CONTENTS Sales Engineering Section..........I-1 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-7 II Service Engineering Section........... II-1 A. General outline ..................II-2 B. Finger control service port system............II-22 C.
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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-7 I - 1...
WSM Minor Change I Sales Engineering Section A. Quick feature chart KX91-3S, KX91-3 , KX101-3 , U35S, U35-3S, U35-3 Safeness upgraded Basic performance improved (new) (1) Full-scale 4-post ROPS/FOPS Greater working range of this class canopy (1) Maximum digging and dumping heights (3) Standard equipped with ROPS/ (2) Maximum digging depth FOPS cabin (cab type)(with...
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WSM Minor Change I Sales Engineering Section KX121-3S, KX121-3 , KX161-3S, KX161-3 , U45-3S, U45-3 New immobilizer system introduced Digital navigation system adopted Service port knob control (Europe) Thumb bracket adopted (North America) Greater engine output (KX161-3S) Travel bi-speed switch (Dozer lever) Sedimenter separately located Independent swing pedal...
KX121-3 and KX161-3 feature the Load Sensing Hydraulic System). Strongest bucket breakout force in its class Kubota's Hydraulic Matching system is unmatched for power or ease of use. Load sensing hydraulics, which automatically regulate and distribute optimum oil amounts to each cylinder, make it ideal for your toughest trenching projects or your lightest dozing tasks.
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KUBOTA engine The ultra powerful, incredibly dependable Kubota diesel engines deliver unmatched horsepower while minimizing emissions to meet EPA standards. They produce quick starts in temperatures as low as - 4 F, low sound as well as low vibration.
C. New innovations DIGITAL PANEL Informative, interactive and functional. Kubota's all-new liquid crystal display (LCD) panel accurately shows easy-to-understand diagnostics and digital readings. The Kubota Intelli- gent Control System (KICS) will even alert the operator to when routine maintenance is due.
The company reserves the right to change the above specifications without notice. This brochure is for descriptive purpose only. Please contact your local Kubota dealer for warranty infomation. For your safety, KUBOTA strongly recommends the use of a Rollover Pro- tective structure (ROPS) and seat belt almost all applications.
WSM Minor Change II Service Engineering Section II Service Engineering Section A. General outline..............II-2 a. New engineering points................ II-2 b. Photos of main modified parts.............. II-3 c. Major specifications incorporated............II-4 d. Quantity water and oil................II-5 e. Quality specifications................II-6 B.
WSM Minor Change II Service Engineering Section A. General outline a. New engineering points PP-version (KTC, KCL, KTA) EU-version KX91-3S, KX121-3S, KX91-3 , U35-3 KX121-3 , U45-3 New contents U35S, U35-3S KX161-3S, KX101-3 KX161-3 U45-3S Digital panel with thumb bracket, option Finger control ser- vice port Breaker switch...
WSM Minor Change II Service Engineering Section b. Photos of main modified parts No.8 Digital meter panel, AI-version No.1 Knob switch No.8 Digital meter panel No.5 Accumulator in pilot line No.4 Arm with thumb bracket No.2 S/P solenoid valve No.7 Two speed switch No.9 Anti-theft system No.6 Fuel-water separator (EU-version)
WSM Minor Change II Service Engineering Section d. Quantity water and oil KX91-3S U35S, U35-3S Unit KX101-3 Remarks KX91-3 U35-3 Radiator 1.93 L.L.C Reserve tank 0.42 Engine Crank case SAE10W30(CD) 1.40 55.0 Hydraulic oil Full ISO 46 14.53 36.0 Hydraulic oil Tank ISO 46 9.51...
WSM Minor Change II Service Engineering Section e. Quality specifications Note: 1. Only those data with bold letter and with shadow are different from those of the previous models before modification. 2. EU-version will be announced later. U35S ( KTC, KCL ), U35-3S ( KTA ), KX91-3S(KTC,KCL,KTA) Machine specification : Service port, Wrist rest, STD-arm, KBT-cab, KBT-bucket.
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) 8 Front attach- Max. digging radius 5255 5245 ment inch 206.9 206.5 Ground level Max. digging 5140 5135 radius inch 202.4 202.2 Ground level Min.
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) 1 Crawler height Include grouser on the spocket inch 16.54 0.31 16.93 0.35 2 Max. crawler height inch 17.72 0.35 17.91 0.55 Engine performance...
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) 1 Boom speed Canopy up 1st Oil temp. 50 5 C up 2nd (122 41 F) down Ground to max. down height (excu- Cabine...
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) 1 Swing speed Canopy Cabine 1 Swing Lock Swivel R&L 10 > 90 deg-swivel, 100 times actual inch 0.39 > digging cylinder dislocation 2 Reciprocating...
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) 3 Arm lever crowd Extend & crowd 16.67 9.81 16.67 4.90 extend 13.73 9.81 13.73 4.90 5 Bucket lever crowd Dump &...
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) 19 Safety lock Up & down lever 7.85 1.96 down 3.92 1.96 Up & down 19.5 down 49.03 9.81 43.4 11.0 23 Travel Hi-Lo change 30.40...
