Kubota KX91-3a, U35-3a, KX121-3a, KX101-3a, KX161-3a Workshop Manual

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WORKSHOP MANUAL

KUBOTA EXCAVATOR

KX91-3S

KX121-3S

U35S,U35-3S

·D

, 101-3

,161-3S

, U45-3S

Minor change Chapter

·D

Code No.97899-61260

Record of Revisions

Symbol Date Main Revised Points & Corrective Measures Person-in-charge

CONTENTS

I Sales Engineering Section............................................... I-1

A. Quick feature chart ................................................................................. I-2

B. Feature discriptions ................................................................................ I-4

C. New innovations ..................................................................................... I-6

D. Specifications: Super series (KTC, KCL, KTA-version).......................... I-7

II Service Engineering Section........................................... II-1

A. General outline ...................................................................................... II-2

B. Finger control service port system....................................................... II-22

C. Hydraulic system modification ............................................................. II-57

D. Hydraulic circuit diagram ..................................................................... II-91

E. Engine upgrade ................................................................................. II-109

F. Electrical system................................................................................ II-114

EU-version

KX91-3D, KX101-3D,KX121-3D, KX161-3D U35-3D, U45-3D

PP-version

KX91-3S, KX121-3S, KX161-3S U35S, U35-3S, U45-3S

Note: EU-version is for KE, KUK, and KBM. PP-version is for KTC, KCL, and KTA.

This WSM minor change edition has been compiled to explain the main contents of the minor change, such as new service port system, new auto-idle system, some hydraulic system change, engine upgrade for KX161-3S, etc. As for the service information which are identical to the machines before minor change,

please refer to the correspondent WSM.

WSM Minor Change I Sales Engineering Section

I Sales Engineering Section

A. Quick feature chart..............................................................I-2

B. Feature discriptions.............................................................I-4

C. New innovations..................................................................I-6

D. Specifications: Super series (KTC, KCL, KTA-version) ......I-7

I - 1

WSM Minor Change I Sales Engineering Section

A. Quick feature chart

a. KX91-3S, KX91-3D, KX101-3D, U35S, U35-3S, U35-3D

Basic performance improved (new)

Greater working range of this class (1) Maximum digging and dumping heights (2) Maximum digging depth

Safeness upgraded

(1) Full-scale 4-post ROPS/FOPS

canopy

(3) Standard equipped with ROPS/

FOPS cabin (cab type)(with

steel-framed skylight) (4) Engine neutral start (5) Travel lock (6) Master key-compatible immo-

bilizer (option)

Operator’s comfort enhanced

(1) Digital navigation system (2) Heater with outside-air inlet

defroster (standard on cab type)

(3) Cup holder

(standard on cab type)

(4) Optional headlights

(option on cab type)

Maintainability

(1) Hydraulic components collectively located

on the right machine side (2) Right hood fully opened (3) Sectional dozer hose, etc.

Better maneuverability

(1) Service port local control (wrist rest type) (2) Travel bi-speed button (dozer lever) (3) Independent swing pedal on the left side (hydraulic pilot)

I - 2

WSM Minor Change I Sales Engineering Section

b. KX121-3S, KX121-3D, KX161-3S, KX161-3D, U45-3S, U45-3D

New immobilizer system introduced

Thumb bracket adopted

(North America)

Travel bi-speed switch

(Dozer lever)

Independent swing pedal

on the right side

(Europe)

Service port knob control

Digital navigation system adopted

Greater engine output (KX161-3S)

Sedimenter separately located

Larger fuel tank capacity

(KX91-3S, KX161-3S)

North America, Australia, Europe

I - 3

WSM Minor Change I Sales Engineering Section

B. Feature discriptions

(Super series)

Boom operation

Kubota's Hydraulic Matching System allows easy, simultaneous and smooth operations of the boom, arm, bucket and house swing. Perfectly matched speed, power and cylinder timing deliver extraordinary responsiveness, even with the slightest operator movements or in the toughest conditions (The KX121-3 and KX161-3 feature the Load Sensing Hydraulic System).

Strongest bucket breakout force in its class

Kubota's Hydraulic Matching system is unmatched for power or ease of use. Load sensing hydraulics, which automatically regulate and distribute optimum oil amounts to each cylinder, make it ideal for your toughest trenching projects or your lightest dozing tasks. In any situation, you can always rely on the KX-3 Super Series for complete work efficiency.

Safety

With our Engine Start Lockout System, the engine cranks only when the safety levers are raised. Our safety Lever Lockout System helps prevent unexpected excavator and attachment movement when entering or exiting the unit. An Auto House Parking Brake automatically locks the house in the position it was in when the engine was shut off. This means that a swing lock pin is no longer required, making the excavator more compact during transport and secure when parked on an incline. And an OSHA certified ROPS/FOPS canopy and cab protects against rollovers or falling objects.

Wide Working Range

The KX-3 Super Series' powerful and responsive front working group is perfect for all your digging, lifting and loading jobs. Plus, with increases and improvements to our bucket capacities, reach and digging depths, the Super Series exceed many of the latest construction site requirements.

I - 4

WSM Minor Change I Sales Engineering Section

Operator comfort

Get total comfort from a spacious operating area that features ultra quietness, deluxe climate control and a high back suspensionengineered seat with adjustable wrist rests. Well-placed controls and levers provide an increase in deck space and foot room. A lowsound-level cab design reduces engine vibration to a minimum. Our ergonomic seat and wrist supports adjust to your individual posture. And with T.P.S.S. technology, change quickly between ISO and SAE operating patterns without tools or leaving your seat, and with only the flick of a switch. Combined, these advantages reduce fatigue while helping to maintain your peak performance (A/C available only on KX121-3 and KX161-3 models).

Easy maintenance

The KX-3 Super Series not only make daily maintenance a breeze, but also make more-detailed periodic maintenance hassle-free as well. Wide opening side and rear covers, as well as centrally located components, give you quick and easy access for the servicing of vital areas like the engine, the fuel/water separator, the radiator, coolant, air filter, control valve and hydraulic tank.

KUBOTA engine

The ultra powerful, incredibly dependable Kubota diesel engines deliver unmatched horsepower while minimizing emissions to meet EPA standards. They produce quick starts in temperatures as low as 4qF, low sound as well as low vibration. They even then follow through with superior fuel-efficiency.

Extraordinary stability and lifting capacity

The KX-3 Series is equipped with innovative and superior counter balancing technology for increased excavator stability. Long tumbler distance, a lower center of gravity and Double Outer Flanged Lower Track Rollers combine to deliver safe and effective performance when working over the side, with hydraulic attachments mounted or when lifting a broad range of heavy objects.

I - 5

WSM Minor Change I Sales Engineering Section

C. New innovations

DIGITAL PANEL

Informative, interactive and functional. Kubota's all-new liquid crystal display (LCD) panel accurately shows easy-to-understand diagnostics and digital readings. The Kubota Intelligent Control System (KICS) will even alert the operator to when routine maintenance is due. Plus, when filling-up with fuel, the KICS informs the operator that the tank is nearly full. The panel reduces excavator downtime and repair fees for a decrease in total operating costs.

Language selection display Information when service time comes Low fuel display

USER-FRIENDLY OPERABILITY

SHORT STROKE OPERATING LEVER

The new operating levers require less effort and shorter movement, increasing control, responsiveness and comfort. With only the slightest flick of the wrist, smooth excavator operation and reduced operator fatigue are assured.

THUMB BRACKET

The optional hydraulic thumb opens up opportunities for loading and material handling tasks. It allows you to pinch material between the thumb and bucket, retracting for normal excavation. Installation time is significantly reduced with the factory installed

2 SPEED SWITCH

The new 2-Speed Travel Switch is conveniently mounted on the dozer lever for easier operation and control. It allows increased floor space as well as advanced user-friendly travel speed changes.

FUEL-WATER SEPARATOR

The Water Separator has been relocated to an easy to reach position under the improved Fuel Filter. This gives the Super Series Models with enhanced fuel and water filtration, increased durability and greater overall excavator performance.

NEW WRIST RESTS

Set the new, custom adjustable armrests to your favorite position, or just move them out of the way. Either way, they help reduce arm movement and operator fatigue for increased job efficiency.

BREAKER SWITCH

The breaker switch lets you manage the hydraulic breaker attachment quickly, easily and without having to reach for the control. Repositioned from the floor, simple forefinger activation as well as convenient thumb operation of the hydraulic breaker is possible.

I - 6

WSM Minor Change I Sales Engineering Section

D. Specifications: Super series (KTC, KCL, KTA-version)

1.Main machine specifications

Model KX91-3S U35S / U35-3S KX121-3S KX161-3S

Type of ROPS/FOPS Canopy / Cab Canopy / Cab Canopy / Cab Canopy / Cab

Type of tracks Steel / Rubber Steel / Rubber Steel / Rubber Steel / Rubber

Engine Model Kubota D1503-M Kubota D1503-M Kubota V2203-M Kubota V2403-M

Output (SAE 1349 gross) HP(kW)/rpm 28.0 (20.9) / 2300 28.0 (20.9) / 2300 42.0 (30.7) / 2250 47.0 (34.6) / 2200

Displacement cu.in. (cc) 91.5" (1499) 91.5" (1499) 134.1" (2197) 148.5" (2434)

Dimensions Overall length ft.in. (mm) 15'7" (4760) 15'5" (4695) 16'9" (5090) 18'8" (5540)

Overall height

Overall width ft.in. (mm) 5'1" (1550) 5'7" (1700) 5'7" (1700) 6'5" (1960)

Min. ground clearance in. (mm) 11.6" (295) 11.4" (290) 13.0" (330) 12.6" (320)

Hydraulic system Pump capacity GPM (l/min) 10.9 (41.4) variable u 2

Auxiliary hydraulic flow GPM (l/min) 10.9 (41.4) 10.3 (39.1) 15.9 (60.0) 19.3 (73)

Max. breakout force

Drive system

Swing system Unit swing speed rpm 9.4 8.9 9.4 9.3

Travel Speed

Max. traction force lbs.(kgf) 5600 (2540) 6098 (2766) 9697 (4398) 12861 (5833)

Tumbler distance ft.in. (mm) 5'1" (1560) 5'6" (1665) 5'8" (1710) 6'6" (1990)

Crawler length ft.in. (mm) 6'7" (2000) 6'11" (2100) 7'2" (2175) 8'2" (2500)

Shoe width in. (mm) 11.8" (300) 11.8" (300) 13.8" (350) 15.7" (400)

Ground contact pressure

Boom swing angle

canopy ft.in. (mm) 8'0" (2440) 8'0" (2440) 8'3" (2495) 8'4" (2540)

cab ft.in. (mm) 8'0" (2440) 8'0" (2440) 8'2" (2480) 8'4" (2540)

5.5 (20.9) Gear u 1

Bucket lbs.(kgf) 8059 (3655) 8397 (3809) 8754 (3970) 11118 (5043)

Arm lbs.(kgf) 3592 (1629) 4222 (1915) 3947 (1790) 4967 (2253)

Low mph (km/h) 1.9 (3.1) 1.9 (3.0) 1.7 (2.7) 1.6 (2.5)

High mph (km/h) 2.9 (4.8) 2.9 (4.6) 3.1 (5.0) 2.9 (4.6)

Canopy Cab Rubber/ Steel

Rubber/Steel psi (kgf/cm2) 4.70 (0.33) / 4.56 (0.32) 4.8 (0.34) / 5.0 (0.35) 4.41 (0.31) / 4.41 (0.31) 3.27 (0.23) / 3.41 (0.24)

Left degree 80 70 80 80

Right degree 50 50 50 50

psi (kgf/cm2) 4.64 (0.33) / 4.70 (0.33) 4.7 (0.33) / 4.8 (0.34) 4.41 (0.31) / 4.55 (0.32) 4.27 (0.30) / 4.41 (0.31)

10.3 (39.1) u 2

5.5 (20.7) u 1

25.0 (94.5) 31.4 (118.8)

Blade

Dimensions

Max.lift above ground in. (mm) 14.6" (370) 14.6" (370) 15.7" (400) 17.9" (455)

Max.drop below ground in. (mm) 14.6" (370) 14.6" (370) 15.9" (405) 14.8" (375)

Hydraulic oil (reservoir/system) gal (l) 9.5 (36) / 14.5 (55) 9.5 (36) / 14.5 (55) 11.6 (44) / 17.7 (67) 11.6 (44) / 17.7 (67)

Fuel reservoir gal (l) 13.2 (50) 10.6 (40) 16.9 (64) 18.5 (70)

Operating weight Including Canopy Rubber/Steel lbs.(kgf) 7110 (3225) / 7319 (3320) 8025 (3640) / 8234 (3735) 9063 (4110) / 9283 (4210) 11532 (5230) / 12348 (5600)

operator's weight 175lbs. Cab Rubber/Steel lbs.(kgf) 7330 (3325) / 7540 (3420) 8267 (3750) / 8477 (3845) 9261 (4200) / 9371 (4250) 11698 (5305) / 12513 (5675)

Width ft.in. (mm) 5'1" (1550) 5'7" (1700) 5'7" (1700) 6'5" (1960)

Height in. (mm) 13.2" (335) 13.2" (335) 13.8" (350) 15.4" (390)

I - 7

WSM Minor Change I Sales Engineering Section

2.DIMENSIONS

3.WORKING RANGE

Model KX91-3S U35S KX121-3S KX161-3S

A Max. digging height ft.in. (mm) 16'3" (4940) 16'3" (4945) 17'10" (5420) 18'9" (5715)

B Max. dumping height ft.in. (mm) 11'7" (3530) 11'7" (3525) 12'9" (3890) 13'8" (4155)

C Max. digging depth ft.in. (mm) 10'5" (3185) 10'4" (3140) 11'6" (3505) 12'7" (3830)

D Max. vertical digging depth ft.in. (mm) 7'10" (2390) 7'4" (2230) 8'2" (2480) 8'6" (2585)

E Max. digging radius @ ground ft.in. (mm) 16'10" (5135) 16'11" (5145) 18'0" (5475) 20'1" (6130)

F Max. digging radius ft.in. (mm) 17'3" (5245) 17'3" (5260) 18'5" (5600) 20'6" (6260)

G Min. turning radius

H Min. tail turning radius ft.in. (mm) 4'4" (1310) 33.5" (850) 4'3" (1300) 3'7" (1090)

W/O ft.in. (mm) 6'2" (1870) 6'7" (2015) 6'9" (2060) 7'11" (2420)

W swing ft.in. (mm) 4'9" (1440) 5'3" (1603) 5'6" (1665) 6'5" (1955)

The company reserves the right to change the above specifications without notice. This brochure is for descriptive purpose only. Please contact your local Kubota dealer for warranty infomation. For your safety, KUBOTA strongly recommends the use of a Rollover Protective structure (ROPS) and seat belt almost all applications.

