95
Engine Specifications……………………………………………………………………………….. 95
F. Performance Curve……………………………………………………………………………………. 96
III. Engine(Engine WSM (Addition))…………………………………………………………………………… 99
IV. Hydraulic system(Mechanism section)……………………………………………………………………….211
A. Features of hydraulic system…………………………………………………………………………..213
B. Hydraulic system specifications………………………………………………………………………..214
C. Main pump……………………………………………………………………………………………215
a. Structure & specifications…………………………………………………………………………215
b. Performance curve…………………………………………………………………………………216
Variable displacement pump………………………………………………………………………..216
Variable displacement pump………………………………………………………………………..217
D. Control valve………………………………………………………………………………………..218
a. Specifications……………………………………………………………………………………218
b. General view of control valve………………………………………………………………………219
c. Control valve circuit diagram………………………………………………………………………221
d. Control valve sectional view……………………………………………………………………….222
e. Arm regeneration circuit…………………………………………………………………………..228
(1) Arm dump…………………………………………………………………………………….228
(2) Arm Crowd……………………………………………………………………………………228
f. Oil flow of lock valve…………………………………………………………………………….229
(1) Operation of lock valve……………………………………………………………………….229
(2) Boom operation……………………………………………………………………………….231
g. Function of lock valve (Anti-drift valve)……………………………………………………………233
(1) Boom cylinder holding function…………………………………………………………………233
(2) Boom up function……………………………………………………………………………..233
(3) Boom-down function……………………………………………………………………………233
h. Relief valve/Anti-cavitation valve………………………………………………………………….234
i. Straight travel circuit……………………………………………………………………………235
j. Other functions…………………………………………………………………………………..236
(1) Interval oil flow…………………………………………………………………………….236
E. Pilot valve………………………………………………………………………………………….237
a. Structure & specifications…………………………………………………………………………237
b. Pilot valve control diagram………………………………………………………………………..239
F. Swivel motor…………………………………………………………………………………………240
a. Structure & specifications…………………………………………………………………………240
b. Function of negative brake…………………………………………………………………………243
(1) Negative brake function(Unload condition)……………………………………………………….243
(2) Negative brake release(On-load condition)……………………………………………………….243
c. Function of valve section………………………………………………………………………….244
(1)Make-up valve…………………………………………………………………………………244
(2)Function of shockless valve…………………………………………………………………….244
(4) Relief valve…………………………………………………………………………………245
(5) Shockless piston……………………………………………………………………………..245
(6) Make-up poppet……………………………………………………………………………….245
G. Rotary joint (Swivel joint)……………………………………………………………………………246
H. Travel motor…………………………………………………………………………………………247
a. Structure & specifications : KTC, KCL, KTA version……………………………………………………247
(1) Relief valve…………………………………………………………………………………247
(2) Shockless piston……………………………………………………………………………..247
(3) Counter balance valve…………………………………………………………………………248
(4) High pressure selection spool………………………………………………………………….248
(5)Hi-Lo change spool…………………………………………………………………………….248
b. Operation of piston motor………………………………………………………………………….249
c. Function of shockless valve………………………………………………………………………..250
I. Other components……………………………………………………………………………………..252
a. Change valve with accumulator : EU version…………………………………………………………..252
(1) Pressure relief valve: a4……………………………………………………………………..253
(2) Pressure relief valve: a5……………………………………………………………………..254
(3) Electro-magnetically directional spool valves……………………………………………………255
b. Pilot filter……………………………………………………………………………………..256
c. Return filter…………………………………………………………………………………….257
d. Suction strainer………………………………………………………………………………….257
J. Hydraulic circuit diagram……………………………………………………………………………..259
a. KX91-3 European – version………………………………………………………………………….259
b. KX101-3 European – version…………………………………………………………………………261
c. KX91-3 KTC, KCL – version………………………………………………………………………….263
d. KX91-3 KTA – version………………………………………………………………………………264
d. Hydraulic components layout………………………………………………………………………..265
a. Actual service port flow:KX91-3 KTA-version only……………………………………………………..267
d. Installing direction of dust seal…………………………………………………………………..269