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WSM Minor Change II Service Engineering Section U35S (KTC, KCL) KX91-3S Specificatios Items Unit Remarks U35-3S (KTA) (KTC, KCL, KTA) Stability 1 Standard arm, Bucket load to Side, Arm extend, Dynamic opera- 10 degrees tip- dozer up bucket crowd tion load limit ping oil temp.50 5 C (122 41 F)
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WSM Minor Change II Service Engineering Section KX121-3S, 161-3S : KTC, KCL, KTA Version Machine specification : Service port, TPSS, Arm rest, Long arm, 4 POSTcanopy, KTC-bucket Specificatios Items Unit KX121-3S KX161-3S Remarks Main Speed JIS A8404 1 Machine size Total length (Transport) 5090 5540...
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WSM Minor Change II Service Engineering Section Specificatios Items Unit KX121-3S KX161-3S Remarks 9 Front attach- Ground level Max. digging 5475 6130 ment radius inch 215.6 241.3 Ground level Min. finish 1805 1940 Bucket bottom radius horizontal inch 71.1 76.4 Max.
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WSM Minor Change II Service Engineering Section Specificatios Items Unit KX121-3S KX161-3S Remarks 1 Boom speed Canopy up (G T) Oil temp. 50 5 C(122 41 up (L T) down(T G) Ground to max. down height (excu- Cabine up 1st lude cushioning) up 2nd down...
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WSM Minor Change II Service Engineering Section Specificatios Items Unit KX121-3S KX161-3S Remarks 1 Swing speed Canopy Cabine 1 Swing Lock Swivel R&L 2, 10 > 90 deg-swivel, 100 times actual inch 0.08 digging cylinder dislocation 2 Reciprocating L / R Swing 90 deg-swivel, motion...
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WSM Minor Change II Service Engineering Section Specificatios Items Unit KX121-3S KX161-3S Remarks 5 Bucket lever crowd Dump & crowd 14.71 4.90 extend 17.65 4.90 7 Swivel (Swing) lever Left & right 14.71 4.90 14.71 4.90 9 Dozer lever Up & down 9.81 4.90 23.54...
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WSM Minor Change II Service Engineering Section Specificatios Items Unit KX121-3S KX161-3S Remarks 19 Safety lock Up & down lever 7.85 1.96 down 3.92 1.96 Up & down 26.48 9.81 down 44.13 9.81 23 Travel Hi-Lo change Super servier have a switch 39.23 9.81 34.32...
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WSM Minor Change II Service Engineering Section Specificatios Items Unit KX121-3S KX161-3S Remarks Stability 1 Standard arm, Bucket load to Side, Arm extend, Dynamic opera- 10 degrees dozer up bucket crowd tion load limit tipping oil temp. 50 5 C (122 41 F) Front, dozer Bucket load to...
WSM Minor Change II Service Engineering Section B. Finger control service port system a. Feature and purpose 1 The service port pedal has been replaced by a lever-top knob switch: Feather-touch finger control realized. 2 The breaker can easily be operated with a button switch. 3 Optimum control feeling adjustments can be made for maneuvering various attachments efficiently.
WSM Minor Change II Service Engineering Section b. Outline of control system 1. Aux. port finger operation Fine control by finger operation Proportionality operation of AUX. port. Full open output hold Switch at the time of breaker operation. Hand operation ON-OFF Switch. (secure safety priority) 2.
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WSM Minor Change II Service Engineering Section 3. Service port system components Meter panel Proportional solenoid valve Main key start Safety lever lock switch Input Output Knob switch EEPROM Main control valve Breaker switch Work Panel switch selector switch lamp switch Thumb cylinder II - 24...
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WSM Minor Change II Service Engineering Section d. Knob structure and function The knob has a built-in IC chip that is different from that for potentiometers. 1)Service mode:Press the center switch of the meter panel to call the service mode. 2)Knob control: Shift the knob to L or R direction to call two way PTO operation.
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WSM Minor Change II Service Engineering Section 2. Basic operation of the knob 1) With the key on When the key is on, the system gets started out of the service mode OFF-position. In other words, the knob is not operative. (This is for safety.) 2) Service mode Press the center switch of the meter panel, and the...
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WSM Minor Change II Service Engineering Section 3. Flow chart; Service port operation Is safety lock lever down position? No service port operation Service port switch Service port switch lamp lights up Is breaker switch ON? Is knob switch shifted? Thumb cylinder Breaker starts.
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WSM Minor Change II Service Engineering Section 4. S/P switch (service port switch) <Function chart> Main key S/P switch Push Effective Service port function Non-effective Safety lock lever Down Warning lamp buzzer (5 ~ 6 sec.) Service port switch (S/P sw) in the middle bottom on the meter panel controls the service port func- tions, such as thumb switch and breaker switch.
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WSM Minor Change II Service Engineering Section 5. How the knob switch works 1) Let's suppose that the breaker has been released. To call the breaker mode again, it is neces- sary to press the back button (breaker switch) of the knob. (This is for safety.) 2) To release the breaker, just move the knob.