4.LIFTING CAPACITY

U35S KX91-3S KX121-3S KX161-3S

LIFTING CAPACITY

OVER-FRONT

LIFT

POINT

HEIGHT

GL 6 2.13 1.61 - 2.13 1.42 - 1.78 1.42 1.36 1.78 1.30 1.03 3.09 2.19 2.01 3.09 1.83 1.46 4.29 2.6 2.12 4.29 2.59 1.66

BLADE DOWN

unit=1000lba unit=1000lba unit=1000lba unit=1000lba unit=1000lba unit=1000lba unit=1000lba unit=1000lba

LIFT POINT RADIUS

(ft)

4 2.79 1.76 1.58 2.52 1.39 1.10 2.42 1.58 1.43 2.29 1.27 1.01 4.03 2.44 2.15 3.15 1.78 1.43 - 3 2.25 - 2.49 1.63

2 3.28 1.91 1.63 2.42 1.35 1.08 2.95 1.74 1.50 2.18 1.23 0.99 4.66 2.67 2.27 3.02 1.73 1.41 3.9 3.33 2.36 3.9 2.4 1.59

0 3.46 1.99 - 2.37 1.33 - 3.22 1.84 1.53 2.11 1.20 0.97 4.89 2.81 2.34 2.96 1.70 1.38 4.73 3.33 2.43 4.3 2.34 1.57

(ft)

8 12 MAX 8 12 MAX 8 12 MAX 8 12 MAX 8 12 MAX 8 12 MAX 8 12 MAX 8 12 MAX

LIFTING CAPACITY

OVER-SIDE

LIFT POINT RADIUS (ft)

LIFTING CAPAC-

ITY OVER-FRONT

BLADE DOWN

LIFT POINT RADIUS (ft)

LIFTING CAPACITY

OVER-SIDE

LIFT POINT RADIUS

(ft)

LIFTING CAPACITY

OVER-FRONT

BLADE DOWN

LIFT POINT RADIUS (ft)

LIFTING CAPACITY

OVER-SIDE

LIFT POINT RADIUS

(ft)

LIFTING CAPACITY

OVER-FRONT BLADE DOWN

LIFT POINT RADIUS (ft)

LIFTING CAPACITY

OVER-SIDE

LIFT POINT RADIUS (ft)

Machine with ROPS canopy and rubber crawler, without bucket

I - 8

WSM Minor Change II Service Engineering Section

II Service Engineering Section

A. General outline...................................................................II-2

a. New engineering points........................................................................ II-2

b. Photos of main modified parts.............................................................. II-3

c. Major specifications incorporated......................................................... II-4

d. Quantity water and oil........................................................................... II-5

e. Quality specifications............................................................................ II-6

B. Finger control service port system ...................................II-22

a. Feature and purpose.......................................................................... II-22

b. Outline of control system.................................................................... II-23

c. Hydraulic circuit diagram .................................................................... II-25

d. Knob structure and function ............................................................... II-26

e. Initial settings of the knob................................................................... II-32

f. S/P valve start point setting................................................................ II-34

g. Manual feeling setting ........................................................................ II-40

h. Panel display operation flow chart...................................................... II-42

i. Proportional control solenoid valve (S/P valve).................................. II-51

j. Other controls..................................................................................... II-55

k. Troubleshooting.................................................................................. II-56

C. Hydraulic system modification .........................................II-57

a. Outline................................................................................................ II-57

b. Hydraulic pump: KX161-3s, KX161-3D ............................................. II-58

c. Control valve ...................................................................................... II-63

d. Accumulator ....................................................................................... II-68

e. Hydraulic system line ......................................................................... II-73

f. Service port (S/P) solenoid valve ....................................................... II-82

g. Travel motor: KX91-3S: PP-version ................................................... II-85

h. Travel motor minor change: KX121-3SD, 161-3SD, U45-3SD......... II-89

D. Hydraulic circuit diagram..................................................II-91

E. Engine upgrade..............................................................II-109

a. General............................................................................................. II-109

b. Engine specifications........................................................................ II-109

c. Engine performance curve ............................................................... II-111

F. Electrical system............................................................II-114

II - 1

WSM Minor Change II Service Engineering Section

A. General outline

a. New engineering points

PP-version (KTC, KCL, KTA) EU-version

No New contents

8 Digital panel 4 Arm with thumb

bracket, option Finger control ser-



vice port 3 Breaker switch 7 Two speed switch 6 Fuel-water separa-

tor 9 Anti-theft system - 5 Accumulator in pilot

control line 2 Proportional control

solenoid valve

10 Upgraded engine

V2403-M -

KX91-3S, U35S, U35-3S

٤ ٤ ٤٤٤٤

KX121-3S, KX161-3S, U45-3S

KX161-3S PP-

version only

KX91-3D, KX101-3D

٤٤٤٤

----

U35-3D KX121-3D,

KX161-3D

U45-3D

II - 2

WSM Minor Change II Service Engineering Section

b. Photos of main modified parts

No.1 Knob switch

No.2 S/P solenoid valve

No.8 Digital meter panel

No.4 Arm with thumb bracket

No.8 Digital meter panel, AI-version

No.5 Accumulator in pilot line

No.6 Fuel-water separator

No.7 Two speed switch

II - 3

No.9 Anti-theft system

(EU-version)

WSM Minor Change II Service Engineering Section

c. Major specifications incorporated

- KX91-3S, KX91-3D, KX101-3D, U35S, U35-3S, U35-3D -

Specs.

STD arm 1550mm 1275mm 1350mm 1350mm 1350mm 1350mm Rubber track 300mm mm300mm mm Iron track 300mm mm300mm mm

Cab (Rops / Fops)

Canopy (Rops / Fops)

Telescopic arm (1246 - 2046)

Bucket Local content mm Local content m

Travel alarm

Canopy light

Arm rest Wrist rest

TPSS

Engines type D1503-M mmmmmm

Third line valve

KTC, KCL KTA EU EU KTC, KCL KTA EU

KX91-3S

{ {

{ ² {{²²²

² { ²²²{ ² ² { ²²²{ ²

{

{ ²² { ²

²²{{²²{

D KX101-3D

KX91-3

Wrist rest mm

U35S U35-3S

U35-3

{{ {{

{

Wrist rest

- KX121-3S, KX121-3D, KX161-3S, KX161-3D, U45-3S, U45-3D -

Specs.

STD arm 1600mm m 1300mm 1780mm m 1480mm 1360mm m Rubber track 350mm mm400mm mm400mm m

Iron track 350mm mm

Cab (Rops / Fops)

Canopy (Rops / Fops)

Telescopic arm (1246 - 2046)

Bucket Local content m Local content mmm Travel alarm

Canopy light

Arm rest

TPSS

Engine type

Third line valve

STD V2203-M-E2BH-2-N V2403-M-E2BH-1 V2203-M-E2BH-2-N Air con. V2203-M-E2BH-3-N V2403-M-E2BH-2 V2203-M-E2BH-3-N

KX121-3S

KTC, KCL KTA EU KTC, KCL KTA EU KTA EU

{ {

²²² ²² ² ² ²

² { ²²{ ² { ² ² { ²²{ ² { ²

Wrist rest

{

{ ² { ² { ²

{{

KX121-3

Wrist rest m

KX161-3S

400mm /

550mm

{{ {{

{

KX161-3D

mmm

Wrist rest

U45-3S

400mm /

550mm

{

U45-3D

Wrist rest

II - 4

WSM Minor Change II Service Engineering Section

d. Quantity water and oil

Radiator

Reserve tank

Engine Crank case

Hydraulic oil Full

Hydraulic oil Tank

Wheel motor

Track roller

Upper roller

Front idler

Fuel tank

Unit

gal

KX91-3S KX91-3

7.3

1.93

1.6

0.42

5.3

1.40

55.0

14.53

36.0

9.51

0.5

0.13 70

0.018 60

0.016 80

0.02

46.5

12.30

KX101-3D

U35S, U35-3S

U35-3D

Remarks

L.L.C

40.6

10.6

SAE10W30(CD)

ISO 46

SAE90 (API GL-4)

SAE30(CD)

Radiator

Reserve tank

Engine Crank case

Hydraulic oil Full

Hydraulic oil Tank

Wheel motor

Track roller

Upper roller

Front idler

Fuel tank

Unit

gal

KX121-3S KX121-3

7.4 (7.7)

1.96 (2.04)

1.1

0.29

8.5

2.25 75

19.8 46

12.2

0.5

0.13 80

0.021 60

0.016 80

0.021 64

16.9

U45-3S

U45-3

KX161-3S

KX161-3

Remarks

0.5

0.13

0.9

0.24

0.013

L.L.C

SAE10W30(CD)

ISO 46

SAE90 (API GL-4)

SAE30(CD)

NOTE: In the super series, coolant amount has been increased due to the warming line of the service

port value.

II - 5

WSM Minor Change II Service Engineering Section

e. Quality specifications

Note: 1. Only those data with bold letter and with shadow are different from those of the previous models before modification.

2. EU-version will be announced later.

U35S ( KTC, KCL ), U35-3S ( KTA ), KX91-3S(KTC,KCL,KTA) Machine specification : Service port, Wrist rest, STD-arm, KBT-cab, KBT-bucket.

No Specificatios Items Unit

Q1 Main Speed JIS A8404

1 1 Machine size

2 1 Weight

3 1 Performance

2Rrpm9r 0.9 9.4 r 0.9 3

7 Gradeability deg 30 30

4 1 Rear end min. turning radius mm 850 r 17 1310 r 26

2 Swivel frame rear ground clearance mm 525 r 11 530 r 11

3 Tambler center distance mm 1670 r 50 1560 r 47

4 Crawler total length mm 2100 r 63 2000 r 60

5 Crawler total width mm 1700 r 34 1550 r 31

6 Min. ground clearance mm 285 r 9290r 9

5 1 Front attach-

ment

2 SAE, JIS m3 0.1 0.1

3 Bucket width mm 555 r 12 555 r 11 Without side cut-

4 Swing angle Canopy L deg 70 r 280r 2 5 Canopy R deg 50 r 248r 2 6 Cabin L deg r 80 r 2 7 Cabin R deg r 48 r 2

Total length (Transport)

Total w i dth

Total height (Canopy)

Total height (Cabin)

Machine weight (Canopy)

Machine weight (Cabin)

Swivel speed

Travel speed

Bucket heaped capacity

Lrpm9r 0.9 9.4 r 0.9

Lubber F1

Lubber F2

Iron F1

Iron F2

CECE m3  0.077

mm 4695 r 94 4760 r 95

inch 184.8 r 3.7 187.4 r 3.7

mm 1700 r 17 1550 r 16

inch 66.9 r 0.7 61.0 r 0.6

mm 2440 r 24

inch 96.1 r 0.9

mm 2440 r 24

inch 96.1 r 0.9

kg 3560 r 71 3225 r 65 Fuel tank

lbs 7848.4 r 156.5 7109.8 r 143.3

kg 3660 r 73 3225 r 67

lbs 8068.8 r 160.9 7109.8 r 147.7

km/h 3.0 r 0.3 3.1 r 0.3

mph 1.86 r 0.19 1.93 r 0.19

km/h 4.6 r 0.5 4.8

mph 2.86 r 0.31 2.98 r 0.31

km/h 2.9 r 0.3 3.0 r 0.3

mph 1.80 r 0.19 1.86 r 0.19

km/h 4.6 r 0.5 4.8 r 0.5

mph 2.86 r 0.31 2.98 r 0.31

inch 33.5 r 0.7 51.6 r 1.0

inch 20.7 r 0.4 20.9 r 0.4

inch 65.7 r 2.0 61.4 r 1.9

inch 82.7 r 2.5 78.7 r 2.4

inch 66.9 r 1.3 61.0 r 1.2

inch 11.2 r 0.4 11.4 r 0.4

yd3 

yd3 0.13 0.13

inch 21.9 r 0.5 21.9 r 0.4

U35S (KTC, KCL)

U35-3S (KTA)