e. Installation of thrust collar on the swing bracket……………………………………………………269
IV. Hydraulic system(Service section)…………………………………………………………………………271
A. Troubleshooting………………………………………………………………………………………273
a. Common Circuit……………………………………………………………………………………273
b. Front Attachment………………………………………………………………………………….275
c. Swivel Circuit……………………………………………………………………………………278
d. Travel Circuit……………………………………………………………………………………280
B. Specifications……………………………………………………………………………………….281
a. Relief valve pressure setting………………………………………………………………………281
b. Pump…………………………………………………………………………………………….283
(1) KE, KDG, KUK version………………………………………………………………………….283
(2) KTC, KCL, KTA version…………………………………………………………………………284
c. Cylinder…………………………………………………………………………………………285
(1) Cylinder operating speed………………………………………………………………………285
(2) Cylinder natural fall amount…………………………………………………………………..285
(3) Cylinder specifications……………………………………………………………………….286
d. Swivel Performance………………………………………………………………………………..289
(1) KE, KDG, KUK version………………………………………………………………………….289
e. Traveling Performance……………………………………………………………………………..290
(1) KE, KDG, KUK version………………………………………………………………………….290
(2) KTC, KCL, KTA version…………………………………………………………………………291
C. Testing……………………………………………………………………………………………..292
a. Testing Instruments & special tools…………………………………………………………………292
b. Pump flow………………………………………………………………………………………..294
c. Pilot pressure……………………………………………………………………………………295
(1) Primary pressure……………………………………………………………………………..295
(2) Secondary pressure……………………………………………………………………………296
d. Main relief valve…………………………………………………………………………………297
e. Overload relief valve……………………………………………………………………………..299
f. Swivel brake valve pressure………………………………………………………………………..301
g. Traveling motor drain amount……………………………………………………………………….303
h. Swivel motor drain amount………………………………………………………………………….304
i. Swivel motor block performance……………………………………………………………………..305
j. Traveling motor block performance…………………………………………………………………..306
k. Operating speed…………………………………………………………………………………..307
(1) Checking each operating speed………………………………………………………………….307
(2) Boom cylinder………………………………………………………………………………..307
(3) Arm cylinder…………………………………………………………………………………307
(4) Bucket cylinder………………………………………………………………………………308
(5) Swing cylinder……………………………………………………………………………….308
(6) Dozer cylinder……………………………………………………………………………….308
(7) Swivel speed…………………………………………………………………………………309
(8) Traveling speed………………………………………………………………………………309
l. Straight travel performance………………………………………………………………………..309
m. Cylinder natural fall amount……………………………………………………………………….310
n. Control and Traveling lever operating force………………………………………………………….310
o. Lever stroke……………………………………………………………………………………..310
p. Specification sheet : Drain amount, Swivel motor……………………………………………………..311
q. Specification sheet : Drain amount, Wheel motor (Travel motor)…………………………………………312
D. Disassembling and Assembling…………………………………………………………………………..313
a. Coupling flange…………………………………………………………………………………..313
b. Pump…………………………………………………………………………………………….314
(1) Components of pump [KX91-3, KX101-3]……………………………………………………………314
(2) Adaptor installation on the pump……………………………………………………………….315
(3) Disassembling and assembling…………………………………………………………………..316
c. Control valve and relief valve……………………………………………………………………..340
(1) General precautions for servicing control valve………………………………………………….340
(2) Components of the control valve………………………………………………………………..342
(3) Inner parts of the control valve……………………………………………………………….343
(4) Adaptor installation………………………………………………………………………….344
(5) Disassembling of the control valve……………………………………………………………..345
d. Pilot valve………………………………………………………………………………………346
(1) Components of the pilot valve………………………………………………………………….346
(2) Adaptor and hose installation………………………………………………………………….347
(3) Disassembling and assembling (KTC, KCL, KTA version)……………………………………………..348
(4) Trouble shooting……………………………………………………………………………..360
e. Swivel motor (KTC, KCL, KTA version)………………………………………………………………..361
(1) Components of the swivel motor…………………………………………………………………361
(2) Inner parts of the swivel motor………………………………………………………………..364