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WSM Minor Change II Service Engineering Section 7. Interrelation among current, pressure and flow Note: Above charts are just the sample figures to illustrate the interrelation among the three parameters. 1. Current: PWM current provided from the panel controller. 2. Pressure: Secondary pilot pressure delivered from S/P solenoid valve. 3.
WSM Minor Change II Service Engineering Section e. Initial settings of the knob 1. Set-up and adjustment of service port This new finger control service port system requires three types of set-up and adjustment proce- dures. Items to set-up When Knob initial set-up 1.
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WSM Minor Change II Service Engineering Section 3. Background and meaning of knob initial set-up 1) The output voltages at the neutral, rightmost and leftmost positions of a knob are entered as ini- tial settings. Accordingly, correlation between the knob's right-left shift and the output voltage is stored in microcomputer memory.
WSM Minor Change II Service Engineering Section f. S/P valve start point setting 1. Performance characteristics profile: Knob shift amount vs Output current Current Proportional control valve A Proportional control valve B 950 mA 450 mA Knob Neutral Right end Left end 1) A dead zone is provided to keep the thumb intact in neutral.
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WSM Minor Change II Service Engineering Section 7) Service engineers do not notice, but at Hirakata Factory and KBM, the starting point has been measured at the service port (red pressure mea- suring port for North America and Europe) and fluctuations have been put in the meter memory.
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WSM Minor Change II Service Engineering Section 2. Background and meaning of start-point setting 1) The purpose of this setting is to keep the knob's operating force of starting the attachment (thumb cylinder) constant whether the engine runs idle or at maximum speed. 2) The proportional control valve's start-point is activated when you have slowly moved the knob to start the attachment that is connected with the service port circuit.
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WSM Minor Change II Service Engineering Section 3. Illustration of the start-point setting Voltage fluctuation signal according to the knob's movement PWM current Pilot secondary pressure signal S/P section Main hydraulic line Move the knob, and you will find the point where the thumb cylinder starts moving. Just when the cylinder gets activated, press the selector switch.
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WSM Minor Change II Service Engineering Section 4. Concrete behavior at the start-point setting PWM input to the solenoid valve (mA) Pilot secondary pressure difference b Machine B Standard Pilot Secondary pressure current Machine A difference a θ θ θ full stroke full stroke Knob control angle: θ...
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WSM Minor Change II Service Engineering Section 5. S/P valve initial set-up flow chart <Machine’s operation cycle> <Operator’s action> When the thumb cylinder starts For the right direction, enter the moving, press the service port knob's output voltage with the button on the panel.
WSM Minor Change II Service Engineering Section g. Manual feeling setting 1. Outline of manual feeling setting Basically, the thumb is supposed to move smoothly by the starting point setting, but one may feel poor. To ensure good feeling, therefore, this mode is added. Setup Service port feeling adjust Right...
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WSM Minor Change II Service Engineering Section 2. Knob shift amount and output current Then actually move the knob, and ensure a good 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.
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WSM Minor Change II Service Engineering Section 2. Display flow chart with photo 1. Turn the starter key to ON KX91-3 (AC position) while pressing the display selector switch on the panel. Then the machine model comes on the display. 2.
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WSM Minor Change II Service Engineering Section 5. Push the display selector Engine start switch long, then the display indicates to “Engine start”. 6. Push the display selector Set up machine switch long, then the display moves to “Set up machine”. 7.
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WSM Minor Change II Service Engineering Section 9. Push the display selector Set up S/P knob switch short, the display indi- cates to “Set up S/P knob”. For the Setting-up of the ser- vice port knob initialization, press the display selector switch long.
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WSM Minor Change II Service Engineering Section 3. Knob initial set-up 1. The LCD display shows as “Set up S/P knob”. Set up S/P Knob 2. Push the display selector switch short, then the display shows “Lift up safety lever“. This is for safety purpose.
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WSM Minor Change II Service Engineering Section 4. S/P valve initial set-up 1. As instructed in page ***, Set up S/P valve you’re required to reach the display shows as “Set up S/P valve”. Safety precaution! Engine is running. 2. Shift down the safety lock Down the safety lever lever down to control the ser- vice port attachment.
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WSM Minor Change II Service Engineering Section 5. Push the display selector S/P port moves right switch at the moment that the Push selector sw actuator cylinder starts mov- ing to extend. Note: In case of thumb cylinder, “right” indicates the cylin- der to extend.
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WSM Minor Change II Service Engineering Section 5. S/P operational feeling adjustment 1. As instructed in page ***, you’re required to reach the Set up display shows as “Set up S/P S/P feeling adjust feeling adjust”. Safety precaution! Engine is running. 2.
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WSM Minor Change II Service Engineering Section 4. Slowly slide the S/P knob S/P right speed switch to right direction and + slow 12 fast - check the actuator’s starting points. If it starts moving too quick, get it slow by pressing the work lamp switch, left end button.
WSM Minor Change II Service Engineering Section i. Proportional control solenoid valve (S/P valve) 1. Outline This valve is the combination of electro magnetic solenoid valve and hydraulic reducing valve. Ordinally solenoid valve is controlled ON-OFF by battery 12 V direct current. But this valve is con- trolled by the PWM (pulse width modulation) current supplied from the micro computer controller incorporated in the meter panel.