KX91-3S

(KTC, KCL, KTA)

r 0.5

0.01

ter

Remarks

II - 6

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

5 8 Front attach-

ment

9 Ground level Max. digging

10 Ground level Min. finish

11 Max. digging depth mm 3115 r 62 3185 r 64

12 Max. vertical digging depth mm 2185 r 44 2390 r 48

13 Max. digging

14 Cabin mm 4660 r 93

15 Max. dump

16 Cabin mm 3265 r 65

17 Max. dump

18 Cabin mm 1125 r 34

19 Mini. turning

20 Cabin mm 2190 r 66

21 Mini. turning

22 Cabin mm -

6 1 Dozer Width mm 1700 r 5 1550 r 5

2 Height mm 335 r 25 355 r 10

3 Max. lift above GL mm

4 Max. below GL mm

Q2 Main Specs JIS A8404

1 1 Bucket tooth slaggish mm 70 >

2 Tilt amount of front attachment mm 10 >

3 Dozer's declination mm 10 >

2 1 Eccentric amount from swing center mm From swivel cen-

2 Distance to swing center mm 72 r 25.0 135 r 25.0

3 1 Approach angle deg 31.4 r 3.5 30 r 3

Max. digging radius mm 5255 r 79 5245 r 79

inch

radius

Conopy mm 4890 r 98 4875 r 98

height

Conopy mm 3470 r 69

height

Conopy mm 1230 r 37 965 r 29

height (Arm vertical)

Conopy mm 2065 r 62 1940 r 116

radius

Conopy mm radius (Left swing)

mm 5140 r 77 5135 r 77

inch 202.4 r 3.0 202.2 r 3.0

mm 1755 r 35 1410 r 28 Bucket bottom

inch 69.1 r 1.4 55.5 r 1.1

inch 122.6 r 2.4 125.4 r 2.5

inch 86.0 r 1.7 94.1 r 1.9

inch 192.5 r 3.9 191.9 r 3.9

inch 183.5 r 3.7

inch 136.6 r 2.7

inch 128.5 r 2.6

inch 48.4 r 1.5 38.0 r 1.1

inch 44.3 r 1.3

inch 81.3 r 2.4 76.4 r 4.6

inch 86.2 r 2.6

inch -

inch 66.9 r 0.2 61.0 r 0.2

inch 13.2 r 1.0 14.0 r 0.4

inch

inch 2.76 >

inch 0.39 >

inch

inch 2.83 r 1.0 5.31 r 1.0

U35S (KTC, KCL)

U35-3S (KTA)

206.9 r 3.1 206.5 r 3.1

370 r 26 375 r 26

14.6 r 1.0 14.8 r 1.0 370 r 26 365 r 26

14.6 r 1.0 14.4 r 1.0

KX91-3S

(KTC, KCL, KTA)

Remarks

horizontal

ter

II - 7

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

4 1 Crawler height mm 420 r 8 430 r 9 Include grouser

inch 16.54 r 0.31 16.93 r 0.35

2 Max. crawler height mm 450 r 9455r 14

inch 17.72 r 0.35 17.91 r 0.55

Q3 Engine performance

1 1 "Max, engine

rpm"

2 1 pump relief rpm - 3 2 pump relief rpm - 4 3 pump relief rpm - - Boom, arm,

5 2 pump relief rpm 2300 < 6 Dozer+2 pump relief rpm 2100 <

2 1 Idler rpm

Q4 Travelling performance

1 1 Travel motor

block performance

2 Travel motor

block performance

2 1 Max, Traction

force

2 F2 kgf 1546 1485

3 1 Travel straight-

ness

2F2 mm600>

3 Dozer F1 mm 600 > Dozer up &

4 Dozer R1 mm 600 >

4 1 Track shoe sag

distance

2 Rubber mm 10 to 15

Q5 Work performance

1 1 Boom lifting capacity kgf 575 434 Front end, Arm

2 Arm digging force kgf 1888 1629 Bucket tooth

3 Bucket digging force kgf

4 Dozer force down kgf

no load rpm 2550 >

L mm 300 > 20 deg, 10 min

inch 11.81 >

Rubber mm 300 >

inch 11.81 >

F1 kgf 2766 2655 On the center

kN 27.1 26.0 lbs 6098 5853

kN 15.2 14.6 lbs 3408 3274

F1 mm 600 > 10m distance

inch 23.62 >

Iron mm 75 to 80

inch 2.95 to 3.15

inch 0.39 to 0.59

kN 5.6 4.3

lbw 1268 957

lbw

U35S (KTC, KCL)

U35-3S (KTA)

1050 r 50

18.5 16.0 4162 3591 2882 / 3810 3655 Machine stance

28.3 / 37.4 35.8 6354 / 8400 8058 2652 2841 Cutting edge

26.0 27.9 5847 6263

KX91-3S

(KTC, KCL, KTA)

Remarks

on the spocket

swivel

down 10m distance

extend bucket crowd, at tooth

root

to JIS bucket tooth root

down force at ground level

II - 8

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

2 1 Boom speed Canopy up 1st sec 2.4 r 0.3 2.1 r 0.3 Oil temp.

2 up 2nd sec 3 down sec 3.0 r 0.3 2.9 r 0.3 4 down sec 5 Cabine up (GoT) sec - 6 up (LoT) sec - 7 down (ToG) sec - 8 down (ToL) sec -

3 1 Arm speed crowd sec 3.1 r 0.3

2 extend sec 2.7 r 0.3 3 r 0.3

4 1 Bucket speed crowd sec 2.6 r 0.3 2.7 r 0.3 Oil temp.

2 dump sec 1.7 r 0.3 1.9 r 0.3

5 1 Dozer speed up (GoT) sec - Max. down to

2 up (LoT) sec 2.2 r 0.3 2.1 r 0.3 Max. up to max.

3 down (ToG) sec - 4 down (ToL) sec 2.9 r 0.3 2.8 r 0.3

6 1 Arm cylinder cavitation mm 5 > Oil temp.

inch 0.20 >

7 1 Max. digging

height radius

2 Cabine mm 3215 r 322

3 Max. dump

height radius

4Cabine mm

5 Bucket bottom

height at arm vertical

6 Cabine mm 1415 r 42

7 Bucket wrist angle degree - 190 r 3

Q6 Swivel, swing performance

1 1 Swivel torque L kgfm 738 627 Arm

2 1 Swivel angle L deg 15 < 20 , 19< Bucket load=JIS

2 R deg 15 < 20 , 19<

3 1 Swivel block performance L deg 5 > 6 >

2Rdeg5>6> 3Ldeg30> 4Rdeg30>

4 1 Swivel start-up speed L sec 2.5 r 0.3 3 r 0.3 0~90 deg swivel

2Rsec2.5r 0.3 3 r 0.3

Canopy mm 2800 2920

inch 110.24 114.96 r 11.50

inch 126.57 r 12.68

Canopy mm

inch 103.19 r 6.18 109.84 r 6.57

inch

Canopy mm 1525 r 46 1265 r 48 Bucket horizon-

inch 60.04 r 1.81 49.80 r 1.89

inch 55.71 r 1.65

kN.m 7.2 6.1

lbs

kgf

kN.m 7.2 6.1

ftlbs

U35S (KTC, KCL)

U35-3S (KTA)

2621 r 157 2790 r 167 at bucket pin

2961 r 178

116.57 r 7.01

5338 4535

m

5338 4535

738 627

KX91-3S

(KTC, KCL, KTA)

292

Remarks

50r5qC (122r41qF ) Ground to max. height (exculude cushioning)

50r5qC (122r41qF)

max. up

down

95r5qC (203r41qF)

tal

extend,show/ Quick

heapedu1.8

II - 9

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

5 1 Swing speed Canopy L sec 5.8 r 0.3 5.9 r 0.5

2Rsec4.6r 0.3 4.5 r 0.5 3 Cabine L sec 4Rsec

6 1 Swing Lock Swivel R&L mm 10 > 90 deg-swivel,

inch 0.39 >

2 Reciprocating

motion

Q7 Hydraulic performance

1 1 Relief pressure setting P1 kgf/cm2 255 r 5 245 At pump delivery

2 P2 kgf/cm2 255 r 5 245

3 P3 kgf/cm2 207 r 5 210

4 P4 kgf/cm2 40 +3, -0

2 1 Cylinder oil

sealing capacity

295r5qC

3Arm50r5qC

4 Bucket 50r5qC

5 Dozer 50r5qC

3 1 Boom cushioning performance 30qC(86qF) sec 3 >

250qC(122qF) sec 0.4 to 1.3 380qC(176qF) sec 0.3 <

Q8 Lever operating force & stroke

1 1 Boom lever operating force up kgf 1.7 r 1.0 1.7 r 0.5

2 down kgf 1.4 r 1.0 1.4 r 0.5

L / R Swing mm 90 deg-swivel,

inch

MPa 25.0 r 0.5 24.0

bar 24.5 r 24.5 24.5

psi 3627 r 71 3485

MPa 25.0 r 0.5 24.0

bar 24.5 r 24.5 24.5

psi 3627 r 71 3485

MPa 20.3 r 0.5 20.6

bar 24.5 r 24.5 24.5

psi 2944 r 71 2987

MPa 3.9 +0.3, -0

bar 3.9 +0.03, -

psi 569 +43, -0

Boom 50r5qC

(122r41qF)

(203r41qF)

(122r41qF)

mm 6 > 20 > Arm extend,

inch 0.24 > 0.79 >

mm 6 > 20 >

inch 0.24 > 0.79 >

inch

mm 25 > Bucket load=JIS

inch 0.98 >

mm 20

inch 0.79

N16.67r 9.81 16.67 r 4.90

lbs 3.7 r 2.2 3.7 r 1.1

N13.73r 9.81 13.73 r 4.90

lbs 3.1 r 2.2 3.1 r 1.1

U35S (KTC, KCL)

U35-3S (KTA)

20 > 15 > height 1m, 10

0.79 > 0.59 >

KX91-3S

(KTC, KCL, KTA)

Remarks

100 times actual digging cylinder dislocation

100 times

50r5qC

bucket

min.

heapedu1.8

II - 10

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

1 3 Arm lever crowd kgf 1.7 r 1.0 1.7 r 0.5 Extend & crowd

N16.67r 9.81 16.67 r 4.90

lbs 3.7 r 2.2 3.7 r 1.1

4 extend kgf 1.4 r 1.0 1.4 r 0.5

N13.73r 9.81 13.73 r 4.90

lbs 3.1 r 2.2 3.1 r 1.1

5 Bucket lever crowd kgf 1.2 r 1.0 1.2 r 0.5 Dump & crowd

N 11.77 r 9.81 11.77 r 4.90

lbs 2.6 r 2.2 2.6 r 1.1

6 extend kgf 1.2 r 1.0 1.2 r 0.5

N 11.77 r 9.81 11.77 r 4.90

lbs 2.6 r 2.2 2.6 r 1.1

7 Swivel (Swing) lever R kgf 1.2 r 1.0 1.2 r 0.5 Left & right

N11.77r 9.81 11.77 r 4.90

lbs 2.6 r 2.2 2.6 r 1.1

8Lkgf1.2r 1.0 1.2 r 0.5

N11.77r 9.81 11.77 r 4.90

lbs 2.6 r 2.2 2.6 r 1.1

9 Dozer lever up kgf 2.0 r 0.5 Up & down

N 19.61 r 4.90

lbs 4.4 r 1.1

10 down kgf 2.0 r

N19.61r 4.90

lbs 4.4 r 1.1

11 Travel lever L Forward kgf 1.8 r 0.5

N 17.65 r 4.90

lbs 4.0 r 1.1

12 Back kgf 1.8 r 0.5

N17.65r 4.90

lbs 4.0 r 1.1

13 R Forward kgf 1.8 r 0.5

N 17.65 r 4.90

lbs 4.0 r 1.1

14 Back kgf 1.8 r 0.5

N17.65r 4.90

lbs 4.0 r 1.1

15 Accelerator lever up kgf 5.0 r 1.0 AI-version has

N 49.03 r 9.81

lbs 11.0 r 2.2

16 down kgf

lbs

17 Swing pedal R kgf 5.0 r 1.0

N49.03r 9.81

lbs 11.0 r 2.2

18 L kgf 5.0 r 1.0

N 49.03 r 9.81

lbs 11.0 r 2.2

U35S (KTC, KCL)

U35-3S (KTA)

0.5

3.5 r 1.0

34.32 r 9.81

7.7 r 2.2

KX91-3S

(KTC, KCL, KTA)

Remarks

accel.