(3) Assembling of the swivel motor (KTC, KCL, KTA version)……………………………………………367
f. Traveling motor…………………………………………………………………………………..372
(1) Components of the traveling motor (KTC, KCL, KTA version)…………………………………………372
(2) Inner parts of the traveling motor……………………………………………………………..376
(3) Assembling of the traveling motor (KTC, KCL, KTA version)…………………………………………380
g. Rotary joint……………………………………………………………………………………..391
(1) Inner parts of the rotary joint………………………………………………………………..391
(2) Assembling of the rotary joint…………………………………………………………………392
(3) Adaptor installation on the rotary joint (KTC, KCL, KTA version)…………………………………..393
h. Cylinder (KE, KDG, KUK version)…………………………………………………………………….394
(1) Inner parts of the cylinder……………………………………………………………………394
(2) Tightening torque…………………………………………………………………………….399
(3) Disassembling and assembling…………………………………………………………………..401
h. Cylinder (KTC, KCL, KTA version)……………………………………………………………………406
(1) Inner parts of the cylinder……………………………………………………………………406
(2) Tightening torque…………………………………………………………………………….411
(3) Disassembling and assembling…………………………………………………………………..413
(4) Inspection…………………………………………………………………………………..416
i. Other hydraulic device…………………………………………………………………………….417
(1)Change value………………………………………………………………………………….417
(2) TPSS valve (KTC, KCL, KTA version only)…………………………………………………………419
j. Hose…………………………………………………………………………………………….420
(1) Pilot hose…………………………………………………………………………………..420
(2) Delivery hose………………………………………………………………………………..423
(3) Hose connection around Rotary Joint (KTC, KCL, KTA version)……………………………………….426
(4) Hose connection on control valve (KTC, KCL, KTA version)………………………………………….427
(5) Return circuite (KTC, KCL, KTA version)…………………………………………………………429
(6) Drain circuit (KTC, KCL, KTA version)…………………………………………………………..430
(7) Traveling motor and dozer……………………………………………………………………..431
V. Electrical system(Mechanism section)……………………………………………………………………….433
A. Outline……………………………………………………………………………………………..435
B. Components & harness layout……………………………………………………………………………437
C. Couplers, KX91-3, 101-3 Standard version………………………………………………………………..438
D. Function of main circuit………………………………………………………………………………439
a. Battery circuit (Standard-version)………………………………………………………………….439
b. Safty Relay circuit (Automatic release function) Standard-version………………………………………440
(1) Operation……………………………………………………………………………………440
(2) Function chart of auto release controller……………………………………………………….441
c. Auto glow circuit (Standard-version)………………………………………………………………..442
(1) Function…………………………………………………………………………………….442
d. Fuel control circuit (STD, AI-version)………………………………………………………………444
(1) Function…………………………………………………………………………………….444
(2) Engine stop solenoid (STD, AI-version)………………………………………………………….445
e. Engine oil pressure sensor circuit (STD, AI-version)………………………………………………….446
Oil switch………………………………………………………………………………………446
f. Horn circuit (STD, AI-version)……………………………………………………………………..447
(1) Structure……………………………………………………………………………………447
(2) Function…………………………………………………………………………………….447
(3) Current flow…………………………………………………………………………………448
(4) Horn circuit…………………………………………………………………………………449
g. Cab & Working lamp circuit (STD, AI-version)…………………………………………………………450
h. Meter panel (Standard-version)……………………………………………………………………..451
i. Heater circuit (STD, AI-version)……………………………………………………………………452
j. Travel hi-speed control circuit (STD, AI-version)…………………………………………………….453
k. Auto idle control system (AI-version)……………………………………………………………….454
(1)Purpose………………………………………………………………………………………454
(2)Auto idle function mechanism……………………………………………………………………454
(3) AI function layout……………………………………………………………………………455
(4) Behavior when the control lever is returned to neutral……………………………………………456
(5) Behavior when the control lever is operated:…………………………………………………….457
(6) AI motor normal-turn circuit…………………………………………………………………..458
(7) AI motor reverse-turn circuit………………………………………………………………….459
l. Battery direct line (AI-version)……………………………………………………………………460
m. Starter lock relay & auto release relay (AI-version)………………………………………………….461
(1) Safety start system…………………………………………………………………………..461