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WSM Minor Change II Service Engineering Section 2. Structure and function (Hydraulic symbols) Solenoid magnetic force Spring load Pressure applied II - 52...
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WSM Minor Change II Service Engineering Section 3. Function theory Behavior of proportional valve Balance of proportional valve forces Pressure receiving Transfer area difference spring Proportional solenoid Reducing valve spool magnetic force hydraulic pressure force Behavior of solenoid proportional valve Definitions of values : Solenoid magnetic force generated according to current = C1 x I (C1 and I are solenoid's intrinsic constant and current, respectively.)
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WSM Minor Change II Service Engineering Section Spool control performance I-P curve Pa (MPa) Current (A) Spool opening area Suction prevention against interference (Opening area symmetrical right and left on standard type) A - T P - A Spool opening stroke (mm) A - T: Actuator to tank P - A: Pump to actuator II - 54...
WSM Minor Change II Service Engineering Section j. Other controls 1. Model number display Displayed in the case of AI specifications. 2. Automatic service port identification With the key on, a current of 250 mA or so is made to flow in the service port proportional control valve.
WSM Minor Change II Service Engineering Section k. Troubleshooting Troubleshooting Following troubleshooting is based on below preconditions. Therefore: 1. Hydraulic oil quality and quantity are normal. 2. Hydraulic pump P are OK. 3. All the functions except service port system are normal. Fail symptom Suspected causes Check points...
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WSM Minor Change II Service Engineering Section C. Hydraulic system modification a. Outline In order to improve further “Load Sensing Performance”, pump and control valve have been changed in several parts. Main parts of minor change are as follows. 1. Hydraulic pump: KX121-3S , 161-3S , U45-3 (1) Valve plate opening performance improved End milling finish to V-shape notch (2) Piston shoe type change...
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WSM Minor Change II Service Engineering Section b. Hydraulic pump: KX161-3s, KX161-3 1. Pump installation: KX161-3S , U45-3 (1) Adapter tightening torque P port (G3/4) 117.6 ~ 127.4N m (12.0 ~ 13.0kgf m) , CH port (G1/4) 24.5 ~ 29.4N m (2.5 ~ 3.0kgf m) port (G3/8) 49.0 ~ 53.9N m (5.0 ~ 5.5kgf m) II - 58...
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WSM Minor Change II Service Engineering Section 2. Piston pump: KX161-3S (PP), KX161-3 (EU), U45-3 (EU, KTA) II-59...
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WSM Minor Change II Service Engineering Section 3. Specifications of pump Model: PSVL-54CG Piston pump power constant characteristics: KX161-3 , U45-3 Item Specifications Remarks Displacement Piston pump 13.0 ~ 54.0 cm /rev Gear pump Pilot pump Gear pump 4.0 cm /rev Direction of rotation Right (Clockwise)
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WSM Minor Change II Service Engineering Section d. Accumulator 1. Structure and specifications: PP-version PP-version has newly adopted the accumulator. (12) (1) Valve screw (2) Protecting cop (3) Seal ring (4) Retainer (5) Marking (6) Shell (7) Diaphragm (8) Valve poppet (9) Hex.
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WSM Minor Change II Service Engineering Section 2. Change valve with accumulator: EU-version 2-1 Structure Maker: Hydro control As for EU-version accumulator, structure and specifications almost all remains same as before. filter Swivel motor Pilot valve(Right) Pilot valve(Left) To swivel joint To pump P 2-2 Specifications 1) Max.
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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) II - 70...
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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 ~ 4.3kgf m) II - 72...
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Travel motor: KX91-3S: PP-version In this minor change, KX91-3S, U35S and U35-3S shockless valve spool has been deleted from the travel motor. Still Kubota’s engineering has achieved the improved feeling at start-up and stop. Here are the explanation in detail how done.
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WSM Minor Change II Service Engineering Section 2) Better feeling at start and stop To improve the start-up feeling, the counter- balance spool must be activated quickly to keep the start-up pressure at port M2 low. To enhance the stop feeling, on the other hand, the brake pressure at port M2 should rise smoothly.
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WSM Minor Change II Service Engineering Section 4) Improvement of the counterbalance spool performance The characteristics and responsiveness of the counterbalance spool's variable orifice are adjustable to better control the M2 port pressure. At the start, the spool's spring force gets weak for the counterbalance spool to switch over at low pressure.
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WSM Minor Change II Service Engineering Section 5) Performance comparison 140.00 350.0 100.00 250.0 60.00 150.0 20.00 50.0 0.00 0.00 0.05 0.15 0.25 0.35 0.45 0.00 0.10 0.20 0.30 0.40 0.50 Time (sec) Time (sec) Fig. 7 New type: Low speed FIg.
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WSM Minor Change II Service Engineering Section E. Engine upgrade a. General Only the engine of KX161-3S for PP-version (KTC, KCL, KTA) has been upgraded due to the strong market requirement. b. Engine specifications KX161-3 Model V2403-M-E2BH-1 (Standard-version) V2403-M-E2BH-2 (Air conditioner-version) No.