II - 11

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

1 19 Safety lock

lever

20 down kgf

21 L up kgf 2.7 r 1.0 Up & down

22 down kgf 6.0 r 1.0 5.0 r 1.0

23 Travel Hi-Lo change kgf 1.5 r 0.5 3.1 r 1.0

2 1 Boom lever stroke up mm 110 r 10

2 down mm 110 r 10

3 Arm lever stroke crowd mm 110 r 10

4 extend mm 110 r 10

5 Bucket lever stroke crowd mm 85 r 10

6 Bucket lever stroke extend mm 85 r 10

7 Swivel, swing lever stroke R mm 85 r 10

8Lmm85r 10

9 Dozer lever stroke up mm 55 r 10

10 down mm 55 r 10

11 Tra vel lever

stroke

12 Back mm 73 r 10 75 r 10

13 R Forward mm 73 r 10 75 r 10

14 Back mm 73 r 10 75 r 10

15 Accel. Lever mm 55 r 10 65 r 10

Rupkgf0.8r 0.2 Up & down

N7.85r 1.96

lbs 1.8 r 0.4

lbs

N26r 10

lbs 19.5 r 7.4

N49r 10 49.03 r 9.81

lbs 43.4 r 7.4 11.0 r 2.2

N39r 10 30.40 r 9.81

lbs 10.8 r 3.6 6.8 r 2.2

inch 4.33 r 0.39

inch 3.35 r 0.39

inch 55.00 r 0.39

inch 2.17 r 0.39

L Forward mm 73 r 10 75 r 10

inch 2.87 r 0.39 2.95 r 0.39

inch 2.17 r 0.39 2.56 r 0.39

U35S (KTC, KCL)

U35-3S (KTA)

0.4 r 0.2

3.92 r 1.96

0.9 r 0.4

KX91-3S

(KTC, KCL, KTA)

Remarks

II - 12

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit

Q9 Stability

1 1 Standard arm,

Dynamic operation load limit

2 Front, dozer upkgf -

3 Bucket load to

4 Front, dozer upkgf - 294

5 Standard arm,

static limited load

6 Front kgf 450 428

Q10 Comfortability

1 1 Noise level At operator's

2Cabdb(A)81 > Cab door close 3 Noise 4db(A)95>

Bucket load to 10 degrees tipping

tip fully

Bucket load to tip fully

ear LPA

source;LWA

Side, dozer up

Side kgf 430 393

Canopy db(A)

7m db(A)

kgf - Arm extend,

N-

lbs -

Nlbs kgf - 276

N - 2706.64 lbs - 608.5

N - 2883.16 lbs - 648.2

N 4216.86 3854.01 lbs 948.0 866.4

N 4412.99 4197.25 lbs 992.1 943.6

U35S (KTC, KCL)

U35-3S (KTA)

81 > 80 >

KX91-3S

(KTC, KCL, KTA)

b u c k e t c r o w d oil temp.50r5qC (122r41qF)

Remarks

II - 13

WSM Minor Change II Service Engineering Section

KX121-3S, 161-3S : KTC, KCL, KTA Version Machine specification : Service port, TPSS, Arm rest, Long arm, 4 POSTcanopy, KTC-bucket

No Specificatios Items Unit KX121-3S KX161-3S Remarks

Q1 Main Speed JIS A8404

1 1 Machine size Total length (Transport) mm 5090 r 102 5540 r 111

inch 200.4 r 4.0 218.1 r 4.4

2 Total width mm 1700 r 17 1960 r 20

inch 66.9 r 0.7 77.2 r 0.8

3 Total height (Canopy) mm 2495 r 25

inch 98.2 r 1.0

4 Total height (Cabin) mm 2480 r 25 2540 r 25

inch 97.6 r 1.0 100.0 r 1.0

2 1 Weight Machine weight (Canopy) kg 4030 r 81 5065 r 101 Fuel tank

lbs 8884.5 r 178.6 11166.3 r 222.7

2 Machine weight (Cabin) kg 4095 r 82 5140 r 103

lbs 9027.8 r 180.8 11331.6 r 227.1

3 1 Performance Swivel speed L rpm 9.2 r 0.9 9.3 r 0.9

2Rrpm9.2r 0.9 9.3 r 0.9 3 Travel speed Lubber F1 km/h 3.0 r 0.3

mph 1.86 r 0.19

4 Lubber F2 km/h 5.0 r 5 4.6 r 0.5

mph 3.11 r 3.11

5 Iron F1 km/h 2.9 r 0.3

mph 1.80 r 0.19 1.43 r 0.12

6 Iron F2 km/h 4.7 r 0.5

mph 2.92 r 0.31

7 Gradeability deg 30 30

4 1 Rear end min. turning radius mm 1300 r 26 1090 r 22

inch 51.2 r 1.0 42.9 r 0.9

2 Swivel frame rear ground clearance mm 574 r 11 620 r 12

inch 22.6 r 0.4 24.4 r 0.5

3 Tambler center distance mm 1710 r 51 1990 r 60

inch 67.3 r 2.0 78.3 r 2.4

4 Crawler total length mm 2175 r 65 2500 r 75

inch 85.6 r 2.6 98.4 r 3.0

5 Crawler total width mm 1700 r 34 1960 r 39

inch 66.9 r 1.3 77.2 r 1.5

6 Min. ground clearance mm 330 r 10 320 r 10

inch 13.0 r 0.4 12.6 r 0.4

5 1 Front attach-

ment

2 SAE, JIS m3 0.12 0.14

3 Bucket width mm 600 r 12 Without side cut-

4 Swing angle Canopy L deg 75 r 2 5 Canopy R deg 48 r 2 6 Cabin L deg 75 r 2 7 Cabin R deg 48 r 2 8 Max. digging radius mm 5600 r 16 6260 r 94

Bucket heaped capacity

CECE m3

yd3

yd3 0.16 0.18

inch 23.6 r 0.5

inch 220.5 r 0.6 246.5 r 3.7

2.5 r 0.2

1.55 r 0.12

2.86 r 0.31

2.3 r 0.2

4.2 r 0.4

2.61 r 0.25

ter

II - 14

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks

5 9 Front attach-

ment

10 Ground level Min. finish

11 Max. digging depth mm 3505 r 70 3830 r 77

12 Max. vertical digging depth mm 2480 r 74 2585 r 78

13 Max. digging

14 Cabin mm 5420 r 108 5715 r 14

15 Max. dump

16 Cabin mm 3890 r 78 4155 r 83

17 Max. dump

18 Cabin mm 1250 r 37 1285 r 39

19 Front attach-

ment

20 Cabin mm 2060 r 62 2420 r 73

21 Mini. turning

22 Cabin mm 1665 r 50 1995 r 59

6 1 Dozer Width mm 1700 r 51960r 5

2 Height mm 350 r 20 360 r 10

3 Max. lift above GL mm 395 r 50 455 r 50

4 Max. below GL mm 410 r 50 370 r 50

Q2 Main Specs JIS A8404

1 1 Bucket tooth slaggish mm 50

2mm0

3 Dozer's declination mm 3

2 1 Eccentric amount from swing center mm 195 170 From swivel cen-

2 Distance to swing center mm

3 1 Approach angle deg 30 r 3 4 1 Crawler height mm 470 r 9 520 r 10 Include grouser

2 Max. crawler height mm 490 r 10 550 r 11

Ground level Max. digging radius

radius

Conopy mm 5420 r 108 5715 r 14

height

Conopy mm 3890 r 78 4155 r 83

height

Conopy mm 1250 r 37 1285 r 39

height (Arm vertical)

Mini. turning radius

radius (Left swing)

Conopy mm 2060 r 62 2420 r 73

Conopy mm 1665 r 50 1955 r 59

mm 5475 r 82 6130 r 92

inch 215.6 r 3.2 241.3 r 3.6

mm 1805 r 36 1940 r 39 Bucket bottom

inch 71.1 r 1.4 76.4 r 1.5

inch 138.0 r 2.8 150.8 r 3.0

inch 97.6 r 2.9 101.8 r 3.1

inch 213.4 r 4.3 225.0 r 0.6

inch 153.1 r 3.1 163.6 r 3.3

inch 49.2 r

inch 49.2 r 1.5 50.6 r 1.5

inch 81.1 r 2.4 95.3 r 2.9

inch 65.6 r 2.0 77.0 r 2.3

inch 65.6 r 2.0 78.5 r 2.3

inch 66.9 r 0.2 77.2 r 0.2

inch 13.8 r 0.8 14.2 r 0.4

inch 15.6 r 2.0 17.9 r 2.0

inch 16.1 r 2.0 14.6 r 2.0

inch 1.97

inch 0

inch 0.12

inch 7.68 6.69

inch

inch 18.50 r 0.35 20.47 r 0.39

inch 19.29 r 0.39 21.65 r 0.43

1.5 50.6 r 1.5

horizontal

ter

on the spocket

II - 15

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks

Q3 Engine performance

1 1 Max, engine

rpm

2 1 pump relief rpm - 3 2 pump relief rpm - 4 3 pump relief rpm - - Boom, arm,

5 2 pump relief rpm 2250  2150d 6 Dozer+2 pump relief rpm 2250

2 1 Idler rpm 1100 +50, -150

Q4 Travelling performance

1 1 Travel motor

block performance

2 Travel motor

block performance

2 1 Max, Traction

force

2 F2 kgf 1455 1972

3 1 Travel straight-

ness

2F2 mm600

3 Dozer F1 mm 600 Dozer up &

4 Dozer R1 mm 600

4 1 Track shoe sag

distance

2 Rubber mm 10 r 5

Q5 Work performance

1 1 Boom lifting capacity kgf 734 790 Front end, Arm

2 Arm digging force kgf 1790 2253 Bucket tooth

3 Bucket digging force kgf 3005 5043 Machine stance

4 Dozer force down kgf 3160 4170 Cutting edge

no load rpm 2450 d

Lmm272 300t 261 , 300t 20 deg, 10 min

inch 10.71  11.8t 10.28 , 11.8t

Rubber mm 272  300t 261 , 300t

inch 10.71 11.8t 10.28 , 11.8t

F1 kgf 3081 4083 On the center

kN 30.2 40.0 lbs 6792 9001

kN 14.3 19.3 lbs 3208 4348

F1 mm 600 10m distance

inch 23.62

Iron mm 40 r 5

inch 1.57 r 0.20

inch 0.39 r 0.20

kN 7.2 7.7

lbw 1618 1742

kN 17.6 22.1

lbw 3946 4967

kN 29.5 49.5

lbw 6625 11118

kN 31.0 40.9

lbw 6967 9193

2400 d

swivel

2200 , 2100d 2200 , 2100d 1200 +50, -150

down 10m distance

extend bucket crowd, at tooth

root

to JIS bucket tooth root

down force at ground level

II - 16

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks

2 1 Boom speed Canopy up (GoT) sec 2.7 r 0.3 Oil temp.

2 up (LoT) sec 4.9 r 0.3 3 down(ToG) sec 4 down sec 5.1 r 0.3 4.6 r 0.3 5 Cabine up 1st sec 6 up 2nd sec 4.9 r 0.3 4.7 r 0.3 7 down sec 8 down sec 5.1 r 0.3 4.6 r 0.3

3 1 Arm speed crowd sec 3.2 r 0.3 3.1 r 0.3

2 extend sec 2.8 r 0.3

4 1 Bucket speed crowd sec 2.7 r 0.3 2.9 r 0.3 Oil temp.

2 dump sec 2.2 r 0.3 2 r 0.3

5 1 Dozer speed up (GoT) sec 1.2 r 0.3 1.5 r 0.3 Max. down to

2 up (LoT) sec

3 down(ToG) sec 1.4 r 0.3 4 down (ToL) sec 3.0 r 0.3 3.8 r 0.3

6 1 Arm cylinder cavitation mm 0, 5 t 0, 0.5 t Oil temp.

inch 0 0

7 1 Max. digging

height radius

2 Cabine mm 2825 r 282 3640 r 364

3 Max. dump

height radius

4 Cabine mm 2790 r 167 3325

5 Bucket bottom

height at arm vertical

6 Cabine mm 1585 r 415 1600

7 Bucket wrist angle degree 197 r 3 168.5 r 3

Q6 Swivel, swing performance

1 1 Swivel torque L kgfm 840 1265 Arm

2Rkgfm 840 1265

2 1 Swivel angle L deg 20 17 Bucket load=JIS

2Rdeg2017

3 1 Swivel block performance L deg 0

2 R deg 0 5 > 3 L deg 30 30 > 4 R deg 30 30 >

4 1 Swivel start-up speed L sec 2.1 r 0.3 2.5 r 0.3 0~90 deg swivel

2Rsec2.1r 0.3 2.5 r 0.3

Canopy mm 2825 r 282 3640 r 364

inch 111.22 r 11.10 143.31 r 14.33

Canopy mm 2790 r 167

inch 109.84 r 6.57

inch 109.84 r 6.57 130.91

Canopy mm 1585 r 415 1600 Bucket horizon-

inch 62.40 r 16.34 62.99

kN.m 8.2 12.4

ftlbs 6075 9149

kN.m 8.2 12.4

ftlbs 6075 9149

2.7 r 0.3

2.3 r 0.3 2.5 r 0.3 Max. up to max.

