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WORKSHOP MANUAL

KUBOTA EXCAVATOR

U35

Code No.97899-60640

Record of Revisions Rapport de Révision Inspektionsaufzeichnungen Symbol Symboles Symbol

Date Date Datum

Main Revised Points & Corrective Measures Principaux points de révision et mesures correctives Hauptpumkte der Inspektion und korrektive Mßsnahmen

Person-in-charge Personne responsable Verantwortlicher

CONTENTS I General

II Machine body • Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II-M-1 • Service Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II-S-1

III Engine • Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-M-1 • Engine WSM . . . . . . . . . . . . Refer to KX91-3, 101-3 WSM

IV Hydraulic System • Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-M-1 • Service Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-S-1

V Electrical System • Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-M-1 • Service Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-S-1

To THE READER! Although some components are different, like TPSS valve for KTC, KCL, KTA version and accumulator and quick coupler pressure gauge for EU-version, U35 and U35-3 have basically same structure and functions. Still, EU and KTA market have already been introducing previous model of U-35 but KTC and KCL for the first time. Therefore, we have slightly different model names as follows. U35-3 : EU market (KE, KUK, KBM), KTA U35 : KTC, KCL market

I. General A. Body and engine identification marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-2 B. Safty precautions for servicing, disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . I-S-3 a. b. c. d.

Safty measures before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-3 Safty measures during work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-3 Preparation for disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-4 Precautions for disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-4

C. IMPORTANT SAFTY PROCESS AND CRITICAL FUNCTIONAL PROCESS . . . . . . . . . I-S-5 a. Essential Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5 b. Important Safety Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5 c. Important Critical Functional Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-5

D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING . . . . . . . . . . . . . . . . . . . . I-S-5 E. Servicing Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM KX91-3, 101-3 F. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6 a. KTC, KCL, KTA-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-6 b. EU(KE, KDG, KUK)-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-7 c. Hydraulic Oil Check for machines with Hydraulic Breakers . . . . . . . . . . . . . . . . . . . . . I-S-8

G. Water and oil quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-9 H. Recommended oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-10 I. Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-11 J. Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12 a. b. c. d. e. f. g.

Hose screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12 Joint bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-12 Tightening torque table for hose clamp (Screw type). . . . . . . . . . . . . . . . . . . . . . . . . . I-S-13 Nuts for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-13 Tightening torque of bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-14 Types and materials of bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-14 Washer-equipped elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-15

K. Machine Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-S-16

I-S-1

A.Body and engine identification marks If trouble should occur during use, or if servicing is necessary, contact the dealer who handles the machine. At the time please inform the deals of (1) Model of machine and serial number

Name plate

2-47, Shikitsuhigasi 1-Chome, Naniwa-ku, Osaka, 556-8601 JAPAN MODEL SERIAL No. ENGINE No. PRODUCT IDENTIFICATION NUMBER

1 2 3 4

No. 1 2 3 4

Items Machine model Serial No. Engine No. PRODUCT IDENTIFICATION No.

Contents ; Example U35 20001 2L2958 >JKUU0353LO1H20001<

RA018-5772

Code No. : RA018-57721

(2) Machine serial number

(3) Engine serial number e.g. D1503-2L0025 “2” indicates year of 2002 and “L” indicating June. So, 2L indicates that the engine was manufactured in June 2002.

I-S-2

Engine serial number

B.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.

b. Safty measures during work (1) Protectors 1. Wear goggles when using chisels for chipping. 2. Use appropriate protectors during welding. 3. Wear a helmet when working with a crane or at elevated locations.

I-S-3

(2) Team work 1. When working with two or more people, divide the work and maintain close communication. 2. Clane work must be carried out using predetermined signals.

(3) Disassembly and assembly 1. Do not wear gloves when using hammers. 2. Use rods of the specified soft material for removing pins. Do not use a hammer as a pad. 3. Do not place fingers in holes when centering. 4. Heavy parts must be adequately supported before removingbolts.

(4) Cranes 1. In principle, use a crane for objects heavier than 44lb (20kg). 2. Crane operation and hoisting must be performed only by qualified personal. 3. Pay careful attention to the center of gravity when hoisting, and do not stand under the lifted objects.

(5) Others 1. To work under a jacked-up carrier, be sure to place wood pieces under it. 2. When charging batteris, make sure there are no open flames in the immediate vicinity. 3. All electric tools must be grounded. 4. Before welding the machine, remove the battery. • When removing the battery, be sure to disconnect negative (-) cord first. • When mounting the battery, be sure tp connect the positive (+) cord first.

c. Preparation for disassembly (1) Cleaning Remove mud and dirt from the body before disassembly.

(2) Acceptance inspection The machine must be checked before it is disassembled to record existing conditions, such as those listed below. Model, serial number, and hourmeter reading • Reason for repair and repair history • Element stains • Fuel and oil condition • Parts damage *(Take photographs if nessesary.)

(3) Equipment and tools prepare equipment, tools, cranes and parts storage racks as required.

d. Precautions for disassembly and reassembly (1) Disassembly 1. Follow the specified disassembly procedures. 2. Make alignment marks to insure correct reassembly. 3. Arrange disassembled parts in an orderly way, and attach identification tags or put marks if needed.

(2) Reassembly 1. Clean all parts before assembly. Repair any scratches or dents. Take special precautions against dirt and dust. 2. Parts with rust-preventive coatings must be assembles only after removing the corting. 3. Separated parts must be correctly reassembled using alignment marks. 4. As a rule, use a press to reassembled bearings, bushing and oil seals. Use pads when using a hammer.

I-S-4

C.IMPORTANT SAFTY PROCESS AND CRITICAL FUNCTIONAL PROCESS The following instructions are related to essential adhesives, important safety process S and critical functional process A .Pay special attention in servicing these process. (Pay also close attention in reconnecting the electrical cables.)

a. Essential Adhesives Type of screw adhesive • Unless otherwise specified, use Three-Bond 1324 adhesive (medium-duty type). Keep the screw threads free of oil and water. Type of instantaneous adhesive • Use Three-Bond 1733 or Three-Bond 1741E adhesive. Keep the bond areas free of oil and water.

b. Important Safety Process S . 1.Reconnecting the fuel hose (clearance, hose routes, clamps, etc.) 2.Electrical cabling (engine, instrument panal, controls, etc.) (wiring routes, clamps and couplers)

c. Important Critical Functional Process A . 1. Setting up the travel wheel motor (tightening torque) 2. Reassembling the rotary joints (joint direction and shaft set-up) 3. Installing the swivel base bearing and the swivel motor (tightening torque) 4. Fitting the pump couplings (tightening torque)

D.IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING a Operate the Machine and check for Unusual Noise and Vibrations. b Make Sure the Safety decals and Wireharness Clamps are in their Specified Positions. c With the Machine Front in a Specified Posture, Check the Amount of Hydrauric Oil Checking the oil level (For further datails, refer to the Operator’s Manual of each model.) 1) Park the machine on a level ground. 2) Make sure the hydrauric oil temperature is in the range of 10-30°C (50-86°F) and see if the oil level is within the specified zone of the oil level gauge. 3) Keep the machine front as shown as following posture. Posture: Extend the rods of the arm and bucket cylinders nealy half. Place the bucket on the ground, the offset swing at the center, and the dozer also on the ground.

I-S-5

F. Maintenance intervals a. KTC, KCL, KTA-version No.

Check points

Hour meter indicator Intervals 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 Consequently

check Daily check change Fuel check Daily check 2 check Daily check 3 Engine oil change check Daily check 4 Hydraulic oil change ––– Daily check 5 Lubrication points check Daily check 6 Radiator and oil cooler 7 Washer liquid (cabin type) check Daily check 8 Engine and electrical wiring check Daily check drain 9 Fuel tank, Fuel filter check 10 Battery condition 11 Greasing swing bearing teeth ––– adjust 12 Fan belt tension check hoses and 13 Radiator clamps replace clean Outer filter element replace 14 Air element Inner element replace 15 Greasing swing ball bearings ––– replace 16 Fuel filter element Engine oil KX91-3 replace 17 filter KX121-3 change 18 Drive unit oil 19 Hydraulic return filter element replace 20 Hydraulic suction filter element replace 21 Filter in the pilot hydraulic system replace injection nozzle 22 Fuel check injection pressure change Front idler and track roller oil 23 24 Alternator and starter motor check 25 Injection pump check 26 Radiator system rinse check 27 Fuel line and Intake air line replace 1 Coolant

every 2 years every 250 hrs every 1000 hrs *1

every year every 50 hrs every 50 hrs every 50 hrs every 200 hrs every 200 hrs every 2 years every 200 hrs every 1000 hrs every 1000 hrs every 200 hrs every 400 hrs every 250 hrs every 500 hrs every 500 hrs every 500 hrs every 1000 hrs every 1000 hrs every 1500 hrs every 2000 hrs every 2000 hrs every 3000 hrs every 2 years every 200 hrs every 2 years

*2 *2 *2

@ @

IMPORTANT: First operation *1 When using a hydraulic breaker, change hydraulic oil and return filter according to the table on Hydraulic Oil Change (Including Exchange of the Suction Filter in the Hydraulic Tank) under EVERY 1000 SERVICE HOURS in the chapter REGULAR CHECKS AND MAINTENANCE WORK . *2 Clean and replace the air filter more frequently if used under dusty conditions. By heavy soiling, replace the filter. *3 Replace only if necessary. *4 Consult your local KUBOTA Dealer for this service. The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction. Please see the Warranty Statement in detail.

I-S-6

Operator Services

b. EU(KE, KDG, KUK)-version

The services identified with must be carried out at the specified service hours after initial operation. 1.) Under dusty conditions the air filter must be cleaned more frequently or renewed. 2.) When using a hydraulic hammer over 20 % every 800 h. When using a hydraulic hammer over 60 % every 300 h. When using a hydraulic hammer over 40 % every 400 h. When using a hydraulic hammer over 80 % every 200 h. 3.) When using a hydraulic hammer up to 50 % every 200 h. When using a hydraulic hammer over 50 % every 100 h. 4.) Earlier if necessary. 5.) At least annually.

Servicing by skilled personnel or KUBOTA dealer

I-S-7

c. Hydraulic Oil Check for machines with Hydraulic Breakers The Hydraulic oil change after 1000 operating hours in the operator’s manual is based on the type of work done. Following inspection measure are valid when hydraulic breakers are used: 1. Changing and filling up of hydraulic oil 1) The hydraulic oil must be changed more often when breakers are used because the machine is subject to harder conditions than at normal excavating work. 2) Use only the recommended oils mentioned in the operator’s manual when changing or fill oil. 3) When filling up oil, never mix oils of different makes. 2. Changing the return filter and oil 1) The filter must be changed more often because of contamination resulting from the frequent assembly and disassembly of the hoses. 2) Use the correct replacement filter. 3) Oil change according to operating hours.

(1)

(2) (3)

Normal excavator work

Breaker work portion

(1) Return (2) P port (3) Breaker

I-S-8

Hydraulic oil

Return Filter

every 1000 Hrs.

500 Hrs.

20%

every 800 Hrs.

40%

every 400 Hrs.

60%

every 300 Hrs.

More than 80%

every 200 Hrs.

Suction Filter

300 Hrs. 1000 Hrs. 100 Hrs.

G.Water and oil quantity Unit

U35, U35-3

KX91-3

KX101-3

Radiator

L gal

5.6 1.48

←

Reserve tank

L gal

1.6 0.42

←

Without filter

L gal

5.3 1.40

←

SAE10W30(CD) Gauge center

Hydraulic oil

Full

L gal

55.0 14.53

←

ISO 46

Hydraulic oil

Tank gauge center

L gal

36.0 9.51

←

ISO 46

Wheel motor

L gal

0.5 0.13

←

SAE90 (API GL-4)

Track roller

cc gal

70 0.018

←

SAE30(CD)

Upper roller

cc gal

60 0.02

←

SAE30(CD)

Front idler

cc gal

80 0.02

←

SAE30(CD)

Fuel tank

L gal

40 10.6

46.5 12.30

←

Engine Crank case

Remarks Kubota LLC-N-50F 50%

Inspection of hydraulic oil When checking the hydraulic oil level, satisfy the following conditions and make sure the oil level is above the center the oil gauge. The oil level is within the shaded area shown in the figure at left. 1) Oil temp. should be between 10 ~ 30 °C, 50 ~ 86 °F. 2) Stance of front attachment : Swing : Straight forward Arm : Vertical to the ground Bucket : On the ground at its bottom Dozer blade : Down to the ground

3)Air breather hose is connected to the oil tank. (Not pressurized type.) I-S-9

H.Recommended oil IMPORTANT: 1. Before delivery the hydraulic oil used was an ISO 46 viscosity grade. 2. Use engine oil API service classification CD, CE or CF. 3. Use SAE 90 (API, CLA/GL5) as drive unit oil for all seasons. Application In winter or by low temperatures

Engine oil

In summer or by high ambient temperatures All-Season Engine oil

In winter or by low temperatures

Gear oil

In summer or by high ambient temperatures

Viscosity

Shell

Mobil

Exxon

SAE 10W

Shell Rotella T10W Shell Rimula 10W

Mobil Delvac 1310

XD-3 10W XD-3 Extra 10W

SAE 20W

Shell Rotella T20W-2 Shell Rimula 20W-2

Mobil Delvac 1320

XD-3 20W-20 XD-3 Extra 20W-20

SAE 30

Shell Rotella T30 Shell Rimula 30

Mobil Delvac 1330

XD-3 30 XD-3 Extra 30

SAE 40

Shell Rotella T40 Shell Rimula 40

Mobil Delvac 1340

XD-3 40 XD-3 Extra 40

SAE 50

Shell Rotella 50

Mobil Delvac 1350

Multipurpose

Shell Rotella T15W

SAE 75

SAE 80

SAE 90

SAE 140

Mobilube HD80W-90 Shell Oil S8643

MIL-L-2105C

Mobilube HD80W-90 Shell Spirax HD80W Mobilube 46

MIL-L-2105

Mobilube HD80W-90

MIL-L-2105C

Mobilube HD85W-140

MIL-L-2105C

Shell Spirax HD140

Mobilube HD80W-140

MIL-L-2105C

Shell Spirax HD90

Multipurpose

Shell Spirax HD80W Shell Spirax HD85W

Mobilube HD80W-90

GX80W-90

In winter or by low temperatures

ISO 32

Shell Tellus T32

Mobil DTE-Oil 13

NUTO H32

ISO 46

Shell Tellus T46

Mobil DTE-Oil 15

NUTO H46

ISO 68

Shell Tellus T68

Mobil DTE-Oil 16

NUTO H68

Grease

Shell Alvania EP2

Mobilux EP2

BEACON Q2

Fuel

Light oil No. 2-D (ASTM D975)

Fuel under -5 °C (+23 °F)

Light oil No. 1-D (ASTM D975)

Hydraulic oil

MIL-L-2104C MIL-L-2104D

XD-3 15W-40 XD-3 Extra 15W-40

All-weather gear oil

In summer or by high ambient temperatures

MIL-Standard

I-S-10

MIL-L-2105C

I. Filters Name & Fig. Engine oil filter

Specifications item

KX91-3, 101-3, U35, U35-3

Cartridge code No.

1C020-32430

Percolation area

0.29 m2

Remarks

Percolation grade Relief valve setting

2 1.0 +0.3 -0.1 kgf/cm

Element material

Paper 15 kgf/cm2

Air cleaner, outer

Outer filter code No.

T0270-16320

Percolation area

1 m2

Percolation grade Element material

Paper

Inner element code No.

T0270-93220

Percolation area

262 cm2

Percolation grade

250 mesh

Element material

SUS 304

Element code No.

RA211-51280

Filtering area

800 cm2

Percolating grade

15 ± 5 µ at 0.4l/min

Strainer code No.

68773-6221-0

Air clreaner, inner Fuel filter

Suction filter

KBM-make : 69481-62211

Percolation area

Return filter

Percolation grade

150 mesh (105 µ)

Screen material

BSW2-1/2H

Filter code No.

68651-62120

KBM-make : RG518-62131

Percolation area

4400 cm

Percolation grade

10 µ

Pressure loss

0.6 kgf/cm2 <

Relief valve setting

1.0 ± 0.15 kgf/cm2

Burst pressure in new

6 kgf/cm2 <

Element material

Filter paper KBM-make : RG518-62640

Pilot filter

Element kit code No.

RD401-61270

Filtering rate

10 µ

Durable pressure

70 kgf/cm2

Valve setting pressure

1.5 kgf/cm2

I-S-11

J. Tightening torque a. Hose screw

Metric Size Hose Tightening torque N·m kgf·m ft·lbf

Thread size (piping screw)

Wrench size (reference)

Thread size (piping screw)

Torque N·m kgf·m ft·lbf

M12 × 1.5

20 ~ 30 2.0 ~ 3.1 14.75 ~ 22.13

Union nut section

Taper thread section

1/8”

7.8 ~ 11.8 N·m 0.8 ~ 1.2 kgf·m 5.8 ~ 8.7 ft·lbf

14.71 ~ 19.61 N·m 1.5 ~ 20 kgf·m 10.85 ~ 14.47 ft·lbf

17 mm 0.67 in

M14 × 1.5

20 ~ 30 2.0 ~ 3.1 14.75 ~ 22.13

1/4”

24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7

36.3 ~ 44.1 3.7 ~ 4.5 26.8 ~ 32.5

19 mm 0.75 in

M16 × 1.5

30 ~ 50 3.1 ~ 5.1 22.13 ~ 36.9

3/8”

49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8

49.0 ~ 68.6 5.0 ~ 7.0 36.2 ~ 50.6

22 mm 0.87 in

M18 × 1.5

30 ~ 50 3.1 ~ 5.1 22.13 ~ 36.9

1/2”

58.8 ~ 63.7 6.0 ~ 6.5 43.4 ~ 47.0

83.4 ~ 88.3 8.5 ~ 9.0 61.5 ~ 65.1

27 mm 1.06 in

M22 × 1.5

40 ~ 60 4.1 ~ 6.1 29.5 ~ 44.25

3/4”

117.7 ~ 127.5 12.0 ~ 13.0 86.8 ~ 94.0

127.5 ~ 147.1 13.0 ~ 15.0 94.0 ~ 108.5

36 mm 1.42 in

1”

137.3 ~ 147.1 14.0 ~ 15.0 101.3 ~ 108.5

147.1 ~ 166.7 15.0 ~ 17.0 108.5 ~ 123.0

41 mm 1.61 in

b. Joint bodies Tightening torque N·m kgf·m ft·lbf

Thread size (piping screw)

Spanner size (reference)

Remarks Steel pipe (OD)

R (tapered thread)

G (straight thread)

1/8”

19.6 ~ 29.4 N·m 2.0 ~ 3.0 kgf·m 14.5 ~ 21.7 ft·lbf

17 mm 0.67 in

8 mm 0.31 in

1/4”

36.3 ~ 44.1 3.7 ~ 4.5 26.8 ~ 32.5

W/O-ring Joint Torque 58.8 ~ 78.5 6~8 43.4 ~ 57.9

19 mm 0.75 in

12 mm 0.47 in

3/8”

39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2

W/O-ring Joint Torque 78.5 ~ 98.1 8 ~ 10 57.9 ~ 72.3

23 mm 0.91 in

1/2”

49.0 ~ 68.6 5.0 ~ 7.0 36.2 ~ 50.6

W/O-ring Joint Torque 117.7 ~ 137.3 12 ~ 14 86.8 ~ 101.3

26 mm 1.02 in

I-S-12

When in steel pipe is in use.

15 mm 0.59 in

16 mm 0.63 in

c. Tightening torque table for hose clamp (Screw type) Tightening torque N·m kgf·m ft·lbf

No.

Dia. (mm)

Code No.

Ø12 ~ 16

09318-89016

Ø19 ~ 25

09318-89024

Ø31 ~ 40

09318-89039

Ø36 ~ 46

09318-89045

Ø15 ~ 25

RC101-64580

Ø26 ~ 38

68311-72820

Ø13 ~ 20

RB101-63630

Ø40 ~ 55

RC411-63180

Ø77 ~ 95

69284-63170

Ø50 ~ 60

RC401-63190

Ø32 ~ 44

RD411-63820

2.5 ~ 3.4 25 ~ 35 1.84 ~ 2.51 4.9 ~ 5.9 50 ~ 60 3.61 ~ 4.35 3.4 ~ 4.4 35 ~ 45 2.58 ~ 3.31 4.9 ~ 5.9 50 ~ 60 3.61 ~ 4.35

d. Nuts for piping Steel pipe size (O.D. × I.D. × Thickness)

Tightening torque N·m kgf·m ft·lbf

Spanner size (reference)

8 × 6 × 1 mm 0.31 × 0.24 × 0.04 in

29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9

17 mm 0.67 in

10 × 7 × 1.5 mm 0.39 × 0.28 × 0.06 in

39.2 ~ 44.1 4.0 ~ 4.5 28.9 ~ 32.5

19 mm 0.75 in

12 × 9 × 1.5 mm 0.47 × 0.35 × 0.06 in

53.9 ~ 63.7 5.5 ~ 6.5 39.7 ~ 47.0

21 mm 0.83 in

16 × 12 × 2 mm 0.63 × 0.47 × 0.08 in

88.3 ~ 98.1 9.0 ~ 10.0 65.1 ~ 72.3

29 mm 1.14 in

18 × 14 × 2 mm 0.71 × 0.55 × 0.08 in

127.5 ~ 137.3 13.0 ~ 14.0 94.0 ~ 101.3

32 mm 1.26 in

27.2 × 21.6 × 2.8 mm 1.07 × 0.85 × 0.11 in

235.4 ~ 254.97 24.0 ~ 16.0 173.6 ~ 188.1

41 mm 1.61 in

I-S-13

Remarks

When sleeve nut is in use.

e. Tightening torque of bolts and nuts Refer to the tightness torque table below. Bolts, Nuts

Nomial Dia. SS41

S40C, S45C

SCr4

7.8 ~ 9.3 N·m 0.80 ~ 0.95 kgf·m 5.8 ~ 6.9 ft·lbf

9.8 ~ 11.3 N·m 1.00 ~ 1.15 kgf·m 7.2 ~ 8.3 ft·lbf

12.3 ~ 14.2 N·m 1.25 ~ 1.45 kgf·m 9.0 ~ 10.5 ft·lbf

17.7 ~ 20.6 N·m 1.80 ~ 2.10 kgf·m 13.0 ~ 15.2 ft·lbf

23.5 ~ 27.5 N·m 2.40 ~ 2.80 kgf·m 17.4 ~ 20.3 ft·lbf

29.4 ~ 34.3 N·m 3.00 ~ 3.50 kgf·m 21.7 ~ 25.3 ft·lbf

M10

39.2 ~ 45.1 N·m 4.00 ~ 4.60 kgf·m 28.9 ~ 33.3 ft·lbf

48.0 ~ 55.9 N·m 4.90 ~ 5.70 kgf·m 35.4 ~ 41.2 ft·lbf

60.8 ~ 70.6 N·m 6.20 ~ 7.20 kgf·m 44.8 ~ 52.1 ft·lbf

M12

62.8 ~ 72.6 N·m 6.40 ~ 7.40 kgf·m 46.3 ~ 53.5 ft·lbf

77.5 ~ 90.2 N·m 7.90 ~ 9.20 kgf·m 57.1 ~ 66.5 ft·lbf

103.0 ~ 117.7 N·m 10.50 ~ 12.00 kgf·m 75.9~ 86.8 ft·lbf

M14

107.9 ~ 125.5 N·m 11.00 ~ 12.80 kgf·m 79.6 ~ 92.6 ft·lbf

123.6 ~ 147.1 N·m 12.60 ~ 15.0 kgf·m 91.1 ~ 108.5 ft·lbf

166.7 ~ 196.1 N·m 17.00 ~ 20.00 kgf·m 123.0 ~ 144.7 ft·lbf

M16

166.7 ~ 191.2 N·m 17.00 ~ 19.50 kgf·m 123.0 ~ 141.0 ft·lbf

196.1 ~ 225.6 N·m 20.00 ~ 23.00 kgf·m 144.7 ~ 166.4 ft·lbf

259.9 ~ 304.0 N·m 26.50 ~ 31.00 kgf·m 191.7 ~ 224.2 ft·lbf

M18

245.2 ~ 284.4 N·m 25.00 ~ 29.0 kgf·m 180.8 ~ 209.7 ft·lbf

274.6 ~ 318.7 N·m 28.00 ~ 32.50 kgf·m 202.5 ~ 235.1 ft·lbf

343.2~ 402.1 N·m 35.00 ~ 41.00 kgf·m 253.2 ~ 296.5 ft·lbf

M20

333.4~ 392.2 N·m 34.00 ~ 40.00 kgf·m 245.9 ~ 389.3 ft·lbf

367.7 ~ 431.5 N·m 37.50 ~ 44.0 kgf·m 271.2 ~ 318.2 ft·lbf

519.8 ~ 568.8 N·m 53.00 ~ 58.00 kgf·m 383.3 ~ 419.5 ft·lbf

f. Types and materials of bolts and nuts [ex. bolts] Types

Material

Tensile strength

Hardness

SS41

Over 392 MPa 4000 kgf/cm2 56892 lbf/in2

HRB 62 ~ 98

No mark or marked 4

S40C S45C

Over 686 MPa 7000 kgf/cm2 99561 lbf/in2

HRC 20 ~ 28

Marked 7

SCr4

Over 882 MPa 9000 kgf/cm2 128007 lbf/in2

HRC 28 ~ 34

Marked 9

I-S-14

Bolt head marking

g. Washer-equipped elbow Tightening torque Size

N·m

kgf·m

ft·lbs

G1/4

25 ~ 30

2.5 ~ 3.0

18 ~ 22

G3/8

49 ~ 54

5.0 ~ 5.5

36 ~ 40

G1/2

59 ~ 64

6.0 ~ 6.5

43 ~ 47

G3/4 G1

118 ~ 127

12.0 ~ 13.0

87 ~ 94

Tightening procedure 1) Connecting with the valve • Screw in the elbow by hand until the washer comes into contact. Note:Clean up hte mating seal boforehand.

2) Positioning • Turn the elbow back to its set position. Note:Do not make any more than one turn back.

3) Fixing • Tighten up the lock nut with a wrench. • Lock nut tightening torque G1/4:25 ~ 30 N·m (2.5 ~ 3.0 kgf·m, 18 ~ 22 ft·lbs) G3/8:50 ~ 55 N·m (5.0 ~ 5.5 kgf·m, 36 ~ 40 ft·lbs) G1/2:60 ~ 65 N·m (6.0 ~ 6.5 kgf·m, 43 ~ 47 ft·lbs) G3/4:118 ~ 127 N·m (12.0 ~ 13.0 kgf·m, 87 ~ 94 ft·lbs) G1:118 ~ 127 N·m (12.0 ~ 13.0 kgf·m, 87 ~ 94 ft·lbs)

I-S-15

K.Machine Quality Specifications U35 : KTC, KCL ; U35-3: KTA ; U35-3: KE, KDG, KUK Machine specification:Service port, Wrist rest, STD-arm, KBT-cab, KBT-bucket No

Specifications Items

Main Spec. JIS A8404

Machine size

Weight

Performance

4695 ± 94

inch

184.8 ± 3.7

191.5 ± 3.7

Total width

1700 ± 17

←

inch

66.9 ± 0.7

←

2440 ± 24

←

inch

96 ± 0.9

←

Total height (Cabin)

2440 ± 24

←

inch

96.1 ± 0.9

←

Machine weight (Canopy)

3560 ± 71

3490 ± 70

lbs

7848.4 ± 156.6

7694.1 ± 154.3

Machine weight (Cabin)

3660 ± 73

3590 ± 72

lbs

8068.8 ± 160.9

7914.5 ± 158.7

Swivel speed

9.0 ± 0.9

8.9 ± 0.9

9.0 ± 0.9

8.9 ± 0.9

km/h

3.0 ± 0.3

←

mph

1.86 ± 0.19

←

Iron F1

rpm rpm

Rubber F2

L R Rubber F1

Iron F2

Gradeability

km/h

4.6 ± 0.5

←

mph

2.86 ± 0.31

←

km/h

2.9 ± 0.3

←

mph

1.80 ± 0.19

←

km/h

4.6 ± 0.5

←

mph

2.86 ± 0.31

←

deg

Rear end min. turning radius

850 ± 17

←

inch

33.5 ± 0.7

←

Swivel frame rear ground clearance

525 ± 11

←

inch

20.7 ± 0.4

←

Tambler center distance

1670 ± 50

←

inch

65.7 ± 2.0

←

Crawler total length

2100 ± 63

←

inch

82.7 ± 2.5

←

1700 ± 34

←

inch

66.9 ± 1.3

←

285 ± 9

←

inch

11.2 ± 0.4

←

0.093

yd3

0.122

0.1

0.13

555 ± 12

550 ± 11

Crawler total width

Min. ground clearance

Front attachment

Bucket heaped capacity

CECE

SAE, JIS

yd 3

Bucket width

Swing angle

Canopy L

inch

21.9 ± 0.5

21.7 ± 0.4

deg

70 ± 2

←

50 ± 2

←

Canopy R

deg

Cabin L

deg

Cabin R

deg

I-S-16

Remarks

4865 ± 95

Total height (Canopy)

Travel speed

U35-3 (EU)

Total length (Transport)

2 3

U35(KTC, KCL) U35-3(KTA)

Unit

Fuel tank

Without side cutter

No 5

Specifications Items 8

Front attachment

5755 ± 79

inch

226.6 ± 3.1

213.0 ± 3.2

Ground level Max. digging radius

5140 ± 77

5300 ± 80

inch

202.4 ± 3.0

208.7 ± 3.1

Ground level Min. finish radius

1755 ± 35

inch

69.1 ± 1.4

Max. digging depth

3115 ± 62

inch

122.6 ± 2.4

123.6 ± 2.5

Max. vertical digging depth

2185 ± 44

2340 ± 47

Max. digging height

Max. dump height

Max. dump height (Arm vertical)

Mini. turning radius

Mini. turning radius (Left swing)

Bucket bottom horizontal 3140 ± 63

inch

86.0 ± 1.7

92.1 ± 1.9

4890 ± 98

4830 ± 97

inch

192.5 ± 3.9

190.2 ± 3.8

4660 ± 93

4830 ± 97

inch

183.5 ± 3.7

190.2 ± 3.8

Conopy

3470 ± 69

3455 ± 69

Conopy

inch

136.6 ± 2.7

136.0 ± 2.7

3265 ± 65

3455 ± 69

inch

128.5 ± 2.6

136.0 ± 2.7

1230 ± 37

1255 ± 38

inch

48.4 ± 1.5

49.4 ± 1.5

1125 ± 34

1255 ± 38

inch

44.3 ± 1.3

49.4 ± 1.5

2065 ± 62

2255 ± 68

inch

81.3 ± 2.4

88.8 ± 2.7

Cabin

2190 ± 66

2255 ± 68

inch

86.2 ± 2.6

88.8 ± 2.7

Conopy

inch

Cabin

inch

Width

1700 ± 5

←

inch

66.9 ± 0.2

←

Height

335 ± 25

←

inch

13.2 ± 1.0

←

Max. lift above GL

360 ± 25

370 ± 26

inch

14.2 ± 1.0

14.6 ± 1.0

340 ± 24

370 ± 26

inch

13.4 ± 0.9

14.6 ± 1.0

Dozer

Max. below GL

Main Specs JIS A8404

Bucket tooth slaggish

70 >

←

inch

2.8 >

←

Tilt amount of front attachment

10 >

←

inch

0.4 >

←

Dozer's declination

10 >

←

inch

0.4 >

←

Distance from tooth tip to cylinder protector

72 ± 25

←

inch

2.8 ± 1.0

←

Approach angle

deg

31.4 ± 3.5

←

I-S-17

Remarks

5410 ± 81

Cabin

Conopy

Cabin

U35-3 (EU)

Max. digging radius

U35(KTC, KCL) U35-3(KTA)

Unit

F = 30 kgf

No 4

Specifications Items 1

Crawler height

Max. crawler height

Engine performance

Max, engine rpm

2 3 4

Variable pump

6 2

Travelling performance

Travel motor block performance

Max, Traction force

420 ± 8

←

inch

16.54 ± 0.31

←

450 ± 9

←

inch

17.72 ± 0.35

←

rpm

2550 >

←

rpm

2 pump relief

rpm

3 pump relief

rpm

2 pump relief

rpm

2300 <

←

Dozer+2 pump relief

rpm

2100 <

←

rpm

1050 ± 5

←

300 >

←

inch

11.81 >

←

mm(inch)

300 >

←

inch

11.81 >

←

kgf

2766

←

27.1

←

lbs

6098

←

kgf

1546

←

15.2

←

Idleing rpm

Travel straightness

600 >

←

inch

23.62 >

←

600 >

←

inch

23.62 >

←

Dozer F1

600 >

←

inch

23.62 >

←

Dozer R1

600 >

←

inch

23.62 >

←

Iron

75 ~ 80

←

inch

2.95 ~ 3.15

←

Rubber

10 ~ 5

←

inch

0.39 ~ 0.20

←

kgf

575

670

5.6

6.6

lbw

1267.7

1477.1

kgf

1878

1870

Track shoe sag distance

Work performance

Boom lifting capacity

Arm digging force

Bucket digging force

Dozer force

down

18.4

18.3

lbw

4140.3

4122.6

kgf

3176

3180

31.1

31.2

lbw

7001.9

7010.7

kgf

2838

2835

27.8

lbw

6256.7

6250.1

I-S-18

Remarks Include grouser on the spocket

Boom, arm, swivel

20 deg, 10 min Engine stop Oil temp..50 ± 5 °C

Slip. 70% of theoretical traction force. Relief. 60% of theoretical traction force.

←

lbs 3

U35-3 (EU)

1 pump relief

no load Gear pump

U35(KTC, KCL) U35-3(KTA)

Unit

10m distance

Dozer up & down 10m distance

Iron. Tread to tread.

Rubber. Tread to tread.

Front end, Arm extend bucket crowd, dozer down. Bucket tooth root Arm length : U35 = mm U35-3 = Machine stance to JIS bucket tooth root

Cutting edge down force at ground level

No 2

Specifications Items 1

Boom speed

Canopy

sec

2.4 ± 0.3

2.5 ± 0.3

up 2nd

sec

down

sec

3.0 ± 0.3

3.1 ± 0.3

down

sec

up (G → T)

sec

2.5 ± 0.3

up (L → T)

sec

down (T → G)

sec

3.1 ± 0.3

down (T → L)

sec

Cabine

Arm speed

sec

3.1 ± 0.3

3.3 ± 0.3

sec

2.7 ± 0.3

2.8 ± 0.3

crowd

sec

2.6 ± 0.3

2.7 ± 0.3

dump

sec

1.7 ± 0.3

1.9 ± 0.3

up (G → T)

sec

up (L → T)

sec

2.2 ± 0.3

2.1 ± 0.3

Max. down to max. up

down (T → G)

sec

Max.up to ground

down (T → L)

sec

2.9 ± 0.3

Max. up to max. down

←

inch

0.20 >

←

Oil temp. 1300 rpm 95 ± 5 °C(203 ± 41 °F) Bucket heaped.