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WSM Minor Change II Service Engineering Section Engine electric components KX161-3 Fuel injection pump type PFR4Mtype mini-pump Nozzle type DNOPD mini-nozzle 13.7-14.7 140-150 Injection pressure kgf/cm 1991-2133 Dynomo 12VÅA540W Manufacturer P/N 101211-3781 Regulator adjusting voltage 14-15 Battery type 90D26R Nominal capacity of 5hrs rating Specific gravity of electrolite 1.28Å}0.01 Starter motor...
Development concept ........II-115 b. Outline of Kubota ICS (Intelligent Control System) ... . II-118 c.
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WSM Minor Change II Service Engineering Section a. Development concept 1. Background of Adoption of New Meter (1) The L1 (3-ton class) Series, which was released in Japan in 1999 for domestic users, adopted a new meter of LCD type (called YUYU NAVI). Since then, this meter has been one of the sales points of the Series.
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WSM Minor Change II Service Engineering Section (Reference) 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 selection screen (KCL-ver) Fig.
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: KX91-3S· , 101-3 , 121-3S· , 161-3S· , U35S, U35-3 , U45S· North America & Function EU-version Oceanea KICS;Kubota Intelligent Control System, LCD(liquid crystal display) with character and illustration Yes (delete Yes (delete Maintenance indication upon hour meter method:manual)
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WSM Minor Change II Service Engineering Section b. Outline of Kubota ICS (Intelligent Control System) II-118...
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WSM Minor Change II Service Engineering Section c. Operating Mode 1. Outline In operating mode, normally LCD shows 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, item No.1, 2, 3, 4, 5, 11, 12, 13, 14, 21, 22, 23, 24, 25, 51, 52, 53, 54, 55, 61, will be indicated according to the machine conditions.
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WSM Minor Change II Service Engineering Section 2. LCD display list Below list shows all LCD letter indications for both oparating mode. In operating mode, data 003 ~ 022 and 082, 084 will be on the display according to the machine condition. In case of non AI, non S/P control machines, date 008 ~ 022 except 017, 018, 019, 020, 021 won’t come up to show.
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WSM Minor Change II Service Engineering Section Caution and warning 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 down the lock lever for service port (8) Maintenance indications...
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WSM Minor Change II Service Engineering Section d. Service mode menues 1. Outline Service mode is basically for dealer’s service personel. This mode is so designed to initialize machine’s condition, additional 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.
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WSM Minor Change II Service Engineering Section 3. Main menues and functions 3-1 Selection Method of 11 Languages (EU-version only) If the key is turned ON with the display selector pressed, the name of the model presently selected will appear. When the finger is off the display selector, the next language selection screen will appear. The infor- mation on the selected model is important.
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WSM Minor Change II Service Engineering Section 3-2 Tester mode Items such as the present battery voltage can be displayed by selecting Diagnosis and Tester. (See fig. 2.) (Without AI) (AI) Fig.2. Tester menu • Engine -> Engine revolution XXXX rpm A revolution sensor is mounted to the injection pump gear.
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WSM Minor Change II Service Engineering Section 3-3 Fail recoord dump The fail record can be displayed by selecting Diagnosis and Fail record. (See fig. 3.) By selecting the Fail record, the system reads the contents of the EEPROM and checks the information on failures.
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WSM Minor Change II Service Engineering Section 3-5 Machine model setup Model settings can be made by selecting Set up and Set up machine. (See fig. 6.) Here, information on the model and the country of manufacturer is selected. By selecting the country of manufacturer, European specifications and North American specifications are distinguished.
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WSM Minor Change II Service Engineering Section 3-6 Overheat set-up Note: Diagnosis Set up Engine start Set up machine Set up overheat warning By selecting , and , overheat warning settings can be made. By turning the overheat warning ON, the overheating warning function will be enabled and the overheat warning will be output when the preset temperature is reached.
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WSM Minor Change II Service Engineering Section 3-8 Harness check Mode By selecting Other menu and Circuit check Engine stop, the present conditions of the harness connector can be checked (See fig. below.). When the Circuit check Engine stop is selected, the message "Checking touch harness" will appear at the moment the engine revolution drops below 800 rpm.
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WSM Minor Change II Service Engineering Section 3-9 All Fail Record All the accumulated failure records can be shown by selecting Other menu, Other menu, and All fail record (See Fig.6.). By selecting All fail record, the first hour meter items generated after shipping through the last one will be shown.
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WSM Minor Change II Service Engineering Section 3-12 Service hour meter A service maintenance message will appear when the preset hour meter item is activated. The message will disappear in 10 seconds. Hereafter, whenever the key is turned OFF and ON, the mes- sage will appear for the first 10 seconds.
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WSM Minor Change II Service Engineering Section 3-13 Servive hour meter check The service hour meter can be checked and altered by selecting Other menu, Other menu, and Service hour meter. Only the display selector switch is used to make value changes. The service hour meter will be changed when the meter is replaced, because the service hour meter will not be synchronized with the hour meter, and warnings will not be displayed in a timely manner.
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WSM Minor Change II Service Engineering Section 3-17 Auto glow control The glow will be turned ON for an optimum time according to the temperature of engine cooling water. 3-17-1 Key-ON Processing Water temperature: The glow-ON time is obtained from the glow time map (see Fig. 1, 2). The glow will not, however, turn ON while the engine is working or the temperature is 81 C or over.
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WSM Minor Change II Service Engineering Section Glow ON/OFF Conditions The glow will turn ON under any of the following conditions: The engine revolution is 1000 rpm or below; the engine oil pressure switch is OFF (the input terminal of the engine oil pressure switch is H); the charge is OFF (the L input terminal is H).
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WSM Minor Change II Service Engineering Section 3. FYI (For your information) water [V] temp [°C] 0.33 0.409 0.504 0.634 0.795 1.26 1.58 1.96 2.86 3.36 3.77 4.15 4.44 4.66 4.89 4.94 II-136...
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WSM Minor Change II Service Engineering Section 3-18 Travel high - low switch control 1. Change travel speed by pressing the high - low switch on the dozer control lever. Refer to the control flow. 2. The travel mechanism will start in low gear to ensure safety when the key is turned ON. 3.
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WSM Minor Change II Service Engineering Section 3-19 Fuel amount control 1. Outline A map indicating the voltage and fuel relationship has been prepared by plotting each determined input voltage based on the float position of the fuel sensor and the remaining fuel. The power supply voltage (5V) is input into the microcomputer according to the partial voltage varied with the float position.
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WSM Minor Change II Service Engineering Section 2. Meter display 1) The LCD with four vertical dots and 37 horizontal dots is used to display the fuel gauge. Fuel level (Litter) KX41-3 KX61-3, 71-3 Full in tank 19 ± 3 42 ±...
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WSM Minor Change II Service Engineering Section 3. Fuel Replenishment Assist Function While replenishing fuel by pressing any switch after the key is turned OFF, the buzzer interval will change according to the quantity of fuel replenished. When the fuel in the tank is not much, the buzzer will be heard at long intervals.
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WSM Minor Change II Service Engineering Section 3-20 Starter auto release control 1. Outline 1) If the key freezed in the start position, the auto release relay is turned OFF to prevent damage to the starter motor. At the same time, the glow relay will be turned OFF forcibly to prevent damage to the glow plug.
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WSM Minor Change II Service Engineering Section 3-21 Service mode menu list English name meaning and explanation data023 Indicates the model name. data024 Indicates the model name. data025 Indicates the model name. data026 Indicates the model name. data027 Indicates the model name. data028 Indicates the model name.
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WSM Minor Change II Service Engineering Section <Service mode menu list> English name meaning and explanation data055 Literary it means other menus. This means micro computor is ready to check electrical harness conditions, break data056 or breaking. In this case, for your sefety engine should be off. This means micro computor is checking the harness conditions.
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WSM Minor Change II Service Engineering Section e. New auto idling (AI) control system (1)Purpose When you interrupt a job and set the control lever to neutral, the engine will come to the automatic idling rpm in 4 seconds. This helps save energy and keep quiet. (2)Auto idle function mechanism 1.
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WSM Minor Change II Service Engineering Section (3) New auto idling modification 1. Interlocked with lever 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.
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WSM Minor Change II Service Engineering Section 3. AI function layout Electric accelerator AI controller Acceleration sensor signal AI pressure switch signal C5 C6 Switch operating pressure 25 3 kgf/cm Output Governor sensor Engine AI motor 20 3 kgf/cm Pull cable Governor Governor position data lever...
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WSM Minor Change II Service Engineering Section 4. Behavior when the control lever is returned to neutral Electric accelerator AI motor Engine speed indication Machine status Motor drive (operation or neutral) Acceleration cable Governor position Engine speed sensor Governor potentiometer Governor lever Control lever Lever...
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WSM Minor Change II Service Engineering Section 5. Behavior when the control lever is operated: Electric accelerator AI motor Engine speed indication Motor drive Machine status (operation or neutral) Governor position Acceleration cable Governor potentiometer Governor lever Control lever AI pressure switch Pilot valve Pilot pump •...
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WSM Minor Change II Service Engineering Section 6. AI motor normal-turn circuit AI controller unit Engine speed sensor Speed Power detection OFF by operating AI effective with the lever engine started AI pressure switch signal AI pressure switch OFF Voltage change AI control timer circuit Engine speed signal...
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WSM Minor Change II Service Engineering Section 7. AI motor reverse-turn circuit AI controller unit Engine speed sencor Speed Power detection OFF by operating AI effective with the lever engine started AI pressure switch signal AI switch OFF Voltage change AI control timer circuit Engine speed signal...
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WSM Minor Change II Service Engineering Section 8. AI motor returning function This function is newly incorporated in this new series. In the previous models, KX121-3, 161-3. AI motor’s position is only controlled by the accel. sensor dial. Therefore, suppose that operator turns off the starter key at the accel. sensor dial max. position. Then next time when he turns the main key, engine starts at max.
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WSM Minor Change II Service Engineering Section (4) Idle-up control The idling speed increases by 150 rpm when the water temperature drops below 30 centi-degrees. (Reason:Even at the same governor position, the engine speed drops about 150 rpm at the temperature of - 18 centi-degrees.) <Function chart>...
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WSM Minor Change II Service Engineering Section (5) Compressor control When the compressor is on, the idling speed is raised by 150 rpm. The idea is as follows. If the compressor is repeatedly turned on and off kept off for 3 seconds, the idling speed gets back to its original rpm.
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WSM Minor Change II Service Engineering Section Idling RPM of AI - version incorporated in the controller program. KTC, KCL, KTA EU - version canopy canopy KX41-3 KX61-3 KX71-3 KX91-3 1050 1150 1050 KX101-3 1050 1150 KX121-3 1100 1200 1100 1200 KX161-3 1100...
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WSM Minor Change II Service Engineering Section (7) Engine speed sensor The engine speed sensor is a quick-response 0.7 ± 0.2 mm proximity switch. When the teeth of a gear pass close, the magnetic field inside the switch changes and the variation is converted to pulses. The number of pulses for "t"...
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WSM Minor Change II Service Engineering Section (8) Governor sensor Code No.:RP421-5371-1 Specifications 1. Rated voltage :DC5V 2. Total resistance :2K ± 3. Insulasion resistance :100M or more 4. Output performance Lever angle Effective mechanical range Effective electrical range Signal Power, 5V Circuit diagram (C1)
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WSM Minor Change II Service Engineering Section (9) Accel sensor (Electric accelerator) Code No. (Accel sensor is in Min. position) (Accel sensor is in Max. position) Ω Ω Ω Ω is contact resistance. (Sample data)[ ] How to get R Accel sensor position Min.
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WSM Minor Change II Service Engineering Section (10)AI pressure switch C/N RC411-53681, 25kgf/cm , Normal close type 1. Function When the pressure sensed by the oil pressure detection circuit for auto idle control has dropped below 20 kgf/cm , the contact of the AI switch, shown at left, gets closed.
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WSM Minor Change II Service Engineering Section f. Main component’s function (1) Auto release function 1. Auto release Circuit diagram & function Auto release relay (Starter relay) NO - type Key SW Key ON Start Is the key switch set at "START" longer than 30 seconds? Engine speed sensor Has the engine started?
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WSM Minor Change II Service Engineering Section 3) If the key switch fails to return and the engine speed sensor is also in trouble a.Key switch start signal 30 sec b.Engine speed sensor signal Switch c.Release relay solenoid turned off If the key switch start signal is detected to have been on for 30 seconds, the automatic release con- trol system (3) lets the transistor's base current flow, which turns on the release relay solenoid (1) and turns off the relay switch.
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WSM Minor Change II Service Engineering Section 3. Operational flow chart II-161...
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WSM Minor Change II Service Engineering Section II-162...
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WSM Minor Change II Service Engineering Section < Engine speed and condition of auto release relay > Engine speed : N Time : T Auto release relay KX61-3 ~ KX161-3S· KX41-3 = > = > 1000 Within 6 seconds 801 ~ 950 1001 ~ 1150 After 6 seconds Within 0.5 seconds...
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WSM Minor Change II Service Engineering Section (2) Travel hi-speed control circuit Hi-Low SW EEPROM Program (Meter panel) Troubleshooting: Travel hi-speed malfunction 1. Turn the key switch to the ON position to see if 12 V is applied to terminal 2 of the travel hi-speed switch. 2.
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WSM Minor Change II Service Engineering Section (3) Meter panel (Controller unit) Meter Panel controller unit ON-2-18 Motor Power supply ON-17-3 ON-17-1 ON-17-4 ON-17-2 AI Self-hold relay ON-1-12 Lever Lock SW ON-1-11 AI Self-hold Relay ON-2-14 Start SW ON-1-9 ON-1-1 AC-1 Glow relay ON-17-4...
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WSM Minor Change II Service Engineering Section g. Failure Diagnosis 1. Failure display and diagnosis criteria The following table 1 shows data on failure diagnosis, for operating mode and service mode. Note: • Display items of the system in service mode can be checked with the fail record. •...
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WSM Minor Change II Service Engineering Section Display Function stop EEPROM Buzzer Lamp Reset method Method of diagnosis point address Operating mode service mode 21 AUX.volum 21 AUX volum Momen- Cancel AUX 72, 92 At 5 V (normal). tarily AUX specifications. AUX mode turns ON.
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WSM Minor Change II Service Engineering Section 2. Fail record in EEPROM If the sensor or actuator line has an error, the output of the actuator will stop and the LCD will display the contents of the error while the error point is written to the EEPROM. Fig. 2 and fig. 3 show the address allo- cation of the EEPROM.
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WSM Minor Change II Service Engineering Section 2-3 Erasing Method of Error Log The error log will be deleted by selecting Error Log Delete in Diagnosis Mode. In the software, only the 0th to third bits (the accumulated number of errors) in EEPROM addresses 85 through 103 will be zero cleared, but hour meter data will not be zero cleared.
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WSM Minor Change II Service Engineering Section Address No. Contents of failure Data bit Check sum, 36 ~ 50 3 Charge 2 Engine oil 4 High voltage 11 Accel sensor 13 AI motor short 14 AI motor break 12 Governor sensor 21 Aux.volume The leftmost 12 bits display the hour meter value of 22 Aux.solenoid L short...
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WSM Minor Change II Service Engineering Section 3. self-diagnosis of controller unit 3-1 Purpose The error diagnosis of the meter is possible by using the self-diagnostic harness. The self-diagnostic function of a conventional model provided with a microcontroller can detect failures in the microcontroller only after all the failure diagnosis of the electrical devices other than the microcontroller is made.
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WSM Minor Change II Service Engineering Section The red and yellow lamps flash alternately. The LCD of the meter flashes black and white alternately. The lamp as shown in the illustration on the right-hand side turns ON and OFF repeatedly. The buzzer beeps.
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Example : No.1 switch is being pushed to NG posi- tion. Note : The self-diagnosic harness will be provided to Kubota Distributors, KTC, KCL, KTA, KE, KUK and KBU only. When in need of the failure diagnosis of the meter panel, please contact them.
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WSM Minor Change II Service Engineering Section 3-3 Failure Display Number of Self-diagnostic Function Table 2. Self - diagnosis of controller, items and methods Fail Check item Check parts Check methods indication Check sum CPU ROM Implement self-checksum. Turn OFF the glow relay and make sure that pin 29 Glow relay output (RXD2 power 7.1) is set to low level.
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WSM Minor Change II Service Engineering Section Fail Check item Check parts Check methods indication Motor Tr1, Tr2, Tr3, and Tr4 are set to low output Motor Tr1, Tr2, Tr3, and Tr4 output level. Input & output AI operation switch input, travel The AI operation switch is set to low level.
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WSM Minor Change II Service Engineering Section FYI (For your information) Check Sum Error 1. A check sum error is checked to see if the contents of the program for microcomputer control are cor- rupted. 2. The control program is saved in the ROM of the CPU. Once data is written to the ROM and shipped to the market, the data cannot be written in the market.
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WSM Minor Change II Service Engineering Section 3-4 Functions of Self-diagnostic Harness The harness short-circuits the input and output terminals of the meter in advance, switches the respec- tive inputs of the meter ON and OFF in sequence, and checks if the data on the output side is normal. Self-diagnosis Yazaki I/O Check if the signal changes in synchronization...
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WSM Minor Change II Service Engineering Section h. Service mode flow chart 1. General 1-1 There are sevral flow charts, depending on the models or machine - versions as below. 1) KX41-3, KX61-3, and KX71-3 have one identical service mode flow chart. Refer to the correspondent WSM.
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WSM Minor Change II Service Engineering Section 1-5.What should you do in the following case? Cases action to be taken (1) Renewal of a meter panel. Machine model set-up Customer purchased a new meter panel from the spare AI or Non - AI selection part center.
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WSM Minor Change II Service Engineering Section II-180...
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WSM Minor Change II Service Engineering Section II-181...
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WSM Minor Change II Service Engineering Section II-182...
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WSM Minor Change II Service Engineering Section II-183...
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WSM Minor Change II Service Engineering Section II-184...
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WSM Minor Change II Service Engineering Section i. Component layout 1. KX91-3S· , 101-3· , U35S, U35-3S· electrical wirling Meter panel Hi-low solenoid Heater switch Unload solenoid Engine pressure switch Starter motor Hi-low switch Glow plug ⎧ S/P switch Fuel pump ⎨...
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WSM Minor Change II Service Engineering Section 2. KX121-3S· , KX161-3S· electrical wiring, A/C Battery Unload solenoid Heater switch Engine speed sensor Meter panel Hi-low solenoid Water temp. Accel dial sensor Control lever R (Auto glow) Hi-low switch Revolution sensor Engine pressure Main key switch switch...
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WSM Minor Change II Service Engineering Section 3. KX121-3S· , KX161-3S· electrical wiring, except A/C Unload solenoid Battery Heater switch Meter panel Hi-low solenoid Water temp. sensor Accel dial (Auto glow) Control lever R Revolution sensor Hi-low switch Engine pressure switch Main key switch Safety lock switch R...
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WSM Minor Change II Service Engineering Section j. Circuit wiring diagram 1. KX91-3S· ,101-3 , 121-3S· , 161-3S· , U35S, U35-3S· , U45-3S· , (S/P, AI) Lever lock Lever Lock Lever Lock-A SW Lever Lock-L SW Solenoid ON-10-2 ON-10-1 ON-11-1 ON-12-2 Key SW ON-11-2...
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WSM Minor Change II Service Engineering Section 2. KX91-3S, U35S, U35-3S : PP - version II-189...
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WSM Minor Change II Service Engineering Section 3. KX91-3 , 101-3 , U35-3 : EU - version II-190...
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WSM Minor Change II Service Engineering Section 4. KX121-3S· , 161-3S· , U45-3S· : EU and PP - version II-191...
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WSM Minor Change II Service Engineering Section II-192...
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KUBOTA Corporation CONSTRUCTION MACHINERY DIVISION 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-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 :+81-72-840-2886 KUBOTA Corporation Printed in Japan 0410.CMC.e.12 Code No.97899-61260...
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