4.7 r 0.3

3.1 r 0.3

1.9 r 0.3

3325 at bucket pin

130.91

5 >

50r5qC(122r41q F) Ground to max. height (exculude cushioning)

50r5qC(122r41q F)

max. up

down

95r5qC(203r41q F)

tal

extend,show/ Quick

u1.8

heaped

II - 17

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks

5 1 Swing speed Canopy L sec 6.7 r 0.7 6.7 r 0.5

2Rsec 3 Cabine L sec 4Rsec6.5 r 0.7 7.7 r 0.5

6 1 Swing Lock Swivel R&L mm 2 2, 10 > 90 deg-swivel,

inch 0.08

2 Reciprocating

motion

Q7 Hydraulic performance

1 1 Relief pressure setting P1 kgf/cm2 250 +10, -5

2P2kgf/cm2-

3P3kgf/cm2-

4P4kgf/cm240r 5.1

2 1 Cylinder oil

sealing capacity

295r5qC

3Arm50r5qC

4Bucket50r5qC

5 Dozer 50r5qC

3 1 Boom cushioning performance 30qC(86qF) sec 3

250qC(122qF) sec 0.4 to 1.3 380qC(176qF) sec 0.3

Q8 Lever operating force & stroke

1 1 Boom lever operating force up kgf

2 down kgf 1.5 r 0.5

3 Arm lever crowd kgf

4 extend kgf 1.5 r 0.5

L / R Swing mm 90 deg-swivel,

inch 

MPa 24.5 +1.0, -0.5

bar 24.5 +10, -5 24.5 +10, -5

psi 3556 +140, -70

MPa -

bar -

psi -

MPa -

bar -

psi -

MPa 3.9 r 5.0

bar 3.9 r 5.0

psi 569 r 73

Boom 50r5qC

(122r41qF)

(203r41qF)

(122r41qF)

mm 20 Arm extend,

inch 0.79

mm 20

inch 0.79

mm 20

inch 0.79

mm 10 Bucket load=JIS

inch 0.39

mm 20 3

inch 0.79 0.12

N 17.65 r 4.90

lbs 4.0 r 1.1

N 14.71 r 4.90

lbs 3.3 r 1.1

lbs 4.0 r 1.1

N 14.71 r 4.90

lbs 3.3 r 1.1

6.5 r 0.7 7.7 r 0.5

6.7 r 0.7 6.7 r 0.5

100 times actual digging cylinder dislocation

100 times

245 +10, -5 At pump deliv-

24.0 +1.0, -0.5

3485 +140, -70

1.8 r 0.5

1.8 r 0.5 Extend & crowd

17.65 r 4.90

ery 50r5qC

bucket

height 1m, 10 min.

heaped

u1.8

II - 18

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks

1 5 Bucket lever crowd kgf 1.5 r 0.5 Dump & crowd

N 14.71 r 4.90

lbs 3.3 r 1.1

6 extend kgf

N 17.65 r 4.90

lbs 4.0 r 1.1

7 Swivel (Swing) lever R kgf 1.5 r 0.5 Left & right

N 14.71 r 4.90

lbs 3.3 r 1.1

8Lkgf1.5r 0.5

N 14.71 r 4.90

lbs 3.3 r 1.1

9 Dozer lever up kgf

N 9.81 r 4.90 23.54 r 4.90

lbs

10 down kgf

N 14.71 r 4.90 23.54 r 4.90

lbs

11 Travel lever L Forward kgf

N 11 .77 r 4.90 14.71 r 4.90

lbs

12 Back kgf

N 11 .77 r 4.90 14.71 r 4.90

lbs

13 R Forward kgf

N 11 .77 r 4.90 14.71 r 4.90

lbs

14 Back kgf

N 11 .77 r 4.90 14.71 r 4.90

lbs

15 Accelerator lever up kgf 5 r 1.0 r AI-version has

N 49.03 r 9.81 -

lbs 11.0 r 2.2 -

16 down kgf 3.5 r 1.0 -

N 34.32 r 9.81 -

lbs 7.7 r 2.2 -

17 Swing pedal R kgf

lbs

18 L kgf

lbs 9.0 r 2.2

1.8 r 0.5

1.0 r 0.5 2.4 r 0.5 Up & down

2.2 r 1.1 5.3 r 1.1

1.5 r 0.5 2.4 r 0.5

3.3 r 1.1 5.3 r 1.1

1.2 r 0.5 1.5 r 0.5

2.6 r 1.1 3.3 r 1.1

1.2 r 0.5 1.5 r 0.5

2.6 r 1.1 3.3 r 1.1

1.2 r 0.5 1.5 r 0.5

2.6 r 1.1 3.3 r 1.1

1.2 r 0.5 1.5 r 0.5

2.6 r 1.1 3.3 r 1.1

accel dial not a lever.

3.4 r 1.0

33.34 r 9.81

7.5 r 2.2

4.1 r 1.0

40.21 r 9.81

II - 19

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks

1 19 Safety lock

lever

20 down kgf 0.4 r 0.2

21 L up kgf 2.7 r 1.0 Up & down

22 down kgf

23 Travel Hi-Lo change kgf 4.0 r 1.0 3.5 r 1.0 Super servier

2 1 Boom lever stroke up mm

2 down mm 72 r 10

3 Arm lever stroke crowd mm 72 r 10

4extendmm72 r 10

5 Bucket lever stroke crowd mm 72 r 10

6 Bucket lever stroke extend mm 95 r 10

7 Swivel, swing lever stroke R mm

8Lmm72 r 10

9 Dozer lever stroke up mm 60 r 10

10 down mm 60 r 10

11 Travel lever

stroke

12 Back mm 70 r 10

13 R Forward mm 70 r 10

14 Back mm 70 r 10

R up kgf 0.8 r 0.2 Up & down

N7.85r 1.96

lbs 1.8 r 0.4

N3.92r 1.96

lbs 0.9 r 0.4

N 26.48 r 9.81

lbs 6.0 r 2.2

4.5 r 1.0

N 44.13 r 9.81

lbs

N 39.23 r 9.81 34.32 r 9.81

lbs 8.8 r 2.2 7.7 r 2.2

inch 2.83 r 0.39

inch 3.74 r 0.39

inch 2.83 r 0.39

inch 2.36 r 0.39

L Forward mm

inch 2.76 r 0.39

9.9 r 2.2

have a switch

72 r 10

70 r 10

II - 20

WSM Minor Change II Service Engineering Section

No Specificatios Items Unit KX121-3S KX161-3S Remarks Q9 Stability

1 1 Standard arm,

Dynamic operation load limit

2 Front, dozer upkgf

3 Bucket load to

4 Front, dozer upkgf

5 Standard arm,

static limited load

6 Front kgf

2 1 Standard arm,

Dynamic operation load limit

2 Front, dozer upkgf

3 Bucket load to

4 Front, dozer upkgf

5 Standard arm,

static limited load

6 Front kgf

Q10 Comfortability

1 1 Noise level At operator's

2 Cab db(A) Cab door close 3 Noise 4 db(A)

Bucket load to 10 degrees tipping

tip fully

Bucket load to tip fully

Bucket load to 10 degrees tipping

tip fully

Bucket load to tip fully

ear LPA

source;LWA

Side, dozer up

Side kgf

Side, dozer up

Side kgf

Canopy db(A)

7m db(A)

kgf Arm extend,

lbs

N lbs kgf

N lbs

N lbs kgf Arm extend,

N lbs

N lbs kgf

N lbs

b u c k e t c r o w d oil temp. 50r5qC (122r41qF)

II - 21

WSM Minor Change II Service Engineering Section

B. Finger control service port system

a. Feature and purpose

1 The service port pedal has been replaced by a lever-top knob switch: Feather-touch finger control

realized. 2 The breaker can easily be operated with a button switch. 3 Optimum control feeling adjustments can be made for maneuvering various attachments efficiently. 4 Safe attachment handling is ensured through fool proof control.

Thumb

Breaker Auger

When a thumb (and tilt bucket) attached, the foot pedal has been used to operate. It has not been easy for fine control in this way. Such operation can now be finely controlled with your hand (thumb) and you can ensure more space around your feet. Service port functions have been tremendously upgraded.

Tilt bucket

II - 22

WSM Minor Change II Service Engineering Section

b. Outline of control system

1. Aux. port finger operation

Fine control by finger operation

c Proportionality operation of AUX. port. d Full open output hold Switch at the time of breaker operation. e Hand operation ON-OFF Switch. (secure safety priority)

2. Control layout

AUX port hand operation

Breaker Lock sw

Option sw

Travel Hi-Low lamp

Option lamp

Travel Hi-Hold sw

Work lamp sw

Display change sw

Anti Theft Antenna

(EU-version only)

Option: KX91-3S,D or above

Accel

Option: KX41-3SV or above

Hand operation ON-OFF sw

AI-sw

Controller

Knob position signal Right proportional control valve output

Input

Breaker mode select signal

signal

Service mode select signal

CPU

II - 23

Out-

put

Left proportional control valve output

WSM Minor Change II Service Engineering Section

3. Service port system components

Meter panel

Main key ON

Safety lever lock switch

Knob switch

o start

Breaker switch

Input

Work

switch

lamp

CPU

EEPROM

S/P

switch

Proportional solenoid valve

Output

Main control valve

Panel selector

switch

Thumb cylinder

II - 24

WSM Minor Change II Service Engineering Section

Main pump, P

Cylinder rod,

thumb release

Thumb cylinder

Main controle valve,

service port section

Cylinder bottom,

thumb crowd

Pilot pump, P

c. Hydraulic circuit diagram

PWM current

II - 25

WSM Minor Change II Service Engineering Section

d. Knob structure and function

The knob has a built-in IC chip that is different from that for potentiometers.

1)Service mode:Press the center switch of the meter panel to call the service mode.

2)Knob control: Shift the knob to L or R direction to call two way PTO operation.

3)Breaker operation:Press the back button of the knob to call the breaker mode.

1. Structure of knob switch

+5 V

PROPORTIONAL OUTPUT

GND

Horn SW



Breaker SW

ELECTRIC CIRCUIT

RED

WHITE

BLACK

BLUE

GREEN

YELLOW

GRAY

1

3

4

7

6

(1)

(2)

(1) Knob switch (2) Horn switch

(3)

(3) Breaker switch

II - 26

WSM Minor Change II Service Engineering Section

2. Basic operation of the knob

1) With the key on

When the key is on, the system gets started out of the service mode OFF-position. In other words, the knob is not operative. (This is for safety.)

2) Service mode

Press the center switch of the meter panel, and the center LED indicator lights up and the system gets in the service mode. Now the knob is operative. Move the knob to the left for the thumb to grasp an object. Move it to the right for the thumb to release it.

3) Breaker mode

The breaker mode is enabled while in the service mode. Press the breaker switch on the back of the knob to activate the breaker. The main pump fully feeds the fluid to the breaker. If the thumb is attached in place, the main pump feeds the full amount of fluid from the service port to the thumb cylinder.

(1) Push the S/P switch on. (2) Press the breaker switch. (3) Breaker starts pounding. (4) Press the breaker switch again. (5) Breaker stops.

4) Releasing the breaker

There are three methods to release the breaker operation. (1) Press the breaker switch again to stop the breaker. (2) Press the service port switch to off position. (The center LED indication goes off.) (3) Or, move the knob for over 0.2 second. (4) Or, lift up the safety lock lever. (5) Turn the main key to off position.

II - 27

WSM Minor Change II Service Engineering Section

3. Flow chart; Service port operation

Key

Is safety lock lever down position?

Yes

Service port switch

Service port switch lamp

lights up

Is breaker switch ON?

Yes

Breaker starts.

OFF

No service port operation

Yes

Is knob switch shifted?

Yes

Thumb cylinder

starts moving.

1) Press breaker switch on again?

2) Move the knob switch?

3) Raise the safety lock lever?

4) Main key off?

One of above operations?

Breaker stops

While breaker is working;

Release the knob switch to neutral.

Thumb cylinder stops.

Yes

II - 28

WSM Minor Change II Service Engineering Section

4. S/P switch (service port switch)

(1) Main key

(2) S/P switch

(3) Service port

function

(4) Safety lock

lever

(5) Warning lamp

buzzer

OFF

Push

Effective

Non-effective

Down

(5 ~ 6 sec.)

Service port switch (S/P sw) in the middle bottom on the meter panel controls the service port functions, such as thumb switch and breaker switch.

In order to get the service port function, first push this switch and then control the two switches on the knob lever.

(1) Service port switch

II - 29

WSM Minor Change II Service Engineering Section

5. How the knob switch works

1) Let's suppose that the breaker has been released. To call the breaker mode again, it is necessary to press the back button (breaker switch) of the knob. (This is for safety.)

2) To release the breaker, just move the knob. This is highly convenient.

3) Let's say that you have forcefully moved the lever to operate the other functions, such as boom up or down or etc. The knob may be momentarily shaken, which may fluctuate the voltage and unnecessarily release the breaker. To avoid this, the knob must be moved for over 0.2 second to release the breaker operation. Just for reference, the knob does not tilt for over 0.2 second under usual lever control conditions.

6. Breaker operation

(1) Main key

(2) Safety lock lever

o start

down

(3) Meter panel controller

(4) Server port switch pushed

(8) Knob switch

(6) Breaker switch

(7) Breaker

(5) Proportional control

solenoid valve

Note: When the safety lock lever is up position, all switches of service port switch, breaker switch and

knob switch don’t function at all. This is also for safety purpose. Therefore, once the safety lock lever is shifted up while service port operation, breaker or thumb cylinder stops. When to start the breaker again, first shift down the safety lock lever, press ON the service port switch and press the breaker switch. Safety lock switch has the priority for the safety.

II - 30

WSM Minor Change II Service Engineering Section

7. Interrelation among current, pressure and flow

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0,1USP$

0$;USP$











3LORWVHFRQGDU\SUHVVXUH>NJ IFP

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&XUUHQWP$



 







2LOIORZDPRXQWOPLQ2LOIORZDPRXQWOPLQ

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

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



       

&XUUHQWP$

Note: Above charts are just the sample figures to illustrate the interrelation among the three

parameters.

1. Current: PWM current provided from the panel controller.

2. Pressure: Secondary pilot pressure delivered from S/P solenoid valve.

3. Flow: Oil flow amount supplied to the thumb cylinder.

II - 31

WSM Minor Change II Service Engineering Section

e. Initial settings of the knob

1. Set-up and adjustment of service port

This new finger control service port system requires three types of set-up and adjustment procedures.

Items to set-up When

Knob initial set-up 1. Knob change

2. S/P valve change

3. Meter panel change

S/P valve start-point set-up 1. S/P valve change

2. Main control valve change

3. Pilot pump change

4. Hydraulic actuator change

Manual feeling adjustment 1. Hydraulic actuator change

2. Operator change and feeling change

2. Purpose

Three settings (right and left ends, and neutral) of the knob are kept in the meter controller’s memory. Note that there are fluctuations from knob to knob. The knob has been factory-set at Hirakata Factory or KBM. When the meter, the knob or the proportional control solenoid valve has been replaced, the knob settings must be manually reprogrammed. If not reprogrammed, the thumb may get activated even in neutral or slowly move even at the right end. The meter memory keeps the following data in the EEPROM addresses

u 8 = 8184 then 5 V.