2800

inch

110.24

3215 ± 322

3250 ± 325

inch

126.57 ± 12.68

127.95 ± 12.8

Bucket speed

Dozer speed

Arm cylinder cavitation Max. digging height radius

Max. dump height radius

Bucket bottom height at arm vertical

Bucket wrist angle

Swivel, swing performance

Canopy

Cabine

Canopy

Cabine

Canopy

Cabine

Swivel torque

Swivel angle

1 2

Swivel block performance

Engine stops

Engine runs

4 4

1 2

Swivel start-up speed Swing speed

Canopy

2 3 4

Cabine

2285 ± 137

32950 ± 198

inch

89.96 ± 5.39

1297.24 ± 7.80

2555 ± 153

inch

100.59 ± 6.02

1525 ± 46

1543 ± 54

inch

60.04 ± 1.87

60.75 ± 2.13

1415 ± 42

1885 + 57

inch

55.71 ± 1.65

74.21 + 2.2

degree

182

kgf·m

738

←

7.2

←

ft·lbs

5338

←

kgf·m

738

←

kN.m

7.2

←

ft·lbs

5338

←

deg

15 <

16 <

deg

15 <

16 <

deg

←

deg

←

deg

30 >

deg

30 >

sec

2.5 ± 0.3

sec

2.5 ± 0.3

sec

5.8 ± 0.3

5.9 ± 0.3

sec

5.8 ± 0.3

5.9 ± 0.3

sec

I-S-19

Oil temp. 50 ± 5 °C (122 ± 41 °F) Ground to max. up

kN·m

2 3

Oil temp. 50 ± 5 °C (122 ± 41 °F) Ground to max. height (exculude cushioning)

extend

2 5

Remarks

crowd

2 4

U35-3 (EU)

up 1st

U35(KTC, KCL) U35-3(KTA)

Unit

at bucket pin

Bucket horizontal

Arm extend Quick operation Engine Max. rpm oil temp. 50 ± 5 °C

Bucket load=JIS heaped×1.8 Engine stop

Engine idle rpm. Loading 0~90 deg swivel

Boom, arm : horizontal bucket crowd. No load. Engine Max. rpm.

No 6

Specifications Items 1

Unit

Swing Lock

Reciprocating motion

Hydraulic performance

Swivel R&L

L/R

Swing

Relief pressure setting

10 >

←

inch

0.39 >

←

kgf/cm2

255 ± 5

←

MPa

25.0 ± 0.5

←

bar

2.5 ± 0.05

←

psi

3627 ± 71

←

kgf/cm2

255 ± 5

←

MPa

25.0 ± 0.5

←

bar

2.5 ± 0.05

←

psi

3627 ± 71

←

207 ± 5

210 ±

20.3 ± 0.5

20.6 ± 0.5

bar

2.0 ± 0.05

psi

2944 ± 71

40 +3, -0

←

MPa

3.9 +0.3, -0

←

bar

3.9 +0.03,. -0

←

psi

569 +43, -0

←

kgf/cm

Cylinder oil sealing capacity

Boom

Arm

Bucket

1 2

Dozer

Boom cushioning performance

3 Q8

Lever operating force & stroke

Boom lever operating force

50 ± 5 °C

←

(122 ± 41°F)

inch

0.24 >

←

95 ± 5 °C

←

(203 ± 41°F)

inch

0.24 >

←

50 ± 5 °C

14 >

←

(122 ± 41°F)

inch

0.55 >

←

50 ± 5 °C

25 >

←

(122 ± 41°F)

inch

0.98 >

←

50 ± 5 °C

←

(122 ± 41°F)

inch

0.79

←

30 °C(86 °F)

sec

←

50 °C(122 °F)

sec

0.4 ~ 1.3

←

80 °C(176 °F)

sec

0.3 <

←

kgf

1.7 ± 1.0

1.5 ± 1.0

17 ± 10

15 ± 10

down

Arm lever

kgf/cm

crowd

extend

lbs

12.3 ± 7.2

10.8 ± 7.2

kgf

1.4 ± 1.0

1.5 ± 1.0

14 ± 9.8

15 ± 9.8

lbs

10.1 ± 7.2

10.8 ± 7.2

kgf

1.7 ± 1.0

1.5 ± 0.5

17 ± 10

15 ± 5

lbs

12.3 ± 7.2

10.3 ± 3.7

kgf

1.4 ± 1.0

1.5 ± 0.5

14 ± 10

15 ± 5

lbs

10.1 ± 7.2

10.8 ± 3.7

I-S-20

Remarks 90 deg-swivel, 100 times actual digging cylinder dislocation 90 deg-swivel, 100 times

MPa

U35-3 (EU)

inch

U35(KTC, KCL) U35-3(KTA)

At pump deliery port including back pressure. Oil temp. 50 ± 5 °C

Arm extend, bucket, crowd, boom up, heaped capacity 10 min. Engine stop

height 1m, 10 min.

Bucket load=JIS heaped×1.8 Arm vertical, dozer down

Measuring point : 20 mm lower from lever tip. Pilot system : Engine max. rpm.

No 1

Specifications Items 5

Unit

Bucket lever

crowd

extend

Swivel (Swing) lever

Dozer lever

down

Travel lever

Back

Accelerator lever

down

Swing pedal

Forward

Back

Forward

Safety lock lever

down

U35(KTC, KCL) U35-3(KTA)

U35-3 (EU)

kgf

1.2 ± 1.0

1.5 ± 0.5

12 ± 10

15 ± 5

lbs

8.7 ± 7.2

10.8 ± 3.7

kgf

1.2 ± 1.0

1.5 ± 0.5

12 ± 10

15 ± 5

lbs

8.7 ± 7.2

10.8 ± 7.2

kgf

1.2 ± 1.0

1.5 ± 0.5

12 ± 10

15 ± 5

lbs

8.7 ± 7.2

10.8 ± 3.7

kgf

1.2 ± 1.0

1.5 ± 0.5

12 ± 10

15 ± 5

lbs

8.7 ± 7.2

10.8 ± 3.7

kgf

2.0 ± 0.5

2.40 ± 0.5

20 ± 5

240 ± 5

lbs

14.5 ± 3.7

kgf

2.0 ± 0.5

20 ± 5

lbs

14.5 ± 3.7

kgf

1.8 ± 0.5

1.6 ± 0.5

18 ± 5

16 ± 5

lbs

13.0 ± 3.7

11.6 ± 3.7

kgf

1.8 ± 0.5

1.6 ± 0.5

18 ± 5

16 ± 5

lbs

13.0 ± 3.7

11.6 ± 3.7

kgf

1.8 ± 0.5

1.6 ± 0.5

18 ± 5

16 ± 5

lbs

13.0 ± 3.7

11.6 ± 3.7

kgf

1.8 ± 0.5

1.6 ± 0.5

18 ± 5

16 ± 5

lbs

13.0 ± 3.7

11.6 ± 13.7

kgf

5.0 ± 1.0

49 ± 10

lbs

36.2 ± 7.4

kgf

5.0 ± 1.0

49 ± 10

lbs

36.2 ± 7.4

kgf

5.0 ± 1.0

6.4 ± 1.0

49 ± 10

63 ± 10

lbs

36.2 ± 7.4

46.3 ± 7.4

kgf

5.0 ± 1.0

6.4 ± 1.0

49 ± 10

63 ± 10

lbs

36.2 ± 7.4

46.3 ± 7.4

kgf

0.8 ± 0.2

0.6 ± 0.2

8±2

6±2

lbs

5.8 ± 1.4

4.3 ± 1.4

kgf

0.8 ± 0.2

0.6 ± 0.2

8±2

6±2

lbs

5.8 ± 1.4

4.3 ± 1.4

I-S-21

Remarks Dump & crowd

Left & right

Up & down

U35-3 EU version has electric accel. dial.

Up & down

No 1

Specifications Items 21

Safety lock lever

Travel Hi-Lo change

Boom lever stroke

Arm lever stroke

Standard arm, Dynamic operation load limit

Bucket load to 10 degrees tipping

1.5 ± 0.5

←

15 ± 5

←

lbs

10.8 ± 3.6

←

110 ± 10

72 ± 10

72 ± 10 2.83 ± 0.39

110 ± 10

72 ± 10

inch

4.33 ± 0.39

2.83 ± 0.39

85 ± 10

75 ± 10

inch

3.35 ± 0.39

2.95 ± 0.39

85 ± 10

75 ± 10

inch

3.35 ± 0.39

2.95 ± 0.39

85 ± 10

75 ± 10

inch

3.35 ± 0.39

2.95 ± 0.39

85 ± 10

75 ± 10

inch

3.35 ± 0.39

2.95 ± 0.39

55 ± 10

←

inch

2.17 ± 0.39

←

down

55 ± 10

←

inch

2.17 ± 0.39

←

73 ± 10

←

inch

2.17 ± 0.39

←

73 ± 10

←

inch

2.17 ± 0.39

←

73 ± 10

←

inch

2.87 ± 0.39

←

73 ± 10

←

inch

2.87 ± 0.39

←

55 ± 10

←

inch

2.17 ± 0.39

←

Forward

Side, dozer up

Front, dozer up

Bucket load to tip fully

←

kgf

4.33 ± 0.39

Accel. lever

Stability

←

43.4 ± 7.4

inch

Back

59 ± 10

lbs

2.83 ± 0.39

Back

110 ± 10

←

4.33 ± 0.39

Swivel lever stroke

←

6.0 ± 1.0

Travel lever stroke

19.5 ± 7.4

kgf

inch

extend

lbs

2.83 ± 0.39

Bucket lever stroke

←

72 ± 10

crowd

Dozer lever stroke

←

4.33 ± 0.39

2.7 ± 1.0 26 ± 10

110 ± 10

extend

kgf N

crowd

Bucket lever stroke

U35-3 (EU)

inch down

down

U35(KTC, KCL) U35-3(KTA)

Unit

Side, dozer up

Front, dozer up

kgf

lbs

kgf N

lbs

kgf

lbs

kgf

lbs

I-S-22

Remarks Up & down

Arm extend, bucket crowd oil temp.50 ± 5 °C (122 ± 41 °F)

No 1

Specifications Items 5

Standard arm, static limited load

Unit Bucket load to tip fully

Side

Front

Long arm, Dynamic operation load limit

Bucket load to 10 degrees tipping

Side, dozer up

U35(KTC, KCL) U35-3(KTA)

U35-3 (EU)

kgf

430

415

4217

4070

lbs

3110

3002

kgf

450

440

4413

4315

lbs

3255

3182

kgf

Arm extend, bucket crowd oil temp.50 ± 5 °C (122 ± 41 °F)

N lbs

Front, dozer up

kgf N lbs

Bucket load to tip fully

Side, dozer up

kgf N lbs

Front, dozer up

kgf N lbs

Long arm, static limited load

Bucket load to tip fully

Side

kgf N lbs

Front

kgf N lbs

Q10

Comfortability

1 2 3 4

Noise level

At operator's ear LPA Noise source;LWA

Canopy

db(A)

80 >

←

Cab

db(A)

80 >

←

db(A) db(A)

I-S-23

Remarks

95 >

Compatibility Table of main components between U35, U35-3. and KX91-3, 101-3 • Compatibility sign : KTC, KCL, KTA-version= KE, KDG, KUK-version= • KTC, KCL, KTA version has non-AI type. AI (Auto Idle) version is standard for EU market. U45-3 is for KE,KDG,KUK and KTA. No. MB-1

Components name

KX91-3

U35, U35-3

KX101-3

Remarks

Bucket

Local content, KX121-3 = 0.12 m3, U45-3 = 0.14 m3, KX161-3 = 0.17 m3

Bucket link

U45-3(EU) & KTC-version are Hirakata make.

Arm

ditto KX121-3 = 1300, KX121-3L = 1600 U45-3 = 1360, KX161-3 = 1480 KX161-3L = 178

Boom

ditto U45-2 = 2740 mm, KX161-3 = 2870 mm KX121-3L = 2660 mm

Swing bracket

Dozer blade

KX161-3 has wide blade for wide track shoe. KX121-3 = 1700, U45-3, KX161-3 = 1960, KX161-3L = 2110

Track frame

KX121-3 EU-version has thift proof plate.

Idler assy

Grease cylinder assy

Idler spring assy

Track roller assy

Upper roller assy

Rubber track

KX121-3 = 350, U45-3, KX161-3 = 400

Iron track

KX121-3 = 350, U45-3, KX161-3 = 400, KX161-3L = 550 EU-version has std and wide track, KTC, KCL has wide track only.

Sprocket

Swivel frame

Swivel bearing

U45-3 and KX161-3 are identical but different buyer.

Counterweight

KX121-3 = 430 + 25 × 2, U45-3 = 280K, KX161-3 = 812K

Seat assy

Rops canopy

Cab assy

EN-1

Engine assy

Oil filter

Engine fan

Radiator assy

Air cleaner

Muffler

Fuel filter

Fuel tank

Coupling flange

Pump housing

64 L

I-S-24

U45-3 is for KE,KDG,KUK and KTA. No.

Components name

KX91-3

U35, U35-3

KX101-3

Remarks

HY-1

Main pump assy

KX121-3 = 42 cc/rev, U45-3, KX161-3 = 54cc/rev

Pilot pump assy

Drive motor assy

V = 33.0 cc/rev, reduction ratio is different.

Swivel motor assy

Relief pressure is different. U45-3 = 165K, KX161-3 = 180K

Rotary joint

Hydraulic oil tank

KX121-3, U45-3, KX161-3 = 44 l Full = 67 l

Suction filter

150 mesh

Return filter

10 µ, 1.0 kg/cm2

Control valve assy

KX121-3 = 250K, U45-3, KX161-3 = 240K

Change valve assy

40 kgf/cm2

TPSS valve assy

Pilot valve assy

Oil cooler

Boom cylinder

Arm cylinder

Bucket cylinder

Dozer cylinder

Swing cylinder

Travel lock cylinder

EL-1

27 kgf/cm2

Battery

95D31R

Alternator assy

12V, 480W

Starter motor assy

12V, 1.4kW

Fuel sensor

Auto release controller

Meter assy(Non AI)

Meter assy (AI)

Wire harness(Non AI)

Wire harness(AI)

AI controller

AI pressure switch

Engine oil pressure SW

Engine speed sensor

Heater assy

Engine stop solenoid

Fuel pump

Auto glow controller

I-S-25

II. Machine Body A. Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3 a. Greasing points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3 b. Component interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-4

B. Component interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-5 a. b. c. d. e. f. g. h.

Bucket interchangeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-5 Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-7 Installing direction of dust seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-8 Installation of bushing and thrust collar on the swing bracket . . . . . . . . . . . . . . . . II-S-8 Installing pin, bush and shim (1):U35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-9 Installing pin, bush and shim (2):U35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-10 Installing pin, bush and shim of bucket : U35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-11 Installing local bucket : U35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-12

II-M-1

II-M-2

A.Front attachment a. Greasing points (1) Keep applying grease until it comes out of the circumference at the other end surface of each rotating part. (2) Apply grease to the end surfaces of all the rotating parts and their related shims.

(1) A-type: Straight type (06611-15010)

(2) B-type: 67°C (06616-25010)

(3) C-type: 90°C (06616-35010) (4) A-type(Pin-greasing)

(10) A-type(Pin-greasing) (11) B-type(Boss-greasing)

(7) A-type(Pin-greasing)

(5) B-type(Boss-greasing)

(12) A-type(Pin-greasing)

(6) A-type(Boss-greasing) (14) B-type

(13) A-type(Pin-greasing) (8) A-type(Pin-greasing) (9) A-type(Boss-greasing) (15) Arm

(16) B-type

(20) B-type (19) A-type

(17) A-type(Pin-greasing)

(21) B-type (18) Swing bracket (22) B-type

(1) A-type: Straight type (2) B-type: 67°C (3) C-type: 90°C (4) A-type(Pin-greasing) (5) B-type(Boss-greasing) (6) A-type(Boss-greasing) (7) A-type(Pin-greasing) (8) A-type(Pin-greasing) (9) A-type(Boss-greasing) (10) A-type(Pin-greasing) (11) B-type(Boss-greasing) (12) A-type(Pin-greasing)

(23) End surface of rotating part

(13) A-type(Pin-greasing) (14) B-type (15) Arm (16) B-type (17) A-type(Pin-greasing) (18) Swing bracket (19) A-type (20) B-type (21) B-type (22) B-type (23) End surface of rotating part

II-M-3

b. Component interchangeability 1. The bucket support is the same in dimensions for the three types (KX91-3, 101-3 and U35-3). This means the bucket is interchangeable among KX-3, U-3 and KX-2 super series and KX series. 2. The KX series bucket can be readily installed on the machine. (The KX3 series pins should be employed.) 3. KX-2 series and U-35, U-45 have shim adjustable mechanism. Therefore, a set of pin, shims and bucket is required to install on KX-3, U-3 series machines. (1)Shim(0.5, 1.0mm-outer dia75mm, Inner dia41mm) (2)Shim(0.5, 1.0mm-outer dia64mm, Inner dia41mm) (3)O-ring φ 80mm)

KX91-2 super series KX91-3, 101-3 U35-3, U35

U-35 bucket

KX91-2 bucket

KX-91,101 series bucket

Arm

Bucket

II-M-4

Arm

Bucket

B.Component interchangeability a. Bucket interchangeability Bucket can be mounted between KX-2 and KX-3 series in each local bucket as shown in the below table. Also below dimensions are for your reference to process local bucket in your place. Still bucket size and weight should be considered for safety, stability and performance. Bucket compatibility

U35, U35-3

KX91-3, 101-3

EU-version

↔

z(KX101-3)

KTC, KCL, KTA-version

↔

z(KX91-3)

KBM-make: U35-3, KX91-3, 101-3

Arm

e k g f

Japan-make: Bucket

a(Bucket) inner dia.

40 +0.10 +0.05

←

b(Link) boss inner dia.

50 +0.025 0

←

c(Bucket) boss inner dia.

40 +0.10 +0.05

←

d(Arm)

50 +0.025 0

←

191.5 ±0.5

185 ±0.5

f(Link)

134 -0.3 -0.6

←

178

180

202

204

221

j(pin dia.)

40 -0.05 -0.07

←

K(Bucket)

134 +1 0

136 +1 0

KTC, KCL, KTA procure their own buckets. Bucket link h i

KX-3, U-3 series

KX-2 super series

KX series

KX-2 series

U-series (U-35, U-45)

z z Shim adjustable mechanism

A set of pin, shim adjuster and bucket is required.

II-M-5

U35-3, KX91-3, 101-3:KBM-make bucket Shaft of φ39.95 must pass through smoothly Weld bead and spattering must be in the area enclosed with the line.(Onry this side)

Shaft of φ39.95 must pass through smoothly Weld bead and spattering must be in the area enclosed with the line.(Onry this side)

L12=63 This area must be filled with welding bead.

Japan-make bucket

Shaft of φ39.95 must pass through smoothly Weld bead and spattering must be in the area enclosed with the line.(Onry this side)

II-M-6

b. Arm

c a

B A

Arm boss width

Arm boss inner dia.

U35, KX91-3 : KBT-make

U35-3, KX91-3, 101-3 : KBM-make

50 +0.025 (1.97”) 0

←

50 +0.025 (1.97”) 0

←

40 +0.10 +0.05 (1.57”)

←

50 +0.025 (1.97”) 0

←

45 +0.10 +0.05

←

134 -0.3 (5.28”) -0.6

←

134 -0.3 (5.28”) -0.6

←

52 +1 0

(2.05”)

51 ±0.5 (2.01”)

145 -0.3 (5.71”) -0.6

147 -0.3 (5.79”) -0.6

62 +1 0

61 ±0.5 (2.40”)

(2.44”)

Above dimension doesn’t include bush.

U35 Length L

U35-3(EU)

1350(53.1in)

Assy code No. RC718-66612

RGXXXX(EU)

KX91-3 1550(61.0in) 1275(50.2in) RC418-67100 RG518-66612(EU) RG518-67113(EU)

II-M-7

KX101-3 1350(53.1in)

1550(61.0in)

RG618-66612(EU)

RG518-67113(EU)

c. Installing direction of dust seal Bush

Dust Seal

Install the dust seals in the direction as shown at left. If in the wrong direction, the sealing effect is adversely affected, which may get the pins worn out earlier. (Enlarged view of dust seal)

OutSide

Toward the Bushing

Jig

Press in Bush

Bush

Dust seal

Bush direction

d. Installation of bushing and thrust collar on the swing bracket 1. Install the thrust collar (t3.5), with its grooved face downward, on top of the swivel frame. 2. Select and install a 0.5 or 1.0 mm(0.02 ~ 0.04”) thick shim to have the clearance smaller than 0.5 mm(0.02”).

Thrust collar (t3.5)

Shim

Thrust collar (t3.5)

II-M-8

e. Installing pin, bush and shim (1):U35 5

6 4 7

8 11

RC418-6668

Boom assy ~ boom cylinder

φ40 Bolt 01173-61290 Stopper nut 02572-50120

2 1 11

RC418-6746

RC418-6658

Stud bolt 01517-61025 Nut 02118-60100

RC411-6659

10 Swing bracket ~ boom cylinder

Bolt 01173-61202 Stopper nut 02572-50120

φ45

5 Swing bracket ~ swing cylinder

φ40

RC411-6657

RC418-6666 RC418-6646

RC418-6633

Swing bracket ~ swivel frame (lower)

φ70

Plate RC411-6648 Bolt 01133-51020 RC418-6636

Boom assy ~ Arm cylinder

φ45

Bolt 01173-51290 Stopper nut 02572-50120

RC418-6645

8 Swing bracket ~ swivel frame (upper)

φ70

RC418-6666

RC418-6632

RC418-6636

Arm assy ~ Arm cylinder

Pin RC101-6636 Split pin 05511-50425

φ45

RC418-6664

RC418-6654

7 Boom assy ~ Swing bracket

φ50

Bolt 01173-51202 Stopper nut 02572-50120

2 Boom assy ~ Arm assy

φ40

RC418-6649 68761-6652

68741-6662

RC418-6744

Bolt 01173-51280 Stopper nut 02572-50120

RC201-6663

6 Swing frame ~ Swing cylinder

φ40

Key plate 68741-6745 Bolt 01133-51225

II-M-9

Bolt 01173-51290 Stopper nut 02572-50120

RC418-6668

Arm assy ~ Backet cylinder

φ40

Bolt 01173-51275 Stopper nut 02572-50120

f. Installing pin, bush and shim (2):U35 1

2 3 4

Looseness at the front * Thrust-oriented gaps at support pins Below 0.6 mm * If over 0.6 mm, add shims for readjustment. (For additional shims, see the drawings.) Lengthwise gaps between swivel frame and swing bracket 0.1 ~ 1.0 mm (0.004 ~ 0.04 in) Positioning of pin lock bolts All bolts to be installed as shown at right Positioning of thrust collars at upper swing support Grooved side to fit on swivel frame

Installing the thrust collars (8) and (9) 1. Fit the grooved thrust collar (with the grooved side downward) at the top. Apply grease to 4 pints of each side. (See Figure A.) (Molybdenum antiseizing agent also applicable) 2. Prepare 2 different-thickness thrust collars for the lower side. First place the 3.5 mm thick (galvanized) thrust collar. Use this if it fits in smoothly. If not, use the 3.2 mm thick (non-galvanized) thrust collar instead. (In other words, select the better thrust collar.)

Boom assy ~ Boom cylinder

φ40

Swing bracket ~ swing cylinder

68131-6772 Shim(1.0) SPCC RD601-6738 Shim(0.5) SPCC Selective use

φ40

10 Swing bracket ~ boom cylinder

RC411-6689 shim(1.0)SK Use one shim for both sides

φ45

Boom assy ~ Arm cylinder

RC411-6688 Shim(0.5) SK Selective use

φ45

RC411-6638 Shim(1.0) SPCC RD601-6637 Shim(0.5) SPCC Selective use

Swing bracket ~ swivel frame (lower)

Thrust collar(3.5) RC411-6682

Thrust collar(4)

Selective use

Arm assy ~ Arm cylinder

φ70

RC411-6683

Groove to be downward

RC411-6689 shim(1.0)SK Use one shim for both sides

φ45

RC411-6688 Shim(0.5) SK Selective use

8 Swing bracket ~ swivel frame (upper)

Thrust collar(3.5) RC411-6687

2 φ70

Boom assy ~ Arm assy

Boom assy ~ Swing bracket

RC411-6692 Shim(0.5) SK Selective use

φ50 RC411-6691 shim(1.0)SK Use one shim for both sides

RC411-6690 Shim(0.5) SK Selective use

Swing fram ~ Swing cylinder

φ40

RC411-6693 shim(1.0)SK Use one shim for both sides

Arm assy ~ Backet cylinder RC411-6693 shim(1.0)SK Use one shim for both sides

φ40

68131-6772 Shim(1.0) SPCC RC601-6738 Shim(0.5) SPCC Selective use

RC411-6692 Shim(0.5) SK Selective use

II-M-10

φ40

g. Installing pin, bush and shim of bucket : U35

16 15

13 Bucket link ~ Bucket cylinder

Dust seal RC411-6678

Pin RC418-6675

Bucket ~ Arm assy

Dust seal RC411-6678

Pin RC418-6676

Bucket hinge pin

Bolt 01133-61630

Spring washer 1

Collar RC401-6662

68271-4217 Bush 68741-6677

18 Cylinder(brade)

- Brade - Track frame

Dust seal RC411-6678

Pin RC411-7444

15 Bucket ~ Bucket link 1 Bucket link(Bucket side)

Bush 68741-6662

Pin RC418-6676

Dust seal RC411-6678

Bolt 01173-61280 Stopper nut 02572-50120

Collar RC401-6662

Nut should be upper side 17 Track frame

- Brade Bolt 01173-61270

Stopper nut 02572-50120

14 Bucket link (2), (3) ~ Arm assy

Pin RC418-6677

Bush 68741-6662 Dust seal RC411-6678

Bucket link(Arm side) Bolt 01133-61630

Spring washer 1 68271-4217

Pin RC411-7443 Collar RC401-6662

II-M-11

Bush 68741-6662

h. Installing local bucket : U35 1

Looseness at the front attachment * Thrust-oriented gaps at pins & bushes Below 0.6 mm * If over 0.6 mm, add shims for readjustment. (For additional shims, see the drawings.)

Bucket Place the bucket links

2 and 3 with their markings outward.

Local bucket (When installing)

Place the bucket link 1 with its marking

inward.

C B

Bucket link:Shim adjustment C-C

When installing o-ring and shim locally.

Rotate smoothly.

B-B

O-ring (68761-6685 )

Arm Bucket link (2) (3)

Bucket

Bucket link (2) (3)

In case of clearance being over 0.02 in.(0.6mm)

Rotate smoothly.

RC411-6693 Shim(1.0, 75-41) RC411-6692 Shim(0.5, 75-41) Selective use A-A

Bucket link (1)

Link 1 In case of clearance being over 0.02 in.(6 mm) RC411-6693 Shim(1.0, 75-41) RC411-6692 Shim(0.5, 75-41) Selective use

Bucket

In case of clearance being over 0.02 in.(0.6mm) RC411-6693 Shim(1.0, 75-41) RC411-6692 Shim(0.5, 75-41) Selective use

[Machine version without bucket:Parts included] U35-3 No 1 2 3 4 5 6 7 8

Part Pin Spacer Plain washer Bolt Grease nipple Shim (1.0, 75-41) Shim (0.5, 75-41) O-ring

Code No. RC418-6676U 68741-6692U 04015-60120 01133-61225 06611-15010 RC411-6693U RC411-6692U 68761-6685U

Q’ty 2 2 2 2 2 2 2 4

A-A

B-B 1

II-M-12

II. Machine Body(Service section) A. Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3 a. b. c. d.

Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-3 Machine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-4 Lever stroke and operating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-6 Dimensions of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-7

B. Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-17 a. b. c. d. e. f. g.

Parts designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-17 Exchange of bucket (Kubota Japan Bucket) . . . . . . . . . . . . Refer to WSM KX91-3, 101-3 Exchange of bucket teeth and side cutter . . . . . . . . . . . . . . . Refer to WSM KX91-3, 101-3 Installing direction of dust seal. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM KX91-3, 101-3 Installation of thrust collar on the swing bracket . . . . . . . . . Refer to WSM KX91-3, 101-3 Installing direction of fixing pin bolts . . . . . . . . . . . . . . . . . . . . Refer to WSM KX91-3, 101-3 Front hoses and clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM KX91-3, 101-3

C. Upper structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-18 a. Swivel frame : U35-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-18 b. Swivel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-19 c. Swivel bearing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-20 d. Traveling lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-21 e. Traveling lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-22 f. Traveling lever lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-23 g. Accel lever (Non AI-version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-24 h. Swing pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-27 i. Auxiliary port pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-28 j. Limit switch installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-29 k. Hour meter cable, engine stop cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-30 l. Cab installation : KTC, KCL, KTA-version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-31 m. Heater hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-32 n. Cab glass replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-33 o. Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-43 p. Weight installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-44

D. Under carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-45 a. b. c. d. e. f. g. h.

Tension spring pre-set length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-45 Additional parts to change from rubber track to iron track . . . . . . . . . . . . . . . . . . . II-S-45 Track Roller and Upper Roller installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-46 Track tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-47 Grease tension cylinder, L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-48 Drive sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-49 Rubber track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-50 Iron track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-S-51

II-S-1

II-S-2

A.Specifications a. Machine Weight (1) KE, KDG, KUK version

Canopy STD. Arm Cabin Canopy Long. Arm Cabin

unit

KX91-3

KX101-3

U35-3

Rubber crawler

3130

3410

3490

Iron crawler

3220

3500

3575

Rubber crawler

3240

3520

3590

Iron crawler

3330

3610

3675

Rubber crawler

3150

3430

Iron crawler

3240

3520

Rubber crawler

3260

3540

Iron crawler

3350

3630

(2) KTC, KCL, KTA version KX91-3

U35(KTC, KCL) U35-3(KTA)

Rubber crawler

kg lbs

3225 7110

3560 7848

Iron crawler

kg lbs

3320 7320

3645 8036

Rubber crawler

kg lbs

3325 7330

3660 8069

Iron crawler

kg lbs

3420 7540

3745 8256

Canopy

Cabin

II-S-3

b. Machine specifications (1) KE, KDG, KUK version Unit

KX91-3

KX101-3

U35-3

Type

Vertical, water-cooled 4 cycle, 3 cylinders diesel

←

Model

Kubota D1503-M-EBH-1-EC

Kubota D1503-M-EBH-2-EC

←

Engine

Output power (DIN70020)

kW PS

19.9 kW/2200rpm 27 PS/2200rpm

20.6 kW/2300rpm 28 PS/2300rpm

←

Displacement

1499

←

Overall length

4760

4920

4865

Overall width

1550

1700

Overall crawler width

1550

1700

Canopy

2440

Cabin

2440

Dimensions

Overall height

Min. ground clearance Max. digging depth

Max. digging height

Max. digging radius

Max. dumping height

289

285

STD. Arm

2900

3095

3115

Long Arm

3175

3295

STD. Arm

4790

4975

Long Arm

4920

5110

STD. Arm

4995

5205

5410

Long Arm

5235

5395

STD. Arm

3400

3580

4830

Long Arm

3540

3725

deg

80 / 50

70/50

Swing angle (left/right) Travel speed

4830

Low speed R/I

km/h

3.0

2.9

High speed R/I

km/h

4.6

rpm

8.9

←

Low speed

kN kgf

26.0 2655

27.1 2765

←

High speed

kN kgf

14.6 1485

15.2 1546

←

Swivel speed Max. traction force

4830

Performance Tumbler distance

1560

1670

←

Tread

1250

1400

Crawler width × No. of shoe × pitch

300 × 80 × 53

300 × 84 × 53

Capacity CECE heaped

0.078

0.093

←

Width

470

550

←

Width × height

1550 × 335

1698 × 336.5

Lift above GL / below GL

350/330

370 / 370

Bucket

Dozer

Note:Kubota Japan Bucket

II-S-4

(2) KTC, KCL, KTA version KX91-3

U35(KTC, KCL), U35-3(KTA)

Type

Vertical, water-cooled 4 cycle, 3 cylinders diesel

←

Model

Kubota D1503-M-EBH-2

←

Gross engine output (SAE J1349)

20.9 kW/2300 rpm 27.9 PS/2300 rpm

←

Displacement

1499 cc(91.4 in3)

←

Overall length

4760 mm(187.4 in)

4695 mm(184.8 in)

Overall width

1550 mm(61.0 in)

1700 mm(66.9 in)

Engine

Dimensions

Overall crawler width Overall height

1550 mm(61.0 in)

1700 mm(66.9 in)

Canopy

2440 mm(96.1 in)

←

Cabin

244 0mm(96.1 in)

←

289 mm(11.4 in)

285 mm(11.2 in)

Min. ground clearance Max. digging depth

STD. Arm

3185 mm(125.4 in)

3115 mm(122.6 in)

Max. digging height

STD. Arm

4940 mm(194.5 in)

4890 mm(192.5 in)

Max. digging radius

STD. Arm

5245 mm(206.5 in)

5255 mm(206.9 in)

Max. dumping height

STD. Arm

3530 mm(139.0 in)

3470 mm(136.6 in)

Low speed

3.0 km/h(1.9 mph)

3.0(1.86)

2.9(1.8)

High speed

4.8 km/h(3.0 mph)

4.6(2.9)

Swing angle (left/right) Travel speed

80 / 50

Swivel speed

70 / 50

9.4 rpm

9.0 rpm

Low speed

26.0 kN 2655 kgf (5853 lbf)

27.1 kN 2766 kgf (6098 lbf)

High speed

14.6 kN 1485 kgf (3274 l bf)

15.2 kN 1546 kgf (3408 l bf)

1560 mm(61.4 in)

1670 mm(65.7 in)

Max. traction force

Performance Tumbler distance Tread

1250 mm(49.2 in)

1400 mm(55.1 in)

300 mm × 80 × 53 mm (11.8in × 80 × 2.09in)

300 mm × 84 × 53 mm (11.8in × 84 × 2.09in)

0.1 m3(3.53 ft3)

←

555 mm(21.9 in)

←

Width × height

1550 × 335 mm(61.0 × 13.2)

1700 × 336.5 mm(66.9 × 13.25 in)

Lift above GL / below GL

350 / 330 mm(13.8 / 13.0 in)

360 / 340 mm(14.2 / 13.4 in)

Crawler width × No. of shoe × pitch (Rubber crawler) Bucket Capacity heaped

SAE

Width Dozer

NOTE : Kubota Japan Bucket

II-S-5

c. Lever stroke and operating force Unit

KX91-3, KX101-3

U35(KTC,KCL) U35-3(KTA)

U35-3: KE, KDG, KUK

Stroke

mm in.