(2) Auto release function (AI- version)…………………………………………………………….462
n. Self holding relay circuit (AI-version)……………………………………………………………..463
o. Water temp. sensor circuit (AI-version)……………………………………………………………..464
p. Meter panel (AI-version)…………………………………………………………………………..465
q. AI controller unit (AI-version)…………………………………………………………………….466
E. Structure and function of main components……………………………………………………………….467
a. Key switch (Engine starter switch)………………………………………………………………….467
b. Water temp. sensor………………………………………………………………………………..467
c. Safty lever lock switch, travel hi-low pedal switch…………………………………………………..468
d. Relay……………………………………………………………………………………………469
e. Engine speed sensor……………………………………………………………………………….470
f. Accel sensor, governor sensor………………………………………………………………………471
g. AI pressure switch………………………………………………………………………………..472
h. Foundamentals…………………………………………………………………………………….473
F. Circuit diagram………………………………………………………………………………………479
a. Electric Circuit Diagram: KX91-3, 101-3 (Standard-version)…………………………………………….479
b. Functional Electric Circuit Diagram: KX91-3, 101-3 (Standard-version)…………………………………..481
c. Electric Circuit Diagram: KX101-3 (AI-version, EU)……………………………………………………483
d. Functional Electric Circuit Diagram: KX101-3 (AI-version, EU)………………………………………….485
e. Cab Electrical Diagram…………………………………………………………………………….487
KX91-3, KTC, KCC, KTA-version……………………………………………………………………..487
f. Harness couplers of KX101-3, AI-version……………………………………………………………..489
V. Electrical system(Service section)…………………………………………………………………………491
A. Troubleshooting………………………………………………………………………………………493
a. General………………………………………………………………………………………….493
(1) How to diagnose………………………………………………………………………………493
(2) INSPECTION OF HARNESS CONNECTOR………………………………………………………………..494
(3) Inspection…………………………………………………………………………………..495
(4) INSPECTION INSTRUMENTS………………………………………………………………………..495
(5) CHECKING SWITCHED…………………………………………………………………………….496
(6) Checking fuses……………………………………………………………………………….497
(7) Solenoid test method………………………………………………………………………….498
(8) Checking relays………………………………………………………………………………499
(9) Checking cables and wires……………………………………………………………………..500
(10) HANDLING ON-VEHICLE BATTERY…………………………………………………………………..500
b. Front attachment………………………………………………………………………………….501
(1) Working lamp failure………………………………………………………………………….501
(2) Safety lever lock circuit malfunction…………………………………………………………..502
c. Engine electrical system…………………………………………………………………………..503
(1) Engine oil pressure failure……………………………………………………………………503
(2) Water temp. sensor circuit malfunction………………………………………………………….505
(3) Fuel sensor circuit…………………………………………………………………………..507
(4) Engine stop solenoid………………………………………………………………………….508
(5) Charging system malfunction……………………………………………………………………509
(6) Auto glow controller………………………………………………………………………….511
(7) Auto release controller……………………………………………………………………….512
d. Auto idle system………………………………………………………………………………….513
(1) Troubleshooting outline………………………………………………………………………. 29
(2) AI pressure switch test method…………………………………………………………………514
(3) Accel & governer sensor test method…………………………………………………………….516
(4) AI motor test method………………………………………………………………………….518
(5) Engine speed sensor…………………………………………………………………………..519
(6) Auto glow circuit…………………………………………………………………………….521
e. AI version: AI controller (built-in microcomputer) Cases of trouble diagnosis with circuit tester………….523
(1) “Water temperature sensor” line in trouble………………………………………………………523
(2) Other circuitry layouts and their trouble diagnosis………………………………………………525
f. Auto Idle(AI) version: Trouble diagnosis with lamp……………………………………………………526
(1) General……………………………………………………………………………………..526
(2) Display and identification of errors in operating mode……………………………………………527
(3) Entering the service mode……………………………………………………………………..528
(4) Working on the 5 menus in the service mode………………………………………………………529
(5) Working on the 3 menus in the service mode………………………………………………………530
(6) Working on the AI motor drive menus in the service mode…………………………………………..531
(7) Entering the setup mode……………………………………………………………………….532
(8) Lamp-identified fail symptoms, trouble spots and possible causes…………………………………..536