1023 But actual data varies as follows.

Address 45: Left end Address 46: Neutral Address 47: Right end

o o o

0.4 a 0.8 V

2.4 a 2.8 V

4.40 a 4.80 V

Voltage

4.5 V (Address 47)

2.5 V (Address 46)

0.5 V (Address 45)

Left end Right end

Neutral

Knob shift amount

(Knob shift angle)

II - 32

WSM Minor Change II Service Engineering Section

3. Background and meaning of knob initial set-up

1) The output voltages at the neutral, rightmost and leftmost positions of a knob are entered as initial settings. Accordingly, correlation between the knob's right-left shift and the output voltage is stored in microcomputer memory.

2) The voltage generated by the knob's movement is converted by the microcomputer to a PWM control current. In this way, ordinary operations can be carried on under proportional control.

3) Also the voltages at the neutral, rightmost and leftmost positions of a new control knob are entered as initial settings in microcomputer memory. Such data serves to control the output voltage in proportion to the knob's movement.

4) Suppose that you have replaced a control knob but forgotten to make its initial settings. The previous knob's data, still in microcomputer memory, may be slightly different from new entries. This may cause different operating feelings.

5) These settings can be made with the key on. Thanks to the built-in temperature compensation function, there is no problem with ambient temperatures in making the settings.

FYI (For Your Information)

1. Knob switch and Hall element (IC chip)

The knob switch has a temperature-compensated Hall element incorporated. The Hall element consists of a magnet and a coil as shown below. A kind of sensor, this switch has the tilt angle Éý, which changes the quantity of magnetism. This quantity is converted to voltage. The input voltage is set at 5 V maximum. With the knob switch at neutral position, the output is about 2.5 V.

2. Hall effect

Let's suppose, as shown in Fig. 1, that a current is applied to a rectan-

Magnetic flux B [T]

gular solid and a magnetic field is added perpendicular to the direction of current. There will be a voltage that is perpendicular to the direction

Length

T [m]

Voltage

of current as well as to the direction of magnetic field. This phenomenon is called the Hall effect, and the voltage thus generated is called the Hall voltage.

Current I [A]

This effect was discovered by American physicist Edwin H. Hall in 1879. The effect has the nature of taking place very frequently with semicon-

Fig. 1 Hall effect

ductors, but rarely with conductors.

3. Hall element

The Hall effect is discussed above. The Hall element includes semiconductors that produce the Hall effect. Given that the effect takes place very frequently with semiconductors, but rarely with conductors, semiconductors are used to make the Hall element. Here are the materials to make the Hall element.

- Silicon (Si)

- Germanium (Ge)

- Gallium arsenide (GaAs)

- Indium arsenide (InAs)

- Indium antimonide (InSb)

V [V]

II - 33

WSM Minor Change II Service Engineering Section

f. S/P valve start point setting

1. Performance characteristics profile: Knob shift amount vs Output current

Current

Proportional control valve BProportional control valve A

Right end

Knob

Left end

950 mA

450 mA

Neutral

1) A dead zone is provided to keep the thumb intact in neutral. Some margins are also given to start the thumb at each end.

2) The right-end, neutral, and left-end settings of the knob are presupposed to be in memory.

3) The profile is flexibly modifiable even for maximum engine rpm and idling speed. When the engine runs at middle speed, for example, the average is determined from the idling map and maximum map and finally outputted.

4) Suppose that the thumb starts moving at the current of 500 mA. The knob's operating map must begin with 450 mA because it is necessary to provide an inching zone and give better feeling.

5) At the 500mA level, however, there could be fluctuations due to the control valve, proportional control valve, hoses and other factors. The meter keeps the initial map and performs as well, but the inching zone might be longer or shorter depending on the machine.

6) The starting point setting is made to cope with such problem. In the setting mode, the meter shows the current gradually higher from 450 mA. When the thumb starts moving, the operator is supposed to press and release the button twice for releasing and grasping of the thumb. The meter memorizes the then setting.

Address 48: Address 49:

o o

Release R Deviation Grasp L Deviation

The following correction is made for control.

Current

950 mA

450 + (The value in the address 49) 450 + (The value in the address 48)

Left end

Neutral

Proportional control valve BProportional control valve A

Right end

Knob

II - 34

WSM Minor Change II Service Engineering Section

7) Service engineers do not notice, but at Hirakata Factory and KBM, the starting point has been measured at the service port (red pressure measuring port for North America and Europe) and fluctuations have been put in the meter memory. At the manufacturing plants, however, the machine is not equipped with any thumb attachment. Actually, the starting point is expected to be measured locally. It would take dealers trouble.

At the manufacturing level, therefore, a pressure take-out plug is prepared. Although a thumb is not attached, a current flows to the proportional control valve and the pressure level changes at a certain point. This pressure level is detected and put into memory.

Note: 450 mA and 950 mA are default values

before setting in the factory. Actual value may differ model by model

(1) Pressure port

and machine by machine after the factory setting up.

8) Fortunately, the dealers are expected to do just the following in the field

(1) Usually Just install the attachment (Thumb) and

connect the service port hoses.

(2) When the meter is replaced Make the knob initial setting

and the starting point setting.

(3) When the knob is replaced Make the knob initial setting.

(4) When the proportional

control valve replaced

Make the starting point setting, knob initial setting

The above knob initial setting and starting point setting are required. Otherwise the performance may be unstable depending on finish accuracies of the component parts.

II - 35

WSM Minor Change II Service Engineering Section

2. Background and meaning of start-point setting

1) The purpose of this setting is to keep the knob's operating force of starting the attachment (thumb cylinder) constant whether the engine runs idle or at maximum speed.

2) The proportional control valve's start-point is activated when you have slowly moved the knob to start the attachment that is connected with the service port circuit.

3) The knob's action point is referred to in some different factors: knob's movement, output voltage, controller's output PWM current, proportional control valve's hydraulic pressure, pilot secondary pressure of service port main control valve, and hydraulic pressure of attachment (thumb cylinder, for example).

4) The start-point setting works as follows. When a component of the service port system line has been replaced, the component with its slightly different individual behavior pattern may delicately affect the line's final output. To compensate such deviation, the initial setting (star-point setting) must be entered in the controller.

5) The following factors are important in affecting the start-point.

(1) Oil temperature (2) Engine rpm (3) Proportional control valve (4) Main control valve, service port section (5) Service port load fluctuations

6) These factors are therefore considered for the start-point setting.

(1) Oil temperature (2) Engine rpm (3) Proportional control valve (4) Main control valve,

50 qC

Idling, Maximum

At each replacement

service port section

(5) Service port load fluctuations

Basically it is preferable to make the setting for each attachment. If it does not feel unusual, however, it can be up to the user's judgment.

II - 36

WSM Minor Change II Service Engineering Section

3. Illustration of the start-point setting

Voltage fluctuation signal according to the knob's

PWM current

Pilot secondary pressure signal

S/P section

Main hydraulic line

movement

Move the knob, and you will find the point where the thumb cylinder starts moving. Just when the cylinder gets activated, press the selector switch. Do this for the right and left movements of the knob. Does control start when the start-point has been reached?

]

Ps [kgf/cm

[mA] Pilot secondary pressure when the thumb cylinder

starts moving.

[mA]

Input current when the thumb cylinder starts moving.

Knob movement [T]

II - 37

WSM Minor Change II Service Engineering Section

4. Concrete behavior at the start-point setting

PWM input to the solenoid valve

(mA)

Pilot secondary pressure

R, full stroke

Machine B Standard

Machine A

Pilot Secondary pressure current

]

difference a

. As

difference b

L, full stroke

:standard knob angle to start S/P

:Machine A knob angle to start S/P before set-up.

:Machine B knob angle to start S/P before set-up.

θbθsθ

Knob control angle: θ

Set-up target is to start attachment (thumb cylinder) at the constant same knob control angle, shown in above Fig., machine A starts at In order to get both machines start at

, machine B at Tb.

, controller outputs the PWM current by adding the difference a

or by subtracting the difference bi to machine A and B respectively. Start point set-up is to test the difference a

, bi and input their data to the controller. So that the control-

ler can calculate and output the required amount PWM current to start the attachment at the same

knob control angle

Why set-up at engine Max. rpm? For safety purpose, start-up point is earlier at engine Max. speed than at idle speed.

II - 38

WSM Minor Change II Service Engineering Section

5. S/P valve initial set-up flow chart

<Machine’s operation cycle> <Operator’s action>

For the right direction, enter the knob's output voltage with the engine at maximum rpm.

Controller

PWM current is outputted.

The proportional control solenoid valve spool starts shifting.

When the thumb cylinder starts moving, press the service port button on the panel.

Enter the start-point output voltage in the controller.

Do the same for the left direction.

Setting complete.

Now the controller's PWM output current has been set so that the thumb

Visually make sure that the cylinder has started moving.

The main control valve spool starts shifting.

The thumb cylinder starts moving.

cylinder starts moving at a preset knob position (an input at maximum rpm). This cylinder behavior occurs at any engine speed.

Precisely speaking, controller’s output current is the same at a preset knob position. Therefore, the solenoid force of the S/P valve and the secondary pailot pressure are identical. So spool shift amount of the main control value section is the same. But as the main pump delivery rate varies and so thumb cylinder’s starting point varies according to the engine speed to same extent. Then why do the start-up setting at max. engine speed? For safety.

II - 39

WSM Minor Change II Service Engineering Section

g. Manual feeling setting

1. Outline of manual feeling setting

Basically, the thumb is supposed to move smoothly by the starting point setting, but one may feel poor. To ensure good feeling, therefore, this mode is added.

Setup Service port feeling adjust

Right

Slow -12 Fast

(This value x 5 mA) is added to the map.

Current

Proportional control valve BProportional control valve A

( Fine adjustment of 450

+ The value of the address 49

+ Fine adjusting value of grasp L )

Right end

Knob

Left end

950 mA

Neutral

The right and left fine adjustment values are put to addresses 62 and 63, respectively, in the memory. These values will become zero when the starting point setting of a model has been made. When address 62 is set at "5", the setoff will be 25 mA: when set at "FFFF", the setoff will be -10 mA.

II - 40

WSM Minor Change II Service Engineering Section

2. Knob shift amount and output current

Then actually move the knob, and ensure a good current-duty map at the current of 500 mA and the oil-flowing current. The proportional control valve, however, is rather unstable in its temperature characteristics (temperature vs. resistance). Such control is still required. (Dark current theory)

Output Current

[mA]

950

850 + (Add.49) +(Add.68)

(Initial value) + (Add.49) +(Add.68)

21819

Knob shift amount

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WSM Minor Change II Service Engineering Section

Finish

Key off

In case of AI-version only

Finish

S/P port moves left

Finish

Set up machine

Key off

Push selector sw

Key off

Diagnosis

Set up AI

Engine start

S/P knob neutral

S/P knob left end

S/P knob right end

S/P port moves right

Push selector sw

Engine max

S/P actuator middle

S/P left speed

+ slow 12 fast -

S/P right speed

+ slow 12 fast -

Engine max

English

:: p

ppp

1. Outline (S/P knob, S/P valve, S/P feeling adjust)

KX91-3

KX101-3 French Set up

:: Other menu

h. Panel display operation flow chart

Set up overheat

warningpSimple modepSet up S/P knob

Lift up safety lever

Down the safety lever

Set up S/P valve

II - 42

Down the safety lever

Set up

S/P feeling adjust

Back tier

WSM Minor Change II Service Engineering Section

2. Display flow chart with photo

KX91-3

English

1. Turn the starter key to ON (AC position) while pressing the display selector switch on the panel. Then the machine model comes on the display.

2. Push the display selector switch long, then language to be selected comes on the display. KTC and KTA version display only English. KCL indicates English or French for selection. EU version has eleven languages to be selective.

Diagnosis

Set up

3. Push the display selector switch long, then the display moves to “Diagnosis”.

4. Push the display selector switch short, then the display moves to “Set up”.

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WSM Minor Change II Service Engineering Section

Engine start

Set up machine

5. Push the display selector switch long, then the display indicates to “Engine start”.

6. Push the display selector switch long, then the display moves to “Set up machine”.

Set up overheat warning

Simple mode

7. Push the display selector switch short, then the display moves to “Set up overheat warning”. Skip this menu.

8. Push the switch short, then the display shows “Simple mode”. Skip this also.

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WSM Minor Change II Service Engineering Section

9. Push the display selector

Set up S/P knob

switch short, the display indicates to “Set up S/P knob”. For the Setting-up of the service port knob initialization, press the display selector switch long. This initialization procedure will be illustrated in another pages.

10.Push the display selector

Set up S/P valve

switch short, the display indicates “Set up S/P valve”.

Set up S/P feeling adjust

Back tier

11.Push the display selector switch short, the display indicates “Set up S/P feeling adjust”.

12.Push the display selector switch short, the display returns to “Set up machine”. Push the display selector switch long, the display returns to “Set up”.

Note: In one of AI-version machine, the display shows “Set up AI” when the display selector switch

is pressed long at “Engine start”.

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WSM Minor Change II Service Engineering Section

3. Knob initial set-up

Set up S/P Knob

S/P knob right end

S/P knob left end

1. The LCD display shows as “Set up S/P knob”.

2. Push the display selector switch short, then the display shows “Lift up safety lever“. This is for safety purpose.

3. Lifting up the safety lock lever moves to the display of “S/P knob right end”.

4. Push the display selector switch short, then the display shows “S/P knob left end”.

S/P knob neutral

Finish Key off

5. Push the display selector switch short, then the display shows “S/P knob neutral”.

6. Push the display selector switch short, the display indicates “Finish Key off”. It means knob initialization has been completely.