110/110 4.3/4.3

←

72/72 2.83/2.83

Up / Down

Force

N kgf lbs

17/14 1.7/1.4 3.7/3.1

←

Up / Down

Stroke

mm in.

110/110 4.3/4.3

←

72/72 2.83/2.83

Crowd / Dump

Force

N kgf lbs

17/14 1.7/1.4 3.7/3.1

←

Crowd / Dump

Stroke

mm in.

85/85 3.3/3.3

←

75/75 3.0/3.0

Crowd / Dump

Force

N kgf lbs

12/12 1.2/1.2 2.6/2.6

←

Crowd / Dump

Stroke

mm in.

85/85 3.3/3.3

←

75/75 3.0/3.0

Right / Left

Force

N kgf lbs

12/12 1.2/1.2 2.6/2.6

←

Right / Left

Stroke

mm in.

75/75 3.0/3.0

←

F/R

Force

N kgf lbs

18/18 1.8/1.8 4.0/4.0

←

16/16 1.6/1.6 3.5/3.5

F/R

Stroke

mm in.

55/55 2.2/2.2

←

Up / Down

Force

N kgf lbs

25/25 2.6/2.6 5.7/5.7

20/20 2.0/2.0 4.4/4.4

24/24 2.4/2.4 5.3/5.3

Up / Down

Acceleration

Force

N kgf lbs

34/34 3.5/3.5 7.7/7.7

49/49 5.0/5.0 11.0/11.0

Swing pedal

Force

N kgf lbs

59/59 6/6 13.2/13.2

49/49 5.0/5.0 11.0/11.0

63/63 6.4/6.4 14.1/14.1

Safety lock lever (Left)

Force

N kgf lbs

26/59 2.7/6.0 6.0/13.2

26/26 2.7/2.7 5.8/5.8

←

Safety lock lever (Right)

Force

N kgf lbs

8/4 0.8/0.4 1.8/0.9

8/8 0.8/0.8 1.8/1.8

6/6 0.6/0.6 1.3/1.3

Traveling Hi/Low change pedal

Force

N kgf lbs

15 1.5 3.3/3.3

←

Boom

Arm

Bucket

Swivel

Travel

Dozer

II-S-6

Remarks

Up / Down

d. Dimensions of Parts (1) Front pins No.

Unit

KX91-3

KX101-3

U35, U35-3

Pin diameter × length

mm in.

φ40 × 160 φ1.57 ×6.30

←

Pin diameter × length

mm in.

φ50 × 278 φ1.97 × 10.94

←

Pin diameter × length

mm in.

φ40 × 155 φ1.57 × 6.10

←

Pin diameter × length

mm in.

φ40 × 132 φ1.57 × 5.20

←

Pin diameter × length

mm in.

φ40 × 114 φ1.57 × 4.49

←

Pin diameter × length

mm in.

φ70 × 141.5 φ2.76 × 5.57

←

Pin diameter × length

mm in.

φ70 × 155 φ2.76 × 6.10

←

Pin diameter × length

mm in.

φ45 × 172 φ1.77 × 6.77

←

Pin diameter × length

mm in.

φ45 × 172 φ1.77 × 6.77

←

Pin diameter × length

mm in.

φ40 ×239 φ1.57 × 9.41

←

Pin diameter × length

mm in.

φ40 × 155 φ1.57 × 6.10

←

Pin diameter × length

mm in.

φ40 × 193 φ1.57 × 7.60

←

Pin diameter × length

mm in.

φ40 × 193 φ1.57 × 7.60

←

Pin diameter × length

mm in.

φ40 × 233 φ1.57 × 9.17

←

Pin diameter × length

mm in.

φ40 × 233 φ1.57 × 9.17

←

O.D.

Length

O.D.

Length

II-S-7

Allowable wear limit

(2) Bucket 1) Bucket dimensions No.

Unit

KX91-3

KX101-3

U35, U35-3

mm in.

45.2 17.8

532 20.9

←

mm in.

470 18.5

550 21.7

←

mm in.

φ76.3 × t9.5 φ3.00 × t0.37

←

mm in.

180 7.09

←

mm in.

136 5.35

←

mm in.

12 0.47

←

mm in.

22 0.87

←

mm in.

68 2.68

←

mm in.

φ65 φ2.56

←

mm in.

φ80 φ3.15

←

mm in.

φ40 φ1.57

←

mm in.

φ40 φ1.57

←

mm in.

613 24.1

←

mm in.

594 23.4

←

mm in.

103 4.06

←

mm in.

170 6.69

←

mm in.

185 7.28

←

mm in.

24 0.94

←

NOTE: KUBOTA JAPAN BUCKET. Local content bucket may differ slightly.

II-S-8

Remarks

2) Bucket installation relevant dimensions 1. KE, KDG, KUK version No.

Unit

KX91-3

KX101-3

U35, U35-3

←

M12 × 1.25

←

29.5

←

19.5

←

1275

1350

←

7.5

←

259

←

295

301

←

153

140.5

←

1151

←

310

←

310

←

165

←

NOTE:

Remarks

KUBOTA JAPAN BUCKET and standard arm. KBM-make bucket may differ slightly.

II-S-9

2. KTC, KCL, KTA version No.

Unit

KX91-3

U35(KTC, KCL) U35-3(KTA)

mm in

62 2.44

←

mm in

M12 × 1.25

←

mm in

58 2.28

←

mm in

65 2.56

←

mm in

29.5 1.16

←

mm in

19.5 0.77

←

mm in

1550 61.0

1350

mm in

10 0.4

←

mm in

260 10.2

←

mm in

301 11.9

←

mm in

140.5 5.5

←

mm in

1235 48.6

1151

mm in

310 12.2

←

mm in

310 12.2

←

mm in

175 6.9

165

Remarks

Above dimension is on Kubota Japan make bucket and arm. Local content bucket may differ slightly.

II-S-10

(3) Rubber crawler Unit Identification mark (Core steel rapping position)

KX91-3

KX101-3

U35, U35-3

∞

A : Lug height

mm in.

25 0.98

←

B : Idler side height

mm in.

24 0.94

←

C : Crawler width

mm in.

300 11.81

←

D : Crawler sag distance

mm in.

10 ~ 15 0.39 ~ 0.59

←

Number of Core Iron Rubber crawler center round length

mm in.

4240 166.93

4452 175.28

←

Core Iron pitch

mm in.

53 2.09

←

Unit

KX91-3

KX101-3

U35, U35-3

Crawler width

mm in.

300 11.81

←

1) Length (A)/(B)

mm in.

406.4/416.4 16.00/16.39

←

2) Height (A)/(B)

mm in.

68/63 2.68/2.48

←

3) Bushing O.D. (A)/(B)

mm in.

28.0/26.5 1.10/1.04

←

4) Bushing I.D. (A)/(B)

mm in.

17.0/19.0 0.67/0.61

←

5) Master pin O.D. (A)/(B)

mm in.

17.0/15.5 0.67/0.61

←

6) Grouser Height (A)/(B)

mm in.

16.5/8.0 0.65/0.31

←

7) Crawler sag distance (1)

mm in.

85 ~ 90 3.35 ~ 3.54

←

8) Crawler sag distance (2)

mm in.

40 ~ 45 1.57 ~ 1.77

←

Remarks

(4) Iron crawler

Number of links

Remarks

(A)New machine reference value (B)Allowable limit

Rubber crawler

Iron crawler

6) 2)

3) 4) 5)

8) D

II-S-11

(5) Track toller, idler, sprocket Unit

KX91-3

KX101-3

U35, U35-3

A : Guide width

(A)/(B)

mm in.

80/76 3.15/2.99

←

B : Outer diameter

(A)/(B)

mm in.

124/120 4.88/4.72

←

C : Roller width

(A)/(B)

mm in.

175/167 6.89/6.57

←

D : Upper roller diameter

(A)/(B)

mm in.

76.3/72.4 3.00/2.85

←

E : Sliding plate thickness

(A)/(B)

mm in.

18/9 0.71/0.35

←

Remarks

(A)New machine reference value (B)Allowable limit C

Unit

KX91-3

KX101-3

U35, U35-3

1) Idler O.D.

(A)/(B)

mm in.

336/328 13.2/12.9

←

2) Guide width

(A)/(B)

mm in.

30/26 1.18/1.02

←

3) Idler width

(A)/(B)

mm in.

72/64 2.83/2.52

←

4) Sprocket wheel O.D..

(A)/(B)

mm in.

361/353 14.21/13.09

←

5) Sorocket wheel width

(A)/(B)

mm in.

30/26 1.18/1.02

←

Remarks

(A)New machine reference value (B)Allowable limit

1) 4)

II-S-12

(6) Dozer Unit

KX91-3

KX101-3

U35-3(EU)

U35(KTC, KCL) U35-3(KTA)

A : Pin diameter × length

mm in.

φ40 × 161 φ1.57 × 6.34

←

B : Pin diameter × length

mm in.

φ45 × 131 φ1.77 × 5.16

←

C : Pin diameter × length

mm in.

φ45 × 131 φ1.77 × 5.16

←

D : Dozer width

mm in.

1548 61.02

←

1698 66.9

1700 66.9

E : Dozer height

mm in.

336.5 13.25

←

F : Dozer length

mm in.

1112 43.78

←

1183 46.6

←

G : Dozer tip plate height × thickness

mm in.

65 × 12 2.56 × 0.47

←

H : Length between dozer arms

mm in.

483 19.01

←

Code No.

RH618-74411

RC418-74411

B F

RC718-74411

D A

II-S-13

(7) Parts weight 1) KE, KDG, KUK version KX91-3

KX101-3

U35(KTC, KCL) U35-3(KTA)

Track frame

360

←

361

Swivel frame

400

←

351

Swing bracket

←

Boom

123

129

←

Standard arm

←

Long arm

←

Bucket

←

Dozer

117

121

127

Weight (left)

←

Weight (right)

←

Weight (rear)

274

464

Rubber crawler

125

135

←

Iron crawler

168

177

←

Arch

←

Engine

155

←

Dry weight

Hydraulic tank

←

With filter

Fuel tank

←

Swivel bearing

←

Buttery

←

Track roller

←

Upper roller

←

Rops/Fops canopy

←

Rops/Fops cabin

188

←

Pump

←

Traveling motor

←

Swivel motor

←

Control valve

←

Without adaptor

Boom cylinder

←

With protector

Arm cylinder

←

Bucket cylinder

←

Swing cylinder

←

Dozer cylinder

←

Rotary joint

←

Remarks

540

The weights listed above are based on calculations and slightly different from actual ones.

II-S-14

2) KTC, KCL, KTA version Unit

KX91-3

U35(KTC, KCL) U35-3(KTA)

Track frame

kg lbs

360 794

←

Swivel frame

kg lbs

400 882

367 809

Swing bracket

kg lbs

71 157

←

Boom

kg lbs

116 256

←

Arm

kg lbs

90 200

75 165

Bucket

kg lbs

62 137

←

Dozer

kg lbs

117 258

123 271

Weight (left)

kg lbs

16 35

Weight (right)

kg lbs

18 40

Weight (rear)

kg lbs

274 604

Rubber crawler

kg lbs

125 276

135 298

Iron crawler

kg lbs

168 370

177 390

Arch

kg lbs

38 84

←

Engine

kg lbs

155 342

←

Dry weight

Hydraulic tank

kg lbs

29 64

←

With filter

Fuel tank

kg lbs

7 15

←

Swivel bearing

kg lbs

36 79

←

Buttery

kg lbs

18 40

←

Track roller

kg lbs

8 18

←

Upper roller

kg lbs

3 7

←

Rops/Fops canopy

kg lbs

74 163

70 154

Rops/Fops cabin

kg lbs

175 386

180 397

Pump

kg lbs

28 62

←

Traveling motor

kg lbs

38 84

←

Swivel motor

kg lbs

37 82

←

Control valve

kg lbs

34 75

←

Without adaptor

Boom cylinder

kg lbs

32 71

←

With protector

Arm cylinder

kg lbs

30 66

←

Bucket cylinder

kg lbs

20 44

←

Swing cylinder

kg lbs

22 49

←

Dozer cylinder

kg lbs

21 46

←

Rotary joint

kg lbs

19 42

←

Remarks

620 1367

The weights listed above are based on calculations and slightly different from actual ones.

II-S-15

(8) Quantity Water and Oil Unit

KX91-3

KX101-3

U35, U35-3

Radiator

L gal

5.6 1.48

←

Reserve tank

L gal

1.6 0.42

←

Without filter

L gal

5.3 1.40

←

SAE10W30(CD)

Hydraulic oil

Full

L gal

55.0 14.53

←

ISO 46

Hydraulic oil

Tank gauge center

L gal

36.0 9.51

←

ISO 46

Wheel motor

L gal

0.5 0.13

←

SAE90 (API GL-4)

Track roller

cc gal

70 0.018

←

SAE30(CD)

Upper roller

cc gal

60 0.02

←

SAE30(CD)

Front idler

cc gal

80 0.02

←

SAE30(CD)

Fuel tank

L gal

46.5 12.30

←

40.0 10.6

Engine Crank case

II-S-16

Remarks

L.L.C 50%

B.Front attachment a. Parts designation

II-S-17

C.Upper structure a. Swivel frame : U35, U35-3

Machine Front

(5)

(4)

(6) (8) (1)

(1): Engine (2): Fuel tank (3): Battery (4): Hydraulic pressure tank (5): Control valve (6): Swivel bearing (7): Swivel motor (8): Hydraulic pump (9): Rotary joint (10): Auto idle motor

(10)

(7) (2) (3)

(9) Rear X-frame structure

Location rotary joint and swivel motor differ from KX91-3 and KX101-3.

II-S-18

b. Swivel bearing U35 Code No. : RC411-19113 for KTC, KCL, KTA

U35-3 Code No. : RG511-19111 for EU

II-S-19

(1)

Outer race

(2)

Inner race

(3)

Pin φ8

(4)

Filler plug φ22

(5)

Ball φ19.05

(6)

Support

(7)

Seal

(8)

Grease Nipple PT1/8

c. Swivel bearing installation (6) Drection of adapter (view right) 45

(1) Machine front direction (3) Grease supply port for ball bearing (Must be faced of the hole on the frame)

(4) Grease supply port for teeth

(5) "S" mark (Soft zone of inner rece)

(8) Swing (9) Ball (10) Teeth

(2) Ball inlet (Soft zone of outer rece)

(7) Grease adapter to be side direction

(1) Machine front direction (2) Ball inlet (Soft zone of outer rece) (3) Grease supply port for ball bearing (Must be faced of the hole on the frame) (4) Grease supply port for teeth (5) "S" mark (Soft zone of inner rece) (6) Drection of adapter (view right) (7) Grease adapter to be side direction (8) Swing (9) Ball (10) Teeth 1. Innerring soft zone: S mark. • Set “S” mark at its right position. 2. Outer-ring soft zone: Ball inlet • This soft zone should be at its left sode. 3. Align the grease nipple hole of the swivel frame with the nipple on the bearing. A 4. Swivel Bearing Tightening • Apply Locktite #271 on the bolts. • Tightening torque: 259.9 ~ 304.0 N·m 26.5 ~ 31.0 kgf·m 191.7 ~ 224.2 ft·lbs • Apply grease to the entire surface of the bearing teeth uniformly.

II-S-20

d. Traveling lever (1) Rod, assy (Travel, right) 125

(3) Do not apply threebond 1324 on rotating portion

(2) Rod, assy (Travel, left) 74.5

(49 9)

(4) Lever (Travel R, TL)

(5) Lever (Travel L, TL)

539

(1) Rod, assy (Travel, right) (2) Rod, assy (Travel, left) (3) Do not apply threebond 1324 on rotating portion (4) Lever (Travel R, TL) (5) Lever (Travel L, TL) (6) Needle bearing (7) View B

(2) (1) 1)

(6) Needle bearing (7) View B

1) Tightening torque: 60 ~ 70 N·m 6.2 ~ 7.2 kgf·m 44.3 ~ 51.6 ft·lbf Apply threebond 1324 on the bolt. 2) Tightening torque: 48 ~ 56 N·m 4.9 ~ 5.7 kgf·m 35.4 ~ 41.3 ft·lbf Apply threebond 1324 on the nut.

No.

Adapter for A

Length of grease tube

1 2 3

68721-6739U 68721-6748U 68721-6748U

68491-1921U(L=850) 68721-6739U RB101-6747Ur(L=650) 68721-6748U RB101-6747Ur(L=650) 68721-6748U

II-S-21

Adapter to supply

e. Traveling lever adjustment

Bracket Front end

Adjust the traveling lever as shown below table. No.

Items

Dimensions

Distance beween bracket front end and newtral position center of Traveling lever grip.

160 mm 6.30 in

Gap between left and right lever to longitudinal direction.

under 5 mm under 0.2 in

Clearance between left and right lever.

11 ~ 17 mm 0.43 ~ 0.67 in

Angle of trabeling lever at neutral position.

14 deg

II-S-22

Remarks Reference valve

f. Traveling lever lock This machine is equipped with the traveling lever lock. When the engine gets started, the pressure oil from the hydraulic pilot pump surpasses the spring force, which unlocks the lever. When the engine stops, the spring force locks the lever again. Take the following steps to adjust the neutral position.

Adjusting the lever's neutral position 1. Lower the lever (TL) against the spring force to unlock the traveling lever.

Rod

Lever (TL)

Spring

2. Adjust the rod so that the traveling lever should be positioned to and for as specified. (See previous page) 3. Return the lever (TL) to the initial position, and make sure the traveling lever gets locked tight again. Traveling lever lock

II-S-23

g. Accel lever (Non AI-version) 67

(1) Lever grip 2

5mm (2.64

0.2in)

(9) Max.

(2) Accel, lever assy

(5) Idle

Accel lever Bush

73")

(0. .5mm

(3) Plate

S.W.

(6) Adjust bolt

18.5mm(0.73")

Bolt

(4) Spring

(10) Adjust bo

(7) Plate

(1)Engine RPM Idling 1000~1100 rpm No load Max. rpm : 2550 >

(2)Accel lever operating force

(8) Accel. cable Washer Pin

Idling to Max., 5.0 kgf Max. to idling, 5.0 kgf

(1) Lever grip 2 (2) Accel, lever assy Accel lever Bush (3) Plate S.W. Bolt (4) Spring (5) Idle (6) Adjust bolt (7) Plate (8) Accel. cable Washer Pin (9) Max. (10) Adjust bolt

II-S-24

(3) AI motor side(AI-version) AI motor assy

Bolt

Bracket

Accel cable Screw

Fix the cable in the middle.

Bolt

Direction of engine MAX. rpm

Bracket 2 Swivel frame

Washer Pin

(4) Engine side Accel sensor

Coupler direction

Fix the cable in the middle

(Catch the acceleration sensor claw tightly in the governor lever groove.)

Engine governor

II-S-25

(5) Accel cable (5) Coating (6) Spring (8) Inner cable (7) Liner

(1) Intermediate stroke (Both sides) 140 (2) 119 (17 equally spaced)

(9) Section A-A

(4) Across opposite sides

(3) Hex nut to be retightened (4 locations) X Y

(1) Intermediate stroke (Both sides) (2) 119 (17 equally spaced) (3) Hex nut to be retightened (4 locations) (4) Across opposite sides (5) Coating (6) Spring (7) Liner (8) Inner cable (9) Section A-A mm (inch) Accel cable

code No.

Standard model

RC411-35151

1141(44.9)

1350(53.1)

Auto idle model

RC411-53631

1291(50.8)

1500(59.1)

II-S-26

h. Swing pedal

(1) Must be turned to level on the neutral

(2) Oil tank

(37) 123

2 ~ 3 mm

(1) Must be turned to level on the neutral (2) Oil tank

II-S-27

i. Auxiliary port pedal

(1) Must be turned to vertical on the neutral

2 ~ 3 mm

(2) Oil tank

(1) Must be turned to vertical on the neutral (2) Oil tank

II-S-28

j. Limit switch installation

Unload safety lock lever, R

Unload safety lock lever, L

(1) Spring

(4) Limit SW

(2) Limit SW

(5) Seat support rubber (1~2 mm for compression) (6) Safety lock lever

(3) Safety lock lever

Travel Hi-Low pedal (7) Limit SW

(1) Spring (2) Limit SW (3) Safety lock lever (4) Limit SW (5) Seat support rubber (1~2 mm for compression) (6) Safety lock lever (7) Limit SW

II-S-29

k. Hour meter cable, engine stop cable (Panel side) From hour meter

(Panel side) Engine stop

Hour meter

Accel, engine stop, Dozer cable

(Panel side) From accel lever Clamp the engine stop and hour meter cables to keep them out of contact with the engine

Engine stop cable route

and fan.

Washer Engine stop lever

Clamp three cables together

Hour meter cable Air inlet hose

Swivel frame

Oil tank

Governor

Stop cable Accel cable

Code band (55311-4126U)

Together with accel cable Engine stop wire (RC717-5323U) Control panel

Hour meter

II-S-30

l. Cab installation : KTC, KCL, KTA-version Mounting bolt

(1) Front, R

(6) Rear, L, R

(5) Engine (4) Rotary joint RC411-4850U (7) Stud(F, R)

02176-60140 (11) Nut 2 RC411-4853U (12) Washer(F)

(8) Tightening torque 107.9~125.5N.m (11.0~12.8kgf.m)

RC411-4857U (19) Washer(1, R) RC411-4856U (20) Cushion rubber(R) RC418-4855U (21) Tube(Stud, R) RC411-4856U (22) Cushion rubber(R)

RC411-4852U (13) Cushion rubber(F) (9) (Front, R)

(15) Tightening torque 107.9~125.5N.m (11.0~12.8kgf.m)

RC411-4852U (24) Tightening torque (14) Cushion rubber(F) 107.9~125.5N.m (16) (Front, L) (11.0~12.8kgf.m)

1.5(Ref. value) 27.5(Ref. value)

RC411-4854U (17) Stud(R) 02176-60140 (18) Nut 2

RP421-4851U (10) Stud(F, L)

1.5(Ref. value) 23.5(Ref. value)

(3) Swivel motor

1.5(Ref. value) 23.5(Ref. value)

(2) Front, L

(25) RP401-42561 Color

RC411-4858U (23) Washer(2, R) (26) (Rear, R&L)

II-S-31

(1) Front, R (2) Front, L (3) Swivel motor (4) Rotary joint (5) Engine (6) Rear, L, R (7) Stud(F, R) (8) Tightening torque (9) (Front, R) (10) Stud(F, L) (11) Nut × 2 (12) Washer(F) (13) Cushion rubber(F)

(14) Cushion rubber(F) (15) Tightening torque (16) (Front, L) (17) Stud(R) (18) Nut × 2 (19) Washer(1, R) (20) Cushion rubber(R) (21) Tube(Stud, R) (22) Cushion rubber(R) (23) Washer(2, R) (24) Tightening torque (25) RP401-42561 (26) (Rear, R&L)

m.Heater hose 1 Hose route No kink Specified clearances to be ensured between the parts.

Heater hose A B

Length

Protection tube

1230 (RC718-4304U) 630 (RC718-4306U)

1000 (RC411-4305U) 400 (RC411-4307U)

Couple the heater cover on the heater. Hose(7, heater) 2 RC717-43081 Hose clamp (spring) 2 09318-88185

Taping position (on one side) Heater

100 Valve

Heater

100 Valve

Pipe joint (S, 13.8) 2 RP401-61861 Hose clamp (Spring type) 2 09318-88185

03514-50514 Tighten up the 3 tapping screws that come with the heater. Couple the heater bracket on the heater cover. Bolt 3 01123-60820

Grommet 2 90407-11211

Keep the heater hoses out of contact with the alternator, fan pulley and V belt. Wire harness should go between hoses.

Hose clamp (spring type) 09318-88185

A B

Hose clamp(spring type) Valve 09318-88185 90038-1112U

A B Pipe joint (T, heater) RC411-4256U Hose (3, heater) RC411-4255U

Hose clamp (spring type) 2 09318-88185

Hose (4, heater) RC411-4257U

Go outer the guide

Go through inside

II-S-32

Adapter (R3/8-R1/2) RC418-4258U

n. Cab glass replacement procedure Cab glass manufacturing method and adhering procedure are different between North American and European specifications in the points as shown in the table below. KTC, KCL, KTA-version KBT make (Ninomiya Industry)

Adhesion type glass: Door glasses (upper and lower), left-side glass, front glass H-rubber fixation: Rear glass, right-side cover glass Slide type glass: Right-side slide glass

EU-version KBM make (Fritzmyer)

Adhesion type glass: Front glass H-rubber fixation: Door glasses (upper and lower), left-side glass, rear glass, right-side cover glass Slide type glass: Right-side slide glass

Below is described how to replace the cab glass KX91-3, KX101-3, KX121-3 and KX161-3 made by KBT. The replacement procedure of cab glass is classified roughly into the following two, depending on the type of adhesive. (1) SIKAFLEX/ULTRA-FAST Curing time is short after application (but longer than one hour). It is necessary to warm adhesive before application. Heat box and electric cartridge gun are needed. Since the replacement/adhering procedure is the same as repairing of car, it should be applied at car repair shop. (2) SIKAFLEX/255 EXTRA Curing time is long. (8 hours) No special tools are needed. Please refer to the replacement/adhering procedures, using two types of adhesive which are described in the following two pages. As for the adhesive to be used, ask your local SIKAFLEX dealer and get SIKAFLEX/255 EXTRA or equivalent. Note: For your reference, the H-rubber replacement procedure and KBT-make KX-2 Series glass replacement procedure are described in the latter half part of the following section.

II-S-33

(1) Application Procedure if SIKAFLEX (ULTRA-FAST)

Start

SIKAFLEX

Cab

Glass

Put SIKAFLEX in hot box and heat it. 40 ~ 60 min.

Remove dust, oil and moisture. Use thinner or the like.

Remove dirt and moisture by No.1 cleaner. (Not necessary unless the glass is stained.)

Apply activator. Drying time: Approx. 20 min.

5 min.

Apply activator. Approx. 20 min.

Drying

time:

10 min. (Application of dam rubber) 15 min.

(Dam rubber can be applied any time.)

20 min. 25 min. 30 min.

Apply primer. Drying time: Approx. 20 min.

35 min. 40 min.

(Application of dam rubber)

45 min. 50 min.

Apply it to glass.

Adhesion of glass

55 min. 60 min.

Apply SIKAFLEX around the glass. (Complete adhesion to cab within 10 min.) It will harden in 30 min. Fix it temporarily by adhesive tape, if necessary.

Shower test can be conducted after 30 min.

Notes: One bottle of SIKAFLEX enables adhesion of 2-2.5 sheets of KUBOTA CAB glass. One bottle of activator/primer (separately sold) reportedly enables application to about 9 sheets of glass. To adhere glass, first press the glass gently to the cab, and then press it with force after appropriately positioned. If it is pressed at first with force, positioning of glass will be difficult.

II-S-34

(2) ULTRA-FAST application manual Broken glass replacement procedure : KX91-3, KX121-3, KX161-3 a. Check the following points prior to replacement of glass.

Glass-1 NKC04089 RC411-46820

Glass: Door-1

Dam rubber-1

NKC04087

NKC04176

RC411-46530

RC411-46830

Glass: Door-1 NKC04088

Dam rubber-1

RC411-46540

NKC04175 RC411-46551 Dam rubber-1 NKC04177

1. Check the part No. of broken glass. 2. In the replacement of door glass, do not dismount the door from the cab. 3. The part Nos. of glass and those of accessories are as shown in the figure above. b. The following description exemplifies the replacement procedure for broken lower glass of the door.

Broken glass

Prepare the following items before starting replacement: 1. Glass: Door/NKC04088 1 sheet 2. Dam rubber /NKC04177 1 set 3. SIKAFLEX/ULTRA-FAST 330 ml 1 bottle 4. SIKA activator 30 ml 1 bottle 5. SIKA primer 30ml 1 bottle 6. Others: Cutter, waste cloth, suction cup, two paint brushes, hot box*, electric cartridge gun* (battery-powered type), adhesive tape. Note: Power supply is needed for *-marked items. Be sure to use the hot box and electric cartridge gun.

Procedure 1. Put SIKAFLEX/ULTRA-FAST (hereafter called "SIKA UF") in the hot box. (Heat it for 20-30 min.) 2. Remove broken glass. Remove old adhesive by cutter. Remove remaining dam rubber.

Note! When the paint is marred by cutter, repair it after the completion of replacing work. Adhesive does not stick to the repaired paint.

Adhesive

II-S-35

Remove adhesive by cutter so that its thickness becomes 1 mm.

3. Clean the adhering area (of glass side and door side) by SIKA activator. (See the SIKAFLEX/ ULTRA-FAST application procedure.) 4. Apply SIKA primer only to door side.

4. Apply SIKA primer by brush. (Hatched area)

5. Apply dam rubber (so that both sides face upward).

5. Apply dam rubber. 6. Apply adhesive SIKA UF to glass. Adhesive SIKA UF

Adhesive applying area Ceramic

Standard adhesive applying area

Working bench

Glass Cut out adhesive at two points (for draining water).

Guide

Point: Application work becomes easy by turning the glass. Pay attention not to damage the glass by turning.

7. Bring up the glass by suction cup and set it to the door. (Clearance between the periphery of glass and the door frame should be uniform.) Point: Press the glass gently to the door frame. Adhere the glass while slowly pressing so that the clearance around the glass should become uniform. When the clearance becomes uniform, then press the entire glass so that it sinks 1 ~ 2 mm below the height of door frame. (When the glass contacts the dam rubber, it sinks 2 mm. Keep this in mind for reference.)

Dam rubber

II-S-36

8. Fix the glass to the door frame by adhesive tape, if necessary (to prevent the glass from shifting downward). The above completes the work. It is okay to splash water over the glass after drying for 30 min, but do not give a strong impact. Do not give an impact by open/close action at least within one hour. Adhesive tape

Note If the door is dismounted from the cab for application work, adjust opening and closing of the door at the time of re-mounting it after the completion of application work.

(3) 255 EXTRA application manual Broken glass replacement procedure a. Check the following points prior to replacement of glass.

Glass-1 NKC04089 RC411-46820

Glass: Door-1

Dam rubber-1

NKC04087

NKC04176

RC411-46530

RC411-46830

Glass: Door-1 Dam rubber-1 NKC04175

NKC04088 RC411-46540

RC411-46551 Dam rubber-1 NKC04177

1. Check the article No. of broken glass. 2. In the replacement of door glass, do not dismount the door from the cab. 3. The article Nos. of glass and those of accessories are as shown in the figure above.

II-S-37

b. The following description exemplifies the replacement procedure for broken lower glass of the door. Prepare the following items before starting replacement: 1. Glass: Door/NKC04088 1 sheet 2. Dam rubber/NKC04177 1 set 3. SIKAFLEX/255 EXTRA 320 ml 1 bottle 4. SIKA activator 30 ml 1 bottle 5. SIKA primer 30ml 1 bottle 6. Others: Cutter, waste cloth, suction cup, two paint brushes, and adhesive tape.

Broken glass

Procedure 1. Remove broken glass. Remove old adhesive by cutter. Note! When the paint is marred by cutter, repair it after the completion of replacing work. Adhesive does not stick to the repaired paint.

Remove remaining dam rubber. Adhesive

Remove adhesive by cutter so that its thickness becomes 1 mm. (Adhesive may be removed completely.)

2. Clean the adhering area (of glass side and door side) by SIKA activator. 3. Apply SIKA primer only to door side.

4. Apply SIKA primer by brush. (Hatched area)

5. Apply dam rubber (so that both sides face upward).

4. Apply dam rubber. 5. Apply adhesive SIKAFLEX/255 EXTRA to the glass. Adhesive SIKAFLEX/255 EXTRA

Adhesive applying area Ceramic

Working bench

Glass Cut out adhesive at two points (for draining water).

II-S-38

Point: Application work becomes easy by turning the glass.

6. Bring up the glass by suction cup and set it to the door. (Clearance between the periphery of glass and the door frame should be uniform.)

Dam rubber

Note! Pay attention not to give damage to the glass while turning. Point: Press the glass gently to the door frame. Adhere the glass while slowly pressing so that the clearance around the glass should become uniform. When the clearance becomes uniform, then press the entire glass so that it sinks 1-2 mm below the height of door frame. (When the glass contacts the dam rubber, it sinks 2 mm. Keep this in mind for reference.)

7. Fix the glass to the door frame by adhesive tape (to prevent the glass from displacing downward). The above completes the work. Leave it in this state for longer than 8 hours.

Adhesive tape

Leave it for 8 hours. Do not open and close the door. Adhesive tape Note

If the door is dismounted from the cab for application work, adjust opening and closing of the door at the time of remounting it after the completion of application work.

II-S-39

(4) H-rubber replacement procedure As shown in SEC A, the glass is fixed to the metal part by inserting the part (2) into the part (1). Thus, it has such advantages that no curing time is needed and replacement is easy, and (though the adhesion method assures a good appearance,) this insertion method is applied extensively in overseas countries. Glass can be removed after inserting a screwdriver into the notch of rubber wedge and removing the rubber wedge. Our experience reveals that the glass, which is bordered with rubber, will not "slip out suddenly"(when it is tapped repeatedly). However, pay due attention not to shed it off when removing.

(2) Section view : GN562500 (1) NUB60098

(3) Ref. dimension line.

(4) SEC A (1) NUB60098 (2) Section view : GN562500 (3) Ref. dimension line. (4) SEC A

II-S-40

(5) Broken glass repairing procedure (for adhered glass KX-2 Series made by KBT) a. Restoration of broken glass 1. Remove pieces of broken glass remaining on the door frame Piano wire (Pull this right and left.)

Adhesive

Remove the remaining pieces of broken glass while cutting hardened rubber-like adhesive by piano wire of about 0.4 mm dia. (Pay due attention not to injure your hand by broken glass and piano wire.)

Remaining pieces of broken glass

2. Remove old adhesive remaining after removal of pieces of broken glass. Cut off the old adhesive evenly. • Pull the rubber adhesive and remove it while cutting off rubber at the frame side by cutter. • Adhesive remaining thick on the frame will cause projection of the glass to be mounted anew or water leakage.