VI. Optional Units………………………………………………………………………………………….539
A. KTA-version………………………………………………………………………………………….541
a. Actual service port flow : KX91-3 KTA-version only……………………………………………………541
1. Test method ; Testing circuit…………………………………………………………………..541
2. Service port flow test sample…………………………………………………………………..542
3. P-Q performance of pump 2………………………………………………………………………543
4. Actual service port flow : KX91-3 KTA-version…………………………………………………….545
5. Actual service port flow : U35-3 KTA-version……………………………………………………..546
b. Breaker performance test sample : KTA-version only……………………………………………………547
1. Test machine :………………………………………………………………………………..547
2. Heat balance test condition…………………………………………………………………….547
3. Breaker operating result : Sample Data…………………………………………………………..547
4. Service port flow for breaker operation, theoretical………………………………………………548
5. Breaker operation test procedure………………………………………………………………..549
6. Test Data Sheet……………………………………………………………………………….550
7. Krupp breaker information………………………………………………………………………551
8. SERVICE PORT OIL FLOW (KTA Version)……………………………………………………………..552
B. KTC-version, optional kit……………………………………………………………………………..553
a. Installation Manual for Canopy Kit………………………………………………………………….553
1. Introduction………………………………………………………………………………….553
2. Item list of canopy kit………………………………………………………………………..553
3. Installation instruction……………………………………………………………………….554
b. Installation Manual for Canopy Kit………………………………………………………………….557
1. Introduction………………………………………………………………………………….557
2. Item list of canopy kit………………………………………………………………………..557
3. Installation instruction……………………………………………………………………….558
c. Working Light Installation Manual…………………………………………………………………..561
1. Introduction………………………………………………………………………………….561
2. Item list of light kit…………………………………………………………………………561
d. Installation Manual for Cabin Kit…………………………………………………………………..567
1. Introduction………………………………………………………………………………….567
2. Item list of cabin kit…………………………………………………………………………567
3. Installation instruction……………………………………………………………………….568
e. Installation Manual for Cabin Kit…………………………………………………………………..575
1. Introduction………………………………………………………………………………….575
2. Item list of canopy kit………………………………………………………………………..575
3. Installation instruction……………………………………………………………………….576
f. Item List of Heat Insulator Kit…………………………………………………………………….583
1. Introduction………………………………………………………………………………….583
2. Item list…………………………………………………………………………………….583
3. Overview……………………………………………………………………………………..583
4. Heat Insulator Installation Instructions…………………………………………………………584
5. Spark Arresting Muffler Installation Instructions…………………………………………………584
6. KX3 Spark Arrester Muffler Maintenance at Every 250 Excavator Service Hours………………………….584
g. Installation Manual Auxiliary Relief Valve and Cylinder Mounting Bracket Kit…………………………….587
1. Introduction………………………………………………………………………………….587
2. SAFE OPERATION BEFORE THUMB INSTALLATION…………………………………………………………587
3. WELDING INSTRUCTIONS…………………………………………………………………………..587
4. Parts list……………………………………………………………………………………588
5. Installation instructions………………………………………………………………………588
h. THIRD LINE KIT……………………………………………………………………………………593
1. Introduction………………………………………………………………………………….593
2. Preparation for installation……………………………………………………………………593
3. Installation instruction……………………………………………………………………….594
4. Inspection after installation…………………………………………………………………..598
i. STEEL CRAWLER KIT (Convert tracks from rubber to steel) INSTALLATION INSTRUCTION FOR MOUNTING STEEL TRACKS….601
1. Removing rubber tracks…………………………………………………………………………601
2. Changing the tension of spring………………………………………………………………….602
3. Mounting iron crawlers…………………………………………………………………………603
4. Adjustiment of crawlers (Steel tracks)…………………………………………………………..603
j. STEEL CRAWLER KIT (Convert tracks from rubber to steel) INSTALLATION INSTRUCTION FOR MOUNTING STEEL TRACKS….605
1. Removing rubber tracks…………………………………………………………………………605
2. Changing the tension of spring………………………………………………………………….606
3. Mounting iron crawlers…………………………………………………………………………607
4. Adjustiment of crawlers (Steel tracks)…………………………………………………………..607
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