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WSM Minor Change II Service Engineering Section

4. S/P valve initial set-up

1. As instructed in page ***,

Set up S/P valve

Down the safety lever

you’re required to reach the display shows as “Set up S/P valve”.

Safety precaution! Engine is running.

2. Shift down the safety lock lever down to control the service port attachment.

S/P actuator middle

Engine max

3. Get the S/P actuator to the middle point of the full stroke by shifting the S/P knob.

4. Set the engine at the max. speed.

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WSM Minor Change II Service Engineering Section

5. Push the display selector

S/P port moves right Push selector sw

switch at the moment that the actuator cylinder starts moving to extend.

Note: In case of thumb cylinder,

“right” indicates the cylinder to extend. “left” indicates to retract.

6. After being pushed in the

S/P port moves left Push selector sw

above, automatically the display moves over “S/P port moves left”. Therefore, push the display selector switch at the moment that the actuator cylinder starts moving to retract.

Finish Key off

7. Then the display changes to “Finish Key off”.

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WSM Minor Change II Service Engineering Section

5. S/P operational feeling adjustment

Set up S/P feeling adjust

Down the safety lever

1. As instructed in page ***, you’re required to reach the display shows as “Set up S/P feeling adjust”.

Safety precaution! Engine is running.

2. Shift down the safety lock lever down to control the service port attachment.

Engine max

3. Set the engine at the max. speed.

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WSM Minor Change II Service Engineering Section

S/P right speed + slow 12 fast -

S/P left speed + slow 12 fast -

4. Slowly slide the S/P knob switch to right direction and check the actuator’s starting points.

If it starts moving too quick, get it slow by pressing the work lamp switch, left end button.

If it starts moving too slow, get it fast by pressing the service port switch, middle button. Digit number indicates the feeling level of slow or fast.

Pressing the display selector switch short, switches the display to adjust the left or right speed.

Finish Key off

After completing the feeling adjustment, just set the key off.

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WSM Minor Change II Service Engineering Section

i. Proportional control solenoid valve (S/P valve)

1. Outline

This valve is the combination of electro magnetic solenoid valve and hydraulic reducing valve. Ordinally solenoid valve is controlled ON-OFF by battery 12 V direct current. But this valve is controlled by the PWM (pulse width modulation) current supplied from the micro computer controller incorporated in the meter panel. Valve spool function is basically the reducing valve same as the hydraulic pilot control valve, normally used for the lever control. Difference is as follows. The hydraulic pilot control valve regulates the pilot pressure, balancing to the operator’s manual force. This S/P valve is regulated by the PWM current. In either case, this pilot pressure is socalled the secondary pilot pressure to control the spool stroke of the main control valve.

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2. Structure and function

(Hydraulic symbols)

Solenoid magnetic force Spring load Pressure applied

sol

PA T

sp2

Fp = P

A

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3. Function theory

Behavior of proportional valve

Balance of proportional valve forces

PA T

Reducing valve spool hydraulic pressure force

sp1

Proportional solenoid magnetic force

Transfer spring

sp2

Behavior of solenoid proportional valve

Definitions of values

: Solenoid magnetic force generated according to current

sol

= C1 x I (C1 and I are solenoid's intrinsic constant and current, respectively.)

sol

: Solenoid's spring load

sp1

: Valve's spring load (constant during pressure control)

sp2

: Pressure applied by setup area difference

= A x Pa (A and Pa are setup area difference and pressure at port A, respectively.)

P: Primary pilot pressure from the pilot pump controlled by the unload relief valve P

: Secondary pilot pressure to control the main control valve spool

Pressure receiving

area difference

Balance of forces

The balance of forces for the valve spool (see above) is expressed like this.

sol

+ F

sp1

= P

When the left term is greater, the spool moves rightward and ports P and A open one after the other. When the right term is greater, the spool moves leftward and ports A and P open one after the other. The above expression is rearranged as follows.

+ F

sol

- F

sp1

+ F

sol

sp2

sp1

A + F

= P

- F

sp2

A

sp2

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WSM Minor Change II Service Engineering Section

Spool control performance I-P curve

Pa (MPa)

3.0

+ F

sol

- F

sol

sp2

Solenoid force (N)

+ F

sol

= P

00.511.5

Current (A)

sp1

2.0

1.0

Spool opening area

21 210

)

Spool opening area (mm

A - T P - A

Spool opening stroke (mm)

Suction prevention against interference (Opening area symmetrical right and left on standard type)

A - T: Actuator to tank P - A: Pump to actuator

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WSM Minor Change II Service Engineering Section

j. Other controls

1. Model number display

Displayed in the case of AI specifications.

2. Automatic service port identification

With the key on, a current of 250 mA or so is made to flow in the service port proportional control valve. When feedback is available, the machine is of service port type. If not, the machine has no service port. This automatic identification is added because some machines have service port and the others have not. It should be noted that the map profile is different from model to model and from destination to destination (Europe and North America).

3. Fool-proof control.

When the service port sensor reads below 0.25 V or over 4.75 V for 0.2 second: Nothing displayed, however, out of the service mode.

4. Idle-up control

The idling speed increases by 150 rpm when the water temperature drops below 30 centi-degrees (Reason: Even at the same governor position, the engine speed drops about 150 rpm at the temperature of -18 centi-degrees.)

5. Compressor control

When the compressor is on, the idling speed is raised by 150 rpm. The idea is as follows. If the compressor is repeatedly turned on and off and kept off for 3 seconds, the idling speed gets back to its original rpm. In this way, the AI motor can be kept from getting activated many times. (Reason: If the compressor is on and the alternator barely generates power, the battery, if connected to an external load, may fail to work.)

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WSM Minor Change II Service Engineering Section

k. Troubleshooting

1. Troubleshooting

Following troubleshooting is based on below preconditions. Therefore: 1. Hydraulic oil quality and quantity are normal.

2. Hydraulic pump P

3. All the functions except service port system are normal.

Fail symptom Suspected causes Check points

a. Service port attachment does

not work at all. (Thumb's failure to move in both directions; Breaker's failure to crush; Auger's failure to turn)

b. Thumb does not work in one

direction at all.

c. Service port attachment

moves slower than specified in both directions.

d. Service port attachment

moves slower than specified in one direction.

e. S/P attachment moves at neu-

tral position of knob switch

, P2, P3, P4 are OK.

1. Knob switch harness is cut or coupler is disconnected.

2. S/P valve harness is broken or coupler is disconnected.

3. S/P valve spool is stuck inside. S/P valve spool.

4. Main S/P valve spool is stuck inside. Main control valve S/P section.

5. S/P valve pressure is quite low in both side.

1. S/P valve solenoid harness is broken one side.

2. S/P valve spool is stuck inside. S/P valve spool.

3. Main control valve S/P section is stuck one side.

4. Knob switch initial setting error. Knob switch initial setting.

5. S/P valve pressure is quite low in one side.

1. S/P valve start-up setting error. Do S/P valve start-up setting.

2. Current amount from the controller is not enough.

3. S/P valve spool moves heavy and slow.

4. S/P valve pressure is low in both sides.

5. Main control valve S/P section spool won’t shift at full stroke.

1. Knob switch initial setting error. Do knob switch initial setting.

2. S/P valve start-up setting error.

3. Manual feeling setting error. Do manual feeling setting.

4. Main control valve S/P section spool one side won’t shift at full stroke.

1. Knob switch initial setting error. Do knob switch initial setting.

2. S/P valve spool is stuck at one side. S/P valve spool.

3. Main control valve S/P section spool is stuck at one side.

Knob harness, fuse and switch coupler.

S/P valve harness and coupler.

Test the S/P valve pressure.

S/P valve harness.

Main control valve S/P section.

Test the S/P valve pressure.

Knob switch initial setting. Meter panel (Controller) output current. S/P valve spool.

Test the S/P valve pressure.

Main control valve S/P section spool.

Do S/P valve start-up setting.

Main control valve S/P section spool.

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WSM Minor Change II Service Engineering Section

C. Hydraulic system modification

a. Outline

In order to improve further “Load Sensing Performance”, pump and control valve have been changed in several parts. Main parts of minor change are as follows.

1. Hydraulic pump: KX121-3SD, 161-3SD, U45-3D

(1) Valve plate opening performance improved

End milling finish to V-shape notch

(2) Piston shoe type change

Multi-pad type to single-pad type (3) Cylinder block center spring foree upgraded (4) Swash plate shape change (5) Swash plate pin shape change (6) PC regulate spool pin dia. I3.5 o I3.2

Horse power spring change (7) LS valve compact size

PC orifice I0.6 added

2. Control valve: KX121-3SD, 161-3SD, U45-3D

(1) Damper chamber added in the unload valve (orifice I1.2) (2) In order to achieve the stable response of PLS signal line;

I1.0 orifice added in valve’s PLS port plug.

Hose volume (1/4” u350mm length) added. (3) Shuttle plate change;

Outer dia is approx. 20Pm larger in minor change (4) Compensation spools of arm, bucket and swivel;

orifice machining deleted.

3. Travel motor: KX121-3SD, 161-3SD, U45-3D

(1) Moter swash plate: Light weight type (2) Hi-Low piston: Shape change (3) Thrust plate: Shape change (4) Sun gear: Snap ring removed (5) Ring nut: Casting iron to steel iron (6) Reduction gear case drain port size: G 1/4, hex. 6 o G 3/8, hex. 8

4. Role of hose volume (1/4” u350mm)

The hose volume control that is attached on the control valve serves as a sort of damper. At a start of operation in particular (to start traveling, for example), it is effective in avoiding a sudden surge pressure and preventing the machine from starting with a jerk. In other words, violent fluctuations of load pressure can be eased, which improves the operator’s control feeling. Below discussed is a theoretical explanation of the hose volume control behavior. At very low temperatures, the throttling effect of the orifice in the system is greatly affected, usually causing delays in response. Let’s suppose shifting the travel lever forward under low temperatures, for example. Possibly the machine may fail to respond quickly or it may take too much time to get started. In such cases, preferably remove the hose volume control for better damping effect, and install the plug attached on previous models. Keep in mind, however, that the higher the oil temperature rises, the quicker the reaction becomes.

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WSM Minor Change II Service Engineering Section

b. Hydraulic pump: KX161-3s, KX161-3D

1. Pump installation: KX161-3SD, U45-3D

(1) Adapter tightening torque

P port (G3/4) 117.6 ~ 127.4N P

, PLS, CH port (G1/4) 24.5 ~ 29.4Nm (2.5 ~ 3.0kgfm)

port (G3/8) 49.0 ~ 53.9Nm (5.0 ~ 5.5kgfm)

m (12.0 ~ 13.0kgfm)

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WSM Minor Change II Service Engineering Section

2. Piston pump: KX161-3S (PP), KX161-3D (EU), U45-3D (EU, KTA)

63(&,),&$7,21





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7,*+7(1,1*72548(

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WSM Minor Change II Service Engineering Section

3. Specifications of pump

Model: PSVL-54CG Piston pump power constant characteristics: KX161-3D, U45-3D

Piston pump power constant characteristics: KX161-3S

Item Specifications Remarks

Basic spec.

Displacement Piston pump

13.0 ~ 54.0 cm

/rev Gear pump -

Pilot pump

4.0 cm

/rev

Gear pump

Direction of rotation Right (Clockwise) As seen from the shaft Pilot relief set press 3.9 MPa Drain pressure Less than 0.098 MPa

Section press -0.04 ~ 0.07 MPa

HYD. oil: VG46, HYD. oil temp: 50 qC,

2450 rpm Filter 10 Pm equivalent Straner 150 mesh HYD. contamination classes W ithin NAS 9

Customer spec.

Engine horse power

KX161-3D, U45-3D 28.7 / 29.4 kw KX161-3S 34.6 kw (Gross)

Shaft speed

KX161-3D, U45-3D

1000 ~ 2250 rpm Max. unloaded:

less than 2450 rpm

KX161-3S

1000 ~ 2200 rpm Max. unloaded:

less than 2450 rpm

Max. working Pressure

Piston pump 24.5 MPa Piston pump pressure: P Gear pump -

Pilot pump 4.12 MPa

Pilot pump pressusre: P

Max. pump flow

Piston pump 118.8 (121.5) L/min at 2200 (2250) rpm Gear pump Pilot pump 8.8 (9.0) L/min at 2200 (2250) rpm

Max. input torque

KX161-3D, U45-3D 108.0 (108.0) Nm at 2200 (2250) rpm KX161-3S 118.0 Nmat 2200 rpm

HYD. oil

Oaphny super hydro 46 Shell terras K46

VG46 equivalent

Hydraulic oil temperature at tank

Ordinary use: -10 ~ +80qC Short time use: -20 ~ +90qC

Drive system Input shaft: Direct drive No radial load

General spec.