3. Cleaning of frame Wipe off wastes of dam rubber and adhesive remaining on the frame by isopropyl alcohol.

II-S-41

b. Adhesion of glass 1. Apply primer to the adhering area of window frame. (1) Stir primer by shaking the bottle well. (2) Film thickness should be thicker than 5 micron without irregularity. (3) Primer drying time Natural drying: Longer than 2 min. and shorter than 3 hrs. 2. Apply dam rubber to the indoor side of window frame. 3. Cleaning of glass Clean stained glass by isopropyl alcohol. 4. Apply adhesive to the applying area (of ceramic-coated side) or the body side.

Glass

12mm

Ceramic-coated side

Body side 8mm

Dam rubber

How to cut the nozzle tip.

Adhesive (Minimum sectional area)

• Apply adhesive either to glass side or to body side for easiness of work depending on the width of adhesive application and other conditions. 5. Adhere the glass by pressing while positioning it. 6. For good appearance, apply adhesive around the glass. Apply masking tape.

7. Leave it not applying any impact until the adhesive dries completely. Summer season: Approx. 12 hours Winter season: Approx. 24 hours 8. Completion of application work Adhesive: Sika Japan, Ltd. SIKAFLEX 250-Z Primer: Sika Japan, LTD. SIKA PRIMER As for overseas market, please ask your local SIKAFLEX dealer and get the equivalent adhesives and primer.

II-S-42

o. Seat belt

Bolt

II-S-43

p. Weight installation 1 Mount the weight Tightening torque 367.7 ~ 431.5 N·m (37.5 ~ 44.0 kgf·m) Apply screw lock agent. (Locktite 271) 2 Noise absorber As shown in Fig.

RC411-4836U Sponge (2, protector)

RC411-4835U Sponge (1, protector)

II-S-44

D.Under carriage a. Tension spring pre-set length * Set to the cotter pin closest to the following dimension. Rubber track (1)

(2)

(3)

(4)

(5)

9.53’’ ± 0.04

Part

(1)

Idler assy

(2)

Plate

(3)

Bolt

(4)

Cylinder assy R

(*)

Cylinder assy L

(5)

Spring assy

Iron track (1)

(2)

(3)

(4)

(5)

Tightening torque of idler assy mounting bolts (3). 77.4 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.1 ~ 66.5 ft·lbs

9.88’’ ± 0.04

b. Additional parts to change from rubber track to iron track No

Part

Code No.

Q’ty

(1)

Guide

RC411-2182-0

(2)

Hollar bolt

68541-2118-0

(3)

Plate

RC411-2181-0

(4)

Bolt

01135-61225

* Reposition the nut to change the spring’s preset length. Rubber track

II-S-45

Iron track

c. Track Roller and Upper Roller installation (1) Truck roller, Assy

(2) Bolt Washer, Spring Washer, Plain

(1) Truck roller, Assy (2) Bolt Washer, Spring Washer, Plain (3) Mount track rollers to the track frame without clearance on this portion. (4) Iron crawler type (5) Rubber crawler type (6) Bolt Washer, Spring Nut (7) Carrier roller, Assy

(3) Mount track rollers to the track frame without clearance on this portion.

(4) Iron crawler type (5) Rubber crawler type

273 ± 0.5

(10.75 ± 0.02”)

294 ± 0.5

(11.57 ± 0.02”)

(6) Bolt

(7) Carrier roller, Assy

Washer, Spring Nut

1. Remove the stuck oil and paint on the track roller and track frame for mounting track roller. 2. Tightening torque for mounting track roller. 103 ~ 117.7 N·m 10.5 ~ 12.0 kgf·m 76.0 ~ 86.8 ft·lbf Apply threebond #1305 on the femail thread. 3. Tightening torque for mounting upper roller. 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kgf·m 57.2 ~ 66.5 ft·lbf Apply locktite #271. II-S-46

d. Track tension adjustment Rubber track Run the rubber track so that its seam marking (∞) should come at the top center with the track idler roller between adjacent links.

(1) Sprocket side 10~15mm (0.4 ~ 0.6in)

(2) Secondary track roller

(3) Idler side

(4) Seam (marked with ∞)

(5) Link (6) Track roller

Iron track

75~80mm (3.0~3.1in)

(1) Sprocket side (2) Secondary track roller (3) Idler side (4) Seam (marked with •) (5) Link (6) Track roller

II-S-47

e. Grease tension cylinder, L P/N = RC411-21503

(1)

Cylinder tube, L

(3)

Nipple, assy

(5)

Bulk up ring 60

(2)

Rod

(4)

Dust seal

(6)

O-ring

1. Durable pressure = 44.1 MPa (450 kgf/cm2) No pressure leakage is allowed at peak pressure of 98.1 MPa (1000 kgf/cm2) 2. Tightening torque of grease nipple = 98~107.8 N·m (1~11 kgf·m)

II-S-48

f. Drive sprocket

Straight section to be more than 18 Drill

Setup surface

Machined range

Hardness 52-59 HRC range

1. Reference pitch = 101.6 - 0.5 2. Number of torque = 21 0

3. P.C.D. = 344.7 - 3 +1

4. Outer dia = 361 - 2

II-S-49

Tooth quenching state (sectional view)

g. Rubber track Model

Part No. = RC511-22311 300 × 84 × 53

KX91-3

Part No. Nominal size Center circumference

Specifications 1. Steel cord strength = 9800 N/piece, 1000 kg/pc. +2 2. Steel cord number = 36 -0 3. Rubber thickness = 31mm(1.23 inch) Endless = 36 mm(1.42 inch) 4. Rubber strength = 140 kgf/cm2 or more 5. Steel cord overlap length = 9 pitch, 477 mm(18.8 inch)

Following logo 0. 5 mm embossed, 2 locations

Center of core

II-S-50

U35-3, KX101-3

h. Iron track Model

KX91-3

U35-3, KX101-3

Number of links

Weld zone to be smooth and gently sloped (Gap to be less than 0.5)

Hole φ17+0.55 +0.40 Hole φ28-- 0.15 0.20 Shaft φ280- 0.04 Hole φ17+0.05 0 Shaft φ17+0.21 +0.17

Weld zone to be smooth and gently sloped (No undercut and overlap allowed)

Section D - D Insert the pin and bend its shank enough.

Beads at arc starting and ending spots to be welded smoothly on base metal.

52 (inner bead) 70 (outer bead)

(1)

Master link, L

(4)

Master pin

(7)

Track link, L

(2)

Master link, R

(5)

Track shoe

(8)

Track link, R

(3)

Bush

(6)

(9)

Track pin

II-S-51

II-S-52

III.Engine A. Engine mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-3 B. Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-5 C. Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-6 D. Pump coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-7 E. Fuel hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-M-8 F. Engine overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM KX91-3, 101-3

III-M-1

III-M-2

A.Engine mount a Mounting the engine support Tightening torque 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) Apply screw locktite(Locktite 271) b Mounting the engine bracket Flat washer to be installed at the upper step only. Tightening torque 77.5 ~ 90.2 N·m (7.9 ~ 9.2 kgf·m) Apply screw locktite (Locktite 271)

c Installing the rubber cushion Use the specific flat washer, mentioned below, when installing the rubber cushion of the engine (at the weight side) onto the swivel frame. Flat washer(RC411-4214U) Tightening torque 77.5 ~ 90.2 N·m (7.9 ~ 9.2 kgf·m) Apply screw locktite(Locktite 271)

(1) Install the flat washer at this spot only. Washer (04013-60120)

(2) Washer (RC411-4214U)

(1) Install the flat washer at this spot only. (2) Washer

III-M-3

(1) Machine front 01133-61025 (3) Bolt 53511-2717U (4) Washer

01133-61020 (2) Bolt

RC411-4291U (5) Bracket1 RC411-4293U RC411-4292U (6) Support1 (8) Bracket2 RC411-4292U RC411-4295U (9) Stopper2 (7) Stopper1 (10) Machine front RC411-4219U (11) Stopper4

RC411-4297U (12) Stopper3 (13) Weight RC417-4299U (14) Shock absorber

RC411-4294U (15) Support2

III-M-4

(1) Machine front (2) Bolt (3) Bolt (4) Washer (5) Bracket1 (6) Support1 (7) Stopper1 (8) Bracket2 (9) Stopper2 (10) Machine front (11) Stopper4 (12) Stopper3 (13) Weight (14) Shock absorber (15) Support2

B.Radiator a Clearance between radiator core (Fin) and fun. A port. 85-92 mm Fan to be stretched evenly out of the fan shroud.

b Clearance between fan and fan shroud. B port. 10 mm (0.4”) or more. c Mount the cushion rubber on the bracket. Rubber claws to be tight in position.

85 ~ 92 mm

(1) 10 mm or more

(3) B port (2) 10 mm or more

(4) A port

6C040-5858U (5) Cushion rubber

(1) 10 mm or more (2) 10 mm or more (3) B port (4) A port (5) Cushion rubber

(6) Be sure that the claws are tight in the bracket holes.

III-M-5

(6) Be sure that the claws are tight in the bracket holes.

C.Muffler (1) Clamping the muffler pipe Tightening torque: 3.9 ~ 5.9 N·m (0.4 ~ 0.6 kgf·m)

(3) Applying the thermal insulators (1, muffler) (RC411-4246U) and (2, muffler) (RD4114247U) Apply the thermal insulator (1, muffler) on both sides of the muffler first and then another thermal insulator (2, muffler). Finally bind the muffler's both ends with the wires (07811-10984).

(2) Ensuring the clearance between muffler pipe outlet and weight hole

(4) Assembling order * Temporarily tighten the bolts (A), (B) and (C). No gaps at the tightened faces (a, b and c) * (A): First to tighten up * (B): Second to tighten up * (C): Third to tighten up * (D): Fourth to tighten up Tightening torque: 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m)

Tail pipe

Clearance to be over 15 mm(0.59 inch)

Weight Tail pipe not to stretch out of the weight end

a surface

(Both sides)

3 1 2 3 4 5 6 7 8

4 b surface B

D 5

c surface 2

III-M-6

Muffler Bracket pipe Stay U - bolt Heat insulator, 1 Heat insulator, 2 Wire

1 1 1 1 1 2 1 2

D.Pump coupling Coupling RC411-4263U Bolt (RC601-4263U) 3 pcs

(1) Apply grease on spline section Proper amount to be applied (No overflow allowed) No grease to be stuck on the rubber Wipe off grease immediately as required. (2) Tighten coupling bolts(RC601-4263U) * Locking/sealing-processed Tightening torque 107 ~ 117N·m (11 ~ 12 kgf·m) Do not use screw lock agent.

Spline part Apply grease

Pump housing RC411-4269U

When reassembling the pump housing, replace the existing starter assembly mounting bolts (top) with the 01133-61035 ones. (Use the same stud bolts, however.)

III-M-7

010

Housing, pump

090

Pin, Straight

100

Coupling

110

Bolt, Hex-Soc-HD

120

Assy pump, Piston

E.Fuel hoses (1) S Fuel hose route No contact with sharp edge, hot surface and moving part No clamping between the fuel hose and electrical cables Over-tightness and local slack not allowed Hose not to be flattened * Be careful when clamping the hose. Specified dimensions to be strictly followed (2) Protection tube Hose Length should be securely correct. Fuel tube

Length

Protect-tube L

(A)

850 mm (09664-80850)

705 mm (68841-5131U)

(B)

500 mm (09664-80500)

(C)

1600 mm (09664-81600)

1300 mm (RC411-5143U)

(D)

1600 mm (RC418-5149U)

1500 mm (RC418-5144U)

(E)

300 mm (09664-80300

Hose clamp (A)(B)(C) Pipe clip 14911-4275U (D) Engine side Hose clamp (screw type) 09318-88080 Tank side Pipe clip 14971-4275U (E) Pipe clip 14911-4275U

(RC718-5111U)

(RD411-5115U)

Fuel filter assy

Fuel tank

70 2.76"

Base (Drain)

III-M-8

(R1401-5135U) Fuel pump

75 2.95"

(RC411-5131U)

C Engine

(1) Drain (2) Bolt (3) Plug (4) Washer with rubber (5) Hose clamp (6) Bolt (7) Grommet (8) Code clamp

III-M-9

(9) Fuel tank (RC718-5111U)

(9) Fuel tank (10) Fuel gauge unit (11) Spring washer (12) Nut (13) Gasket (14) Tightening torque (15) Fuel cap B

(10) Fuel gauge unit (RC417-5114U) (11) Spring washer (04512-60050) (12) Nut (02054-60050) (13) Gasket (36330-75311) (14) Tightening torque:3~4 N.m (0.3~0.4 kgf.m) (15) Fuel cap 0.67~0.90 ft.lbs) (RD411-5112U)

(04717-01000)

(7) Grommet

(01133-61220)

(6) Bolt

(5) Hose clamp

(RC411-4158U)

(RC411-4149U) (55311-4126U)

(8) Code clamp

(4) Washer with rubber

(3) Plug

(06331-35010)

(01133-61020)

(2) Bolt

(1) Drain

(RC411-5131U)

III-M-10

IV.Hydraulic system(Mechanism section) A. Features of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-3 B. Hydraulic system specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-4 C. Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-5 a. Structure & specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-5 b. Performance curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-6

D. Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-7 a. b. c. d. e. f. g. h. i. j.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-7 General view of control valve . . . . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3 Control valve circuit diagram . . . . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3 Control valve sectional view . . . . . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3 Arm regeneration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-8 Oil flow of lock valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-9 Function of lock valve (Anti-drift valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-13 Relief valve/Anti-cavitation valve . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3 Straight travel circuit. . . . . . . . . . . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3

E. Pilot valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-14 a. Structure & specifications : U35(KTC, KCL), U35-3(KTA) . . . . . . . . . . . . . . . . . . . IV-M-14 b. Pilot valve control diagram : U35(KTC, KCL), U35-3(KTA) . . . . . . . . . . . . . . . . . . IV-M-16 c. KBM-make : Pilot valve : U35-3(EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-17

F. Swivel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-18 a. b. c. d.

Structure & specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-18 Function of negative brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-21 Function of valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-22 Swivel Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-23

G. Rotary joint (Swivel joint) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-26 H. Travel motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-27 a. Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-27 b. Travel motor specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-30

I. Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to WSM KX91-3, 101-3 a. b. c. d.

Change valve with accumulator : EU version Pilot filter Return filter Suction strainer

J. Hydraulic circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-33 a. b. c. d.

U35-3 European - version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-33 U35 : KTC, KCL - version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-34 U35-3 : KTA - version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-35 Hydraulic components layout : U35, U35-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-M-36

IV-M-1

IV-M-2

A.Features of hydraulic system No.

Function

Detail

Higher hydraulic pressure. (250 k on P1 and P2 only) (About 120% higher than ever before)

The powerful hydraulic system (with higher relief pressure) provides the following good points in terms of the power (size) and speed (flow rate) required. 1.Smaller actuators (boom, arm, bucket cylinder and travel motor) 2.Smaller pump and control valve and improved heat balance (passage pressure loss) thanks to low flow rate. Which in turn contribute to the advantages below. 3.Right-side centralized arrangement of hydraulic equipment 4.Improved stability (lighter-weight attachment cylinder) 5.Total hydraulic cost cutting, and others.

Redesigned boom anti-drift valve.

The minimum boom down speed can be controlled by the main spool, which helps inch the attachment more finely. (On conventional types, the inching is limited by the drain circuit’s minimum leak amount.)

Straight travel circuit adopted.

In traveling and moving the front attachment at once, the third pump’s flow rate serves to control the attachment. This circuit is activated once the machine travels to the right or left and the front attachment is moved.

Reduced shock at a stop of upcoming boom.

The control valve’s main spool works to make fine-tuning. (The boom up/slowreturn throttle and the pilot valve (boom down) primary-pressure shortcut are left out.)

Pilot valve redesigned.

(Kawasaki-made)

The vertical stroke is made greater from 5.2 mm to 6.4 mm (to eliminate jerking at vertical rotation). The secondary pressure is also made higher from 19.5 kgf/ cm2 to 27.0 kgf/cm2 for improved controllability.

Swivel negative brake and planetary single-step reduction gear adopted.

Release the lever lock, and the negative brake gets activated to keep the parked machine even on a slope. The number of reduction gearing parts has been cut down, and the cylinder block is commonly used.

Filter added to swivel make-up circuit.

An 80-mesh filter has been additionally mounted at the swivel make-up port adaptor to keep clean the make-up check valve in the motor.

Travel motor swash plate reconfigured and travel bi-speed circuit redesigned.

Simpler structure and better function.

Hydraulic equipment back pressures reduced.

Brand-new change valve introduced (lever lock and bi-speed travel).

The circuitry is configured to keep the travel motor, swivel motor, pilot valve and other related devices nearly free from back pressure. The pilot valve push-rod sealing effect in particular is highly expected. Cost cutting advantage.

(11)Arm regeneration (12)Variable displacement pump (13)Priority throttle of boom-bucket simultaneous operation (14)Check valve for swival anti-cavitation (15)Auto idle version(EU-version only)

IV-M-3

B.Hydraulic system specifications Machine model Engine RPM Pump

2300rpm

Maker

Uchida

AP2D18

Variable pump,2 + Gear pump

+gear pump

P1, P2

39.1L/min (17.0cc/rev)

←

20.7L/min (9.0cc/rev)

←

8.7L/min (3.8cc/rev)

←

NABCO

←

Type

BCV35

←

Main relief P1, P2 pressure P3

24.5(250)

←

19.6(200)

←

3.92(40)

←

Maker

kubota

Type

WM18NL

Maker

P4 Travel motor

U35-3(EU)

Type

Delivery rate

Control valve

U35(KTC, KCL), U35-3(KTA)

Two speed piston motor Equivalent capacity Speed(R) Traction force(R) Swivel motor

3.0/4.6 km/hr

2.9/4.5km/hr

1.30/0.85 (2940kg)

1.25/0.81(3200kg)

Maker

kubota

Type

SM29G

Position motor with negative brake

Equivalent capacity

290 cc/rev

290cc/rev

Relief pressure

20.1(205)

Swivel speed

9.0rpm

8.9rpm

Torque Cylinder

879/574 cc/rev

Boom

Arm

Bucket

Swing

Dozer

63.9(627)

75.2(738)

Bore dia.

φ80

←

Rod dia

φ45

←

Stroke

504.5mm

←

Cushon

35mm

←

Bore dia.

φ75

Rod dia

φ45

Stroke

583.5mm

Cushon

Bore dia.

φ65

Rod dia

φ40

Stroke

516mm

Bore dia.

φ80

Rod dia

φ40

Stroke

408.5mm

Bore dia.

φ90

Rod dia

φ45

Stroke

154

IV-M-4

←

C.Main pump a. Structure & specifications

P4 gear pump P3 gear pump

Machine model Engine RPM Pump

KX91-3 2200

2300*

Pilot control system relief valve is installed in change valve.

KX101-3(EU only)

U35, U35-3

2300rpm

←

Maker

Uchida

←

Type

AP2D18

←

Variable pump,2 + Gear pump

←

+gear pump

←

Delivery

P1, P2

39.6L/min (18.0cc/rev)

41.4*

39.1L/min (17.0cc/rev)

←

20.9L/min

(9.5cc/rev)

21.9*

20.7L/min (9.0cc/rev)

←

8.4L/min

(3.8cc/rev)

8.7*

8.7L/min (3.8cc/rev)

←

* KTC, KCL, KTA version

IV-M-5

b. Performance curve Variable displacement pump Type=AP2D18LV1RS7-920-O

U35, U35-3, KX101-3 Type of pump

AP2D18

GSP2-09

G1-03

24.5(250)

19.6(200)

3.9(40)

17.0 × 2

9.0

3.8

39.1 × 2

20.7

8.7

0.5(5) → 19.6(200)

Operating pressure MPa(kgf/cm2) Displacement Delivery rate

cm /rev L/min 2

P3 shift pressure MPa(kgf/cm ) Input power kW(PS) Input shaft horse power kW(PS) Input shaft torque N·m(kgf·m) Control type Operating RPM Rotating direction

min-1

Suction pressure Weight

MPa(kgf/cm2)

15.6(21.2) → 9.2(12.5) 72.7(7.4) Total horse power control

0.6(0.8) → 8.0(10.9) 17.5(22.8) → 18.7(24.2) 77.2(7.9)

0.6(0.8)

2300 Clockwise, viewed from input shaft side

-0.02 ~ +0.15(-0.2 ~ +1.5) at intet port 2400rpm. Applox. 27.5

Theoretical curve

Shift pressure P3 MPa (kgf/cm2)

Pressure ΣP=P1+P2 MPa (kgf/cm2)

U35, U35-3, KX101-3

Min-flow curve

Delivery amount Q1, Q2 L/min

IV-M-6

D.Control valve a. Specifications 68.6N(7kgf) 88.3N(9kgf)

Spool leakage, condition Swing (A2,B2) port Boom lock (A9) port Other ports

9.81MPa(100kgf/cm2),37cSt 3cm3/min or less 1cm3/min or less 7cm3/min or less

Tank back pressure, allowable

0.98MPa(10kgf/cm2)

Contamination level

NAS class 9 or better

Travel straight (Pa) Stroke

Spool operating force Return spring at neutral at full stroke

Pilot pressure

Machine model Main relief pressure setting

Overload relief pressure setting

U35, U35-3, KX101-3

KX91-3

MRV1 MRV2

23.5 0

MRV3

19.6MPa(200kgf 0 kgf/cm2) at 20.9L/min

Dozer bottom(B3)

24.0 0

Arm bottom(A5) Arm rod(B5) Bucket bottom(B10)

27.5 0

Boom bottom(A10) Boom rod(B9)

27.0 0

Bucket bottom(B10)

27.5 0

+0.49

MPa(240 0 kgf/cm2) at 39.6L/min +5

+0.49

MPa(245 0 kgf/cm2) at 5L/min

+0.49

MPa(280 0 kgf/cm2) at 5L/min

+0.49

MPa(275 0 kgf/cm2) at 5L/min

+0.49

MPa(280 0 kgf/cm2) at 5L/min

+0.49

MPa(200 0 kgf/cm2) at 20.7L/min

+0.49

MPa(285 0 kgf/cm2) at 5L/min

+0.49

MPa(280 0 kgf/cm2) at 5L/min

+0.49

MPa(285 0 kgf/cm2) at 5L/min

19.6 0

28.0 0 27.5 0 28.0 0

3.92MPa (40kgf/cm2)

Control valve Machine model Control valve type

U35, U35-3, BCV35

Section width

31mm

Totale length

412mm

Main spool dia.

φ12

Pilot line air-bleeding

MPa(250 0 kgf/cm2) at 39.1L/min

Pilot primary pressure

Spool stroke

+0.49

24.5 0

Pilot section

7mm

Mechanism section

7mm

Travel straight section

5mm

Orifice dia.

φ0.50 equiv.

Stroke

6mm or more

Boom up section

Auto-bleeding

IV-M-7

e. Arm regeneration circuit (1) Arm dump Relief pressure:27.5

+0.49

0 +0.5

[280

MPa +0.49

Relief pressure:27.5

kgf/cm2]

0 +0.5

at 5 L/min

[280

T.T. 39.2 N·m [4 kgf·m]

MPa

kgf/cm2] at 5 L/min

T.T. 39.2 N·m [4 kgf·m]

Arm dump Pilot secondary pressure

2d 2e

2b 2a 1

11 12

5 14 13 15 7 T.T. 5.88~6.86 N·m [0.6~0.7 kgf·m]

T.T. 3.92~4.9 N·m [0.4~0.5 kgf·m]

(15) Check valve for regeneration

Security use Locktite #242

T.T. : Tightening torque

(2) Arm Crowd Relief pressure:27.5

+0.49

0 +0.5

[280

MPa

kgf/cm2]

Relief pressure:27.5

+0.49

0 +0.5

at 5 L/min

T.T. 39.2 N·m [4 kgf·m]

[280

MPa

kgf/cm2] at 5 L/min

T.T. 39.2 N·m [4 kgf·m]

Arm crowd Pilot secondary pressure

2d 2e 9

T.T. 3.92~4.9 N·m [0.4~0.5 kgf·m] Security use Locktite #242

IV-M-8

11 12

5 14 13 15 7 T.T. 5.88~6.86 N·m [0.6~0.7 kgf·m]

(15) Check valve for regeneration T.T. : Tightening torque

f. Oil flow of lock valve (1) Operation of lock valve 1) Holding When the boom spool is in the neutral position, the pilot piston chamber (a) is connected to the drain passage via the pilot port for lock valve releasing (Pb8’) and also the piston chamber (b) is connected to the drain passage via the drain port (Dr). This holds the piston (A) in the state as shown below. As illustrated below, the hold pressure of the boom cylinder acts on the lock valve chamber, pressing the needle valve and the lock valve against the needle valve seat and the body seat, respectively. This prevents leakage from the boom cylinder head, thus keeping the boom cylinder from moving due to leakage.s Boom cylinder

Lock valve chamber Pilot piston chamber (b) Piston A A9 Dr

Pb8

Pilot piston chamber (a)

Body seat

Needle valve seat Lock valve Needle valve

IV-M-9

2) Releasing When the pilot pressure acts on the pilot port for lock valve releasing (Pb8’), the piston (A) moves to the right to push open the needle valve via the piston (B). At this time, the return hydraulic oil from the boom cylinder flows through the orifice of the lock valve, passes through the lock valve chamber, pilot piston and oil passage in this order, pushes up the steel ball, and flows to the tank passage through the notch of the boom spool. Because the needle valve is now open, the pressure in the lock valve chamber drops. As a result, the pressure of the return hydraulic oil from the boom cylinder opens the lock valve and the return hydraulic oil from the boom cylinder flows to the tank passage through the notch of the boom spool.

To tank

Boom cylinder

Steel ball

Lock valve chamber Oil passage

Pb8

Piston A

Lock valve

Piston B

Pilot piston chamber

Needle valve

IV-M-10

Orifice

(2) Boom operation 1) Boom-up operation When the boom-up action is taken, the secondary pressure from the pilot control valve is conducted to the port “Pa8”, shifting the boom spool. Because the bypass passage is now blocked at the boom switching section, the hydraulic oil coming from the port “P1” flows through the parallel passage via the check valve located above the travel spool bypass passage to the parallel passage in the boom switching section. Because the passage leading to the lock valve is connected to the bridge passage as a result of the spool being shifted, the hydraulic oil in the parallel passage passes through the load check valve in the boom switching section, flows through the bridge passage, and pushes the lock valve open (free flow state). Then, after flowing into the port “A9”, it is supplied to the boom cylinder head. The return hydraulic oil from the boom cylinder rod side, on the other hand, flows into the port “B8” and flows to the tank passage via the notch of the spool. As a result, the boom cylinder gets extended to move up the boom. Boom cylinder

Check valve A9

Parallel passage

Bridge passage

Pilot passage

Pb8

Pb8 Pa8 Bypass passage Parallel passage

From pump P1

Travel R Boom

Pb8 Pa8

Lock valve

Pb8

To A9 port Lock valve

IV-M-11

2) Boom-down operation When the boom-down action is taken, the secondary pressure from the pilot control valve is conducted to the ports “Pb8” and “Pb8’”, shifting the boom spool. Because the bypass passage is now blocked at the boom switching section, the hydraulic oil coming from the port “P1” flows from through the parallel passage via the check valve located above the travel spool bypass passage to the parallel passage in the boom switching section. Because the port “B8” is connected to the bridge passage as a result of the spool being shifted, the hydraulic oil in the parallel passage passes through the load check valve in the boom switching section, flows through the bridge passage, and flows into the port “B8”. Then it is supplied to the rod side of the boom cylinder. The return hydraulic oil from the boom cylinder head, on the other hand, flows into the port “A9”, passes through the lock valve released by the port “Pb8’” pressure, and flows to the tank passage via the notch of the spool. As a result, the boom cylinder gets contracted to move down the boom. Boom cylinder

Bridge passage

Parallel passage

Pilot passage

Pb8

Pb8 Pa8 Bypass passage From pump P1

Parallel passage

From pump P1

Travel R

Pb8

Boom Pa8 Lock valve Pb8 Lock valve

IV-M-12

g. Function of lock valve (Anti-drift valve) (1) Boom cylinder holding function

Cylinder bottom pressure,Pb

Cylinder bottom pressure, Pb

F1=Pb × A1 F2=Pb × A2 F3=Pb × (A1 – A2) F3=F1 – F2

Main poppet is pushed to seal by the force of F3( = F1 – F2) and spring.

F3=F1—F2 A3=A1—A2

(2) Boom up function Boom-up pressure(Pump pressure),Pp

Cylinder bottom pressure, Pb

A3=A1—A2

Cylinder bottom pressure,Pb

A2 A1 F1

Pb A1 – Pb A2 < Pp × (A1 – A2) Pb (A1 – A2) < Pp × (A1 – A2)

F1=Pb × A1 F2=Pb × A2 F3=Pp × (A1 – A2)

Pump pressure,Pp is larger than Pb,cylinder bottom pressure. Therefore, main poppet is pushed to open.

(3) Boom-down function

Small poppet

Main poppet Cylinder bottom pressure, Pb

Pilot secondauy pressue

Small oil flow

Presure loss, UP

Pb-UP Pilot secondary pressure applies on the end of piston and small poppet is pushed to open. So pressure in the chamber is dumped to tank port. Thus main poppet opens.

IV-M-13

E.Pilot valve assy No.=RC411-61721 (Kawasaki HI make)

a. Structure & specifications : U35(KTC, KCL), U35-3(KTA) 121: Not to be reused. 212: Grease is applied on each top part. 217: Shim for adjusting secondary pressure 1 sheet with designed thickness t = 0.4 301: Grease is applied on each rotational part of the universal joint.

Tightening torque list No.

SCREW SIZE

125

TIGHTNING TORQUE

No.

PART NAME

Q’ty

No.

PART NAME

Q’ty

213

Seal

501

BELLOWS

20.6 ± 1.5 N·m (210 ± 15 kgf·cm)

212

ROD, push

312

NUT, adjusting

211

PLUG

302

PLATE, circular

201

SPOOL

301

JOINT

151

PLATE

241-2

SPRING

131

BUSH

241-1

SPRING

126

PIN, spring

221-2

SPRING

125

SCREW, S.M.C

221-1

SPRING

217

WASHER 2

122

O-RING

216-2

SEAT 1, spring

121

WASHER, seal

216-1

SEAT 1, spring

111

PLATE, port

214

O-RING

101

CASING

301

M14

47.1 ± 2.9 N·m (480 ± 30 kgf·cm)

312

M14

68.6 ± 4.9 N·m (700 ± 50 kgf·cm)

IV-M-14

hex,

Specifications (1) (2) (3) (4) (5) (6) (7) (8) (9)

MAX PRIMARY PRESSURE : MAX BACK PRESSURE : RATED FLOW : SECONDARY PRESSURE CHARACTRISTICS : OPRERATING TORQUE : MAX. ALLOWABLE EXTERNAL TORQUE : HYDRAULIC OIL : OIL TEMP. RANGE : FILTER :

6.9 NPa(70 kgf/cm2) 0.3 NPa(3 kgf/cm2) 15 l/min Refer to the “Control Diagram“ shown below. Refer to the “Control Diagram“ shown below. Refer to the “MAX. allowable external torque“ shown below. MINERAL HYDRAULIC OIL -20°C ~ 90°C A filter of 40 ~ mesh and ever should be applied at the entrance of port P for preventing the spool sticking.

Operating specifications (1)

PRIMARY PRESSURE

3.9 NPa(40 kgf/cm2)

IV-M-15

(kgf/cm2)

(N·m)

(MPa)

(kgf/cm2)

b. Pilot valve control diagram : U35(KTC, KCL), U35-3(KTA)

(mm)

(deg)

IV-M-16

(kgf/cm2)

(N·m)

(MPa)

(kgf/cm2)

(mm)

c. KBM-make : Pilot valve : U35-3(EU) Ports 1, 2, 3, 4

IV-M-17

F. Swivel motor a. Structure & specifications (2)Shockless spool

Brake relief pressure

Filter

(3)Make up port

(1)Reloef valve Filter

Specifications Displacement

29.271 cc/rev

Reduation ratio

9.90

Total displacement

289.78 cc/rev

Max. flow amount

20.90 l/min

Theoretical RPM

72.1 RPM

Theoretical output torque

905 N·m (92.2kgf·m)

Relief pressure setting

20.1 MPa (205 kgf/cm2) at 20.9 l/min

Mechanical brake torque

951 N·m (97 kgf·m) or more

Negative brake releasing pressure

< 1.5 MPa (15 kgf/cm2)

Drain pressure

< 0.3 MPa (3 kgf/cm2)

Teeth No.

Filter

200 mesh (0.074 mm)

O-ring type

IV-M-18

(3)

Ball bearing

(17)

Brake piston

(38)

Spring guide

(4)

Shaft

(23)

Valve assy

(43)

Poppet guide

(5)

Circlip

(24)

Valve housing

(61)

Gear case assy

(6)

Thrust plate

(25)

Poppet

(66)

Pinion shaft

(7)

Cylinder block

(29)

Shockless piston

(71)

Planetary gear

(13)

Piston plate

(33)

Relief valve assy

(73)

Thrust plate

(15)

Retainer holder

(34)

Volve housing

(75)

Filter

(16)

Frictio plate

IV-M-19

020

:Ball bearing

130

:Friction plate

360

:Motor cover

030

:Shaft

:Cylinder block

480

:Filter

050

:Trust plate

140

:Piston brake

520

:Cylinder block sub-assy

110

:Retainer plate

170

:Negative spring

540

:Seal kit

120

:Retainer holder

180

:Poppet

:Piston assy

250

:Relief valve

010

:Gear case

050

:Piston shaft, 10T

020

:Ball bearing

070

:Holder

030

:Oil seal

090

:Needle bearing

040

:Ball bearing

100

:Planetary gear

IV-M-20

120

:Thrust plate

b. Function of negative brake

Brake bearing, 12pcs

Brake piston

Swivel make-up port

O-ring Filter

P-port

O-ring Friction plate

(1) Negative brake function(Unload condition) No pressure is applied at the P-port, which means there is no piston driving force. In this state, the force of negative brake springs pushes down the negative brake piston to get the friction plate between the piston and the casing. By so doing, the friction plate is held in this position by a friction force. Because the motor’s cylinder block and the friction plate are spline-coupled, the cylinder block is held and thus the motor is braked.

(2) Negative brake release(On-load condition) A pilot pressure is applied at the P-port, generating a driving force to the negative brake piston. In this state, the piston driving force surpasses the force of negative brake springs to push up the negative brake piston. By so doing, the friction plate gets free from the friction force, allowing the motor to run freely.

To upward

P-port Clearance (Applox. 1mm)

Friction plate

IV-M-21

c. Function of valve section (1)Make-up valve When the swivel frame has been once accelerated and then decelerated with the control lever, the oil supplied to the P1 port by the pump drops. But the inertia of the swivel frame forces the hydraulic motor to run for pumping. By this, the oil amount being supplied runs short and the P1 port comes under a slightly negative pressure. To avoid this, as the P1 port pressure drops, the make-up valve's poppet is opened to allow in the return oil to compensate for such oil shortage.

(2)Function of shockless valve 1) When the pressure oil comes to the P1 port at a start or stop, the oil flows through the orifice, which is located in the poppet and relief valve body, and into the chamber A of the free piston. With the orifice in effect, the back pressure (Pb) of the poppet is kept below the pressure (Pa) being exerted on the poppet (Pa>Pb). In this design, the relief valve works at a pressure below the set pressure, allowing the pressure oil into the low-pressure (P2) side. (Primary relief pressure) 2) The primary relief pressure continues to work until the free piston reaches its stroke end. The free piston's stroke speed is controlled by 4 orifices: 2 orifices at the inlet relief valve and 2 at the outlet one. 3) When the free piston has reached its stroke end, the pressure loss due to the above orifice effect turns zero. This means that the poppet's back pressure (Pb) becomes equal to the pressure (Pa) applied on the poppet (Pa = Pb). The relief valve that has worked at the primary relief pressure is now activated by the set pressure. (Secondary relief pressure)

Above illustration is taken from U-WSM for functional explanation purpose. IV-M-22

d. Swivel Performance (1) KE, KDG, KUK version Manufacturer

KX91-3

KX101-3, U35-3

KAYABA&T/B

←

Remarks

←

Model Capacity

cc/rev

286.0

←

Brake valve pressure

Mpa kg/cm2

16.7 170.3

20.2 206.0

Drain amount

at lock

l/min

4.0

←

Actual value

measurement

Drain amount

while rotating

l/min

0.5

←

Actual value

measurement

Swivel speed

rpm

8.9

←

3 times rotation swivel speed

sec

20.2

21.3

mm/min

←

Capable swivel rotation angle

deg.

←

Play at the tip of bucket

24.0

28.0

KX91-3

U35

Kubota SM29G

← ←

289.8 17.7

← 20.1 205 2916

Swivel block engine stop

performance

Swivel block performance engine running

Reference value

(2) KTC, KCL, KTA version Manufacturer Model

Swivel speed 3 times rotation swivel speed Swivel block performance at engine stop

cc/rev in3/rev Mpa kg/cm2 psi L/min G/min L/min G/min rpm sec mm/min in/min

Swivel block performance at engine running

mm/min in/min

Capacity

Capable swivel rotation angle

deg.

Play at the tip of bucket

mm in.

16.7 170.3 2422 4.0 1.06 0.5 0.13 9.4(8.5~10.3) 19.1 6> = 0.24 > = 30 > = 1.18 > = 19 < = 70 > = 2.76 > =

Motor slippage

rpm

Swivel torque

N·m kgf·m ft·lbs

Brake valve pressure Drain amount

at lock, 0 rpm

Drain amount

while rotating, 600rpm

Reduction ratio

Motor Swivel/ pinion

← ← 9.0(8.1~9.9) 20.0 5> = 0.20 > =

←

Remarks

Applied pressure: Brake valve pressure Applied pressure: 10.8 MPa, 110 kgf/cm2, psi No load. Slope:20degree 1min. Lever lock released

15 < =

←

Force:30kgf

1.0 > =

←

Applied pressure: 6.9 MPa, 70 kgf/cm2, psi

6149 627 4345 9.90

7238 738 5338

Quick operation

8.00

←

IV-M-23

←

(3) Inner parts of the swivel motor KE, KDG, KUK version

O-ring

Collar

Bearing

Motor housing Kit

Spring

O-ring

Collar washer

Base plate

Plug

Circrip

Check valve

O-ring

Valve plate

Spring

Bearing

Steel disc

O-ring

Motor shaft assy

Friction plate

Plug

Thrust plate

O-ring

Piston

Brake spacer

Relief valve assy

Retainer plate

O-ring

Spherical bush

O-ring

Pun

Brake piston

Plug

Cylinder block

Spring

Screw

IV-M-24

Pinion shaft

Nut

Motor adaptor

Frange

Output assembly

Sun gear

Nilos ring

Reduction assembly

Screw

Bearing

O-ring

Hydraulic motor

Gearbox housing

Toothed ring

Screw

Seal ring

Reduction assembly

Plug

IV-M-25

G.Rotary joint (Swivel joint) 020 :Packing 030 :Packing 040 :Shaft 050, 060 :Spacer 080 :O-ring 090 :Cover 130 :Stay 160 :Stopper

Outer side

Stopper

Seal lip

(Bolt)

Seal, enlarged Lower side Nut Spring W Bolt

Shaft Coller Machine right

Seal Body Seal

(Dozer side)

Coller Stay

Circlip O-ring Circlip Cover

Bolt

IV-M-26

H.Travel motor a. Structure U35(KTC, KCL), U35-3(KTA) Flange holder Reduction case Swach plate Cylinder block Counter balance valve Relief valve

Shockless spool Hi-Lo change spool

High pressure selection spool Drain plug with O-ring

Hi-Lo change piston 2 → 1 pc

(1)Relief valve (2)Shockless piston Relief valve assy

Relief valve assy

Plug Spring Shockless piston Relif valve Relief valve tightning torque : 58.8 ~ 68.6 N·m(6.0 ~ 7.0 kgf·m) Plug tightning torque : 58.8 ~ 68.6 N·m(6.0 ~ 7.0 kgf·m)

IV-M-27

(3) Inner parts of the traveling motor 1) KE, KDG, KUK version

Hub

Circlip

O-ring

Valve plate

Plug

Ball

Bearing

Orifice

Motor seal ring

O-ring

Plug

Bearing

O-ring

Spring

Plug

Piston

Base plate

Spring

Motor shaft assy

Plug

Check valve

Swash plate

O-ring

Screw

Piston

Spring seat

Valve housing

Retainer plate

Spring

Plug

Spherical bush

O-ring

Plug

Cylinder block

Plunger assy

Screw

Spring holder

Orifice

O-ring

Spring

Spool

Collar washer

Spring

IV-M-28

Circlip

1st. RED. assembly

Circlip

Plug

Circlip

Spacer

Cover assembly

Planetary assembly

Spacer

Pad

Gearbox housing

Centering ring

O-ring

Circlip

Hydraulic motor

Sun gear

Bearing

IV-M-29

b. Travel motor specification (1) KE, KDG, KUK version KX91-3 Manufacturer

KX101-3, U35-3

KAYABA + T/B

Model

702CKSP-MAG18V

Capacity

cc/rev

Relief valve pressure

Mpa kg/cm2

24.7 252

←

Climbing ability

deg.

←

N kgf

Max. traction force

Reference value

mm/10min

300

←

km/h

3.0

←

km/h

4.6

←

sec./10m sec./32.8ft

10.9 ~ 13.3

←

sec./10m sec./32.8ft

7.1 ~ 8.8

←

Crawler rotation speed

1F 2F

sec/ 1 rev

4.8 3.2

5.2 3.4

Straight travel performance

1,2F

mm/10mm

> 600 =

←

cc/min

←

cc/min

←

cc/min

←

cc/min

←

Traveling block performance

Traveling speed

10m traveling time

Drain amount at lock Drain amount while rotating

Remarks

IV-M-30

Allowable value of new machine Testing angle : 20deg

(2) KTC, KCL, KTA version Manufacturer

KX91-3

U35, U35-3

Kubota

←

Motor assy code No.

Remarks

RC411-6180U WM18NL

←

cc/rev in3/rev

18 1.10

←

1st

cc/rev in3/rev

879.4 53.6

←

2nd

cc/rev in3/rev

537.7 35.0

←

48.636

←

24.5 250 3553

←

Model Capacity

Motor dischange

Rotation ratio Relief valve pressure

Mpa kg/cm2 psi

Climbing ability

deg.

←

kN kgf lbf

24.9 2543 5605

27.1 2766 6098

Slip, 70% of absolute force

kN kgf lbf

15.2 1550 3417

15.2 1546 3408

Relief, 60% of absolute force

mm/10min ft/10min

300 > = 1

←

Allowable value of new machine Testing angle : 20deg

km/h mph

3.1 (2.8~3.4)

km/h mph

4.8 (4.3~5.0) 3.0

sec./10m sec./32.8ft

10.9 ~ 13.3

sec./10m sec./32.8ft

6.8 ~ 8.4

Crawler rotation speed

1F 2F

sec/ 1 rev

4.8 3.1

Straight travel performance

1,2F

mm/10mm ft/32.8ft

> 600 = > 1.97 =

←

cc/min G/min

> 4= > 1.06 =

←

cc/min G/min

4 1.06

←

cc/min G/min

> 0.5 = > 0.13 =

←

Applied pressure: 12.7MPa, 130kgf/cm2, psi

cc/min G/min

> 0.5 = > 0.13 =

←

Applied pressure: 14.7MPa, 150kgf/cm2, psi

rpm

> 0.05 =

←

Applied pressure: 6.9MPa, 70kgf/cm2, psi

Max. traction force

Traveling block performance

Traveling speed

10m traveling time

Drain amount at lock

Drain amount while rotating

Motor slippage

IV-M-31

R:3.0(2.7~3.3) I:2.9(2.6~3.2) R:4.6(4.1~5.1) I:4.6(4.1~5.1) R

:10.9~13.3

I:11.3~13.8 R:7.1~8.8 I:7.1~8.8

Applied pressure: 17.2MPa, 175kgf/cm2, psi

IV-M-32

J. Hydraulic circuit diagram a. U35-3 European - version

IV-M-33

b. U35 : KTC, KCL - version

IV-M-34

c. U35-3 : KTA - version

IV-M-35

d. Hydraulic components layout : U35, U35-3 (18)Suction filter

(20)Change valve(KTC, KCL, KTA) (17)Return filter (16)Hydraulic oil tank

(1)Main pump

(4)Control valve assy

(19)Oil cooler

(21)Check valve

4 1 T

(10)Swing cylinder

P 2

(13)Arm cylinder

3 4

T 2 3

(9)Travel motor, R (12)Boom cylinder

(2)Pilot valve L

(5)Swivel motor

(3)Pilot valve, R

(11)Dozer cylinder

(7)TPSS valve (KTC, KCL, KTA) (8)Travel motor, L

(15)Service port (22)Grease tension cylinder (14)Bucket cylinder (6)Rotary joint

Note: (7)TPSS valve and (20)Change valve are for KTC, KCL, KTA - version.

IV-M-36

IV.Hydraulic system(Service section) A. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-3 a. b. c. d.

Common Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-3 Front Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-5 Swivel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-8 Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-10

B. Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-11 a. b. c. d. e.

Relief valve pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-11 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-13 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-15 Swivel Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-18 Traveling Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-19

C. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-21 a. Testing Instruments & special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-21 b. Pump flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-23 c. Pilot pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-24 d. Main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-26 e. Overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-28 f. Swivel brake valve pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-30 g. Traveling motor drain amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-32 h. Swivel motor drain amount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-33 i. Swivel motor block performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-34 j. Traveling motor block performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-35 k. Operating speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-36 l. Straight travel performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-38 m. Cylinder natural fall amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-39 n. Control and Traveling lever operating force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-39 o. Lever stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-39

D. Disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-40 a. b. c. d. e. f. g. h. h. i. j.

Coupling flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Control valve and relief valve . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Swivel motor (KTC, KCL, KTA-version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-40 Traveling motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Rotary joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-41 Cylinder (KE, KDG, KUK version) . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Cylinder (KTC, KCL, KTA version). . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Other hydraulic device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to WSM of KX91-3, 101-3 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-S-50

IV-S-1

IV-S-2

IV-S-3 Yes

Does this symptom disappear with engine stop?

Yes

2) Actuator functions even with lever in neutral

Is there unusual noise at pump with lever operation?

Yes

Check, readjust or replace pilot valve.

Internal leakage of actuator.

Yes

Does air intake through suction line or water mixed?

Is pilot circuit secondary pressure normal?

Is pilot pump delivery rate OK?

Abnormal function of main control valve. (1) Valve return spring damage. (2) Spring bolt loosen. (3) Spool stick.

Yes

Is hydraulic tank filled?

Is pilot circuit primary pressure over 40 kgf/cm2 (569 psi)?

1) All actuators don’t function with any lever operation

Is suction strainer clogged?

Is pilot pump suction line OK?

Yes

Others Check any abnormal conditions such as pump inlet section, spline shaft or coupling flange.

Replenish hydraulic oil.

Remove and check suction line or replace hydraulic oil.

Clean suction strainer.

Disassemble or replace main pump.

Check main control valve for air bleeding through orifice or spool stick.

Clean or replace line filter.

Relief valve of solenoid change valve is abnormal. Remove, readjust or replace.

Check suction line for not enough suction function or clean suction filter.

Check & replace pilot pump.

A.Troubleshooting

a. Common Circuit

IV-S-4

3) Hydraulic oil temp. is excessivly high.

Yes

Is return line pressure normal?

Yes

Is air flow regulator plate damaged, missing or incorrectly installed?

Is fan belt slipping?

Are oil cooler fins clogged?

Is return filter clogged?

Is relief valve functioning continually or any abnormal operation?

Yes

Is some metal particle clogged in line?

Need inspection of contamination caused clogging.

Check oil quality.

Possibly special machine modification. No

Disassemble and clean.

Yes

Applicational mismatch.

Replace or correctly install the air flow regulator plate.

Adjust fan belt.

Clean oil cooler fins.

Disassemble and clean the appropriate components.

Need operational instruction. Operator training.

Yes

Is primary pilot pressure delivered?

Is primary pilot pressure normal (40 kgf/cm2)?

Is secondaly pilot pressure applied on main control valve spool?

Can that cylinder maintain the front attachment in neutral?

1) Specific actuator (cylinder) doesn’t move while lever is shifted.

IV-S-5 No

Yes

Is overload relief valve normal? No

Yes

Check change valve line filter and pump.

Pilot valve defected. Disassemble and clean or replace.

Pilot hose defect. Replace.

Control valve spool is stuck. Need air bleed or remove and clean check valve with throttle.

Check & clean overload relief valve.

Check cylinder rod seal. Renew if needed.

In case of boom cylinder ; Check boom anti-drift valve poppet.

b. Front Attachment

IV-S-6

Yes

Replace overload relief valve.

Adjust accelerator cable and lever

Replace fuel filter and air cleaner element.

Check change valve, Line filter and pump.

Pilot valve defects Disassemble and clean, or replace.

Control valve spool doesn’t have full stroke. Loosening return spring bolt. Remove, readjust and clean. Or replace.

Does governor lever reach to max. speed stopper when accelerator lever is in Max.?

In primary pressure of pilot valve lower than 40 kgf/cm2?

Yes

See item b.1).

Yes

Remove and replace cylinder rod packing

Is engine running Max?

Yes

Is overload relief valve normal?

Is secondary pilot pressure applied on main control valve spool?

Is specific cylinder slow?

All of boom, arm and bucket cylinders have slow speed.

2) Front cylinder’s operating speed is slow.

IV-S-7

Does fail symptom change when engine stops?

4) Front natural fall amount is excessive.

Is all actuator’s digging force weak?

3) Digging force is weak.

Yes

Does main pump have abnormal noise?

Yes

Specific one actuator is weak digging force.

Yes

Are there any scratches on control spool, spring damage or looseness of bolt?

Is operating oil shortage?

Is main relief valve set pressure normal?

Yes

Is secondary pilot pressure more than 19 kgf/cm2 in pilot chamber of main control valve?

Yes

Isn’t suction line loosened?

Yes

Pilot valve has some defect. Disassemble or replace.

In case of spool scratch, replace control valve. Spring damage, replace. Looseness of bolts, retighten.

Disassembe or replace cylinder rod packing.

Retighten.

Main pump has problem. Suction filter may be clogged.

Cavitation. Add oil.

Adjust or replace main relief valve.

Main pump delivery amount decreased. Disassemble or replace.

Main control valve spool doesn’t shift in full stroke. Spool sticks. Disassemble and service.

See item b 1).

Disassemble and replace cylinder packing.

Do the other actuators function normally?

1) Swivel doesn’t function.

Yes

Is secondary pilot pressure of swivel port normal?

Only swivel and arm don’t function

Yes

All the others doesn’t function

Is intake pressure of swivel motor normal?

Yes

Is primary pilot pressure in left side pilot valve more than 40 kgf/cm2?

IV-S-8 Swivel motor turns but body doesn’t swivel. No

Yes

Is drain amount normal?

Does motor unit turn?

Swivel motor doesn’t turn.

Yes

Is secondary pilot pressure of port 1, 2, 3, 4 normal?

Yes

Is swivel motor drain amount normal?

Yes

Swivel relation parts defect. Check oil level.

Swivel motor defect.

Control valve defect.

Check pilot system pressure.

Swivel bearing, Pinion gear defect.

Main control valve swivel section defect. Spool stick.

Swivel motor defect.

Left side pilot valve defect.

Check again swivel and arm separately.

Left side pilot valve defect.

See item b 1).

Refer to common circuit.

c. Swivel Circuit

IV-S-9

Only swivel?

Yes

Isn’t one way swivel smooth?

3) Swivel functions is not smooth.

Single swivel operation doesn’t have enough power.

On slope, swivel upward isn’t enough.

No swivel force.

2) Swivel force is not enough.

Yes

Only swivel doesn’t work, other function are normal.

Yes

Swap swivel overload relief valve. Does symptom change? Yes

No accelerator power but Yes brake force is normal.

No Yes

Swap pilot hoses of right and left swivel. Does symptom change?

Is swivel drain amount normal?

Either right swivel accelerator and left swivel brake, or left swivel accel and right swivel brake is abnormal.

Yes

One direction has no swivel force.

Is secondary pilot pressure swivel ports normal?

Does secondary pilot pressure function smoothly?

Check overload relief pressure.

Yes

Is secondary pilot pressure for swivel normal?

Swap pilot hoses of right and left swivel. Does symptom change?

Yes

check pilot valve.

Check pilot valve spool.

Check swivel motor and swivel relation parts.

Check swivel motor.

Check main pump.

Replace swivel overload relief valve.

Replace pilot valve.

Replace control valve spool.

Check pilot system and pilot pump.

Check swivel motor.

Check main pump.

Either forward or reverse has no travel force.

One side travel motor doesn’t have travel force in forward and reverse direction.

1) No travel force.

IV-S-10

Yes

Plug the outlet port of travel circuit on rotary joint. Is relief pressure normal?

Swap travel motor assy. Does symptom change?

Swap hoses of F and R on control valve. Does symptom change?

Swap brake relief valve of motor valve. Does symptom change?

Swap hoses between control valve and main pump. Does symptom change?

Yes

Swap hoses of F and R on control valve. Does symptom change?

Does control valve spool shift in full stroke?

Travel reduction gear has probrem.

Yes

Control Spool doesn’t shift in full stroke. Readjust or replace.

Internal leakage of rotary joint. Replace seals.

Spool sticks. Replace.

Brake relief valve defect.

Track shoe or other under carriage have probrem.

Repaire reduction gear.

Internal leakage of rotary joint. Replace seals.

Travel motor defect. Readjust or replace.

Control valve spool doesn’t shift in full stroke. Readjust or replace.

Main pump defect.

d. Travel Circuit

B.Specifications a. Relief valve pressure setting

Main relief valve (bench data) No. 1

Valve location

Operating work

Unit

KX91-3

KX101-3

U35, U35-3

P1 Control valve

Travel right, Boom, Bucket

Mpa kgf/cm2 psi

23.5 240 3414

25.0 255 3627

24.5 +0.3 - 0.2 250 +3 -2 3556 +43 -28

P2 Control valve

Travel left, Arm, Auxiliary

Mpa kgf/cm2 psi

23.5 240 3414

25.0 255 3627

24.5 +0.3 - 0.2 250 +3 -2 3556 +43 - 28

Dozer, Swing, Swivel

Mpa kgf/cm2 psi

19.6 200 2845

←

19.6 +0.3 - 0.2 280 +3 -2 2845 +43 - 28

Control valve spool

Mpa kgf/cm2 psi

3.9 40 569

←

3.9 +0.3 -0 40 +3 -0 569 +43 -0

P3 Control valve

P4 Change valve

Remarks

Main relief valve (at the measurement port on the machine) KE, KDG, KUK version No.

Valve location

Operating work

Unit

KX91-3

P1 Control valve

Travel right, Boom, Bucket

Mpa kgf/cm2

25.0 ± 0.5 255 ± 5

P2 Control valve

Travel left, Arm, Auxiliary

Mpa kgf/cm2

25.0 ± 5 255 ± 5

P3 Control valve

Dozer, Swing, Swivel

Mpa kgf/cm2

20.3 ± 0.5 207 ± 5

P4 Change valve

Control valve spool

Mpa kgf/cm2

3.9 +0.2 -0 250 +2 -0

IV-S-11

KX101-3

U35-3

Remarks

Main relief valve (at the measurement port on the machine) KTC, KCL, KTA version No.

Valve location

Operating work

Unit

KX91-3

U35 U35-3

P1 Control valve

Travel right, Boom, Bucket

Mpa kgf/cm2 psi

24.0 ± 0.5 245 ± 5 3485 ± 270

25.0 ± 0.5 255 ± 5 3627 ± 70

P2 Control valve

Travel left, Arm, Auxiliary

Mpa kgf/cm2 psi

24.0 ± 0.5 245 ± 5 3485 ± 70

25.5 ± 0.5 255 ± 5 3627 ± 70

P3 Control valve

Dozer, Swing, Swivel

Mpa kgf/cm2 psi

20.6 ± 0.5 210 ± 5 2987 ± 70

20.3 ± 0.5

3.9 - 0

+0.2

3.9 - 0

Control valve spool

Mpa kgf/cm2 psi

40 - 0

+28

569 - 0

P4 Change valve

40 - 0 569 - 0

Remarks

207 ± 5 2944 ± 70 +0.2

+28

Overload relief valve (At the measurement port on the machine.) All-version. No.

Valve location

Operating work

Unit

KX91-3

KX101-3

U35 U35-3

Control valve

Boom up Boom down

Mpa kgf/cm2 psi

27.0< 275< 3911<

27.5< 280< 3983<

29.4< 300< 4267<

Control valve

Bucket crowd

Mpa kgf/cm2 psi

27.5< 280< 3983<

27.9< 285< 4054<

29.9< 305< 4338<

Control valve

Arm dump Arm crowd

Mpa kgf/cm2 psi

27.5< 280< 3983<

27.9< 285< 4054<

29.9< 305< 4338<

Control valve

Dozer down

Mpa kgf/cm2 psi

24.0< 245< 3485<

←

27.0< 275< 3911<

Swivel motor

Swivel, R &L

Mpa kgf/cm2 psi

16.7< 170< 2418<

201< 205< 2916<

20.6< 210< 2987<

Travel motor

Travel, R & L, F & R

Mpa kgf/cm2 psi

24.5< *1 250< 3556<

28.4< *1 290< 4125<

Remarks

*1 Overload relief pressure should be inspected at engine 1500 rpm. *2 Main relief valve pressure should be raised up by 10 kgf/cm2 (0.98 MPs, 140 psi) over the expected overload relief pressure. *3 Above data in the shows bench-set pressure valve and sign < means allowable minimum pressure valve at the measurement port on the machine. *4 *1 indecates only for KTC, KCL, KTA-version. EU version doesn’t have overload relief valve.

IV-S-12

b. Pump (1) KE, KDG, KUK version Unit Manufacturer

KX91-3

←

AP2D18

←

rpm

2200

2300

←

P1,P2

Mpa kgf/cm2 psi

23.5 240 3414

24.5 250 3556

←

Mpa kgf/cm2 psi

19.6 200 2845

←

MpaMpa kgf/cm2 psi

3.9 40 569

←

P1,P2

cc/rev in3/rev

18.0 1.1

17.0 1.0

←

cc/rev in3/rev

9.5 0.6

9.0 0.5

←

cc/rev in3/rev

3.8 0.2

←

P1,P2

L/min gal/min

39.6 10.5

39.1 10.3

←

L/min gal/min

20.9 5.5

20.7 5.5

←

L/min gal/min

8.4 2.2

8.7 2.3

←

P=0 kgf/cm2 P=0 psi

L/min gal/min

39 10.3

←

P=200 kgf/cm2 P=2845 psi

L/min gal/min

36 9.5

38 10.0

←

P=240 kgf/cm2 P=3414 psi

L/min gal/min

31 8.2

33 8.7

←

P=250 kgf/cm2 P=3556 psi

L/min gal/min

---

31 8.2

←

Rated pump rpm

Theoretical discharg capacity

Theoretical discharg capacity at rated load

Variabel displacement pump discharge capacity at specified operating pressure P=P1+P2 P3=5 kgf/cm2 (71 psi)

U35-3

Uchida Hydraulics

Model

Rated load pressure

KX101-3

IV-S-13

Remarks

(2) KTC, KCL, KTA version KX91-3

U35(KTC, KCL) U35-3(KTA)

Manufacturer

Uchida Hydraulics

←

Model

AP2D18

←

rpm

2300

←

P1,P2

Mpa kgf/cm2 psi

23.5 240 3414

24.5 250 3556

Mpa kgf/cm2 psi

19.6 200 2845

←

Mpa kgf/cm2 psi

3.9 40 569

←

P1,P2

cc/rev in3/rev

18.0 1.1

17.0 1.0

cc/rev in3/rev

9.5 0.6

9.0 0.5

cc/rev in3/rev

3.8 0.2

←

P1,P2

L/min gal/min

41.4 10.9

39.1 10.3

L/min gal/min

21.9 5.8

20.7 5.5

L/min gal/min

8.7 2.3

P=0 kgf/cm2 P=0 psi

L/min gal/min

39 10.3

←

P=200 kgf/cm2 P=2845 psi

L/min gal/min

36 9.5

38 10.0

P=240 kgf/cm2 P=3414 psi

L/min gal/min

31 8.2

33 8.7

P=250 kgf/cm2 P=3556 psi

L/min gal/min

31 8.2

Unit

Rated pump rpm

Rated load pressure

Theoretical discharg capacity

Theoretical discharg capacity at rated load

Variabel displacement pump discharge capacity at specified operating pressure P=P1+P2 P3=5 kgf/cm2 (71 psi)

IV-S-14

Remarks

c. Cylinder (1) Cylinder operating speed U35(KTC, KCL) U35-3(KTA)

Unit

U35-3(EU)

Remarks

(A)

(B)

(A)

(B)

Boom cylinder

sec.

2.4

± 0.3

2.5

2.8

Boom cylinder

Down

sec.

3.0

± 0.3

3.1

± 0.3

Boom cylinder

cushion

sec.

0.4 ~ 1.3

Arm cylinder

Crowd

sec.

3.1

± 0.3

3.3

± 0.3

Arm cylinder

Dump

sec.

2.7

± 0.3

2.8

± 0.3

Bucket cylinder

Crowd

sec.

2.6

± 0.3

2.7

± 0.3

Bucket cylinder

Dump

sec.

1.7

± 0.3

1.9

± 0.3

Swing cylinder

Left

sec.

5.8

± 0.3

5.9

± 0.3

Swing cylinder

Right

sec.

5.8

± 0.3

5.9

± 0.3

Dozer cylinder

sec.

2.2

± 0.3

2.1

± 0.3

Dozer cylinder

Down

sec.

2.9

± 0.3

2.9

± 0.3

GL to Max. height (exclude cushion time) Max. height to GL 50 °C (122 °F) Cylinder full stroke Cylinder full stroke Cylinder full stroke Cylinder full stroke

(A)New machine reference valve (B)Allowable limit

(2) Cylinder natural fall amount U35(KTC, KCL) U35-3(KTA)

Unit

(A)

(B)

U35-3(EU) (A)

Remarks

(B)

Load weight

kg lbs

285 628

Boom cylinder

mm in

6 0.24

30 1.18

6 0.24

30 1.18

Arm cylinder

mm in

14 0.55

70 2.76

14 0.55

70 2.76

Bucket cylinder

mm in

25 0.98

125 4.92

25 0.98

125 4.92

Dozer cylinder

mm in

20 0.79

100 3.94

20 0.79

100 3.94

include bucket weight

(A)New machine reference valve (B)Allowable limit

IV-S-15

(3) Cylinder specifications 1) KE, KDG, KUK version

Boom

Unit

KX91-3

KX101-3

Tube I.D. × Rod O.D.

φ80 × φ45

φ85 × φ45

←

Stroke

506

501.5

Max.retraction length

Seal Kit No.

Arm

828.5 RH618-67501

600 ± 120 92 ± 12

600 ± 120

←

Tube I.D. × Rod O.D.

φ75 × φ45

←

Stroke

583.5

←

Max.retraction length

896.5

←

RG518-67630

←

Piston tightning torque

N·m kgf·m

600 ± 120 92 ± 12

←

Tube I.D. × Rod O.D.

φ65 × φ40

←

Stroke

539

←

Max.retraction length

834

←

RG518-67840

←

Piston tightning torque

N·m kgf·m

475 ± 95 48 ± 10

←

Tube I.D. × Rod O.D.

φ80 × φ40

←

Stroke

408.5

←

Max.retraction length

692.5

←

RG208-94410

←

Piston tightning torque

N·m kgf·m

475 ± 95 48 ± 10

←

Seal Kit No.

Dozer

833 RG618-67540

N·m kgf·m

Seal Kit No.

Swing

870 RG518-67560

Piston tightning torque

Seal Kit No.

Bucket

U35-3

Tube I.D. × Rod O.D.

φ90 × φ45

←

Stroke

154

←

Max.retraction length

492

←

RG518-75130

←

N·m kgf·m

600 ± 120 92 ± 12

←

Unit

KX91-3

Seal Kit No. Piston tightning torque

Remarks

2) KTC, KCL, KTA version U35 (KTC, KCL), U35-3 (KTA) Remarks Cab

Boom

Tube I.D. × Rod O.D.

mm in.

φ80 × φ45 φ3.15 × φ1.77

Stroke

mm in.

506 19.9

Max.retraction length

mm in.

870 34.3

Seal Kit No.

RC411-71380

Canopy ←

512.5

527.5 857.5

RC718-6750

RC718-67901

Piston tightning torque

N·m kgf·m ft·lbf

932 95.0 687

←

Piston screw size

mm in.

M36 × 2

←

Width for tightning by spanner

mm in.

55 2.17

←

IV-S-16

U35 (KTC, KCL), U35-3 (KTA) Unit

KX91-3

Remarks Cab

Arm

Bucket

Swing

Dozer

Canopy

Tube I.D. × Rod O.D.

mm in.

φ75 × φ45 φ2.95 × φ1.77

←

Stroke

mm in.

583.5 23.0

←

Max.retraction length

mm in.

896.5 35.3

←

RC411-71530

←

Piston tightning torque

N·m kgf·m ft·lbf

1079 110.0 796

←

Piston screw size

mm in.

M33 × 2

←

Width for tightning by spanner

mm in.

50 1.97

←

Tube I.D. × Rod O.D.

mm in.

φ65 × φ40 φ2.56 × φ1.57

←

Stroke

mm in.

467 18.4

←

Max.retraction length

mm in.

774.5 30.5

←

RC411-71760

←

Seal Kit No.

Seal Kit No. Piston tightning torque

N·m kgf·m ft·lbf

637 65.0 470

←

Piston screw size

mm in.

M30 × 1.5

←

Width for tightning by spanner

mm in.

50 1.97

←

Tube I.D. × Rod O.D.

mm in.

φ80 × φ40 φ3.15 × φ1.57

←

Stroke

mm in.

408.5 16.1

←

Max.retraction length

mm in.

692.5 27.3

←

RC601-75260

←

Piston tightning torque

N·m kgf·m ft·lbf

784 79.9 578

←

Piston screw size

mm in.

M30 × 1.5

←

Width for tightning by spanner

mm in.

50 1.97

←

Tube I.D. × Rod O.D.

mm in.

φ90 × φ45 φ3.54 × φ1.77

←

Stroke

mm in.

154 6.1

←

Max.retraction length

mm in.

492 19.4

←

Seal Kit No.

RP401-71150

←

Piston tightning torque

N·m kgf·m ft·lbf

932 95.0 687

←

Piston screw size

mm in.

M36 × 2

←

Width for tightning by spanner

mm in.

55 2.17

←

Seal Kit No.

IV-S-17

d. Swivel Performance (1) KE, KDG, KUK version Manufacturer

KX91-3

KX101-3

U35-3

KAYABA&T/B

←

Model

Remarks

Capacity

cc/rev

296.0

←

Brake valve pressure

Mpa kg/cm2

16.7 170.3

20.2 206.0

←

Drain amount

l/min

40 > =

←

l/min

0.5 > =

←

Swivel speed

rpm

8.9

←

8.0 ~ 9.8 rpm

3 times rotation swivel speed

sec

20.2

21.3

←

22.5 ~ 18.4 sec

mm/min

←

mm/min

←

Capable swivel rotation angle

deg.

←

Play at the tip of bucket

24.0

28.0

←

KX91-3

U35, U35-3

Manufacturer

Kubota

←

Model

SM29G

←

Drain amount

Swivel block engine stop

at lock while rotating

performance

Swivel block performance engine running

Reference value

(2) KTC, KCL, KTA version Remarks

U35 : RC511-6190U

Capacity

cc/rev in3/rev

289.8 17.7

←

Brake valve pressure

Mpa kg/cm2 psi

16.7 170.3 2422

20.1 205 2916

Drain amount

at lock

l/min gal/min

4> = 1.06 > =

←

Drain amount

while rotating

l/min gal/min rpm

0.5 > = 0.13 > = 8.9

9.0

8.1 ~ 9.9 rpm 18.2 ~ 22.2

Swivel speed 3 times rotation swivel speed

←

sec

20.2

20.0

performance

mm/min in/min

6 0.24

5> 0.20>

Swivel block performance engine running

mm/min in/min

30 1.18

30> 1.18>

Capable swivel rotation angle

deg.

15<

Play at the tip of bucket

mm in.

24.0 0.94

35 1.38

N·m (kgf·m)

20.1 205

←

Swivel block engine stop

Brake torque (Negative brake)

IV-S-18

Reference value

e. Traveling Performance (1) KE, KDG, KUK version KX91-3 Manufacturer Model

KX101-3

U35-3

KAYABA + T/B

←

702CKSP-MAG18V

←

Capacity

cc/rev

←

Relief valve pressure

Mpa kg/cm2

24.7 252

←

Climbing ability

deg.

←

N kgf

27.1 2766

N kgf

15.2 1546

Max. traction force

Remarks

Reference value

Allowable value of new machine Testing angle : 20deg

mm/10min

300

←

km/h

3.0

←

R2.7 ~ 3.3

I2.6 ~ 3.2

km/h

4.6

←

4.1 ~ 5.1

←

sec./10m sec./32.8ft

10.9 ~ 13.3

←

10.9 ~ 13.3

11.3 ~ 13.8

sec./10m sec./32.8ft

7.1 ~ 8.8

←

7.1 ~ 8.8

←

Crawler rotation speed

1F 2F

sec/ 1 rev

4.8 3.2

5.2 3.4

Straight travel performance

1,2F

mm/10mm

> 600 =

←

l/min

> 4=

←

l/min

> 4=

←

l/min

> 0.5 =

←

l/min

> 0.5 =

←

Traveling block performance

Traveling speed

10m traveling time

Drain amount at lock

Drain amount while rotating

IV-S-19

←

Reference value

(2) KTC, KCL, KTA version KX91-3

U35(KTC, KCL) U35-3(KTA)

Manufacturer

Kubota

←

Model

WM18NL

←

U35 : RC411-6180U

Capacity

cc/rev in3/rev

18 1.10

←

Relief valve pressure

Mpa kg/cm2 psi

24.5 250 3553

←

Climbing ability

deg.

←

kN kgf lbf

24.9 2543 5605

27.1 2766 6098

kN kgf lbf

15.2 1550 3417

15.2 1546 3408

mm/10min ft/10min

300 1

←

km/h mph

3.0 1.88

R 3.0 1.86

I 2.9 1.80

km/h mph

4.8 3.0

4.6 2.86

←

sec./10m sec./32.8ft

10.9 ~ 13.3

11.3 ~ 13.8

sec./10m sec./32.8ft

6.8 ~ 8.4

Crawler rotation speed

1F 2F

sec/ 1 rev

4.8 3.1

Straight travel performance

1,2F

mm/10m ft/32.8ft

> 600 = > 1.97 =

←

l/min gal/min

> 4= > 1.06 =

←

l/min gal/min

> 4= > 1.06 =

←

l/min gal/min

> 0.5 = > 0.13 =

←

l/min gal/min

> 0.5 = > 0.13 =

←

Max. traction force

Traveling block performance

Traveling speed

10m traveling time

Drain amount at lock

Drain amount while rotating

Remarks

at bench set value

Reference value

Allowable value of new machine Testing angle : 20deg

Reference value

IV-S-20

7.0 ~ 8.8

7.0 ~ 8.8 Reference value

Reference value

C.Testing a. Testing Instruments & special tools (1) Gauges and special tools for pressure testing 1. Pressure hose 2. Pressure gauge; 2.94 MPa, 30kgf/cm2, 427 psi For Secondary pilot pressure test. 3. Pressure gauge; 5.88 MPa, 60kgf/cm2, 853psi For primary pilot pressure test. 4. Pressure gauge; 64.3 MPa, 350kgf/cm2, 4978psi For main relief pressure and overload relief pressure test. 5. Pipe joint (S, F2 - F2) code No.: 69181-63191 6. Pressure test plug; PT 1/8 7. Allen wrench; M5 8. Plug; PT 1/8 Code No.: 68311-13381 9. Wrench; Size 17 - 19 mm

IV-S-21

(2) Flow meter and special tools for flow testing 1. Flow meter; Flowtech Inc. make 2. Loading handle 3. Male-female joint 1” × 1” 4. joint 1” × 1/2” 5. Hose 1/2” 6. O-ring

Drawing of (3) Male - female joint 1” × 1”

IV-S-22

b. Pump flow 1 2 3, 4. 5. 6. 7.

Connect the tester to the pump discharge side. Be careful not to connect the wrong port. Open the loading valve of the tester to start the engine. Increase the engine speed to the maximum speed. While slowly closing the loading valve, apply the rated load pressure (test pressure) to the pump. Measure the discharge and pump rpm (engine rpm). Calculate the volumetric efficiency and judge the usability of the pump. Perform steps 1 to 6 above for each pump.

[Procedure for Pump Performance Test] The pump performance test proceeds as follows: apply the specified hydraulic load to the pump discharge side, measure the discharge at the specified revolutions, and determine the volumetric efficiency. Volumetric efficiency

Discharge at the rated load ×100 (%) Theoretical discharge

[Caution] 1. The volumetric efficiency of the pump is proportional to its revolutions and is inversely proportional to the load pressure. The test should therefore be made with the engie revolutions increased to a maximum. 2. The volumetric efficiency is the ratio of theoretical discharge (Calculated value) to discharge per revolution of pump (c.c./rev) with the rated load. The rated load shall be the main relief setting pressure. 3. Because the pump revolutions are usually decreased, be sure to convert the measured value of discharge with the rated load into rpm. Discharge at the rated load = (cc/rev)

Measured discharge (l/min) × 1000 Measured pump speed

4. The criterion for judging pump performance shall satisfy the standards of volumetric coefficiency. 5. Hydraulic oil temperature must be 50 ± 5°F, 122 ± 8°F. (1) Tank (2) Pump (3) Tester (4) Control valve

IV-S-23

c. Pilot pressure (1) Primary pressure • Measurement method

1. Remove the side cover of the tank. 2. Set a pressure gauge to the measuring port. 3. Start the engine and run it at the maximum speed. Take 2 or 3 measurements to have an exact reading. 4. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F. KE, KDG, KUK version Reference Value

4.31 ± 0.3 MPa 44 ± 3 kgf/cm2

Measurement port

KTC, KCL, KTA version Reference Value

Measurement port

KTC, KCL, KTA version

IV-S-24

4.1 ± 0.3 MPa 42 ± 3 kgf/cm2 600 ± 43 psi

(2) Secondary pressure • Measurement method

[Ex: Measurement with the arm crowd] 1. Remove the side cover of the tank. 2. Connect a T joint to the arrow-marked point and set the pressure gauge there. 3. Start the engine and run it at the maximum speed. Take 2 or 3 measurements to have an exact reading. 4. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F. KE, KDG, KUK version Reference Value

2.6 ± 0.2 MPa 27 ± 2 kgf/cm2

T joint setting port

KE, KDG, KUK version KTC, KCL, KTA version Reference Value

T joint setting port

KTC, KCL, KTA version IV-S-25

2.6 ± 0.2 MPa 27 ± 2 kgf/cm2 385 ± 30 psi

d. Main relief valve • Measurement method

1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there. 2. Start the engine and run it at the maximum speed. Get the following main relief valves activated. P1: Bucket movement P2: Arm movement P3: Swing and dozer movement 3. Take 2 or 3 measurements for each of P1, P2 and P3 to have their respective exact readings. 4. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F.

(1)KE, KDG, KUK version U35-3 KE, KDG, KUK version

P1 Reference Value

25.0 ± 0.5 MPa 255 ± 5 kgf/cm2

P3 20.3 ± 0.5 MPa 207 ± 5 kgf/cm2

(2)KTC, KCL, KTA version U35(KTC, KCL), U35-3(KTA) P3

U35 U35-3

25.0 ± 0.5 MPa 255 ± 5 kgf/cm2 3627 ± 70 psi

20.3 ± 0.5 MPa 207 ± 5 kgf/cm2 2944 ± 70 psi

KX91-3

24.0 ± 0.5 MPa 245 ± 5 kgf/cm2 3485 ± 70 psi

20.6 ± 0.5 MPa 210 ± 5 kgf/cm2 2987 ± 70 psi

KTC, KCL, KTA version

IV-S-26

• Location of the Main relief valve

• Adjustment of the relief valve 1. Loosen the lock nut of the relief valve. Using a hex wrench, turn the adjusting screw to reach the specified setting. Then tighten up the lock nut. Clockwise turn raises the pressure, and counterclockwise turn lowers it. 2. Run the engine at the maximum speed. Move the levers and make sure the pressure setting.

IV-S-27

e. Overload relief valve • Measurement method

1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there. 2. Raise the pressure setting of the main relief valve about 0.98 MPa (10 kgf/cm2, 142 psi) over that of the overload relief valve. P1 discharge [Boom up/down, Bucket dump/crowd] P2 discharge [Arm dump/crowd, Auxiliary port] P3 discharge [Dozer down] 3. Run the engine at the speed of 1500 rpm. Move the levers to get the overload relief valve activated. Measure the pressure setting. 4. Take 2 or 3 measurements to have the exact reading.

KE, KDG, KUK version

As for the pressure value, refer to page IV-S-11~12.

KTC, KCL, KTA version

IV-S-28

• Location of the overload relief valve

• Adjustment of the overload relief valve 1. Loosen the lock nut of the overload relief valve. Using a hex wrench, turn the adjusting screw to reach the specified setting. Then tighten up the lock nut. 2. Run the engine at the maximum speed. Move the levers and make sure the pressure setting.

IV-S-29

f. Swivel brake valve pressure • Measurement method

1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there. 2. Bring the bucket in contact with a solid block. Slowly move the bucket toward the block. With the engine at 1500 rpm, measure the relief pressure. 3. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F.

KE, KDG, KUK version

KTC, KCL, KTA version

IV-S-30

• Adjustment of the brake 1. Loosen the lock nut of the relief valve. 2. Using a hex wrench, turn the adjusting screw to reach the specified setting. Then tighten up the lock nut. 3. Run the engine at 1500rpm. Move the levers and feel the pressure setting. 4. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F.

KE, KDG, KUK version

IV-S-31

g. Traveling motor drain amount 1. Disconnect the drain hose from the travel motor and connect another hose (the pressure gauge hose will do) where the drain hose was disconnected. 2. Float the crawlers as shown as below. 3. Run the engine one minute at max. rpm with the lever in the forward position and measure the amount of hydraulic oil in the pan. 4. If the measurement exceeds the specification, determine the cause and replace the assembly. 5. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F. Reference value : Drain amount at lock, 1F, 2F 4LPM > = (1.06 GPM > =) Drain amount while rotating, 1F, 2F 0.5LPM > = (0.13 GPM > =)

Never place your body under the crawler.

IV-S-32

h. Swivel motor drain amount 1. Remove right side cover. 2. Locate front attachment to traveling position. Bucket should be located 1 m above from ground. 3. Remove drain hose of the swivel motor and recieve drain oil in a suitable reservoir. 4. Swivel the machine one minute at max. engine rpm and measure amount of hydraulic oil in the reservoir. Make sure nobody is around swivel radius area. Reference value : Drain amount at lock:4 LPM > =(1.06 GPM > =) > Drain amount while rotating:0.5LPM =(0.13 GPM > =)

IV-S-33

i. Swivel motor block performance 1. Locate the machine on the 20 deg. slope. 2. The front position is of arm dump and bucket crowd. Keep the boom so that the boom end pin is alignedwith the bucket pin. 3. Mark the outer ring of swivel bearing and truck frame. 4. Unlock the safety lock lever, and measure the one minute shifting distance between them with engine idling rpm. 5. Load on the bucket should be as follows. KX91-3: 280 kg - include bucket weight (620 lbs) KX101-3: 285 kg - include bucket weight (630 lbs) U35, U35-3: 250kg(550 lbs) Include bucket weight Reference value : at engine stop : 5mm/min (0.20inch/min) at engine run : 30mm/min (1.18inch/min) 6. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F.

IV-S-34

j. Traveling motor block performance 1. Park the machine on a 20deg. slope. Keep front at traveling position. 2. Put marks on the truck frame and the crawler. 3. Measure 10 minutes slip-distance without engine running. 4. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 8°F. Reference Value

IV-S-35

300mm/10min 1ft/10min

k. Operating speed (1) Checking each operating speed. [Important points] 1. Measure full stroke operating time with no load on the standard bucket. 2. Make several mesurement and use average time for judgement. 3. Two different measurements are expected for the forward and backward movements as well as the right and left swivelings. Obtain their respective measurements. Do not calculate for their average. 4. Before operation, make sure nobody is around the machine.

[Measurement conditions] 1. 2. 3. 4.

Engine rpm is max.. Hydraulic temperature is 50 ± 5°C, 122 ± 8°F. Ground is flat. Measure time after several pre-operation.

(2) Boom cylinder 1. Arm and bucket cylinder shouls be most shorted position. 2. Measure the time from the bucket is on the ground to the boom highest position, and from the boom highest position to the ground. Note:The cushioning time is not included.

Reference Value

U35 U35-3(KTA) U35-3(EU)

Up Down Up Down

2.1 ~ 2.7sec 2.7 ~ 3.3sec 2.2 ~ 2.8sec 2.8 ~ 3.4sec

(3) Arm cylinder 1. Position the boom and arm as showm at left. 2. Measure the arm cylinder full stroke operating time.

Reference Value

IV-S-36

U35 U35-3(KTA) U35-3 U35-3(EU)

Crowd Dump Crowd Dump

2.8 ~ 3.4sec 2.4 ~ 3.0sec 3.0 ~ 3.6sec 2.5 ~ 3.1sec

(4) Bucket cylinder 1. Position the boom and arm as showm at left. 2. Measure the bucket cylinder full stroke operating time.

Reference Value

U35 U35-3(KTA) U35-3(EU)

Crowd Dump Crowd Dump

2.3 ~ 2.9sec 1.4 ~ 2.0sec 2.4 ~ 3.0sec 1.6 ~ 2.3sec

(5) Swing cylinder 1. Position the boom, arm and bucket as showm at left. (with the bottom of the bucket about 1 m (33 ft) above from the ground.) 2. Measure the swing cylinder full stroke operating time. (right to left and left to right)

Reference Value

U35 U35-3(KTA) U35-3(EU)

Left Right Left Right

5.5 ~ 6.1sec 4.3 ~ 4.9sec 5.6 ~ 6.2sec 5.6 ~ 6.2sec

(6) Dozer cylinder 1. Place the bucket on the ground. Position the machine as shown at left for the dozer to make a full stroke. 2. Measure the dozer cylinder full stroke operating time.

Reference Value

IV-S-37

U35 U35-3(KTA) U35-3(EU)

Up Down Up Down

1.9 ~ 2.5sec 2.6 ~ 3.2sec 1.8 ~ 2.4sec 2.6 ~ 3.1sec

(7) Swivel speed 1. Position the boom, arm and bucket as showm at left. 2. Measure three times rotation time. 3 times Reference Value

U35 U35-3(KTA) U35-3(EU)

18.2 ~ 22.2 18.4 ~ 22.5

(8) Traveling speed 1. Travel the machine untill getting max. speed. 2. After getting max. speed, measure the 10 m (33 ft) traveling time.

Reference Value

U35 U35-3(KTA) U35-3(EU)

1F 2F 1F 2F

Rubber track

Iron track

10.9~13.3 7.0~8.8 10.9~13.3 7.1~8.8

11.3 ~ 13.8 7.0 ~ 8.8 11.3 ~ 13.8 7.1 ~ 8.8

l. Straight travel performance 1. Travel the machine untill getting max. speed. 2. Measure the vertical distance from the traveling line. Reference Value

IV-S-38

Under 600 mm/10 m (22.6 in/33 ft)

m.Cylinder natural fall amount 1. Locate the machine on the flat ground, and put the load the bucket. Load on the bucket should be as follows. U35, U35-3KX101-3:285 kg - include bucket weight 2. Arm cylinder must be fully retracted. Bucket cylinder must be fully extended. 3. Locate the bottom of bracket about 1 m above from the ground. Stop the engine. 4. Mark on the rod of each cylinder. 5. Measure the fall distance after 10 min.

Reference Value

See item III.B.c.(2)

n. Control and Traveling lever operating force 1. Stop the engine. 2. Measure force of right and left control and traveling levers. 3. Start the engine, operate the control lever or traveling lever for a full stroke, and measure the max. operating force. 4. Make three measurements and take their average. 5. Hydraulic oil tempreture must be 50 ± 5°C, 122 ± 9°F. Reference Value

See item II.c

o. Lever stroke 1. Stop the engine. 2. Move each lever from neutral to full stroke end, and measure each stroke with respect to the top center of the each lever glip. 3. If any lever is loose at its neutral position, measure the stroke from each loose end. 4. Make three measurements and take their average. Reference Value

IV-S-39

See item II.c

D.Disassembling and assembling e. Swivel motor (KTC, KCL, KTA-version) 1. Installing of swivel motor Tightening torque 116.7 ~ 196.1 N·m (17.0 ~ 20.0 kgf·m) Apply screw lock tight(Locktight271)

3. Adapter tightening torque 1/4 : 25.4 ~ 29.4 N·m (2.5 ~ 3.0 kgf·m) 3/8 : 49.1 ~ 53.9 N·m (5.0 ~ 5.5 kgf·m) 1/4 taper screw : 19.6 ~ 29.4 N·m (2.0 ~ 3.0 kgf·m)

2. Installing angle of adapter See Fig. (1) Travel lock cylinder (2) Pilot valve, Left P port

(3) Change valve (4) Pilot valve, Right P port

(5) Bolt

(6) Control valve Swivel, L

(7) Control valve Swivel, R (8) Hydraulic tank (9) Adapter(G4-13) (10) Return pipe

(14) Adapter(cross, G1/4) O-ring

(11) Adapter O-ring (12) Adapter(filter) O-ring

(13) Filter O-ring 15

(15) Hose shouldn’t be twisted and go over Hi-Low change hose.

(1) Travel lock cylinder (2) Pilot valve, Left (3) Change valve (4) Pilot valve, Right (5) Bolt (6) Control valve Swivel, L (7) Control valve

Swivel, R (8) Hydraulic tank (9) Adapter(G4-13) (10) Return pipe (11) Adapter O-ring (12) Adapter(filter) O-ring IV-S-40

(13) Filter O-ring (14) Adapter(cross, G1/4) O-ring (15)Hose shouldn't be twisted and go over Hi-Low change hose.

g. Rotary joint (1) Inner parts of the rotary joint

010

Assy joint, Swivel

070

Circlip, Internal

130

Stay

020

Gasket

080

O-ring

140

Bolt

030

Gasket

090

Cover

150

Bolt

040

Shaft, Swivel joint

100

Circlip, Internal

160

Stopper

050

Collar

110

Plug

170

Bolt

060

Collar

120

Plug

180

Washer, Spring

IV-S-41

(2) Assembling of the rotary joint Plug (PT 1/8)

Outside

Plug (PT 1/4)

Rip

Enlarged Drawing

Bolt (1)

Shaft (Swivel joint) Bolt (3) Coller (Swivel joint) Packing (1)

(Rightside of machine)

Body (Swivel joint) Packing (2)

(Blade side)

Coller (Swivel joint) Stay (Swivel joint)

Circlip O-ring Circlip Cover

Bolt (2)

1. Place the packing (1) with its lip in the arrow direction, as shown above. Apply grease over the inner and outer surfaces of the packing (1) beforehand. 2. Apply grease over the inner and outer surfaces of the packing (2) beforehand. 3. Apply screw adhesive (Three Bond #1324) to the bolt (1). 4. Apply screw adhesive (Three Bond #1324) to the bolt (2). Bolt tightening torque: 77.5 ~ 90.2 N·m 7.9 ~ 9.2 kg·m 57.2 ~ 66.5 ft·lbf 5. Apply screw adhesive to the bolt (3). 166.7 ~ 196.1 N·m 17.0 ~ 20.0 kg·m 123.0 ~ 144.6 ft·lbf IV-S-42

(3) Rotary joint seal installing procedure 1) Place the seal in the jig.

2) Using the fixing bar, bend down the seal as shown in the photo.

3) Insert the jig with seal and align the groove. Using the fixing bar, preperly place to fit the seal in the groove of the rotary joint body.

4) (When removing the seal:) Using the picing bar, take out the seal. Do not reuse the old seal again.

IV-S-43

(4) Jig picture

Jig body Fixing jig Picking jig

IV-S-44

(5) Jig drawing

IV-S-45

(6) Adaptor installation on the rotary joint (KTC, KCL, KTA version)

Machine front

All adapters except D, G, F, dr are to be Adapter installed upward

Adapter(L, G1/4-G1/4) O-ring

D(L, F)

A(Hi-speed)

C(Dozer up)

Left side

B(Dozer down) Adapter(L, G3/8-G3/8) O-ring

Right side E(R, F)

121 F(L, R)

G(Travel R, R) dr(Drain)

Adapter(L1/2, 3/4UNF) O-ring

20 30

Machine rear Place the shaft with the port A in the arrow direction.

(Drain port)

(Body)

(Shaft) Adaptor (Bussing)

(Drain port)

Adaptor (G4-13)

Adaptor(L, G1/4-G1/4)

Adaptor (L, G3/8-G3/8) (Hose, gooseneck angle) Adaptor (Hose, gooseneck angle Horizontal direction) Adaptor (Horizontal direction) (G4-13)

Adaptor

(Hose, gooseneck)

Adaptor (Hose, gooseneck 10°upward)

Note: The adaptors at the ports D, E, F and G are unified-threaded. Tighten these adaptors to the torque of 44.1 ~ 53.9 N·m, 4.5 ~ 5.5 kgf·m, 32.5 ~ 39.8 ft·lbf.

IV-S-46

h. Cylinder (EU-version) (3) Disassembling and assembling : EU-version 1)Proceeding Disassembly and Reassembly of BOOM-Cylinders. (EX. Boom Cylinder) DISASSEMBLY Place the cylinder into a vise fitted out with soft jaws. Clamp moderately to avoid deformations of the cylinder tube. Buckle out the collar of the notch and unscrew the cylinder head (mark26) with the help of a hook wrench. When the cylinder head is mounted with glue (never on first mounting) and difficult to unscrew, you have to warm up the cylinder head about 250°C. Prefer a pistol pipe oven instead of a blowpipe. Unscrew completely the cylinder head and take out carefully the kit cylinder rod. CONTROL Make a visual control of the whole cylinder. Degrease and clean up the inside of the cylinder tube. Be sure that the inside is free of technical pollution like oxidation or stripes.

REASSEMBLY Apply hydraulic oil on the piston seals with a paint brush. Move the kit cylinder rod 2/3 of his length into the cylinder tube (mark34). ← Assure a well alignement to the axe of the cylinder tube. Apply hydraulic oil on cylinder head seals and engage the cylinder head . ← Be sure that the seals are not degraded when you engage the cylinder head into the locked zone. Block it up with the tightening torque mentioned on drawing. Save the cylinder head by buckling the collar in one notch. Enter the whole rod to abutment. PRECAUTIONS • Use only non-agressive solvants like AXETHANE 212, cold degreaser. • Try to protect all openings and components when not in use. • If possible, test the cylinder before mounting on machine.

IV-S-47

2)Proceeding Disassembly Reassembly Kit Boom-Cylinder Rod (EX. Boom Cylinder) DISASSEMBLY Place the kit cylinder rod into a vise fitted out with soft jaws to protect the surface and to avoid turnability. Take off the locking screw (mark6) and unscrew completely the piston (mark8) with the help of a hook wrench. Take off the piston seals (mark 7/9/10). Take care about grooves and chamfers. Take off the distance tube (mark2) and the damping ring (mark1). Remove the cylinder head (mark26) ring from the back to avoid seals' damaging. Take off the seals from the cylinder head (mark12/13/14/ 15/16). CONTROL Degrease and clean up piston and cylinder head. Grooves, chamfers and fronts must be without damages. Be sure that there are no coarse dust particles in the grooves and insides. Control every seal and change if necessary. Control the surface eveness with the help of a comparator. Check the absence of mechanical spalling and pollution. REASSEMBLY Grease all internal seals with hydraulic oil. The cylinder head must be mounted from the back to the cylinder rod. Assemble the piston on the cylinder rod. Use the tightening torque mentionned on drawing. Place the locking screw (mark6) with one drop of glue and give a blow of the tap next (2mm) to the entree of the internal screw thread to lock.

IV-S-48

Cylinder ; EU-version

IV-S-49

j. Hoses

(21) Blue

(17) Backet (19) Peach

(16) Boom up (18) Light blue

(15) Boom down

(14) Travel, R

(13) Inlet

(12) Travel, L

(11) Arm

45 (10) Service

(9) Travel straight

(8) Dozer

(7) Swing

(1) Yellow (2) Green (3) Gray (4) Brown (5) All other hoses should have same bending radius with this hose. (6) Swivel (7) Swing (8) Dozer (9) Travel straight (10) Service (11) Arm (12) Travel, L (13) Inlet (14) Travel, R (15) Boom down (16) Boom up (17) Backet (18) Light blue (19) Peach (20) Red (21) Blue

(4) Brown

(3) Gray

(2) Green

(1) Yellow

(6) Swivel

(5) All other hoses should have same bending radius with this hose.

(20) Red

(1) Pilot hose(1)

IV-S-50

(2) Pilot hose(2)

(1) Hose outlet of port P, T, boom, arm, total 8 pieces.

(1) Hose outlet of port P, T, boom, arm, total 8 pieces. (2) Outlet of bucket and swivel (port2, 4) (3) (L & R 4 pieces) (4) Code band (5) Code band

(2) Outlet of bucket and swivel (port2, 4) (3) (L & R 4 pieces) (4) Code band

(5) Code band

Pilot valve (L) 1 2 3 4 P T

Swivel, L Arm dump Swivel, R Arm crowd “P” port “T” port

Red Blue Yellow Green White No

Pilot valve (R) Bucket crowd Buum down Bucket dump Boom up “P” port “T” port

Peach L. Blue Brown Gray White No

IV-S-51

(1) White tape Bind here

Clamping method of pilot hose, L

(2) Align the coupler ends

(8) Pilot valve (L) Arm dump

(7) Pilot valve (L) Arm crowd

(6) Pilot valve (L) Swivel (R)

(5) Pilot valve (L) Swivel (L)

(4) Pilot valve (L) T port

(3) Pilot valve (L) P port

(3) Pilot hose(3)

IV-S-52

(1) White tape Bind here (2) Align the coupler ends (3) Pilot valve (L) P port (4) Pilot valve (L) T port (5) Pilot valve (L) Swivel (L) (6) Pilot valve (L) Swivel (R) (7) Pilot valve (L) Arm crowd (8) Pilot valve (L) Arm dump

V. Electrical system(Mechanism section) A. Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Refer to WSM of KX91-3, 101-3 B. Components & harness layout. . . . . . . . . . . . . . . . .Refer to WSM of KX91-3, 101-3 C. Couplers, KX91-3, 101-3 Standard version . . . . . .Refer to WSM of KX91-3, 101-3 D. Function of main circuit . . . . . . . . . . . . . . . . . . . . . .Refer to WSM of KX91-3, 101-3 a. Battery circuit (Standard-version) b. Safty Relay circuit (Automatic release function) Standard-version c. Auto glow circuit (Standard-version) d. Fuel control circuit (STD, AI-version) e. Engine oil pressure sensor circuit (STD, AI-version) f. Horn circuit (STD, AI-version) g. Cab & Working lamp circuit (STD, AI-version) h. Meter panel (Standard-version) i. Heater circuit (STD, AI-version) j. Travel hi-speed control circuit (STD, AI-version) k. Auto idle control system (AI-version) l. Battery direct line (AI-version) m. Starter lock relay & auto release relay (AI-version) n. Self holding relay circuit (AI-version) o. Water temp. sensor circuit (AI-version) p. Meter panel (AI-version) q. AI controller unit (AI-version)

E. Structure and function of main components . . . . . .Refer to WSM of KX91-3, 101-3 a. b. c. d. e. f. g. h.

Key switch (Engine starter switch) Water temp. sensor Safty lever lock switch, travel hi-low pedal switch Relay Engine speed sensor Accel sensor, governor sensor AI pressure switch Foundamentals

F. Circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-3 a. b. c. d.

Components and harness layout : U35, U35-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-3 Electric Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-5 Electric wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-9 Couplers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-M-13

V-M-1

V-M-2

F. Circuit diagram a. Components and harness layout : U35, U35-3 (Non-AI-version)

WATER TEMP. SENSOR (AUTO GLOW)

WATER TEMP. SENSOR (METER)

METER PANEL HORN SWITCH

LEVER LOCK (COUPLER TAPE) WORK LAMP CIGAR SWITCH SOLENOID HORN RELAY (B,B) LIGHTER TRAVEL HI-LOW KEY LIGHT RELAY (B,Y) SOLENOID SWITCH HEATER CHECK RELAY (B,R) Y SWITCH G CAB RELAY (B,Br) ENGINE SPEED SENSOR ENGINE STOP SOLENOID

HEATER RELAY LEVER LOCK SWITCH

LEVER LOCK SWITCH

STARTER LOCK RELAY (L,L) GLOW RELAY FUSE BOX ENGINE OIL SWITCH ALTERNATOR SLOW BLOW STARTER FUSE (60A) MOTOR

CAB +B CON. CAB GND CON.

FUEL PUMP

WORK LAMP

FUEL SENSOR SAFETY CONTROLLER BATTERY

AUTO GLOW UNIT POWER OUTLET

HORN

SLOW BLOW FUSE (50A) TRAVEL HI-LOW SWITCH V-M-3

b. Electric Circuit Diagram AI-version

V-M-5

Non-AI-version

V-M-6

c. Electric wiring Diagram AI-version

V-M-7

Non-AI-version

V-M-8

d. Couplers AI-version

V-M-9

Non-AI-version

V-M-10

V. Electrical system(Service section) A. Electrical Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-3 B. Wire harness installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-6 a. b. c. d. e. f. g.

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-6 Engine earth, starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-7 Main harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-9 Coupler insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-10 Control box harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-11 Engine harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-12 Front harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-13

C. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-15 a. b. c. d. e. f.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-15 Troubleshooting flow chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-24 Front attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-29 Engine electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-31 Auto idle system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-42 AI version: AI controller (built-in microcomputer) Cases of trouble diagnosis with circuit tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-52 g. Cases of trouble diagnosis with circuit tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-S-55 h. Auto Idle(AI) version: Trouble diagnosis with lamp . . . . . . . . . . . . . . . . . . . . . . . . V-S-56

V-S-1

V-S-2

A.Electrical Equipment Specifications Fig. Battery

Alternator

Starter motor

Item Part No. Capacity (5 hr) Type Dimensions (L × W × H) (mm) Electrolyte specific gravity (20 °C) Cold cranking ampere Amount of electrolyte Weight Part No. Type B terminal tightening torque, M6 Nominal voltage Max. output Rotating direction Allowable load at L terminal Regulator control voltage Weight Part No. Type Nominal voltage Nominal output Time rating Rotating direction No load ltest Load test

Glow plug

No. of pinion gear Part No. Type Resistance Tightening torque

Oil switch

Thermostat unit

KX91-3, 101-3, U35, U35-3 RC411-53250 (KBM:RG511-53250) 55 Ah 80D26R 256 × 169 × 223 1.28 ± 0.01 4.5 l (1.19 us gal) 18 ug (40 lbs) T1060-15603 IC regulator built-in type 1.8 N·m (80 kgf·m) 579 ft·lbs 12 V 40 A (5000 rpm) at 13.5 V Clockwise viewed from pulling side lamp 12 V : 3.4 W × 6 14.2 ~ 14.6 V 2.75 kg (6.06 lbs) RC411-53200 Reduction type 12 V 1.4 kW 30 seconds Clockwise, viewed from pinion end at 11.5 V, 90 A Max. : 3000 rpm Min. at 8.5 V and torque 13.24 N·m (1.35 kgf·m) : 350A Max. 8 16415-65510 Two materials coil 11.7 ± 0.2 Ω after 6 seconds at DC 11 V, 10 Ω at 20 °C Body : M10 × 1.25 : 20 ~ 25 N·m(2.0 ~ 2.5 kgf·m) Nut (M4 × 0.7) : 10 ~ 18 N·m(1.0 ~ 1.8 kgf·m)

Part No.

15531-39010

Operating pressure

0.5 ± 0.1 kgf/cm2, 490 HPa, 7.1 psi 0.45 V > at 0.3 A 1 MΩ < 5 W (lamp) N.C. 31351-3283-0 50 °C : 153.9 Ω 80 °C : 51.9 Ω 100 °C : 27.4 Ω

Voltage reduetion Insulation resistance Rated load Switch type Part No. Resistance Tightening torque

150 ± 30 kgf·cm

V-S-3

Remarks

Fig. Fuel unit

Horn

Fuel pump

Change valve

Item

KX91-3, 101-3, U35, U35-3

Part No. Sliding resistance value Sliding resistance value

RC417-51140

Part No. Current ampere Sound level

RD408-53360 (KBM : RG201-53360) 3±1A 113 ± 5 dB (A) at 2 m

Frequency

420 ± 30 Hz

Part No. Operating voltage range Max. operating ampere

RD411-51350 DC 8.5 ~ 16.5 V 1.5 A >

Full delivery amount at free flow

400 cm3/min <

Relief pressure setting

3.92 +0.2 MPa (40 +2 kgf/cm2) at 8.8 L/min 0 0 RD411-61250 11.1 ~ 13.5 Ω

Full : 3 ± 2, Half : 32.5, Empty : 110 ± 2 Ω

Part No. Unload valve coil resistance High-Low change valve coil resis11.1 ~ 13.5 Ω tance Part No. Pull-in coil resistance

10 LPM, 4.9 MPa (50 kgf/cm2) 1A021-60013 1.0 ~ 1.5 Ω

Hold coil resistance

16.0 ~ 18 Ω

Part No. Operating voltage Air gap (mm) Sensing frequency Output type

T1060-32270 DC 7 ~ 16 V 0.5~0.9 (0.7) 1 Hz ~ 7kHz Open collector VH = 4.8 V, VL = 0.8 V

Rated flow and pressure Engine stop solenoid

Engine speed sensor

Output voltage

Accel sensor

Gear RPM Part No. Electrical effective angle Mechanical effective angle Operating voltage Total resistance Insulation resistance Part No.

600 T1060-32280 110° ± 3° 120° ± 5° DC 5 V 2 kΩ ± 20 % 100 MΩ <

Part No.

T1063-65660 -20 °C : 18.8 ± 26 kΩ 40 °C : 1.1364 kΩ 100 °C : 0.1553 kΩ Thermistor type 17.7 ± 2.0 N·m (180 ± 20 kgf·cm)

Governor sensor

Thermo sensor

Temp. -Resistance Type Tightening torque

V-S-4

Remarks

Fig. Auto idle motor

Glow relay

Meter panel

Item Part No. Operating voltage range No load speed No load current Motor seized current Motor seized torque Reduction ratio Part No. Rated coil voltage and current Lowest operating voltage Return voltage Current capacity Part No. Tach meter Hour meter

Part No. Capacity Type

Halogen lamp

Part No.

T0270-75300

Part No. Operating voltage, ampere Continuity resistance Operating stroke Insulation Operating force at full stroke Switch type Part No. Glow time

RC411-53473 DC 14 V, 1.5 A 0.2 Ω 9 ± 0.5 mm 1 MΩ < 32 ± 4 N N.O. RC417-53790 -20 °C or line break : 12 seconds

Part No.

34673-86400

Part No. Starter release engine RPM

RC417-53700 850 ± 75 rpm (482 ± 42.5 Hz)

Starter re-entry engine RPM

255 rpm > (145 Hz >)

Part No. Switch type Part No.

N.C. (0.2 Ω) 69741-5351-0

Part No.

RG518-62601

Temp. gauge

Fuel gauge Work lamp (Boom)

Work light (Cab) Safety lock SW

Auto glow controller

Wiper motor Auto release controller

AI pressure switch Heater Unload valve

KX91-3, 101-3, U35, U35-3 RC411-53640 10 ~ 15 V 56 rpm > 3.7 A > 17.7 A > 4.51 N·m < , 46 kgf·cm < 1 : 65 RP421-53730 12 V, 0.19 ± 0.04 A (at 20 °C) 6V 1~5V 0.1 ~ 40 A RC417-53112 Cable 700 rpm → indicates 2600rpm Cable 30000 turns → indicates 1 hour 43.5 Ω → 85 °C 14.1 Ω → 125 °C 9.7 Ω → 140 °C 7 Ω → Full 32.5 Ω → Half 95 Ω → Empty 3G710-75910 55 W

AI controller

V-S-5

Remarks

B.Wire harness installation a. Precautions S

(1) No contact with the peripheral parts along the route Unprotected members not to be in contact

(2) Checking the routes 1. Fuel hose not to be clamped together 2. Couplers, terminals, etc. to be connected tight enough to withstand usual pulling force 3. Clamps to be surely folded

(3) Clamping the harness at the specified points 1. White-colored tapings to be clamped 2. Clamps to be surely folded 3. Harness-fixed clamps * Anchor-shaped clamps to be inserted deep to the stoppers * Threaded clamps to be inserted deep enough

(1) Taping

(3) Clamp

(2) Harness

(1) Taping (2) Harness (3) Clamp

1) The harness tapings indicate the clamping positions. Clamp at these specified points. 2) Clamp the harness tight enough not to come off nor get loose. 3) Insert the handgrip-equipped harness deep into their mating holes. * Do not allow the harness to come out of the corrugated slit. * Catch the cord clamp at the corrugated winding. must be based on a theory and be supported by facts and must not be based on intuition only. [1] Harness with band clips * Insert the band clips in their mating holes to clamp the harness. (4) Band clip

V-S-6

(5) Harness

(4) Band clip (5) Harness

b. Engine earth, starter switch S

(1) Tightening torque of the cable fixing nut to the sel-motor terminal Tightening torque 5.9 ~ 11.8 N·m (0.6 ~ 1.2 kgf·m)

(2) Installation of starter switch (RC411-5346U) 1. Starter switch groove to be fitted to the projection of the cover (top right) 2. Nut tightening torque 4.0 ~ 5.0 N·m (0.4 ~ 51 kgf·m)

(1) Projection (Back side)

(2) Cover (R, upper) RC417-4476U

(3) Checking the automatic starter release function Start the engine, place the key switch back to the start position and make sure the starter is not activated.

(3) Groove

(4) Starter switch (RC411-5346U)

(5) Oil switch (6) Starter assy (8) Oil switch (7) Starter, +

(9) Wire harness (10) Front (11) Battery cord (positive)

(12) Starter assy

(15) Bolt (VT, M8)

(14) Cord (Body earth)

(13) Battery cord (positive)

V-S-7

(1) Projection (Back side) (2) Cover (R, upper) (3) Groove (4) Starter switch (5) Oil switch (6) Starter assy (7) Starter, + (8) Oil switch (9) Wire harness (10) Front (11) Battery cord (positive) (12) Starter assy (13) Battery cord (positive) (14) Cord (Body earth) (15) Bolt (VT, M8)

V-S-8

c. Main harness Panel

Panel

Starter lock relay

Heater relay

Horn relay Refer to Fig. 1. Horn SW

Heater

Socket for canopy Check relay Horn SW

Refer to Fig. 1.

Lever lock relay Key SW

Lamp relay

To auto release controller

Cab relay

Light SW To auto glow controller

To work lamp Cab

Heater SW Work lamp

Refer to Fig. 2. Cab earth

Ciggar (Cab only) Diode (Horn)

Horn

Engine harness Slow blow fuse To auto release controller

Fuel harness Refer to Fig. 1.

Hi-Low SW

Glow relay

Main harness

Lever lock SW

Refer to Fig. 2.

Fuel pump

Refer to Fig. 4.

Fuel sensor

Battery cord (Earth)

(1) Wire harness (Main) (2) Wire harness (Work lamp) (3) Wire harness (Fuel lamp) (4) Wire harness (Engine) (5) Wire harness (Horn)

Refer to Fig. 3.

V-S-9

d. Coupler insertion S

(1) Coupler insertion To be tightly coupled Insert the coupler until it clicks. (If it does not click, try it again.) Then pull the harness gently to make sure it does not come off. (Pull with 29.7 N (3 kg) or less force.)

(1) Slow blow fuse

(2) To engine

(12) Water temp. sensor

[Fig.3]

(13) Glow plug

(3) Alternator

(4) Fun belt cover (5) Clamp (14) No bent

(6) Heater hose

(15) Metal clamp accompanying the alternator (16) Positioning clamp accompanying the harness (17) Pass in this direction.

[Fig.1]

(7) Ciggar lighter

[Fig.2]

[Fig.4] (18) Place the box with the fuse-out side upward.

(8) Heater SW

(11) Earth

(19) Fuse box

(10) Battery earth cord

(9) Work lamp SW

V-S-10

(1) Slow blow fuse (2) To engine (3) Alternator (4) Fun belt cover (5) Clamp (6) Heater hose (7) Ciggar lighter (8) Heater SW (9) Work lamp SW (10) Battery earth cord (11) Earth (12) Water temp. sensor (13) Glow plug (14) No bent (16) Positioning clamp accompanying the harness (17) Pass in this direction. (18) Place the box with the fuse-out side upward. (19) Fuse box

e. Control box harness [Fig. 1]

D view

C view Relay

Relay

Canopy (Work lamp)

Lamp

Cab (Room lamp)

(Front) Check

Green

Red

Yellow

Brown

Relay (PTO) Only for cab

Glow relay

Horn

Note : On the canopy type machine, couple the heater relay and the cigarette lighter harness with the speed clamp.

[Fig. 4]

[Fig. 2] F view

E view

C Socket assy

Auto release controller Insert the coupler in the clamp for the right-hand seat support.

Wire harness (Main)

Auto glow controller

Wire harness (Engine) Auto glow controller

Auto release controller

Horn switch wiring at the right of the operation mount Clamp the wires first and then move the lever in all directions to see if there is a finger-thick clearance. 200 mm up to the clamp

Crimp the end with a crimping tool.

V-S-11

Be sure to fix the main harness connector and the wiring clamp on the bracket.

f. Engine harness (19) Glow plug (20) Glow plug (21) Lever lock solenoid (lower side) (22) Hi-Low solenoid (upper) (23) Change valve (24) Oil SW (25) Glow Plug (26) Water temp. sensor (27) Starter

(10) Black (11) Green-White (12) Black (13) Engine speed sensor (14) Starter (15) Oil SW (16) Slow blow fuse (60A) (17) Alternator (18) Water temp. sensor

(1) Refer to Fig. 2 (2) Main harness (3) Main harness (4) Diode (5) Gromet (6) Hi-Low solenoid (7) Lever lock solenoid (8) Water temp. sensor (9) Yellow

(28) Alternator (29) Slow blow fuse (60A) (30) Engine speed sensor (31) Engine stop solenoid

[Fig. 1]

B (20) Glow plug (21) Lever lock solenoid (lower side) (22) Hi-Low solenoid (upper)

(6) Hi-Low solenoid (11) Green-White

(9) Yellow

(7) Lever lock solenoid (10) Black (4) Diode

(23) Change valve (12) Black (8) Water temp. sensor

(2) Main harness (24) Oil SW

A [Fig. 1] (5) Gromet

(27) Starter

(1) Refer to Fig. 2 (16) Slow blow fuse (60A) (17) Alternator

(3) Main harness

(25) Glow Plug (26) Water temp. sensor

[Fig. 2] D (28) Alternator

(13) Engine speed sensor

(14) Starter

(18) Water temp. sensor

(31) Engine stop solenoid

(30) Engine speed sensor D

(15) Oil SW (19) Glow plug

V-S-12

B [Fig. 1]

(29) Slow blow fuse (60A)

g. Front harness (1) Harness clamp at the light Pass this clamp between the SP pipe and the boom. (2) Push in the hole (3) The harnesses up to the terminals are different from each other. Slacken them near the light and keep the terminals in different positions. Then insert them into the box. (4) Clamp (5) Cord clamp (6) Clamp (7) Insert type (8) ClampInsert type (9) Insert (10)Clamp

(4) Clamp (5) Cord clamp

(6) Clamp (7) Insert type (1) Harness clamp at the light Pass this clamp between the SP pipe and the boom.

(8) Clamp Insert type

(2) Push in the hole (3) The harnesses up to the terminals are different from each other. Slacken them near the light and keep the terminals in different positions. Then insert them into the box.

(9) Insert

(10) Clamp

V-S-13

V-S-14

C.Troubleshooting a. General (1) How to diagnose The most important point in troubleshooting is to determine "Probable Causes". Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes. Therefore, unnecessary checks can be eliminated. The determination of the probable causes must be based on a theory and be supported by facts and must not be based on intuition only.

TROUBLESHOOTING STEPS If an attempt is made to solve a problem without going through correct steps for troubleshooting, the problem symptoms could become more complicated, resulting in failure to determine the causes correctly and making incorrect repairs.The four steps below should be followed in troubleshooting. Observation of Problem 1 Symptoms

Observe the symptom carefully. Check if there are also other problems.

Determination of Probable 2 Causes

In determining the probable causes, it is necessary to check the wiring diagram to understand the circuit as a system. Knowledge of switches, relays and other parts is necessary for accurate determination. The causes of similar problems in the past must be taken into account.

Checking of Parts Associated 3 with Probable Causes and Determination of Faulty Parts.

Troubleshooting is carried out by making step by step checks until the true cause is found. Always go through the procedures considering what check is to be made where for the best results.

Repair and Confirmation

After the problems are corrected, be sure to check that the system operates correctly. Also check that new problems have not been caused by the repair.

FOUR BASIC CHECKING ITEMS FOR ELECTRICAL DIAGNOSIS

1. 2.

3. 4.

This manual contains the cable diagrams as well as the individual circuit drawings, operational explanations, and troubleshooting hints for each component required to facilitate the task of troubleshooting. The information is compiled in the following manner: “Power source” Is the supply voltage as specified? (Battery voltage at 12 V or microcomputer output at 5 V) If not specified, the system fails to work. “Continuity” Is there continuity along the specified lines and wire harnesses? Are the system’s resistance values as specified? If not specified, no current flows. “Earth” Is the system completely grounded? If not grounded as specified, the electrical circuitry fails to function well. “Insulation” Are the system’s insulation resistances as specified? If an electric leak occurs, the current gets out of spec and the electrical devices malfunction. V-S-15

(2) INSPECTION OF HARNESS CONNECTOR CONTINUITY AND VOLTAGE TEST FOR CONNECTOR Following procedures shall be followed for testing continuity and voltage at connector in order to prevent improper contact and deterioration of waterproof in connector.

CONVENTIONAL (NON-WATERPROOF) CONNECTOR Check shall be done by inserting a probing needle from harness side.

WATER PROOF CONNECTOR Caution Do not insert probing needle from harness side as it will deteriorates waterproof and cause for rusting.

CHECK FOR IMPROPER ENGAGEMENT OF TERMINAL When terminal stopper of connector is out of order, engagement of male and female terminals becomes improper even when connector itself is engaged perfectly and terminal sometimes slips out to rear side of connector. Ascertain, therefore, that each terminal does not come off connector by pulling each harness wire.

ENGAGING AND DISENGAGING OF CONNECTOR TERMINAL Connector which gives loose engagement shall be rectified by removing female terminal from connector housing and raise its lance to establish securer engagement. Removal of connector housing and raise its lance to establish securer engagement. Removal of connector terminal used for control circuit shall be done in the following manner.

COMPUTER CONNECTOR (1) Insert screwdriver [1.4 mm (.06 in.) width] as shown in the figure, disengage front holder and remove it. (2) Insert harness of terminal to be rectified deep into connector from harness side and hold it there.

V-S-16

V-S-17

(3) Inspection 1) Visual and aural checks Check relay operation, blower motor rotation, light illumination, etc. visually or aurally. The flow of current is invisible but can be checked by the operation of the parts.

2)Simple checks For example, if a headlight does not come on and a faulty fuse or poor grounding is suspected, replace the fuse with a new one or ground the light to the body by a Jumper wire to determine which part is responsible for the problem.

3)Checking with instruments Use and appropriate instrument in an adequate range and read the indication correctly. You must have sufficient knowledge and experience to handle instruments correctly.

(4) INSPECTION INSTRUMENTS In inspection, make use of the following instruments. 1)Test lights A test light consists of a 12 V bulb and lead wires. It is used to check voltages or shortcircuits.

2)Self-power test light A self-power test light consists of bulb, battery and lead wires connected in series. it is used to check continuity or grounding.

V-S-18

3)Jumper wire A jumper wire is used to close an open circuit. Never use one to connect a power supply directly to a load.

4) Voltmeter A voltmeter is used to measure the circuit voltage.Normally, the positive (red lead) probe is applied to the point of voltage measurement and the negative (black lead) probe to the body ground.

5)Ohmmeter An ohmmeter is used to check continuity or measure resistance of a switch or coil. If the measuring range has been changed, the zero point must be adjusted before measurement.

(5) CHECKING SWITCHES In a circuit diagram, a switch is represented by a symbol and in the idle state. 1) Normal open or normal close switch Switches are classified into those which make the circuit open and those which make the circuit closed when off.

V-S-19

(6) Checking fuses A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead is grounded. (Change the key switch position adequately so that the fuse circuit becomes live.)

State of fuse blown due to overcurrent

State of fuse blown due to thermal facigue

CAUTIONS IN EVENT OF BLOWN FUSE When a fuse is blown, there are two probable causes as follows: One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of the two causes is responsible can be easily determined by visual check as described below. (1) Fuse blown due to current exceeding rating The illustration shown the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one hastily since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for short-circuit and check for abnormal electric parts. Only after the correction of such shortening or parts, fuse of the same capacity should be used as a replacement. Never use a fuse of larger capacity than the one that has blown, If such a fuse is used, electric parts or wirings could be damaged before the fuse blows in the event an overcurrent occurs again. (2) Fuse blown due to repeated current on/off The illustration shown the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after fairly long period of use and hence is less frequent than the above type. In this case, you may simply replace with a new fuse of the same capacity.

V-S-20

(7) Solenoid test method

1. When current flows through the coil of a relay, its core is magnetized to attract the iron piece, closing (ON) the contact at the tip of the iron piece. When the coil current is turned off, the iron piece is made to return to its original position by a spring, opening the contact (OFF).

Red lead

Black lead

Pointer circuit tester

Digital circuit tester (resistance range)

[TIPS] The circuit tester is battery-powered. The battery voltage is applied across the resistor, by which a current flows and the resistance is measured. The built-in battery’s polarities are different between the pointer type and digital type as illustrated below. In measuring the resistance of a diode-fitted coil, make connection between the positive (+) output terminal of the built-in battery and the cathode of the diode.

Incorrect conection

(Pointer type)

(Digital type)

Cathode

Built-in battery

(Pointer type)

(Digital type)

V-S-21

Anode

(8) Checking relays

2. By using a relay, a heavy current can by turned on and off by a switch of small capacity. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing at this time to the switch is the relay coil current only and is very small.

3. The relays may be classified into the normal open type and the normal close type by their contact construction. Note : The deenergized state means that no current is flowing through the coil and the energized state means that current is flowing through the coil.

When a normal close type relay as illustrated here is checked, there should be continuity between terminals (1) and (2) and between terminals 3 and 4 when the relay is deenergized, and the continuity should be lost between terminals 3 and 4 when the battery voltage is applied to the terminals I and 2. A relay can be checked in this manner and it cannot be determined if a relay is okay or faulty by checking its state only when it is deenergized (or energized).

V-S-22

(9) Checking cables and wires 1) Check connections for looseness, rust and stains. 2) Check terminals and wires for corrosion by battery electrolyte, etc. 3) Check terminals and wires for open circuit or impending open circuit. 4) Check wire insulation and coating for damage, cracks and degrading. 5) Check conductive parts of terminals for contact with other metallic parts (vehicle body and other parts). 6) Check grounding parts to verify that there is complete continuity between attaching bolt(s) and vehicle body. 7) Check for incorrect wiring. 8) Check that wirings are so clamped as to prevent contact with sharp corners of the vehicle body, etc. or hot parts (exhaust manifold, pipe, etc.). 9) Check that wirings are clamped firmly to secure enough clearance from the fan pulley, fan belt and other rotating or moving parts. 10)Check that the wirings between the fixed parts such as the vehicle body and the vibrating parts such as the engine are made with adequate allowance for vibrations.

(10)HANDLING ON-VEHICLE BATTERY When checking or servicing does not require power from the on vehicle battery, be sure to disconnect the cable from the battery (-) terminal. This is to prevent problems that could be caused by shorting of the circuit. Disconnect the () terminal first and reconnect it last. Caution 1. Before connecting or disconnecting the negative cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semiconductor parts being damaged.)

V-S-23

b. Troubleshooting flow chart (1) Starter motor failure to turn on Key switch at START position, but the starter fails to turn on to start the engine.

Are both the right and left lever lock switches on? (Are both the safety levers up?)

Turn off both the lever lock switches. (Lift both the safety levers.)

Yes

Is there battery voltage at starter terminal B?

Yes

Is the starter solenoid activated? Does the pinion sound clicking?

Battery defective.

Does the auto release controller relay sound clicking?

Yes

Starter defective.

Auto release controller relay defective.

Harness in poor contact.

V-S-24

(2) Auto release malfunction 1. Turning sensor out of contact or broken. 2. Relay.

The auto release function fails. The starter motor may wrongly get activated.

Does the key switch return to AC or OFF position?

Turn off both the lever lock switches. (Lift both the safety levers.)

Key switch defective. Replace it with new one.

Auto release controller functioning. Starter terminal B stuck.

Yes

Is the starter solenoid activated? Does the pinion sound clicking?

Yes

With the key switch at ON position, is there 12 V at terminal S?

Yes

Auto release controller defective.

Yes

Turning sensor coupler disconnected during engine run. Auto release function wrongly kept on.

V-S-25

(3) Electronic accelerator failure Electronic accelerator turned, but the engine rpm remains the same.

Does the system lamp light up during engine run?

Yes

1l Accelerator sensor broken. 2l Governor sensor broken. 3l AI motor coupler disconnected.

Microcomputer fuse blown out. Microcomputer power failure.

Does the system lamp light up when the key is turned on?

Yes Cable disconnected. AI motor stuck.

V-S-26

(4) Auto glow failure With the key switch at START position, the starter gets activated but the engine fails to start.

The glow lamp is not preheated.

Does the glow lamp light up when the key is turned on?

Yes Glow plug terminal disconnected.

Glow plug defective.

Does the glow relay sound clicking when the key is turned on and off?

Yes Glow lamp broken.

Meter panel power failure.

Does the glow relay sound clicking with the key switch at START position?

Yes Glow relay functioning, but glow controller possibly defective. Water temperature sensor defective (harness possibly short-circuited).

No Take the glow relay out of the machine, check up the relay.

Does the glow relay function?

Yes Auto glow controller defective.

Glow relay defective.

V-S-27

(5) AI system failure Auto idling malfunction. Auto idling malfunction.

Control lever at NEUTRAL position, but the engine fails to reach the idling speed.

Control lever activated, but the engine rpm does not rise.

(1)

AI switch is on?

(2) (3) (4) (5) (6) (7) (8) (9)

AI pressure sensor coupler disconnected? AI pressure switch circuit broken? Hydraulic valve pressure sensor line clogged (pressure sensor off)? Microcomputer power line fuse blown out? Accelerator sensor broken? Governor sensor broken? AI motor coupler disconnected? AI motor stuck?

(1)

Pressure sensor switch kept on.

(2)

Insufficient pressure in the hydraulic valve pressure sensor line.

V-S-28

Take measures according to indicator lamp.

c. Front attachment (1) Working lamp failure

1) Check for continuity to make sure the working lamp’s 10A fuse is not blown out.

2) Check for continuity to make sure the working lamp’s bulb is not broken.

3) Pull the harness to see if the working lamp terminal and the relay couplers are not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.)

4) Battery voltage check 1. Disconnect coupler of working light. 2. Turn on key switch. 3. Check if batteryvoltage is at (+) terminal. (How to release harness clamp)

V-S-29

(2) Safety lever lock circuit malfunction 1) Check battery voltage at (+) terminal of coupler. Check the fuse if no voltage were tested.

2) Check lever lock switch for continuity by operating the lever.

3) Pull the harness to see if the coupler is not out of the lever lock solenoid valve. (Pull by a 3 kg or less force.) 4) Continuity test of corresponding harness are required.

5) Solenoid valve check 1. Coil resistance Specification: 6 - 15 Ω • Shown here is a measurement with digital tester. (Note that the positive (+) and negative (-) connections are reversed with the analog type.) 2. Coil insulation Specification: Over 1 MΩ

V-S-30

d. Engine electrical system (1) Engine oil pressure failure 1) Check engine oil pressure lamp. Lamp condition

Engine Condition Before engine starts After engine starts

Normal ON OFF

Trouble case (1) ON ON

Trouble case (2) OFF OFF

Trouble case (1):Engine oil pressure is low or oil switch fails. Trouble case (2):Wire harness is cut or oil switch fails. 2) Check oil amount and replenish if nessesary. 3) Pull the harness to see if the oil switch coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) • If out of position, attach the coupler tightly and check the meter reading again. 4) Check battery valtage at (+). Terminal of wireharness coupler. If no battery voltage, check the fuse and continuity of wireharness. 5) Check continuity of oil switch between switch terminal and body earth. Engine condition Continuity of oil switch Engine stop Yes Engine starts No Engine oil switch is NC (Normal close) type.

6) Check engine oil pressure Idling rpm

0.4 MPa(4 kgf/cm2)

MAX. rpm

0.6 MPa(6 kgf/cm2)

• Oil switch operating pressure Ref. value:0.05 ± 0.01MPa (0.5 ± 0.1kgf/cm2)

Oil switch Condition Engine stops

Engine starts

V-S-31

Engine oil pressure

(2) Water temp. sensor circuit malfunction There are two sensors installed on the engine. 1. For warning lamp and gauge 2. For auto glow system

1) Check couplers Pull the harness to see if the water temperature sensor coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) • If out of position, attach the coupler tightly and check the lamp and gauge again.

2) Check battery voltage at (+) terminal of harness coupler. If no battery voltage, check the fuse and continuity of wireharness.

V-S-32

3) Water temperature sensor check • Disconnect the coupler from the water temperature sensor and measure the resistance referring to the figure at right.

The temperature vs. resistance curve must meet the criteria listed below.

-20 40 100

Resistance (kΩ)

Resistance (Ω)

Temp (°C)

Water temp. vs Sensor resistance

18.80 ± 12.6% 1.136 ± 8.4% 0.1553 ± 4.5%

Water temp. (°C)

V-S-33

(3) Fuel sensor circuit 1) Pull the harness to see if the fuel sensor couplers and the relay couplers are not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) • If out of position, attach the coupler tightly and check the meter reading again.

2) Check battery voltage at (+) terminal of wireharnesscoupler. If no battery voltage, check the fuse and continuity of wireharness.

3) Fuel sensor check • Apply the positive (+) test lead to the coupler-fitted terminal. • Apply the negative (-) test lead to the plated part to measure the resistance. • Ref. value Float position

1/2

Resistance (Ω)

3±2

32.5 ± 4

110 ± 7

4) Directly connect the (+) terminal of wireharness coupler to the earth. Then meter gauge indication raises gradually up to full range. Because resistance is 0Ω. In this case, meter gauge function is normal.

V-S-34

(4) Engine stop solenoid (C/N 1A021-6001-3) Operation of engine stop solenoid can be test as in the pictures. 1) Connect 12 V battery voltage to two terminal of engine stop solenoid. 2) Get body earth as shown in picture. 3) Then plunger pin will be pulled in. This means pull-in coil is normal.

Hold coil

Pull-in coil

4) Take off pull-in coil terminal connection. 5) Plunger pin still keeps pulling in. This means hold-coil is normal.

Pull-in coil

Hold coil

Connector

6) Take off second terminal connection. 7) This time plunger pin should be pushed out by spring. This means engine stop solenoid functions normal.

Pull-in coil Battery

V-S-35

Hold coil

(5) Charging system malfunction 1) Check charge lamp condition. Lamp condition

Engine Condition Engine stops Engine starts

Normal ON OFF

Trouble case (1) ON ON

Trouble case (2) OFF OFF

Trouble case (1):Fan belt breakage, B-terminal failure charging system malfunction. Trouble case (2):Wireharness problem, L-terminal failure 2) Pull the harness to see if the alternator coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) • If out of position, attach the coupler tightly and check the lamp.

3) Check for continuity to make sure the 60A slowblow fuse (60A) is not blown out.

4) Check for continuity to make sure the 15A fuse is not blown out. (For the travel hi-speed and fuel pump) • If this fuse is blown out, both the fuel pump and travel hi-speed control do not work.

V-S-36

5) Check battery voltage at B-terminal of wireharness coupler. If no battery voltage, check the fuse and continuity of wireharness.

6) Alternator check 1) Measure the voltage between the alternator’s terminal B and the body ground. Make sure the measurement is 12 V or so. If the measured voltage is lower than this, it means that the battery capacity may be low or that the wire connections before the alternator may be loose. 2) Next start the engine and measure the voltage being generated while the alternator is running. For this, measure the voltage between the alternator’s terminal B and the body ground. Make sure the measurement goes up to 14 V or so (alternator-generated voltage). If the measurement is still the battery voltage (12 V or so), it means that the alternator or the regulator may be in trouble.

V-S-37

(6) Auto glow controller (C/N RC417-53791) 1) If the automatic glow controller seems to malfunction, take it out of the machine, as shown at left, and check the performance of the controller itself referring to the circuit diagram below. 2) The circuit diagram below shows the actual connections. In practice, apply the battery voltage between the coupler pin 3, and ground the coupler pin 4. 3) When the coupler pins 5 and 6 are connected as shown in the diagram, the glow lamp stays on for a certain period of time, and the relay gets activated, it means that the automatic glow controller functions well. 4) If the water temperature sensor signal is not fed to the coupler pin 2, the controller will be in action for about 12 seconds the same way as for the -20 °C condition. Auto glow controller

Key SW

Glow relay Glow lamp

Battery

Water temp. sensor

Circuit diagram to test

3 Note : If a test-purpose glow lamp is not available, set the circuit tester to the V range and watch the tester's pointer movement.

3 4

2 4

3 12 seconds: Without temp. sensor

With temp. sensor

V-S-38

5) Practical inspection Checking the auto glow controller on actual machines 1. Set the key switch to AC position. 2. Make sure the glow lamp lights up. Turn on the key switch and set it to AC position.

Does the glow lamp light up?

Does the glow relay turn on?

Yes

The lamp does not light up if the water temperature is over 81°C. Check the glow relay performance.

Glow lamp broken on meter panel.

Meter panel power failure.

Does the glow lamp go out within the specified time?

Yes

Auto glow controller defective.

Auto release controller defective. Glow lamp wrongly kept on. (Starter possibly burnt-out)

The auto glow controller functions.

V-S-39

(7) Auto release controller (C/N RC417-53791) 1) If the automatic release controller seems to malfunction, take it out of the machine, referring to the photo at left. 2) Referring to the circuit diagram below, ground the terminal E and connect the terminals Acc and C to the battery's 12V terminal. Now the relay gets activated, which closes the B-S contact. 3) Make sure the B-S contact closes and opens according to the input voltage at Acc, as shown below.

(1) Speed sensor

(2) Key SW

(4) Auto release controller (3) Battery

(6) Acc:AV0.85 (White)

(8) P:AV0.85 (Yellow)

(7) C:AV0.85 (Black, White)

(9) E:AV0.85 (Black)

V-S-40

(1) Speed sensor (2) Key SW (3) Battery (4) Auto release controller (5) Starter (6) Acc:AV0.85 (White) (7) C:AV0.85 (Black, White) (8) P:AV0.85 (Yellow) (9) E:AV0.85 (Black)

(5) Starter

Connect the terminals C and E to the battery's positive and negative terminals, respectively, and the line B-C turns on. This means the relay functions well. Then connect the terminal Acc to the battery's positive terminal, feed the pulse signal from the engine turning sensor to the terminal P, and the relay turns off. Such behaviors indicate that the auto release controller functions as specified. On actual machines, check the voltage at terminal S with a tester. Set the key switch to START position, and the relay turns on and the battery voltage gets applied at terminal S. When the engine has started, the relay will turn off and the voltage at terminal S will be back to 0 V. This means the controller functions well.

B C

V-S-41

e. Auto idle system (1) Troubleshooting outline The auto idle mechanism consists mainly of the following 8 components. They are systematically interactive. AI operation switch

Acceleration sensor AI motor Governor sensor

AI controller AI control lamp

AI pressure switch

Engine speed sensor Below listed are typical possible troubles and causes of the auto idle mechanism. To pinpoint a trouble spot, check the relevant component for performance and the harness for continuity. Let’s suppose that the above 7 components, except for the AI controller, are found functioning well and that there is no problem with the hydraulic system. In such case, it is advisable to replace the AI controller itself with new one and check its performance.

a.Typical trouble

b. Possible causes and correction

1. Accelerator lever moved, but engine speed did 1. Acceleration sensor defective. not change accordingly. 2. AI motor defective. 3. Governor sensor defective. 4. Acceleration cable defective. 2. Control lever at neutral, but engine speed not 1. AI pressure switch defective. idling. 2. Speed sensor defective. 3. AI motor defective. 3. Control lever moved with engine idling, but 1. AI pressure switch defective. engine speed failure to rise. 2. Speed sensor defective. 3. AI motor defective.

V-S-42

(2) AI pressure switch test method 1) Pull the harness to see if the AI pressure switch coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) If out of position, attach the coupler tightly and check the performance again.

2) Disconnect the AI pressure switch coupler and start the engine. Apply the circuit tester to the switch terminal to check continuity. For continuity or no continuity while in normal condition and in trouble, see the table below. (continuity : Yes or No) Control lever position Neutral Shifting

Normal Yes No

Trouble case (1)

Trouble case (2)

Yes Yes

No No

Trouble case (1): AI sensing pressure is low. AI pressure switch malfunction. Trouble case (2): AI pressure switch malfunction. AI pressure switch is NC (Normal close) type. 3) Check battery voltage at (+) terminal of wireharness coupler. If no battery voltage, check the fuse and continuity of wireharness.

V-S-43

4) Inspect AI control pressure Control pressure

AI pressure switch

Engine rpm.

25 ± 3 kgf/cm2

OFF

Idling to MAX.

20 ± 3 kgf/cm2

MAX. to Idling

AI pressure SW is N.C.(normal close) type.

AI control pressure

V-S-44

(3) Governer sensor test method 1) Turn the accelerator knob and check to see if the engine speed rises smoothly from the idling to maximum level. If so, the sensors function well. If not, go to the next step. 2) Pull the harness to see if the governor sensor coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) If out of position, attach the coupler tightly and check the meter reading again. 3) Control voltage test Disconnect the sensor coupler. With the key switch at the ON position, measure the voltage between the coupler terminals [1] and [3] to see if it is 5 V. Take the same procedure for the acceleration sensor and governor sensor. 4) Continuity test With the key switch at the OFF position, check continuity between the related wire harness terminals. If there is no continuity, a wire may be broken. Follow the circuit diagram in checking for a broken wire.

V-S-45

5) Sensor test (Governor sensors) 1. Check sensor’s resistance (1) [1] - [3] : 2 kΩ ± 20 % (2)

2 20 0

Turn the potentiometer shaft, and the resistance between the terminals [1] and [2] will drop smoothly from about 2 kΩ to 100-200 Ω. (3)

3 20 0 Turn the potentiometer shaft, and the resistance between the terminals [2] and [3] will rise smoothly from about 100-200Ω to about 2 kΩ.

(4) Turn the sensor shaft about 180° by hand, and release it to make sure it returns itself. If any of the above performances and resistances is not found as specified, it means the sensor itself may be in trouble. Replace the sensor with new one.

V-S-46

2kΩ Ω

(4) AI motor test method 1) Turn the accelerator knob and check to see if the engine speed rises smoothly from the idling to maximum level. 2) Check for continuity to make sure the 15 A AI fuse is not blown out.

3) Pull the harness to see if the AI motor coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) • If out of position, attach the coupler tightly and check the performance again.

4) Continuity test With the key switch at the OFF position, check continuity between the related wire harness terminals. If there is no continuity, a wire may be broken. Follow the circuit diagram in checking for a broken wire.

5) AI motor check (Fig. 6) Apply 12 V between the AI motor coupler terminals [1] and [2] to make sure the motor gets started. Reverse the connections and make sure the motor runs in the opposite direction. * Precautions ! Feed the power for 1 second or shorter. This test can also be made by disconnecting the acceleration cable and keeping the AI motor on the machine.

V-S-47

(5) Engine speed sensor This engine speed sensor is provided for AI control and starter auto-release control. As ever before, the meter reading of the engine speed is sent through the tachmeter cable to the speed gauge. If the AI controller malfunctions and this speed sensor is a suspect, take the following test procedure. 1) Pull the harness to see if the engine speed sensor coupler is not out of position. Be sure that the coupler harness is tightly connected. (Pull by a 3 kg or less force.) * If out of position, attach the coupler tightly and check the performance again.

2) Voltage check (Fig. 5) • Disconnect the engine speed sensor coupler. • Turn the key switch to the ON position. 1 Measure the voltage between the speed sensor coupler terminals [1] and [3] to make sure it is 12 V. 2 Measure the voltage between the speed sensor coupler terminals [1] and [2] to make sure it is 5 V. * Measurements 12 V and 5 V: Check the speed sensor. * Other measurements: Measure the voltages in the steps (3) and (4) below. Check for continuity. 3 Measure the voltage between the speed sensor coupler terminal [3] and the body ground to make sure it is 12 V. 4 Measure the voltage between the speed sensor coupler terminal [2] and the body ground to make sure it is 5 V. 3) Continuity test With the key switch at the OFF position, check continuity between the related wire harness terminals.

V-S-48

(Main power)

4) Engine speed sensor check • Disconnect the speed sensor from the engine and check the sensor. * Keep in mind that the positive (+) and negative (-) leads are differently connected between the pointer and digital types. * Bear in mind that when the power supply is connected, a short-circuit might occur. * Shown below is the measuring procedure with the pointer and digital types. Test by either one that you have in the shop.

Digital diode tester range

Black lead

Pointer resistance mode

Black lead Red lead

*Orient the metallic scale end toward the sensor and move it in the arrow directions passing the front of the sensor. Details of Sensor coupler

Red lead

(1) Ground (2) Signal (3) Power

[REFERENCE] • In measuring with the pointer type, make sure the pointer swings. Set the tester range between 1 Ω and 1 kΩ. (Too small a range makes it difficult to recognize the pointer swing.) • In measuring (diode test) with the digital type, make sure the reading changes between the 0.0-1.5 range and the over-range.

V-S-49

(6) Auto glow circuit 1) Water temperature sensor circuit check When the water temperature sensor and its wiring function, the engine’s water temperature is detected and the glow plug is preheated for a time required to get the engine started. 2) First make sure the water temperature sensor functions. Disconnect the water temperature sensor coupler and put your fingers in slight contact with the glow relay. Now turn the key switch to the ON position and feel the glow relay clicking. • When it clicks, check the glow plug coupler as well as the glow relay. • If it does not click, measure the voltage, check for continuity (Fig. 4), and check the glow relay (Fig. 5). 3) Voltage check • Keep the glow relay coupler in position. • Turn the key switch to the ON position. 1. Measure the voltage between the auto glow relay coupler terminals [3] and [4] as well as between [1] and [2] to see if it is 12 V. • 12 V reading for both: Check the glow relay. • Other reading: Measure the voltage in Step (2) below. Also check for continuity. 2. Measure the voltage between the glow relay coupler terminal [4] and the body ground to see if it is 12 V.

V-S-50

Battery (5A main power)

4) Continuity check • Turn the key switch to the OFF position. • Disconnect the meter coupler . • Disconnect the glow relay coupler . 1. Check for continuity between the meter coupler terminal [13] and the auto glow relay coupler CN terminal [1]. 2. Check for continuity between the meter coupler terminal [12] and the glow relay coupler terminal [2]. 3. Check for continuity between the glow relay coupler terminal [3] and the glow plug coupler. 4. Check for continuity between the glow relay coupler terminal [4] and the battery’s positive (+) terminal.

5) Glow relay check 1. Disconnect the glow relay coupler. Measure the resistance between points (1) and (2) on the glow relay alone. Specification

52 - 80 Ω

Actual measurement

About 65 Ω

2. Apply 12 V between points (1) and (2) of the glow relay to check for continuity between points (3) and (4).

V-S-51

Battery

f. AI version: AI controller (built-in microcomputer) Cases of trouble diagnosis with circuit tester If the auto idle control system malfunctions or the electrical circuitry gets in trouble on the AI type machines, a cause of trouble can be traced by checking the status of signals to the AI controller. Referring to “Functions and status of signals sent from the sensors to the AI controller”, let’s discuss how to trace the causes of troubles in terms of the signal status.

(1) “Water temperature sensor” line in trouble 1) The water temperature sensor’s detection voltage is formed by a thermistor. The voltage plotted in the chart below is fed to the microcomputer through the circuit shown below.

(1) Check point (2) Sensor (3) Constant voltage power circuit (4) Microcomputer (5) CPU

(3) Constant voltage power circuit (1) Check point

Voltage

(2) Sensor

(4) Microcomputer

Temperature

5v R

Vin =

(5) cpu r

Water temperature

Glow time

-40 -15 -10 0 10 20 40 30 80 81 100

12 12 11 9 6.5 5.3 3.8 3.3 3 0 0

×r R+r The value r varies depending on water temperature. Thus the water temperature versus the microcomputer input voltage is plotted in the chart above.

Thermistor resistance 71770 11123 6544 3997 2525 1100 530 277

Glow Time(sec)

The input voltage to the microcomputer is expressed

155

Water temperature

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(2) Sensor

2) If the water temperature sensor voltage at the microcomputer input terminal is measured to be “0 V” or “5 V”, the following cases are taken into consideration. 1. “0 V” measurement Let’s suppose that 5 V is being supplied (1) AI controller from the constant voltage power circuit but the measured voltage is 0 V. (3) Constant voltage • There is a short-circuit, which interrupts power circuit the 5 V supply from the constant voltage power circuit. • The circuit in the controller is broken, which interrupts the 5 V output to the (4) Microcomputer water temperature sensor circuit.

(5) Line thought to be short-circuited (6) Line thought to be broken

2. “5 V” measurement Let’s suppose that 5 V is being supplied from the constant voltage power circuit and the measured voltage is 5 V. • The circuit is open (broken) somewhere.

(9) Constant voltage power circuit

(7) Sensor

(1) AI controller (2) Sensor (3) Constant voltage power circuit (4) Microcomputer (5) Line thought to be short-circuited (6) Line thought to be broken (7) Sensor (8) AI controller (9) Constant voltage power circuit (10) Microcomputer (11) Line thought to be broken

(8) AI controller

(10) Microcomputer

(11) Line thought to be broken

3) With these results in mind, go to the next procedure “Checking the sensor and actuator”. 4) Checking the sensor itself Disconnect the sensor coupler from the microcomputer. Check the sensor for continuity. For the water temperature sensor, its resistance corresponding to the water temperature will be measured. If there is no continuity, it means there may be a broken wire or the sensor may malfunction. For the switch, see if it is of Normally open or Normally closed type. The Normally closed type shows continuity. 5) Checking the wire harness When the sensor itself is found functioning, check the wire harness insulation.

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(2) Other circuitry layouts and their trouble diagnosis The AI controller may also be incorporated in the following circuits with sensors, switches and actuators. The procedure of trouble diagnosis is almost the same as discussed before. You are requested to train yourself, with a circuit tester in one hand and the circuit diagram in the other, to learn about the electronic control circuit. 1) Vcc voltage (5 V) application Governer sensor

AI controller

a Vcc sv

Constant voltage power circuit

3 b Vs Microcomputer

2 c E 1

Measure the voltages at points “a”, “b” and “c” in the figure above to see if the sensor or the AI controller malfunctions. 2) With external input signal and external output AI controller Constant voltage power circuit

12v

off AC

b Microcomputer AI control lamp

AI control switch

Measure the voltages at points “a” and “b” in the figure above to see if the sensor or the AI controller malfunctions. The AI motor circuit can also be readily diagnosed, referring to “g. AI controller unit of Mechanism chapter”

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g. Cases of trouble diagnosis with circuit tester

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h. Auto Idle(AI) version: Trouble diagnosis with lamp (1) General On the AI type machines, the AI controller’s input and output signals are used for AI control. A program has been factory-installed in the microcomputer to detect and display these input and output signals for easy trouble diagnosis. The error display comes in the following 3 modes.

1)Operating mode: The machine condition during ordinary run and operation is detected and displayed. As shown in Table 1, fail symptoms are identified by the number of blinks of the system lamp.

2)Setup mode: The AI control settings are made and saved in the AI controller in this mode. When the AI control devices (such as acceleration sensor, governor sensor, AI motor and acceleration cable) have been disassembled and reassembled at the factory or workshop, possible small deviation produced in fabricating or fitting these devices can be detected and the initial settings can be resumed.

3)Service mode: If a trouble occurs with the AI control system components, for example, the trouble spot can be located. Then a service engineer is supposed to operate the machine and diagnose the trouble and to restore the function. This mode includes the following menus. The service engineer uses the AI operation switch for trouble diagnosis. 1) Top menu Note : (EEPROM means electrically 2) Trouble indicator lamp menu for usual control erasable program read only 3) Engine speed sensor check menu meomry . In this case, it con4) AI pressure switch/water temperature sensor check tains data of machine condimenu tions in the micro computer.) 5) Sensor break check menu (Accel, & governor) 6) Fail record display menu 7) Fail record delete menu 8) EEPROM read menu 9) AI motor drive menu 10)Engine idling speed adjusting menu (2) AI operation switch (1) Electric accelerator (1) Electric accelerator (2) AI operation switch (3) System lamp(Red) (4) AI lamp(Green)

(3) System lamp(Red)

(4) AI lamp(Green) V-S-56

4)AI controller identification Tokai Rika

Idle speed set in the controller (rpm)

RC417-53752 RC417-53753

415-1UUU 415-2UUU

1050 1050

RD118-53751

431-0UUU

1050

AI controller model-wise

Kubota

Engine Idle speed No adjustable Yes U35, U35-3, U45-3 Engine Idle speed Yes KX121-3, KX161-3 adjustable

KX101-3

Compatible

Machine set idle speed Cab KX91-3 KX101-3 U35-3 U35 KX121-3 KX161-3 U45-3

1050 ± 50

1200 ± 50

1100 ± 50

1200 ± 50

415-2E 24 Original maker’s code No. Modify No

Date

Year 2002

Month

Digit 2 indicates that idle speed can be adjustable Except ‘415-1UUU’, all other AI controller are possible to adjust the engine idle speed

8 pin coupler

AI controller

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Canopy

(2) Display and identification of errors in operating mode If any of the AI control devices gets in trouble during the machine run, the system lamp (red) starts blinking and indicates the type of error as listed in Table 1.

Table 1 System lamp blinks in operating mode Fail No. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Fail symptom Water temperature sensor line break Acceleration sensor line break Governor sensor line break AI motor drive line break Self-holding relay circuit malfunction AI motor drive line short-circuit AI motor restrict malfunction Engine speed sensor line break Starter motor auto release Battery voltage abnormal Controller system malfunction

Trouble indicator lamp blinking times in operating mode 2 3 4 5 6 10 11

Remarks: 1. The lamp keeps blinking for a predetermined time. The microcomputer has been programmed to recognize these errors as machine troubles. 2. If the detection voltage of the acceleration sensor or governor sensor drops and stays below 0.2 V for 150 msec or so, for example, the microcomputer judges this as a breakdown and gives a signal to make the lamp blink. 3. If two or more failures occur at a time – governor sensor line break and AI motor drive line break at once, for example, the lamp starts blinking twice and 3 times soon after. This cycle is repeated. Blinking pattern One time

Two times

Three times

In case No.1 and No. 2 fails exist, lamp blinking pattern should be as follows. Lamp ON Lamp OFF

Fail contents only in the operating mode are recorded in the AI controller.

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(3) Entering the service mode Of the 3 couplers that are connected with the AI controller, disconnect the 8-pin coupler.

Turn the AI operation switch to the OFF position.

Turn the key switch to the ON position or get the engine started. (Decide which way according to the diagnosis menu.) To set up, engine speed goes up and down by itself for a while.

Reconnect the 8-pin coupler.

(1) Top menu

The red and green lamps blink alternately.

Now the service mode is established. Make sure that the red and green lamps are blinking alternately and that the top menu of the service mode appears. (Precautions in handling the key switch in the service mode) 1. For checking the points starting with the top menu (1), first get the engine started. 2. For checking on the menus that follow the sensor break check menu (5), you may also take the procedure with the key switch at the ON position. In such case, turn the AI operation switch on and off on the top menu (1) screen to skip the menus (2), (3) and (4) and go direct to the menu (5). (1) Top menu

(6) Fail record display menu

(2) Trouble indicator lamp menu for usual control

(3) Engine speed sensor check menu

(10)Engine idling speed adjusting menu

(4) AI pressure switch/ water temp. sensor check menu.

(7) Fail record delete menu (8) EEPROM read menu KeyOff. (9) AI motor drive menu KeyOff.

(5) Sensor break check menu (Accel, & governor)

Check with key switch on and engine stop condition

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(4) Working on the 6 menus in the service mode (1) Top menu

The red and green lamps blink alternately.

Turn the AI operation switch to ON first and then to OFF. 1) Take this action within 2 seconds, and the green lamp stays on and the menu (2) is called up. 2) Take this action within 3-40 seconds, and the red and green lamps start blinking slowly and the menu (6) is called up. 3) Take this action over 40 seconds, and the red and green lamps start blinking quickly and the menu (9) is called up. (2) Trouble indicator lamp menu for usual control Normally the red and green lamps stay off. If any trouble exist, red lamp blinks according to Table 2. Turn the AI operation switch to ON first and then to OFF. 1)Take this action within 2 seconds, and the green lamp stays on and the menu (3) is called up. (3) Engine speed sensor check menu The engine speed is indicated by the blinking rate of the red lamp. (Example: 2000 rpm → about 20 blinks for 10 seconds) The green lamp stays off. Note: In case of acceleration & governor sensor break, lamp stays off. In case AI motor line break, engine speed can’t be checked Turn the AI operation switch to ON first and then to OFF. 1) Take this action within 10 seconds, and the menu (4) is called up. 2) Take this action over 10 seconds, and the red and green lamps start blinking together slowly and the menu (10) is called up. (10)Engine idling speed adjusting menu Lamps blink as in the following sequence. Red, green, red , green and repeat. 1) Turn the accelerator knob fully to Max. and Min. position for several times. 2) Set the accelerator knob either at Max. or Min. position. If engine idling speed should be increased, then set the knob at Max. position. If engine idling speed should bo decreased, then set the knob at Min. position. 3) Fix the idling speed by the “ON-OFF“ count of AI operationswitch. One count of “ON-OFF“ switching adjust “±50rpm”. • Adjustable idling speed:upper limit=1800rpm, lower limit=1050rpm. • When the adjusting idle speed were reached upper or lower limit, both red and green lamps start blinking together. • While the engine idle speed were between the limits, lamps blink as in the following sequence. Red, red and green, green and repeat. The idling speed will start fixing after 5 seconds of “ON-OFF“ switching. During this time, both lamps blink. 4) After completing properly, the engine idle speed will be renewed. 5) Automatically the menu (3) is called up and the engine speed is indicated by the blinking rate of the red lamp.

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(4) AI pressure switch/water temperature sensor check menu • The red lamp stays off when the water temperature sensor functions, and on if it is defective. • The green lamp is used to check the AI pressure switch line. The lamp lights up when the control lever is moved. The lamp goes out while the control lever stands at neutral. Make this test with the safety lock lever lowered. If the lamp behaves differently, there may be a trouble with the AI pressure switch line. Turn the AI operation switch to ON first and then to OFF. 1) Take this action within 2 seconds, and the green lamp stays on and the menu (5) is called up. (5) Sensor break check menu For safety, pull up the engine stop knob to stop engine. The red lamp is used to check the governor sensor and harness. It stays off when there is no problem, and on if there is a problem. It starts blinking when the problem is solved. The green lamp is used to check the acceleration sensor and harness. It stays off when there is no problem, and on if there is a problem. It starts blinking when the problem is solved. Turn the AI operation switch to ON first and then to OFF. 1) Take this action within 2 seconds, and the green lamp stays on and the top menu (1) is called back. (1) Top menu The red and green lamps blink alternately. (1) AI pressure switch

(2) Cable to AI motor

(3) Governor sensor

(4) Engine speed sensor (1) AI pressure switch (2) Cable to AI motor (3) Governor sensor (4) Engine speed sensor

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(5) Example:Alternation of engine idling speed Please challenge the following examples as your hands-on training, and you’ll soon get used to it.

Example A : Change engine idling speed form 1050 to 1300rpm. 1) Enter to the service mode and go down to ”(3) Engine speed sensor chech menu” and “(10) Engine idling speed adjusting menu”. 2) Turn the accelerator knob fully to Max. and Min. position for several times. 3) Set the accelerator knob to Max. position. 4) Shift the AI operation switch as in the following sequence, and then the engine idling speed increases as in the parenthesis. (AI operation SW) OFF(original position) ON(1100rpm) OFF ON(1150rpm) OFF ON(1200rpm) OFF ON(1250rpm) OFF ON(1300rpm) OFF(Stay for 5 seconds or more) 5) After one minute or so, engine idle speed changes automatically. 6) The menu automatically returns to “(3) Engine speed sensor check menu”.“

Example B : Change engine idling speed from 1300rpm to 1150rpm 1) Enter to the service mode and “(3) Engine speed sensor check menu“ and “(10) Engine idling speed adjusting menu”. 2) Turn the asselerator knob to Max. and Min. position for several times. 3) Set tje accelerator knob to Min. position. 4) Shift the AI operation switch as in the following sequence, and then the engine idling speed decreases as in the parenthesis. (AI operation SW) OFF(original position) ON(1250rpm) OFF ON(1200rpm) OFF ON(11150rpm) OFF(Stay for 5 seconds or more) 5) After one minute or so, engine idle speed changes automatically. 6) The menu automatically returns to”(3) Engine speed sensor check menu”.

Example C : Current engine idling speed is unknown, but required to set the idling speed to 1100rpm. 1) Enter to the service mode and “(3) Engine speed sensor check menu“ and “(10) Engine idling speed adjusting menu”. 2) Turn the asselerator knob to Max. and Min. position for several times. 3) Set tje accelerator knob to Min. position. 4) Turn the AI position swutch to ON and OFF. Take this action for several times unti both red and green lamps start blinking. (This meanes that engine idle speed decreases to lower limit of 1500 rpm) 5) Set the accelerator knob to Max. position. 6) Shift the AI operation switch as in the following sequence, and then the engine idling speed increases as in the parenthesis. (AI operation SW) ON(1050rpm) OFF ON(1100rpm) OFF(Stay for 5 seconds or more) 7) After one minute or so, engine idle speed changes automatically. 8) The menu automatically returns to”(3) Engine speed sensor check menu”.

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(6) Working on the 3 menus in the service mode Key switch is ON position. (1) Top menu

The red and green lamps blink alternately.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Let’s suppose the entries are as shown here according to the lamp light-up. The first [1] and seventh [7] imply water sensor line break and AI motor restrict malfunction, respectively. Turn the AI operation switch to ON first and then to OFF. 1) Take this action within 10 seconds, and the green lamp stays on and the fail record is indicated from the beginning. 2) Take this action slowly within 11-29 seconds, and the fail record delete menu (7) is called up. 3) Take this action slowly over 30 seconds, and the EEPROM read menu (8) is called up. (7) Fail record delete menu Lamps blink as in the following sequence. Red, green, red, red , green and repeat. Turn the AI operation switch to ON first and then to OFF, and the fail record is deleted and the menu (6) is called back. With all deleted, the AI operation lamp (green) alone starts blinking for 11 times. This means all fail record as deleted and menu (6) is already being indicated. (8) EEPROM read menu Lamps blink as in the following sequence. Red, green, red, green, red , green and repeat. Turn the AI operation switch to ON first and then to OFF, and the lamps start lighting up. When the green lamp lights up, write down “0”; when the red lamp does, jot down “1”. Lamp lights up 16 times continuously and goes off. By turning the AI operatin switch to ON and “OFF“ next 16 data come up. Each time the AI operation switch is turned on and off, the read addresses change incrementally and the lamps behave accordingly. (Entry example) Address No. 0 1 2 · 63

Data contents 1000 0000 1001 · 0000

0000 1000 0001 · 0000

1100 0000 0000 · 1000

0000 0000 0000 · 0000

Key OFF V-S-63

Binary data in the left indicates machine conditions and can only be deciphered in KBM or KBT.You are required to send these data for diagnosis in detail.

(7) Working on the AI motor drive menus in the service mode Key switch is ON position (1) Top menu

The red and green lamps blink alternately.

Lamps blink as in the following sequence. Red, green, red, green, red, red , green and repeat.

The AI operation switch is used to run the AI motor directly. Keep in mind that the AI motor must run no longer than 3 seconds. 1) Turn on the AI operation switch an odd-numbered time, and the AI motor runs in the normal direction. The green lamp lights up and the red lamp goes out. 2) Turn on the AI operation switch an even-numbered time, and the AI motor runs in the reverse direction. The green lamp goes out and the red lamp lights up. 3) AI motor runs while AI operation switch is,on. Every time AI operation switch turn ON-OFF, AI motor’s rotating direction changes. 4) Turn off the AI operation switch, and the AI motor stops. Both the green and lamps go out. 5) Finally Key OFF. Note : The AI motor runs very fast. To stop it at a desired position, turn the AI operation switch on and off very quickly. (1) AI pressure switch

(2) Unload solenoid

(3) Hi-Low solenoid (1) AI pressure switch (2) Unload solenoid (3) Hi-Low solenoid

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(8) Entering the setup mode When the AI control components such as sensor and motor have been readjusted and reinstalled, it is necessary to make the control data settings of the AI controller again. Take the procedure below. Of the 3 couplers connected with the AI controller, disconnect the 8-pin coupler.

Stop the engine, reconnect the 8-pin coupler, and repair a trouble spot corresponding to the number of blinks.Refer to Table 3.

(The AI operation switch may be set either at ON or OFF.)

Start the engine.

In case any fail exists:

(Now the setup mode is on.)

(Blinking of red lamp indicates there are errors in the system.) The green lamp stays on, whereas the red lamp is blinking.

The red and green lamps light up.

Turn the electronic accelerator all the way to MAX and MIN several times.

The red and green lamps go off.

(Now the acceleration sensor and governor sensor data as well as maximum and minim engine speeds are programmed in the microcomputer.) If the electronic accelerator weren’t turned to MAX. and Min., acceleration sensor data isn’t programmed in the microcomputer correctly. Therefore, speed control would be abnormal.

Stop the engine.

Reconnect the 8-pin coupler. The AI control settings are complete.

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Table 2 Fail Record Indication First (1)

Last (2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

0:Normal 1:Abnormal (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Water temperature sensor line break Acceleration sensor line break Governor sensor line break AI motor drive line break Self holding relay malfunction AI motor drive line short-circuit AI motor restricted, malfunction Engine rotating sensor line break Starter motor auto release Battery voltage abnormal Controller data abnormal

Table 3 Fail system & lamp indication Operation mode Fail No.

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Fail system

Setup mode

Service mode

Diagnosis

Lamp ONOFF number

Diagnosis

Lamp ONOFF number

Diagnosis

Lamp ONOFF number

° ° ° ° ° ° ° ° ° °

2 3 4 5 6 10 11

° ° ° ° ° ° ° ° ° ° -

2 3 4 5 6 7 8 10 11

° ° ° ° ° ° ° ° ° ° °

1 2 3 4 5 6 7 9 10 11

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Table 4 EEPROM Data Dump Address Add.

Contents

Remarks

Add.

Contents

Remarks

0 1 2 3

Machine model code Accel. sensor Max. value Accel. sensor Min. value Governor sensor Max. value

A/D conversion 8bit A/D conversion 8bit A/D conversion 8bit x4 A/D conversion 8bit x4

32 33 34 35

Fail number Fail sequence Fail number Fail sequence

Governor sensor Min. value

A/D conversion 8bit x2

Fail number

AN5 value at 0A to motor

A/D conversion 8bit x2

Fail sequence

AN5 value at 5A to motor

A/D conversion 8bit x2

Fail number

AN4 value at 0A to motor

A/D conversion 8bit x2

Fail sequence

AN4 value at 8A to motor

A/D conversion 8bit x2

Fail number

Actual current value at 8A to mA motor

Fail sequence

AI motor drive line break AI motor drive line short,CW,ST AI motor drive line short,CW,ST AI motor drive line short,CW,OP AI motor drive line short,CW,OP AI motor drive line short,CCW,ST AI motor drive line short,CCW,ST AI motor drive line short,CCW,OP AI motor drive line short,CCW,OP AI motor restricted

42 43 44 45 46 47 48 49 50 51 52

Fail number Fail sequence Fail number Fail sequence Fail number Fail sequence Fail number Fail sequence Fail number Fail sequence Fail number

AI motor restricted Hunting Hunting Accel. Sensor line break Accel. Sensor line break Governor sensor line break Governor sensor line break Abnormal battery voltage Abnormal battery voltage Engine speed sensor line break Engine speed sensor line break

53 54 55 56 57 58 59 60 61 62 63

Fail sequence Fail number Fail sequence Fail number Fail sequence Fail number Fail sequence Fail number Fail sequence Fail number

Water temp.sensor line break Water temp.sensor line break Current adjusting data abnormal Current adjusting data abnormal AI setup data abnormal AI setup data abnormal Auto release applied Auto release applied Self-holding relay line fail Self-holding relay line fail

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Check sum value of AI setup Check sum value of current adjustment

Serial no. Serial no. Fail sequence

Upper 16 bit Lower 16 bit AI motor drive line break

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Table 5 AI controller coupler numbers Connector A;4P

No. 1 2 3 4

Connector B;8P

No. 1 2 3 4 5 6 7 8

Connector C; 16P

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Connector A;4P

No. 1

Type & color AVSS2, RW AVSS2, WR AVSS2, WB AVSS2, BW

Signal Motor power Motor CCW Motor CW Motor GND

Type & color AVSS0.5, Y AVSS0.5, YB AVSS0.5, YR AVSS0.5, YG AVSS0.5, Lg AVSS0.5, LgR AVSS0.5, LgB AVSS0.5, LgY

Signal AI pressure SW1 AI release SW SW1 SW2(setup) SW3 Line checker,Txd Line checker,Rxd

Type & color AVSS0.5, R AVSS0.5, RB AVSS0.5, RG AVSS0.5, RL AVSS0.5, L AVSS0.5, LR AVSS0.5, LB AVSS0.5, LgY AVSS0.5, LW AVSS0.5, G AVSS0.5, GR AVSS0.5, GW AVSS0.5, V AVSS0.5, P AVSS0.5, BR AVSS0.5, BR

Signal Battery, main Battery, sub +12V Sensor power(+5V) Engine speed sensor Motor governor Accel. VR water temp. sensor Starter motor SW input Auto release relay coil Glow relay coil Self-hold relay System lamp AI lamp Sensor GND main GND

Type & color AVSS0.5, WL

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Signal Test

(8) Lamp-identified fail symptoms, trouble spots and possible causes Fail No.

Fail symptom

(1)

Water temperature sensor line break

(2)

Acceleration sensor line break

Trouble spot

Water temperature sensor

Possible causes

AI controller Engine harness

Main harness

Control panel

AI controller Main harness

Water temperature sensor defective Harness broken Coupler in poor contact or disconnected AI controller defective

Electronic accelerator defective Harness broken Coupler in poor contact or disconnected AI controller defective

Accelerator (Acceleration sensor)

(3)

Governor sensor line break

Governor sensor

AI controller Engine harness

(4)

AI motor drive line break

Main harness

AI controller

AI motor Harness

(5)

Self-holding relay circuit malfunction

Battery

Fusible link

AI controller Fuse Self-holding relay

(6)

AI motor drive line short-circuit

Governor sensor defective Harness broken Coupler in poor contact or disconnected AI controller defective

AI motor defective Harness broken Coupler in poor contact or disconnected AI controller defective

Self-holding relay defective Fuse blown out Harness broken Coupler in poor contact or disconnected AI controller defective

Harness short-circuited AI controller defective AI controller

AI motor Harness

(7)

AI motor restrict malfunction

AI motor

Cable

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Engine governor

Foreign matter stuck in motor arm or governor Cable sliding resistance too high Cable disconnected or broken Cable in poor fitting or maladjusted Governor sensor in poor fitting or loose This indication also occurs if the AI controller settings have not been made after replacing the acceleration sensor or governor sensor.

Fail No.

Fail symptom

(8)

Engine speed sensor line break

(9)

Starter motor auto release

Trouble spot

Engine speed sensor

AI controller Engine harness

AI controller

Possible causes

Main harness

Acceleration cable in poor fitting Engine speed sensor defective Harness broken Coupler in poor contact or disconnected AI controller defective This indication also occurs if you try the trouble diagnosis without starting the engine. Be sure to start the engine for checking this item. Key switch stuck toward ON position

Release relay

Starter

(10)

(11)

Battery voltage abnormal Controller system malfunction

Indicated if the voltage rises above 18 V

AI controller defective This indication also occurs when the AI controller, governor sensor or acceleration sensor has been replaced, but the AI controller settings have not been made yet.

Failure Nos. 4 and 7 are indicated only when there is no problem with failure Nos. 2, 3, 5, 10 and 11. Failure No. 6 is also indicated only when there is no problem with failure Nos. 5, 10 and 11. Because if (2), (3) and (5) were failed, AI controller can’t send any signal to AI motor. Therefore, AI drive line fail can’t be detected.

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Conversion Tables, Tableaux Con versions,

Umr echnungstabelle

a. Length

Longuleur

inch

0.1

0.001

0.03937

0.0032808

0.001094

0.01

0.39370

0.0328080

0.010940

Loeng e

1000

100

39.370

3.2808

1.0936

25.400

2.540

0.02540

0.083333

0.02778

304.800

30.480

0.30480

0.3333

914.4

91.44

0.9144

Ex. 1mm =0.03937in 120mm =120 0.03937=4.7244in 1 mile=1.609km

Air e

b. Ar ea cm

Areal m2

sq.in

sq.ft

sq.yd

0.0001

0.15500

0.0010764

0.0001196

10000

1550.0

10.764

1.1960

6.4516

0.00064516

0.006944

0.0007716

929.03

0.092903

144

0.11111

8361.0

0.8361

1296

Ex. 1m2 =1.1960 sq.yd

1.2m2 =1.2 1.1960=1.4352 sq.yd

Volume

c. Volume

Volume

dm 3(l)

cu.in

cu.ft

cu.yd

Imperial gal

US gal

0.001

61.027

0.035317

0.0013

0.21998

0.26418

1000

61027

35.317

1.3079

219.98

264.18

0.016387

0.00001639

0.578697

0.0000214

0.003605

0.00433

28.3153

0.028315

0.000464

0.037026

6.22786

7.4006

764.584

0.764584

46656

168.152

199.816

4.5465

0.0045465

277.4207

0.16057

0.0059

1.20114

3.7852

0.0037852

231.005

0.13368

0.0050

0.83254

cu.yd/min

L/min

Ex. 0.04m =0.04 1.3097=0.052316 cu.yd 3

d. Flow amount

Decharge int ernes

L/sec

m 3/min

1 16.666

1liter=1000cc=1000cm

Entladung

m 3/h

Inp.gal/min

0.060

3.6

13.197

15.8514

21.192

60.0

219.98

264.1833

35.3165

999.96

US gal/min

0.2778

0.016668

3.6658

4.4032

0.58806

16.668

0.075775

0.0045465

0.27279

1.2011

0.16065

4.5465

0.06309

0.0037824

0.2271

0.8325

0.17768

3.7854

0.47192

1.6989

0.02832

6.22787

7.4855

28.3152

0.016667

0.001

0.06

0.21995

0.264173

0.035317

Ex. 25.6l/sec=25.6 0.06=1.53m3 /min=25.6 e. Force(Weight) Foece(Contr epoids) N

dyn 5

15.8514=405.79584Usgal/min

Kraft(Gewic ht)

kgf

lbw

1.01972 10-1 1.01972 10-6

2.24809 10-1 2.24809 10-6

1 10

1 10-5

9.80665

9.80665 105

2.20462

4.44822

4.44822 105

4.53592 10-1

Ex 1.2kgf=1.2 9.80665=11.76798N=11.76798 2.24809 10-1=2.64555lbw

Emphase

f. Stress

Betonen

MPa or N/mm 2 1 10-6

Pa 1

kgf/mm 2

kgf/cm 2 1.01972 10-5

1.01972 10-7 1.01972 10-1

9.80665

1 102

9.80665 10-2

1 10-2

1 106 9.80665 10

9.80665 104

1.01972 10

Ex. 1.2kgf/cm2 =1.2 9.80665T 10-2=0.1176798 MPa

Pression

g. Pressure

Pruefdruck

Bar

kgf/cm 2

atm

mmH 2O

psi(lbw/in 2)

1 X 10 -6

1 10-5

1.01972 10-5

9.86923 10-6

1.01972 10-1

1.45038 10-4

1 106

1.01972 105

1.45038 102

MPa

0.0980665 1.01325 9.80665 1.33322 6.89474

104

9.80665

1.01972 10

9.86923

9.80665 10-1

9.67841 10-1

1.03323 1.0 10-4

1.03324 104

9.67841 10-5 1.31579 10-3

1.35951 10

10-1 10-6

1.01325 105

1.01325

9.80665

10-4 10-3

1.33322 102

9.80665 10-5 1.33322 10-3 6.89474 10-2

103

6.89474

1.35951 10-3 7.03070 10-2

6.80460 10-2

104

1.0

1.42233 10

1 7.03070 10

1.46959 10 1.42233 10-3 1.93368 10-2

Ex. 120 kgf/ cm2 =120 9.80665 104=11767980Pa=11.76798MPa 1Pa=1N/m2 , 1MPa=1 106Pa

Equivalent travail mecanique de lachaleur

h. Work energy amount

Leistung

kW.h

kgf.m

kcal

ft.lb

2.77778 10-7

1.01972 10-1

2.38889 10-4

7.37555 10-1

3.6 105

3.67098 105

8.6 102

2.65519 105

9.80665

2.34270 10-3

4.18605 103

2.72407 10-6 1.16279 10-3

1.35583

3.76621 10-4

4.26858 102 1.38257 10-1

3.23899 10-4

7.23292

-17.8

3.08743 103

-12.2

-6.7

-1.1

Ex. 12kgf. m =12 9.80665=117.6798J, 1J=1W .S, 1W .h=3600W .S, 1cal=4.1865J

Puissance Wirkungsgrad

i.Work efficiency

l . Temperature Temperature Temper atur

4.4

kgf.m/s

kcal/h

10.0

1.01922 102

1.35962

1.34048

8.6000 102

9.80665 10-3 7.355 10-1

8.43371

21.1

7.5 10

1.31456 10-2 9.85925 10-1

15.6

1.33333 10-2

6.32529 102

26.7

7.60707 10 1.18572 10-1

1.01428

6.41564 102

1.58095 10-3

1.55869 10-3

32.2

100

37.8

110

43.3

120

48.9

130

54.4

140

60.0

150

65.6

160

71.1

170

76.7

180

82.2

Geschwindigkeit

190

87.8

m/sec

km/h

ft/min

mile/h

200

93.3

3.6

3.2808

2.2370

210

98.9 100.0

7.46 10-1 1.16279 10-3

Ex. 10.2PS=10.2 7.355 10 =7.5021kW -1

j.Torque

Couple

kgf.m

Drehmoment ft.lbs

N.m

7.233

9.80665

0.1383

1.35582

0.1020

0.2249

Ex. 12kgf. m =12 9.80665=117.6798N.m k.Velocity

Vitesse

0.2778

54.68

0.6214

212

0.00508

18.288

11.639

220

104.4

230

110.0

240

115.6

0.447

1.6093

0.19398

F=32 + 9/5 C

KUBOTA Corporation

CONSTRUCTION MACHINERY DIVISION 2-47, SHIKITSUHIGASHI 1-CHOME, NANIWA-KU, OSAKA, JAPAN

EDITOR:

CONSTRUCTION MACHINERY MANUFACTURING DEPT. SERVICE SECTION HIRAKATA PLANT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN PHONE :+81-72-840-1195 FAX :+81-72-890-2886

KUBOTA Corporation

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