All efficiency (Typical value) 79 % VG46, 50 qC, 2200 rpm, 13.7 MPa

Control method

Power constant control Load sensing control

Proportional LS control pressure

Horse power setting 24.8 kw at 2200 rpm Max. pump flow (Piston pump) 118.8 r 2.5 L/min VG46, 50 qC, 2200 rpm, P=Min. Max. input torque 105.1 ~ 108.0 Nm at 2200 rpm

Pilot pump flow Mor than 8.0 L/min

VG46, 50 qC, 2200 rpm, P

=4.12 MPa

LS control pressure 1.45 r 0.05 MPa

VG46, 50 qC, 2200 rpm, P

=9.8 MPa

Proportional LS control pressure

1.45 r 0.05 MPa (at 2200 rpm)

0.73 r 0.1 MPa (at 1000 rpm)

VG46, 50 qC, P

=9.8 MPa

SHAFT SPEED 2200rpm

TOTAL INPUT TORQUE 108.0

-2.9

PRESSURE [MPa] DELIVERY FLOW [L/min] PRESSURE [MPa] DELIVERY FLOW [L/min]

PA0= 0.0 QA0= 118.8 PB0= 0.0 QB0= 118.8r2.5 PA1= 9.2 QA1= 117.8 PB1= 7.8 QB1= 117.2r2.5 PA2= 15.3 QA2= 66.0 PB2= 10.8 QB2= 104.1r4.0 PA3= 24.5 QA3= 33.5 PB3= 12.7 QB3= 87.0r4.0

PB4= 16.6 QB4= 61.4r5.0 PB5= 23.5 QB5= 37.0r5.0

SHAFT SPEED 2200rpm

TOTAL INPUT TORQUE 108.0

-2.9

PRESSURE [MPa] DELIVERY FLOW [L/min] PRESSURE [MPa] DELIVERY FLOW [L/min]

PA0= 0.0 QA0= 118.8 PB0= 0.0 QB0= 118.8r2.5 PA1= 10.7 QA1= 117.3 PB1= 10.0 QB1= 117.3r2.5 PA2= 16.7 QA2= 72.0 PB2= 12.0 QB2= 109.0r4.0 PA3= 24.5 QA3= 43.8 PB3= 15.0 QB3= 85.5r4.0

PB4= 18.0 QB4= 68.8r5.0 PB5= 24.5 QB5= 43.8r5.0

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3%4%

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3%4%

3$4$

3$4$

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3%4%

3%4%

PRESSURE: P [MPa]

DELIVERY FLOW: Q [L/min]

PRESSURE: P [MPa]

DELIVERY FLOW: Q [L/min]

P-Q Curve

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WSM Minor Change II Service Engineering Section

1. PP-version (KX161-3S)

c. Control valve

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WSM Minor Change II Service Engineering Section

2. EU, KTA-version (KX161-3DS)

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3. Third line-version: EU & KTA, KX161-3DS

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)

To pump

Hose volume H350

Orifice diameter 1.0

Orifice diameter 0.7

Compensation pulse signal

To pump

Orifice diameter 0.7

Orifice diameter 0.8

Tightening torque: 5±1 N-m

Orifice diameter 1.2

(Before minor change) (After minor change

4. Inlet section; KX121-3SD, 161-3SD

Compensation pulse signal

Section B-B Section B-B

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Spool ID marking on the surface

5. Other section, shuttle plate change

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WSM Minor Change II Service Engineering Section

d. Accumulator

1. Structure and specifications: PP-version

PP-version has newly adopted the accumulator.

(12)

(1)

(2)

(3)

(4)

(5)

(6)

(1) Valve screw (2) Protecting cop (3) Seal ring

(7)

(4) Retainer (5) Marking (6) Shell

(8)

(7) Diaphragm (8) Valve poppet

(9)

(9) Hex. screw 36 (10) Protecting plug (11) Screw type: G 1/2

JIS B2351 Type 0

(12) The gas pressure po is variable

(10)

(11)

with our charging and gouging set. Starting torque screw 20 Nm

1) Type code: SB0210-0.32E1/663U-210LH010

2) Manufacture: HYDAC GMBH

3) Specification

(1) Volume : 0.32 L (0.027 us gal) (2) Permissible max. working pressure :

(3) Charge gas : Nitrogen (N (4) Charge pressure : (5) Media : Mineral oil

(6) Allowable pressure ratio

(Max. pressure / charging pressure)

(7) Temperature of oil : -30 q ~ +80 qC (-86 q ~ +176 qF) (8) Weight : 1.3 kg (2.87 lbs) (9) Surface treatment : Black primer

210 bar (214 kgf/cm

gas)

10±1 bar (10.2±1 kgf/cm2) 1±0.1MPa(145±1.4 psi)

: Under 8 / 1

Example When charging pressure is set 10 bar, should set max. pressure under 80 bar for use.

) 21 MPa(3047 psi)

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WSM Minor Change II Service Engineering Section

2. Change valve with accumulator: EU-version

2-1 Structure Maker: Hydro control

As for EU-version accumulator, structure and specifications almost all remains same as before.

To swivel joint

To pump P

filter

Swivel motor

Pilot valve(Right)

Pilot valve(Left)

2-2 Specifications

1) Max. oil flow : 16 l/min (4.23 Us gal.)

2) Rated voltage and output : 12 V - 18W

3) Coil resistance : 8

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WSM Minor Change II Service Engineering Section

3. Accumulator installation: KX91-3S, U35S, U35-3S(KTA)

1) Bolt tightening torque

48.1 ~ 55.9Nm (4.9 ~ 5.7kgfm)

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WSM Minor Change II Service Engineering Section

4. Accumulator installation: KX121-3S, 161-3S

1) Bolt tightening torque

48.1 ~ 55.9Nm (4.9 ~ 5.7kgfm)

2) Adapter G3/8 tightening torque

37.2 ~ 42.1Nm (3.8 ~ 4.3kgfm)

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WSM Minor Change II Service Engineering Section

KX121-3S is almost same except control valve.

1. Pilot control line: PP-version, KX161-3S

e. Hydraulic system line

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WSM Minor Change II Service Engineering Section

2. Pilot control line: EU-version, KX161-3D

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3. Pilot delivery line: KX161-3S

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WSM Minor Change II Service Engineering Section

m (3.8 ~ 4.3 kgfm)

m (6.0 ~ 6.5 kgfm)

m (1.0 ~ 1.15 kgfm)

G1/2 58.8 ~ 63.7 N

Kubota Japan make is almost same among KX91-3S to KX161-3S

(1) Bolt tightening torque: 9.8 ~ 11.3 N

(2) Adapter tightening torque:G3/8 37.2 ~ 42.1 N

4. Pilot filter

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5. Pilot control line: KX91-3S, U35S, U35-3S (KTA)

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WSM Minor Change II Service Engineering Section

6. Delivery hose: KX91-3S, U35S, U35-3S (KTA)

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WSM Minor Change II Service Engineering Section



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WSM Minor Change II Service Engineering Section

7. Rotary joint hoses: KX91-3S, U35S, U35-3S (KTA)

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WSM Minor Change II Service Engineering Section

m

m)

24.5 ~ 29.4 N

(2.5 ~ 3.0 kgf

G1/4

Pipe joint (L, G1/4-G1/4)

(1) Adapter tightening torque

(RC601-6372

m

m)

(5.0 ~ 5.5 kgf

49.1 ~ 53.9 N

G3/8

Pipe joint (L, G3/8 - G3/8)

(RP201-6181

Pipe joint (T, F2 - F3)

(RC411-6384

8. Change valve

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WSM Minor Change II Service Engineering Section

Adapter tightening torqueG1/4:25.0 ~ 30.0 Nm (2.5 ~ 3.0 kgfm)

1. S/P valve

f. Service port (S/P) solenoid valve

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WSM Minor Change II Service Engineering Section

2. S/P valve

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WSM Minor Change II Service Engineering Section

3. Heat-up circuit

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WSM Minor Change II Service Engineering Section

g. Travel motor: KX91-3S: PP-version

In this minor change, KX91-3S, U35S and U35-3S shockless valve spool has been deleted from the travel motor. Still Kubota’s engineering has achieved the improved feeling at start-up and stop. Here are the explanation in detail how done.

Improvement of start-up and stop feeling

1. Market demand to the travel motor

1) In-shoe type motor  Wheel type motor

2) High speed

3) Traveling feeling

 Hi-Low speed change structure  Shockless relief valve

 Shockless spool

 Anti-void valve

2. Counterbalance mechanism

1) At start-up and while traveling Fig. 1 shows the circuit diagram when the

motor gets started and keeps running. The hydraulic oil from the pump at start of the motor is introduced to port P1. The hydraulic oil flows through the check valve L to keep the motor running. The hydraulic oil at port P1 passes through the orifice L to act against the end of the spool. The spool then moves to the right against the force of spring R. The return oil from the motor flows through the variable orifice of the spool and port P2, and back into the tank. When the return oil passes via the spool's variable orifice, a back pressure occurs at port M2. If the counterbalance spool is slow in motion, therefore, a higher-than-expected pressure is applied at port M2 and you may feel a jolt at the start of the machine. When the motor stops and the control valve gets back to neutral, the hydraulic oil from the pump is cut off and the pressures at ports P1 and P2 become the same as shown in Fig. 1. Then, the spool is affected by the force of spring R and comes back from the state in Fig. 1 to that in Fig. 2. At this time, the outlet port M2 is gradually throttled by the variable orifice. On the other hand, the motor keeps in motion by the inertia force. This produces a brake pressure at port M2, by which the motor gradually slows down and comes to a stop. If the pressure at M2 would rise violently, the motor would come to a sudden stop and you would feel a jolt at the stop.

(2)

(1)

(3)

Fig.1 At start-up and while traveling

(1) Pump (2) Orifice L (3) Check valve L (4) Variable orifice part (5) Counterbalance spool (6) Spring R (7) Control valve (8) Tank

(4)

(8)

(7)

(5)

(6)

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WSM Minor Change II Service Engineering Section

2) Better feeling at start and stop To improve the start-up feeling, the counter-

balance spool must be activated quickly to keep the start-up pressure at port M2 low. To enhance the stop feeling, on the other hand, the brake pressure at port M2 should rise smoothly. In other words, it is important how well the pressure at port M2 can be controlled in starting and stopping the machine.

(2)

(3)

(1)

(4)

(5)

Fig.2 At motor stop

(1) Pump (2) Check valve (3) Counterbalance spool (4) Control valve (5) Tank

3) Conventional pressure control method The pressure at port M2 has been so

far controlled by giving better counter-

Pressure [MPa]

Braking started

balance mechanism response and mounting a relief valve with shockless function. As illustrated in Fig. 6, the

M1 port pressure

9.8

shockless relief valve is activated utilizing the difference between the pressure receiving area (S1) and spring chamber area (S2). While the free

M2 port pressure

9.8

piston provided around the relief housing is moving, the M2 port pressure is held at low level. When the

First speed

Second speed

free piston has completely moved, the relief valve gets activated at a specified pressure. The M2 port pressure is thus raised in two stages, which eases possible violent jolts.

Fig. 3 Brake pressure waveform

(with shockless relief valve)

Shockless relief activated

Fig. 7 shows the brake pressure waveform of the travel motor with shockless relief valve. As clear in this figure, the M2 port pressure is different at a first-speed stop and a second-speed stop. If the stop feeling is adjusted in matching the shockless action pressure with the M2 port pressure for second-speed stop, the feeling will not be just right at the M2 port pressure for firstspeed stop. If adjusted for the first-speed stop, to the contrary, the second-speed stop feels unsmooth. In the existing construction, it is difficult to have both the first-speed and the secondspeed stop feelings equally good.

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WSM Minor Change II Service Engineering Section

4) Improvement of the counterbalance spool performance The characteristics and responsiveness of

the counterbalance spool's variable orifice are adjustable to better control the M2 port pressure. At the start, the spool's spring force gets weak for the counterbalance spool to switch over at low pressure. This makes for smooth start-up. At the stop, the variable orifice's characteristic settings and the counterbalance spool's return time are adjusted to produce the M2 port pressure smoothly. The variable orifice characteristics refer to changes in the counterbalance spool orifice's opening area. As the spool moves, the opening area changes, which produces a

Orifice's opening area

pressure corresponding to the opening area. The counterbalance spool's return time is determined by the spring force and the orifice opening. The stronger the spring force and the larger the orifice opening, the

stroke

quicker the counterbalance spool returns. A weaker spring force and a smaller orifice

Fig. 4 Spool stroke and opening

opening, contrarily, bring back the spool slowly. As discussed above, the counterbalance spool's orifice characteristics and return time are preset, and the actual machine will be matching-tested to achieve better feeling. In case of KX91-3, two orifices are incorporated in the pilot line and counterbalance spool has several holes for the variable orifice function as shown in Fig. 5. With this variable orifice, spool stroke and opening area of the counterbalance spool is as shown in Fig. 4.

Orifice 1 Orifice 2

Small holes for variable orifice

FIg. 5 Counterbalance spool and orifices

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5) Performance comparison

)

350.0

250.0

150.0

Pressure (kgf/cm

50.0

0.0

0.00 0.05 0.15 0.25 0.35 0.45 Time (sec)

FIg. 6 New Type: High speed

350.0

)

250.0

150.0

140.00

)

100.00

60.00

Pressure (kgf/cm

20.00

140.00

)

100.00

0.00

0.00 0.10 0.20 0.30 0.40 0.50 Time (sec)

Fig. 7 New type: Low speed

60.00

Pressure (kgf/cm

50.0

0.0

0.00 0.05 0.15 0.25 0.35 0.45 Time (sec)

Fig. 8 Previous type: High speed Fig. 9 Previous type: Low speed

As above figures indicate that the previous type shows high peak pressure. New type figures show comparatively low peak pressure and regulated. A time to stop is longer by approx. 0.1 second. In this way, traveling shock amount while ordinally working condition is almost equivalent or a little better than the previous type.

Pressure (kgf/cm

20.00

0.00

0.00 0.10 0.20 0.30 0.40 0.50 Time (sec)

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Kubota KX91-3a, U35-3a, KX121-3a, KX101-3a, KX161-3a Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual