Kubota KX36-3 KX41-3S KX41-3V Excavator Workshop Manual - PDF DOWNLOAD

WORKSHOP MANUAL

KUBOTA EXCAVATOR

KX36-3 KX41-3S, KX41-3V Mechanism Chapter

Code No.97899-60810

Record of Revisions Symbol

Date

Main Revised Points & Corrective Measures

Person-in-charge

1

2

3

4

EU - version machine models : KX36-3, KX41-3S, KX41-3V KTC, KCL, KTA version machine model : KX41-3V

CONTENTS I General II Machine Body III Electrical system IV Hydraulic System V Engine

I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2 a. b. c. d. e. f.

Sales feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2 Difference between KX36-3 and KX41-3 . . . . . . . . . . . . . . . . . . . . . . I-2 Quick chart for selling points : KX41-3V . . . . . . . . . . . . . . . . . . . . . . . I-3 Comparison to competitors;EU - version . . . . . . . . . . . . . . . . . . . . . . I-4 New engineering feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5 Compornents compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7

I-1

I. General a. Sales feature Product concept : Comfort in conpact (1) Grade up the basic performance; Digging, filling back and lifting capacity (2) Grade up product feature to differentiate competitor; Digital meter, upper boom cylinder, hose protection Workability

Bucket digging force improvement Variable pump adoption Boom and SP simultaneous operation The maximum digging depth priority High level stability Maintenance Boom cylinder over a boom Hoses arranged inner boom Bucket hose/ SP hose inner Arm Blade hose division New digital meter adoption Amenity Much easier access into cabin Cabin width expansion Operativity Straight travel adoption Smoother operation Safety Engine safety start Travel lock system ROPS, FOPS standard equipment

b. Difference between KX36-3 and KX41-3 Differentiation No1.

KX36-3

KX41-3

Engine

D782 (13 PS)

D902 (16PS)

No2.

Bucket digging forth

1276 kgf

1591 kgf

No3.

Working area (Arm length)

950 mm

1100 mm

No4.

New digital meter

Not equipped

Equipped

No5.

Variable track specification

Not adopted

Adopted

No6.

Travel speed

One speed

Two speed

No7.

Straight travel

Not equipped

Equipped

No8.

Seat grade

Standard seat

High back seat

No9.

Roof window of the cabin

Not equipped

Equipped

I-2

Remark Bucket cylinder is different

Fixed track is same parts KX41-3S, V : EU - version only

I-3

Aux. Hydraulic hoses are routed inside of arm.

Boom cylinder is installed over upside of boom

Increased bucket pin diameter Pin diameter : 30mm

Short stroke operating lever and wrist rest

c. Quick chart for selling points : KX41-3V

D902, 17.0HP 2300rpm

diesel engine

hydraulic pump and Kubota new

Best matching of displacement

on the dozer lever

High speed travel switch

Separated boom swing pedal and auxiliary hydraulic pedal

Digital panel with new navigation system

d. Comparison to competitors;EU - version 1.5 t class Sales features(Sample:EU - version) Bucket digging forth (kgf) Variable pump adoption Workability

Maintenance ability

Boom and SP simultaneous operation Maximum digging depth priority (mm) High level stability Boom cylinder over boom

KUBOTA KUBOTA KX41-3V KX41-2αV

Bobcat 322D

VOLVO EC15B

TAKEUCHI KOMATSU YANMAR TB016 PC12 B15-3

1591

1270

1546

1541

1336

1350

1525

2382

2336

2197

2300

2375

2180

2150

Hoses arranged inner boom Bucket hose/SP hose inner Arm

(bucket)

Divided blade hoses Operator comfort

Much easier access into cabin

(485)

(390)

(420)

(460)

(400)

(450)

(345)

Cabin width expansion

(915)

(845)

(850)

(860)

(902)

(880)

(960)

New digital meter adoption Straight travel adoption Operativity

Smoother operation Wrist-controled lever Engine starting check

Safety

Travel lock system

Others (for KX36-3)

ROPS/FOPS standard equipment Tumbler distance extension (mm) Shoes width extension (mm)

1.3 t class Sales features(Sample:EU - version) Bucket digging forth (kgf) Variable pump adoption Workability

Maintenance ability

Boom and SP simultaneous operation Maximum digging depth priority (mm) High level stability Boom cylinder over boom

KUBOTA KX36-3

KUBOTA KX36-2α

JCB 8015

VOLVO EC13

1276

1245

1122

1122

2230

2170 2102 2010 <Shown by demonstration>

Hoses arranged inner boom Bucket hose/SP hose inner Arm

(bucket)

Operator comfort

Much easier access into cabin Cabin width expansion New digital meter adoption

(bucket)

-

Divided blade hoses (440)

(390)

(550)

-

Straight travel adoption Operativity

-

Smoother operation Wrist-controled lever

-

Engine starting check Safety

Travel lock system

Others (for KX36-3)

ROPS/FOPS standard equipment Tumbler distance extension (mm) Shoes width extension (mm)

1090 230

1010 200

I-4

1008 230

1085 200

e. New engineering feature 1. Hydraulic system 1) New hydraulic circuit with downsized cylinder valve (1) New Hydraulic Circuit Despite the downsizing of the cylinder valve (with an overall length reduced to 335 mm from 368.5 mm), the construction of the interflow circuit for the upward and downward movement of the boom along with the employment of the pump flow unload valve interlocked with an unload lever ensures the smooth operability and stability of the hydraulic system. (a) Boom Upward and Downward Interflow When boom upward and downward pilot signal is input, the inflow section will be switched and the flow of pump number 3 will be guided to the boom section. The total flow of pump number 1 and number 3 will drive the boom cylinder, thus increasing the operation speed of the boom. (b) Unload Section When the safety lever beside the operator's seat is set to the unload position, the spool of the unload section will be switched and the hydraulic oil in pump number 1 and number 2 will flow directly to the tank circuit, thus ensuring safety and protecting the operator from improper control.

2) Flow characteristic simulation for operability improvement (2) Flow Characteristic Simulation To ensure the smooth operability, a fine adjustment to the cylinder valve spool is essential. The flow characteristics of the spool vary with the combination of the squeezed areas of three types of passages. Therefore, a computer simulation was conducted to grasp the flow characteristics, a prototype was manufactured, and a fine adjustment based on the feeling results of operability on an actual model was made to achieve comfortable operability.

I-5

2. Improvement in user-friendliness and operator's range of vision (1) Optimum positioning of levers and other attachments The optimum positioning of the respective levers, pedal, meter, and key was considered in a 3D (CATIA) simulation.

3. Electronic System 1) Digital Navigation System (1) Information-intensive Display The dot-type LCD provides a variety of alarms as well as normal display items supporting 11 languages. Furthermore, the display incorporates a service tester and other versatile functions for improvement in ease of use.

(2) Integration of Functions The integration of functions implemented at the time of the development of the KX91-3, 101-3 Construction Machine has been further developed to include a variety of control functions into a meter for a great decrease in the number of parts along with an increase in functional performance and a reduction in cost. The meter incorporates an auto release, auto glow, finger control service port, auto idling, and two-speed selection functions.

I-6

f. Compornents compatibility Parent

100% compatible

Location

Under carriage

Upper frame

Front attachment

high compatible

low compatible

KX36-3 (EU)

S

V

KX41-3V (US)

9 stacks

Ten stacks

Ten stacks

Ten stacks

Main components 1

Track frame

2

Track roller, idler

3

Blade

4

Travel motor

5

Track shoe

6

Swivel bearing

7

Seat

8

Swivel frame

9

Hydraulic Pump

10

Control valve

11

Engine

12

Bonnet

13

Control box, cover, step

14

Cab

15

Electric parts

16

Control device

17

Swing bracket

18

Boom

19

Arm

KX41-3(EU)

Original design

I-7

I-8

II.Machine Body. . . . . . . . . . . . . . . . . . . . . . . II-2 a. Quality Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-2 b. Main component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II-6

II-1

II.Machine Body a. Quality Specifications No

Specificatios Items

Q1

Main Speed JIS A8404 1

Total length(Transport)

2 1

Unit

Total width Machine size

3

Total height(Canopy)

4

Total height(Cabin)

1

Machine weight (Canopy)

2

Machine weight(Cabin)

KX36-3 EU

KX41-3S

mm

3670 ± 73

3665 ± 73

inch

144.5 ± 2.9

mm

990 ± 10

inch mm

KX41-3V EU KX41-3V US ←

←

144.3 ± 2.9

←

←

990 ± 10

1300/994 ± 13

←

39.0 ± 0.4

39.0 ± 0.4

51.2/39.1 ± 0.5

←

2283 ± 23

←

←

← ←

inch

89.9 ± 0.9

←

←

mm

2283 ± 23

←

←

inch

89.9 ± 0.9

←

←

kg

1440 ± 29

1450 ± 29

1595 ± 32

←

lbs

3174.6 ± 63.9

3197 ± 63.9

3516.337 ± 70.5

←

1540 ± 31

1550 ± 31

kg

3395.1 ± 68.3 3417.13 ± 68.3

lbs

Remarks

Fuel tank

1705 ± 34 3759 ± 75.0

kPa 2

3

Weight

Ground contact press.

(Canopy)

psi kgf/cm2 kPa

Ground contact press.

(Cabin)

4

psi kgf/cm2

1

Swivel speed

2

3

3

rpm

F1

F2

Performance Travel speed

4

R1

5

R2

6

4

Gradeability

9.1 ± 0.9

←

←

←

km/h

2.2 ± 0.2

2.4 ± 0.2

2.2 ± 0.2

2.3 ± 0.2

mph

1.37 ± 0.12

1.49 ± 0.12

1.37 ± 0.12

1.43 ± 0.12

4.3 ± 0.4

4 ± 0.4

4.1 ± 0.4 2.55 ± 0.25

km/h mph

2.67 ± 0.25

2.49 ± 0.25

km/h

2.2 ± 0.2

2.4 ± 0.2

2.2 ± 0.2

2.3 ± 0.2

mph

1.37 ± 0.12

1.49 ± 0.12

1.37 ± 0.12

1.43 ± 0.12

4.3 ± 0.4

4 ± 0.4

4.1 ± 0.4

km/h mph

2.67 ± 0.25

2.49 ± 0.25

2.55 ± 0.25

deg

30 <

←

←

←

1070 ± 21

←

←

←

inch

42.1 ± 0.8

←

←

←

1

Rear end min. turning radius

mm

2

Swivel frame ground clearance

mm

423 ± 8

←

←

426 ± 8

inch

16.7 ± 0.3

←

←

16.8 ± 0.3

3

Tambler center distance

mm

1090 ± 33

←

1230 ± 37

←

inch

42.9 ± 1.3

←

48.4 ± 1.5

←

4

Crawler total length

mm

1445 ± 43

←

1587 ± 48

←

inch

56.9 ± 1.7

←

62.5 ± 1.9

←

mm

990 ± 20

←

1300/994 ± 26

←

inch

39.0 ± 0.8

←

51.2/39.1 ± 1.0

←

mm

230 ± 5

←

←

←

inch

9.1 ± 0.2

←

←

←

mm

167 ± 5

158 ± 5

←

←

inch

6.6 ± 0.2

6.2 ± 0.2

←

←

5

Crawler total width

6

Crawler shoe width

7

rear

Min. ground clearance

II-2

Rated engine RPM, η = 100 %

No

Specificatios Items 1

5

Unit

Engine,SAE J1349 Gross Model name

2

Rated output DIN 70020

3

Rated speed

4

Displacement

1

D782-BH

D902-BH

D902-BH

D902-EBH

11.80 ± 0.30

←

←

ps

12.2 ± 0.3

16.0 ± 0.4

←

←

rpm

2300

←

←

←

L

0.778

0.898

←

←

cc

778

898

←

←

Usgal

0.21

0.24

←

←

Pump delivery

6

Main relief pressure (Bench set)

p3

2

←

←

←

4.39 x 2

4.57 x 2

←

←

2.75, 1.72

2.75, 1.72

←

←

-0.2

←

←

220+3, -2

20.6

-0.2

←

←

←

←

psi

2986

3128

←

←

Mpa

20.1

20.6

←

←

kgf/cm2

205

220

←

←

Bar

201

216

←

←

psi

2915

3128

←

←

←

←

←

40

←

←

←

Bar

39

←

←

←

psi

569

←

←

←

m3

0.035 ± 0.002

0.04 ± 0.002

←

←

0.046 ±

0.052 ±

←

←

0.035 ± 0.002

0.04 ± 0.002

←

←

0.046 ±

0.052 ±

←

←

kgf/cm2

3.9

+0.3

Crawler shoe type CECE

yd

Bucket heaped capacity 2

SAE, JIS

3

Swing angle

5 6

Max. digging radius Front attachment

3

mm

402 ± 10

450 ± 10

←

←

inch

15.8 ± 0.4

17.7 ± 0.4

←

←

L

deg

73 ± 2

73 ± 2

←

←

R

deg

50 ± 2

←

←

mm

3782 ± 57

3910 ± 59

←

←

inch

148.9 ± 2.2

153.9 ± 2.3

←

←

3723 ± 56

3855 ± 58

←

←

151.8 ± 2.3

←

←

Bucket width

4

3

m3 yd

7

Ground level Max. digging radius

mm inch

146.6 ± 2.2

8

Ground level Min. finish radius

mm

1237 ± 25

inch

48.7 ± 1.0

9

Max. digging depth

mm

2227 ± 45

11

Valve bench set

Parking brake type

1

10

21.6

216

210

+3, -2

Travel motor type Under carrage

3

9

←

Swivel motor type

1 8

17.3 x 2 10.4, 6.2

206

Mpa p4

16.6 x 2 10.4, 6.2

Bar

kgf/cm2

p 1, p2

1

Remarks

Hydraulic pump type

Mpa

7

KX41-3V EU KX41-3V US

9.00 ± 0.20

Usgal

3

KX41-3S

kw

L 2

KX36-3 EU

Max. vertical depth

digging

Max. digging height

←

←

48.5 ± 1.0

←

←

2370 ± 47

←

←

1231 ± 25

inch

87.7 ± 1.8

93.3 ± 1.9

←

←

mm

1742 ± 35

1835 ± 37

←

←

inch

68.6 ± 1.4

72.2 ± 1.5

←

←

mm

3458 ± 69

3540 ± 71

←

←

inch

136.1 ± 2.7

139.4 ± 2.8

←

←

II-3

Without cutter

side

Bucket bottom horizontal

No

Specificatios Items 12

Max. dump height

13

Max. dump height (Arm vertical)

14

Mini. turning radius

16

Front attachment

KX41-3S

KX41-3V EU KX41-3V US

mm

2366 ± 47

2455 ± 49

←

←

inch

93.1 ± 1.9

96.7 ± 1.9

←

←

mm

1439 ± 43

1550 ± 47

←

←

inch

56.7 ± 1.7

61.0 ± 1.9

←

←

mm

1147 ± 34

1245 ± 37

←

←

inch

45.2 ± 1.3

49.0 ± 1.5

←

←

mm

512 ± 15

←

←

←

inch

20.2 ± 0.6

←

←

←

mm

323 ± 10

←

←

←

inch

12.7 ± 0.4

←

←

←

mm

990 ± 5

←

1300/994 ± 5

←

inch

39.0 ± 0.2

←

51.2/39.0 ± 0.2

←

mm

230 ± 5

←

←

←

inch

9.1 ± 0.2

←

←

←

180 ± 9

181 ± 9

201 ± 10

←

inch

L Off-set amount

17

KX36-3 EU

mm

Mini. turning radius (Left swing)

15 9

Unit

R

kgf 18

Max. digging force

N lbw

19

Optional bucket range

1

Width

2

Height

3 10

JIS, SAE

inch

Dozer

Max. below GL

6

Displacement capacity

1

Radiator capacity

2

Reserve tank capacity

3

Engine crank case

4

Hydraulic oil (all amount)

5

Hydraulic oil (tank amount)

11

mm

Max. lift above GL

5

Water & oil

yd3

mm

Length

4

m3

inch

7.1 ± 0.4

7.1 ± 0.4

7.9 ± 0.4

←

mm

193 ± 10

←

205 ± 11

←

inch

7.6 ± 0.4

←

8.1 ± 0.4

←

21 ± 1.1

←

←

20 ± 1

m

yd3 L US gal L US gal L US gal Full

Tank

L US gal

5.55 ± 0.29

←

←

5.28 ± 0.26

L

14.5 ± 0.7

←

←

←

US gal

3.83 ± 0.18

←

←

←

6

Wheel motor

L

L

7

Swivel reduction case

8

Track roller

L

9

Front idler

Gear oil

10

Fuel tank

3

US gal

US gal

US gal L US gal L US gal

II-4

Remarks

No

Specificatios Items

Q2

Main Specs JIS A8404 1

1

Bucket tooth slaggish

2

3

Dozer's declination

KX41-3S

mm

53, 73

←

←

inch

2.1, 2.9

←

←

←

mm

< 10

←

←

←

< 0.39

←

←

←

< 10

←

←

←

inch

< 0.39

←

←

←

mm

Distance to swing center

1

Distance to boom pin

2

Boom pin height Min. clearance of bucket teeth to boom cylinder protector

mm

62 -16/+34

167 -16/+34

3

inch

2.4 -0.6/+1.3

6.6 -0.6/+1.3

4

Clearance of boom cylinder to shoe

mm

1

Approach angle

mm inch mm inch mm

inch deg

Distance of crawler end to dozer

mm

4

Clearance of dozer to weight

mm

1

Crawler height

4

Distance to idler center

5

Distance to sprocket center

26.5 ± 2.7

mm

3

Clearance of swivel frame to crawler

exclude grouser

inch

Distance to dozer tip

3

From swivel center

inch

2

Max. crawler height

Remarks

←

inch

2

2

KX41-3V EU KX41-3V US

mm

Eccentric amount from swing center

3

5

KX36-3 EU

1 2

4

Unit

25.5 ± 2.6 From swivel center

inch

inch

inch mm

357 ± 7

inch

14.06 ± 0.28

mm

358 ± 7

inch

14.09 ± 0.28

Include grouser on the spocket

mm inch mm

From swivel centerl

inch mm inch

II-5

b. Main component 1. Swivel bearing

(4)

(1)

(2)

(3)

(1) Seal B (2) S-mark (3) Seal A (4) Rp 1/8, for grease nipple

Number of teeth = 73 Backlash = 0.05 ~ 0.35 mm (0.002 ~ 0.014 inch) P.C.D. = φ 328.5

II-6

2. Track roller

(1) Packing, NBR (2) Spring (3) Reinforce, ring (4) Sleeve (5) Fill grease (5)

Lub oil :Engine oil SAE #30CD class 40 cc Plug :Apply screw lock agent and tightening torque, 0.8 kg·m

II-7

3. Idler and tension spring 3-1 Structure

L

(1) Support 1

(5) Floating seal

(9) Wire

(13) Retainer

(2) Support 2

(6) Bushing

(10) Plug, R 1/8

(14) Nut

(3) shaft

(7) O-ring

(11) Yoke

(15) Split pin

(4) Idler

(8) Spring pin

(12) Spring

(16) Bolt

Pre-set length of spring : L KX36-3 : KX41-3 : KX41-3V :

OK

NO

(Spring roll pin direction) II-8

130 mm (5.12 inch)

4. Pump coupling 4-1 EU - version : KX36-3, KX41-3, KX41-3V

Two Point Pitch

4-2 North America & Oceania - version : KX41-3V

II-9

5. Rubber track

Spec items

KX36-3

KX41-3S, V EU

Type

230 x 32 x 96

230 x 35 x 96

Circunference

3072 ± 10 mm

3360 ± 10 mm

Number of steel cords

48

KX41-3V US

48 ± 4

+2 -0

Thickness of crawler main part

25.0 mm

23.0 mm

Ditto joint parts

28.5 mm

26.5 mm

Core metal Number of core metal (Links)

FCD1200 Austempering 32

FCD450 35

II-10

35

6. Swing bracket (7)

(11)

(12) (8) (9)

(10)

(1)

Swing bracket

(2) ~ (6) Bushing (7)

After installing the bush, pin of φ34.9 goes through smoothy.

(8)

Dimension before bushing.

(9)

Side of the bush (3) should flash the face.

(10) After installing the bush, pin of φ34.9 goes through smoothy.

(11) Side of the bush (2) should behind the surface.

(12) After installing the bush, pin of φ49.95 goes through smoothy.

II-11

7. Bucket link pin : North America & Oceanea

[Unit : mm]

Parts name

Parts No.

Specifications

(1)

Bucket link 1

RB238-66713

Et 125.5 / Wb 40

(2)

Bush A

RB238-66781

φ38 x φ30 x W40

(3)

Pin A dia

RB238-66771

φ30 L : change

(5)

Bucket link 2, 3

(6)

Arm boss

RB238-67112

X85 Y2 / φ55 x φ38 x L125.5

(7)

Bush B

68701-66661

φ38 x φ30 x W35

(8)

Pin B dia

RB238-66751

φ30 L : change

(10)

Bucket cylinder L/S (stroke)

RB238-67802

529 / 805.5 (276.5)

RB238-66722

φ30 - φ30

RB238-66732

II-12

III.Electrical System. . . . . . . . . . . . . . . . . . . III-2 a. b. c. d. e. f. g.

Development concept : KX41-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-2 Outline of Kubota ICS (Intelligent Control System) . . . . . . . . . . . . . . III-5 Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-8 Service mode menues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-12 Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-34 Circuit wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-47 Electrical component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III-53

III-1

III.Electrical System a. Development concept : KX41-3 1. Background of Adoption of New Meter (1) The L1 (3-ton class) Series, which was released in Japan in 1999 for domestic users, adopted a new meter of LCD type (called YUYU NAVI). Since then, this meter has been one of the sales points of the Series.

(2) Presently, the new meter is applied to only models for domestic users. No models for overseas users adopt this meter.

(3) The new meter has a stable reputation for providing advanced performance, convenience, and userfriendliness. This sales point should be added to models for overseas users.

We would like to start adopting the new meter with KX41-3 first, and expand the application range to include higher rank models systematically.

2. Features of New Meter (1) Advanced performance: Digital display (multi-language support), alarm sound, and design performance (see fig. 2 on the right-hand side) (2) Parts integration: Relays and controllers supporting a variety of functions for conventional models are integrated into the new meter for space saving and high cost performance. (Relays partly need to be installed externally.)

(3) Functions in a Wide Variety 1. Warning and self-diagnostic functions: The following items are displayed on the LCD with graphics, failure (warning) numbers, and characters along with an alarm sound.

• Remaining fuel (see fig. 3 on the right-hand side) • Oil pressure (see fig. 4 on the right-hand side) • Charge (see fig. 5 on the right-hand side) • Overvoltage • Overheating 2. Inspection time instruction function: "SERVICE HOURS" appears whenever the time has come for the inspection and replacement of the oil filter as explained in the manual, and prompts the user to make an inspection.

3. Fuel replenishment assist function: The meter beeps intermittently at the time of fuel replenishment, and the interval between beeps is shortened when the tank is almost filled to prevent the fuel from overflowing.

The beep functions with the key turned OFF, but one of the switch needs to be pressed.

4. Service tester function: This function allows the monitoring of the operation of electrical devices (e.g., an oil pressure switch) connected to the meter and provides the history of failures resulted in the past (see figs. 6 and 7 on the right-hand side).

While in harness manipulation mode, it is possible to diagnose and single out harness components that have internal failures (e.g., contact failures).

5. Other functions • Low Travel speed reset at the time of restarting the engine (if the engine is turned OFF with high - low switch set to the high range).

• Engine start check (preventing the engine from starting with the lever unlocked).

• Starter motor automatic disconnection → Auto release • Auto glow • Built-in hour meter and display • Built-in tachometer and display 6. Expansion function for the future (Presently not scheduled to adopt for KX4I-3) • Monitoring with theft prevention set up • Service port (thumb) hand-held proportional control • Air-conditioner idling control • Auto idling III-2

(Reference) LCD Display Examples of New Meter

Fig. 1 Normal screen Key switch ON (Only the glowing moment)

Normal screen (with the tachometer selected)

Normal screen (with the hourmeter selected) Fig. 2 Language selection screen

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7

III-3

3. Electrical system : Functional comparison : KX41-3S, V No.

Function

EU-version

1

KICS;Kubota Intelligent Control System, LCD(liquid cristal display) with character and illustration

2

Maintenance indication upon hour meter

3

Anti-theft system

4

North America Oceanea

Yes

Yes

Yes (delete method:manual)

Yes (delete method:auto)

Yes (sample, date not fixed)

No

AI(Auto idle) function

No

No

5

Engine overheat warning

Yes

No

6

Starter motor auto release function

Yes

Yes

7

Glowplug auto glow function

Yes

Yes

8

Travel high-low switch at lever grip

Yes

Yes

9

Fuel feed assist sound

Yes

Yes

10

Heater

Yes (cab version)

No

11

Rotating lamp

Harness and switch are equipped as standard

Harness is incorporated

12

13

14

15

III-4

&

b. Outline of Kubota ICS (Intelligent Control System)

III-5

III-6

III-7

c. Operating Mode 1. Outline In operating mode, normally LCD shows three types of information.

1) Key switch ON, 2) Normal display, hour meter 3) Normal display, tachometer

When in trouble, LCD shows warning and failure indications as shown below.

In the following list, item No.1, 2, 3, 4, 5, 11, 12, 13, 14, 21, 22, 23, 24, 25, 51, 52, 53, 54, 55, 61, will be indicated according to the machine conditions.

III-8

2. LCD display list Below list shows all LCD letter indications for both oparating mode and service mode.

In operating mode, data 003 ~ 022 will be on the display according to the machine condition.

In case of non AI, non S/P control machines, date 008 ~ 022 except 017, 019, 020, 021 won’t come up to show. name

English

meaning and explanation

data000

This LCD display shows the following conditions;fuel amount, water temp., engine oil pressure, battery, glow plug, and operating hour meter.

data001

This LCD display shows the following conditions;fuel amount, water temp., engine speed.

data002

This LCD display shows the following conditions;fuel amount, water temp., and operating hour meter.

data003

The letter on the LCD indicates the warning of each function;fuel amount shortage

data004

The letter on the LCD indicates the warning of low engine oil pressure

data005

The letter on the LCD indicates the warning of low charging voltage of alternator

data006

The letter on the LCD indicates the warning of each function; higher voltage line connected for example, 24 V battery

data007

The letter on the LCD indicates the warning thepossibility of engine overheating condition EU - version only : 124 ± °C

data008

The letter on the LCD indicates the warning ofaccel sensor line break or shortage

data009

The letter on the LCD indicates the warning of governor sensor line break or shortage

data010

The letter on the LCD indicates the warning of AI motor line shortage.

data011

The letter on the LCD indicates the warning of AI motor line break.

data012

The letter on the LCD indicates the amount of auxiliary port flow.

data013

The letter on the LCD indicates the warning of electrical shortage of aux. solenoid valve left side.

data014

The letter on the LCD indicates the warning of electrical line break of aux. solenoid valve left side.

data015

The letter on the LCD indicates the warning of electrical shortage of aux. solenoid valve right side.

data016

The letter on the LCD indicates the warning of electrical line break of aux. solenoid valveright side.

data017

The letter on the LCD indicates the warning of coolant sensor or water temp. sensor fail.

data018

The letter on the LCD indicates the warning of fuel sensor fail.

data019

The letter on the LCD indicates the warning of 12V sensor supply line shortage.

data020

The letter on the LCD indicates the warning of 5V sensor supply line shortage.

data021

The letter on the LCD indicates the warning of controller error in the meter panel.

data022

The letter on the LCD indicates the warning of AI motor being restricted by any means.

III-9

name

English

meaning and explanation

data023

Indicates the model name.

data024

Indicates the model name.

data025

Indicates the model name.

data026

Indicates the model name.

data027

Indicates the model name.

data028

Indicates the model name.

data029

Indicates the model name.

data030

Indicates the model name.

data031

Indicates the model name.

data032

Indicates the model name.

data033

Indicates the model name.

data034

Indicates the model name.

data035

Owner is expected to select the language he prefers.

data036 data037 data038 data039 data040 data041

This means tester mode which test the following circuit conditions electrically on real time.

data042

The letters and symbols indicate the real time conditions of the following items. engine speed , battery voltage

data043

Engine oil pressure switch condition; on or off, Alternator charging circuit condition; normal or abnormal

data044

Water V indicates water temp. sensor voltage Fuel V indicates fuel sensor voltage

data045

AI SW indicates on or off condition of AI switch. Press indicates AI pressure switch condition.

Motor A means current amount flowing to AI motor.

data046

Accel V indicates voltage amount at accel sensor.

Gover V indicates voltage amount at governer sensor.

data047

Compressor indicates the condition of air conditioner's compressure switch.

data048

Aux. Is abbriviation of auxiliary port and indicates the switch condition, on or off.

Breaker indicates the breaker switch condition ,on or off.

data049

Aux. means in this case auxiliary port solenoid valve.

L;left side, R; right side, A; current amount to each solenoid valve.

data050

Fail record means machines' failure record are stored in the memory and can be shown up on the display. Delete record means you can delete if you want.

data051

First h indicates the operating hours when first failure occurred, last means last fail occurred.

Count indicates the number of fail occurred.

data052

This means no failure occurred in the past.

data053

Back tier indicates that you can return back to one upper tier or same tier by pressing the buttom, for either a long or a short time.

data054

III-10

name

English

meaning and explanation

data055

Literary it means other menus.

data056

This means micro computor is ready to check electrical harness conditions, break or breaking.

In this case, for your sefety engine should be off.

data057

This means micro computor is checking the harness conditions. Service personnel is required to put hands on the suspected harness, then controller detects the break of harness.

data058

This display letter means that AI motor can be controlled by just pressing switches on the panel board.

Aim of this function is to adjust AI motor link to fit the cable not by the accel knob but by switch.

data059

Max(CW) means AI motor link moves toward engine speed Max. direction.

Idle(CCW) means AI motor link moves toward engine speed idle direction.

data060

With this display on, all fail records will be shown up on LCD.

data061

This display means that data in the EEPROM will be shown up on LCD.

data062

These figures and letters indicate the data of EEPROM. Data can be scrolled up by pressing the switch.

data063

This indication shows that micro computor is checking the LCD function.

data064

This shows LCD condition.

data065

This shows LCD condition.

data066

This shows LCD condition.

data067

This indicates the service hours of the machine.

data068

This indicates the hours of machine set up.

data069

This indicates the software version of main controller.

data070

This means initialization of the machine main controller.

data071

This indicates that operator is required to start engine.

data072

This means initialization of the AI system.

data073

This indicates that operator is suggested to turn the accel knob to Max engine speed.

data074

This indicates that operator is suggested to turn the accel knob to idle engine speed.

data075

This means all initialization process has completed and operator is suggested to turn off key.

data076

This means initialization of the machine.

data077

This means initialization of the solenoid valve.

data078

This means initialization of the engine idle speed.

data079

This means initialization of engine overheat warning system.

data080

This indicates the overheat temp. setting value.

data081

This indicates service hour to conduct maintenance job.

data082

These indicates where machine was manufactured.

data083

These letters and signs indicate the switch conditions; safety lock lever, travel high speed and main key position at start or not.

data084

This indicates that operator is suggested to lift up unload lever(safety lock lever).

data085

Simple mode means that min. fail indications are shown up on LCD.

III-11

d. Service mode menues 1. Outline Service mode is basically for dealer’s service personel.

This mode is so designed to initialize machine’s condition, additional attachment and control system. and also diagnose machine trouble. Display indication items are listed in page 3-9 and 3-10, from data number 023 ~ 085.

Following pages include ; 1) Service mode flow chart 2) Main menues in detail

2. Service mode flow chart How to enter the service mode; 1. While pushing the display select switch.

2. Turn the main key switch to ON position.

3. Then you are in the service mode.

III-12

3. Main menues and functions 3-1 Selection Method of 11 Languages If the key is turned ON with the display selector pressed, the name of the model presently selected will appear. When the finger is off the display selector, the next language selection screen will appear. The information on the selected model is important. Therefore, this method enables the confirmation of the model first.

As explained above, the system is designed to support 11 languages, and the language selection screen will appear first. (See fig. ) The selection screen of the 11 languages is written in each of the languages as shown in figure. When a language is selected, a display corresponding to the language will appear.

Direction of arrow ; Push the display selector switch for long time

While pressing the display selector switch, turn the main key ON.

Push the display selector switch for short time

Fig.1. Service Mode Language Selection Screen

III-13

3-2 Tester mode Items such as the present battery voltage can be displayed by selecting Diagnosis and Tester. (See fig. 2.)

Fig.2. Tester menu • Engine -> Engine revolution XXXX rpm A revolution sensor is mounted to the injection pump gear.

The gear ratio varies with the model as described below.

KX41-3's gear ratio: 46 KX61-3 and KX71-3's gear ratio: 54 KX91-3, KX101-3, KX121-3, and KX161-3 gear ratio: 68 Calculation Method A single rotation of the injection pump corresponds to two engine rotations.

The revolution of the engine is calculated by measuring the passing period of the number of gear tooth specified by the timer and obtaining the revolution under the same condition for 60 seconds.

• Battery: Battery Voltage The battery voltage is input into the meter through two diodes. Therefore, the voltage displayed is added with 1.4 V in consideration of the potential drop caused by the diode.

• E. oil: Engine oil switch ON and OFF. • Charge: Alternator L terminal ON and OFF. These switches are turned ON with the engine stopped and turned OFF with the engine started while in normal operation.

• Lever: Lever lock.

• Trave: Running in second gear.

• Start: Start position of key switch.

• Water: Water temperature voltage and water temperature ( C).

• Fuel: Fuel voltage and fuel quantity (in liters).

The quantity of fuel (in litters) displayed is a reference value.

The fuel (in liters) is displayed from data measured according to the model.

• Non anti-theft ver.: Not connected to theft prevention ECU (i.e., no communication is possible with the theft prevention ECU).

III-14

3-3 Fail recoord dump The fail record can be displayed by selecting Diagnosis and Fail record. (See fig. 3.)

By selecting the Fail record, the system reads the contents of the EEPROM and checks the information on failures.

If failures are found, each failure item and the number of times on the hour meter can be scrolled at 1.5-second intervals.

By pressing the display selector just once, the next failure point can be viewed.

If there is no failure, "No fail record" will be displayed.

(See the Section of Fail Safe for failures in detail.)

Fig. 3 Fail record dump

3-4 Deletion of Fail Record The fail record can be deleted by selecting Diagnosis and Delete record. (See fig. 4.)

The message "Fail record deleted" will be displayed when the record is deleted.

By pressing the display selector while this message is displayed, the message to read the fail record will appear again. The message to read the fail record will, however, appear automatically in 3 seconds without pressing the display selector.

Fig. 4 Fail record delete

III-15

3-5 Machine model setup Model settings can be made by selecting Set up and Set up machine. (See fig. 6.)

Here, information on the model and the country of manufacturer is selected.

By selecting the country of manufacturer, European specifications and North American specifications are distinguished.

(If AI optional specifications are provided, the selection of AI as an optional item will appear as well.)

Fig.5 Machine model setu-up Note: By selecting the country of manufacturer, optional functions attached to the country - version, such as the overheating and service auto manual items can be determined automatically.

Fig.6 Machine model set-up

3-6 Overheat set-up Note: By selecting Diagnosis , Set up , Engine start , Set up machine , and Set up overheat warning , overheat warning settings can be made.

By turning the overheat warning ON, the overheating warning function will be enabled and the overheat warning will be output when the preset temperature is reached.

The preset temperature can be adjusted in 10 C increments or decrements.

The value will be negative with the working lamp switch turned ON and positive with the center switch turned ON. The entered value will be determined with the display selector continuously turned ON.

Overheat warning temperature

Adjustable in 10°C increments/decrements

Fig. 7 Overheat Settings In default condition, Overheat warning is OFF for North America and Oceania - version and ON for EU version.

III-16

3-7 Simple mode set-up --- Chinese-version only Simple-mode settings can be made by selecting Set up, Engine start, Set up machine, and Simple mode.

(See fig. - .)

While in simple mode, the output will be turned OFF when the fail-safe function is activated, but no messages will be output. The fuel replenish mode will not be available.

No messages for failures including engine oil failures will be output while in simple mode. In this case, the hour meter cannot be switched over to the tachometer while in normal mode. Therefore, only the hour meter will be displayed. The reason is that the tachometer does not display the engine oil icon.

This meter is used for the U-50-3 meter for China, but the U-50-3 meter for China is shipped with a factory setting made to simple mode.

3-8 Harness check Mode By selecting Other menu and Circuit check Engine stop, the present conditions of the harness connector can be checked (See fig. below.).

When the Circuit check Engine stop is selected, the message "Checking touch harness" will appear at the moment the engine revolution drops below 800 rpm. This mode is available on the condition that the engine is stopped. The mode cannot be selected when the engine revolution is 800 rpm or over.

While in harness check mode, the following items can be checked. Items in parentheses are error criteria.

• Lever lock switch (OFF When lever is down).

• Fuel sensor (Reading of 2 V or more, or 0.2 V or less.).

• Water temperature (Water temperature of 140 C or more, or -30 C or lower.).

• Oil switch (OFF When engine stops and Key is ON).

• Charge circuit (OFF).

If there is any error, a message indicating the position of the error will flash automatically. Simultaneously, the buzzer will beep.

When the error is restored, the buzzer will be turned OFF, but the flashing memory will be kept on hold.

If there are a number of errors, the screen will scroll.

III-17

3-9 All Fail Record All the accumulated failure records can be shown by selecting Other menu, Other menu, and All fail record (See Fig.6.).

By selecting All fail record, the first hour meter items generated after shipping through the last one will be shown.

There are 19 types of failure diagnostic items, and the details of each type of item can be checked. The hour meter will, however, remain even after the failure records are deleted.

3-10 EEPROM read

Fig.6 All Fail Record

The data of the EEPROM can be checked by selecting Other menu, Other menu, and EEPROM read. (See Fig.7.)

Ten items are displayed on each page in hexadecimal, and 13 pages will be used in total.

The EEPROM consists of 128 x 16 bits.

3-11 LCD inspection

Fig.7 EEPROM read

The dot type of the LCD can be checked by selecting Other menu, Other menu, and LCD check. (See Fig. 8.)

Checkered pattern 1, checkered pattern 2, and the outer frame will be displayed. Checkered pattern 1 and checkered pattern 2 are opposite to each other in dot ON-OFF pattern. Missing dots can be checked by using this function. (See Figs.9 and 10.)

Fig.8 LCD check

Fig.9 Frame Display

Fig.10 Checkered Pattern III-18

3-12 Servive hour meter check The service hour meter can be checked and altered by selecting Other menu, Other menu, and Service hour meter.

Only the display selector switch is used to make value changes. The service hour meter will be changed when the meter is replaced, because the service hour meter will not be synchronized with the hour meter, and warnings will not be displayed in a timely manner.

As you reach to this menu, first box is blinking to ready to change the digit. Push the SW in short, the number will be incremented. Push the SW longer, the number will be fixed and shifted to next box. After fixing all boxes, the beep sounds three times and automatically returns to service hour meter with new service hours.

3-13 Servive hour meter delete A deletion method of the service hour meter can be set by selecting Other menu, Other menu, and Service warning selection.

Auto: North America & Oceania - version The service hour meter will be turned off when the key is turned OFF and ON 10 times in total.

Manual: EU - version The service hour meter will be turned off with the working lamp switch pressed continuously for 3 seconds.

Note: Change in Service Hour Meter North American specifications: By default set to auto.

European specifications: By default set to manual.

Turn off the service hour meter with the working lamp switch pressed.

3-14 Set-up time The hour meter used for model settings can be checked by selecting Other menu, Other menu, and Set up hour meter.

3-15 Software version The software version can be checked by selecting Other menu, Other menu, and Soft version.

III-19

3-16 Auto glow control The glow will be turned ON for an optimum time according to the temperature of engine cooling water.

3-16-1 Key-ON Processing Water temperature: The glow-ON time is obtained from the glow time map (see Fig. 1, 2). The glow will not, however, turn ON while the engine is working or the temperature is 81 C or over. The glow icon will appear with the glow turned ON. When the user confirms that the glow icon turns OFF and tries starting the engine, a delay in response (usually 0.5 to 1.5 seconds) will result, during which the temperature of the glow plug will drop. Therefore, the actual glow will be kept turned ON for 2 seconds after the glow icon disappears. This will make a response time lag between the display and glow time, thus making it possible to start the engine smoothly. (See Fig. 3.)

Water temperature ( °C)

Glow time (s)

Glow icon display time (s)

140

0.0

0.0

100

0.0

0.0

81

0.0

0.0

80

3.0

1.0

60

3.3

1.3

40

3.8

1.8

20

5.3

3.3

10

6.5

4.5

0

9.0

7.0

-10

11.0

9.0

-15

12.0

10.0

-40

12.0

10.0

Fig.1.Cooling Water Temperature vs. Glow Time

Fig.2.Graph of Water Temperature vs. Glow Time

Glow continuing Display Glow completes

START Starter switch

ON

OFF

Glow output (new)

ON

OFF

Glow output (conventional)

Glow output holding period

ON

OFF The glow plug is cooled down during this period.

Time

Fig.3.Transition Diagram of Glow and Starter Key

III-20

Glow ON/OFF Conditions The glow will turn ON under any of the following conditions: The engine revolution is 1000 rpm or below; the engine oil pressure switch is OFF (the input terminal of the engine oil pressure switch is H); the charge is OFF (the L input terminal is H). If these conditions are not satisfied, the glow will be turned OFF because controller unit judges that the engine has started.

Relationship between Water Temperature and Dots The gauge of the water temperature uses four dots vertically and 34 dots horizontally.

The relationship between the water temperature and dots is shown below.

Refreshment Cycle of Number of Dots The average temperature of 721 samples obtained at 6.9344-ms intervals (6.9344 ms x 721 = 5 s) is converted into the number of dots to refresh the display.

Enlarged view of water temperature gauge

Water temperature

Dots

40

0

70

14

100

17

110

20

125

34

140

34

Relationship of Water Temperature and Number of Dots

Relationship of Water Temperature and Number of Dots (Graph)

Glow Control (Others) 1. If the grounding of the motor to the engine is improper, the voltage may sneak to the glow relay, thus always turning the glow relay ON. Therefore, when the key is not at the start position, the glow relay will be turned OFF. 2. If the battery is discharged while the key turned ON (In case operator left the key ON) and when the battery voltage is close to the level of triggering the CPU, the following operation may be repeated.

The microcontroller starts and turns the glow relay ON to perform auto glowing.

The glow current flows and the battery voltage drops because the glow relay is turned ON. The microcontroller is reset.

The battery voltage rises because the microcontroller is reset and the glow relay is turned OFF, when no current flows.

The microcontroller is triggered and the glow relay is turned ON because the battery voltage rises.

The above sequence is repeated. Then glow relay contact may have chattering and be damaged.

The glow relay will be always turned OFF in order to prevent the chattering of the above glow relay when the voltage is 7.5 V or below. The similar process will be performed for the relay for the working lamp.

This know - how is to protect the relay itself.

III-21

3. FYI (For your information) water [V]

temp [°C]

0.33

140

0.409

130

0.504

120

0.634

110

0.795

100

1

90

1.26

80

1.58

70

1.96

60

2.4

50

2.86

40

3.36

30

3.77

20

4.15

10

4.44

0

4.66

-10

4.8

-20

4.89

-30

4.94

-40

III-22

3-17 Travel high - low switch control 1. Change travel speed by pressing the high - low switch on the dozer control lever. Refer to the control flow.

2. The travel mechanism will start in low gear to ensure safety when the key is turned ON. 3. With consideration of the change of the operator with the key kept turned ON, the frame mechanism will be set into low gear to ensure safety when the lever lock is lifted up.

4. Control flow chart.

Note: System will always “Reset” to low speed when key is switched “OFF” or safety lock lever is lifted.

III-23

3-18 Fuel amount control 1. Outline A map indicating the voltage and fuel relationship has been prepared by plotting each determined input voltage based on the float position of the fuel sensor and the remaining fuel.

The power supply voltage (5V) is input into the microcomputer according to the partial voltage varied with the float position. Therefore, when calculating the actual quantity of remaining fuel, make a map conversion with consideration of the power supply voltage.

The fuel shortage alarm will be displayed when the quantity of remaining fuel is between approximately 5 and 10 liters, the range of which, however, varies with the model. As a rule of thumb, the fuel will last for approximately one hour after the alarm turns ON. Fuel shortage alarm Model

Fuel residual amount [l]

KX41-3

5±3

KX61-3

7±3

KX71-3

7±3

Voltage and fuel map Circuit diagram & function(Fuel sensor)

(Water temp sensor)

(1)Fuel sensor (2)Water temp sensor (3)Meter (4)AD voltage (Calculation example) Voltage value is 0.899 for example.

Theoretically, water sensor’s resistance is 179.76 Ω

III-24

2. Meter display 1) The LCD with four vertical dots and 37 horizontal dots is used to display the fuel gauge.

Fuel level KX41-3

Amount L (us gal)

Full in tank

19 ± 3

Sensor upper limit

17 ± 3

Sensor lower limit

5±3

(Sample data) 2) A fuel shortage (0.899 V or over) is judged with 8,653 sampling times for 60 seconds. If a fuel shortage is detected 7,780 times or more (i.e., a minimum of 90% of the total), the fuel shortage alarm will be displayed.

3) If the fuel shortage alarm is displayed when the key is turned OFF, data on the alarm will be saved in the microcomputer. If the voltage on average for 0.2 second indicates a fuel shortage (0.899 V or over) when the key is turned ON again, the alarm will be displayed at once.

4) The alarm displayed will be canceled if the alarm cancel voltage (0.719 V or below) is detected 649 times or more (i.e., a minimum of 90% of the total) after the sensor signal is sampled 721 times for 5 seconds.

5) When the engine starts, the sensor float sways greatly, thus resulting in input voltage dispersion.

Therefore, the sampling cycle of the sensor signal is set to 25 seconds.

6) If fuel sensor disconnection occurs, the existence of fuel is not detectable, and the fuel shortage alarm will not turn ON.

III-25

3. Fuel Replenishment Assist Function While replenishing fuel by pressing any switch after the key is turned OFF, the buzzer interval will change according to the quantity of fuel replenished. When the fuel in the tank is not much, the buzzer will be heard at long intervals. When the quantity approaches the full tank level, the intermittent buzzer continues at shorter intervals. When the tank is full, the buzzer will be heard continuously with no intervals to prevent the fuel from overflowing from the tank.

• Beep sound disappears approx 10 seconds after reaching to full of fuel.

• If fuel fank isn’t full, keep sound continues to sound for two minutes in order to alarm.

III-26

3-19 Startor auto release control 1. Outline 1) If the key freezed in the start position, the auto release relay is turned OFF to prevent damage to the startor motor. At the same time, the glow relay will be turned OFF forcibly to prevent damage to the glow plug. (Prevention of startor motor from key freezing) 2) The start of the engine is judged from the engine revolution sensor signal to turn OFF the auto release relay. (Startor auto release) 3) If the key is turned OFF once and reset to the start position immediately while the engine is starting, the pinion gear will engage while the ring gear rotates, which deteriorates the durability of the gears.

Therefore, the mechanism is designed to prevent of the engine from starting in two seconds after the key is turned OFF. (Reentry prevention control) 4) The engine on the KX41-3 does not start at low temperature unless the revolution rises approximately 800 rpm. Therefore, the start of the engine is judged at 1,000 rpm.

(The judgment of the release of the starter has been raised by 200 rpm.)

5) If the key freezes while there is a failure in the engine revolution sensor, the auto release relay will be automatically turned OFF in 30 seconds and power supply to the starter will be stopped. (Prevention of starter burnout damage) The reason the above period is set to 30 seconds is that it will be possible to start the engine by energizing the starter three times for 10 seconds after auto glowing even in winter at a temperature as low as -17 °C. START AC(ON) AUTO RELEASE RELAY (NO) OFF

SAFETY SW R&L

STARTER MOTOR

5V

rpm

CONTROL UNIT

III-27

2. Auto release Circuit diagram & function

Auto release relay (Starter relay) NO - type OFF Key SW

Key ON Start

Is the key switch set at "START" longer than 30 seconds?

Engine speed sensor Has the engine started?

Automatic release control system controller

1) Function chart When in normal operation a.Key switch start signal

About T1 sec

b.Engine speed sensor signal c.Release relay solenoid

When the key switch is returned after the engine got started, the release relay functions as shown below upon engine speed.

Engine speed

Auto release relay (T1, T2)

1000 > = Nx

ON

1001 ~ 1150

ON (Within 6 seconds) OFF (After 6 seconds) ON (Within 0.5 seconds) OFF (After 0.5 seconds)

>

1151 = Nx

2) If the engine has started but the key switch fails to return (key switch failure) a.Key switch start signal

T2 sec

b.Engine speed sensor signal c.Release relay solenoid

Switch turned off

Suppose that the key switch fails to return and the key switch start signal stays on. But if the engine speed sensor signal is fed, the automatic release control system regulates the transistor's base current flow, which turns on the release relay solenoid ON or OFF. III-28

3) If the key switch fails to return and the engine speed sensor is also in trouble a.Key switch start signal

30 sec

b.Engine speed sensor signal Switch turned off

c.Release relay solenoid

If the key switch start signal is detected to have been on for 30 seconds, the automatic release control system (3) lets the transistor's base current flow, which turns on the release relay solenoid (1) and turns off the relay switch. a:Key switch status

b:Engine speed sensor status

c:Release relay solenoid action

(1)

Normal: No particular action

Normal

Normal: No particular action

(2)

Start position → Failure to return

Normal

Relay deactivated 0.5 or 6 seconds according the engine speed.

(3)

Start position → Failure to return

Engine failure to start, or no engine speed sensor signal

Relay deactivated 30 seconds after the key switch turn to "START"

3. Trouble shooting If Engine Does Not Start 1) Check if the safety lock lever is lifted.

Make sure that the safety switch is turned OFF. Take the following steps, set the unit to tester mode, and check the condition of the safety switch.

(Service mode) KX41-3

English

Diagnosis

Tester

Lever travel start

A manual check with a circuit tester is possible.

2) Check if the prevention of start mode reentry is working. (Wait two seconds or more.)

3) Check if the auto release relay is turned OFF. Make a manual check with a circuit tester.

4) Check if the wrong model settings are made.

Depending on the model, the start of the engine is judged at 1,000 rpm or below. Therefore, the release of the starter motor is judged before the startup revolution of the engine is reached.

5) The reason why detecting engine speed is set at 1000 rpm ; If 800 rpm is set to detect the engine start - up speed, the controller stops supplying the current to the startor motor.

Under the low ambient temperature, engine may not start up at around 800 rpm.

Therefor, in order to make sure the actual engine start, sensing engine speed is set higher by 200 rpm.

This varies according to the models.

III-29

4. Operational flow chart 4-1

III-30

4-2

III-31

4-3

< Engine speed and condition of auto release relay > Engine speed : Nx

Time : T1, T2

1000 > = Nx 1001 ~ 1150 >

1151 = Nx

Auto release relay ON

Within 6 seconds

ON

After 6 seconds

OFF

Within 0.5 seconds

ON

After 0.5 seconds

OFF

starter relay = Auto release relay

III-32

3-20 Service hour meter A service maintenance message will appear when the preset hour meter item is activated.

The message will disappear in 10 seconds. Hereafter, whenever the key is turned OFF and ON, the message will appear for the first 10 seconds.

There are two modes (i.e., auto mode and manual mode) to turn OFF the inspection icon perfectly, either of which is selectable by the user's settings.

While the system is in auto mode, the icon will disappear when the key is turned OFF and ON 10 times in total. Then icon will not appear again with the key further pressed. This is convenient because the icon will disappear only with the key turned OFF and ON, in which case the actual maintenance of the equipment will be up to the user's choice.

While in manual mode, the icon will disappear with the working lamp pressed continuously for 3 seconds. In this case, the message will be eliminated after the user's maintenance work. Therefore, the problem of the careless omission of maintenance will be prevented. This method is, however, complicated. Therefore, it is necessary for each dealer to make maintenance management.

When all the described inspection items in the Operation Manual are considered, a message will be displayed at 50-hour intervals, which is not so meaningful. In view of the foregoing, important items (e.g., items related to the engine oil, operating oil, air filter, and engine oil filter) should be targeted so that a message will appear in the case of maintenance necessity for any of these items. The meter with North American specifications and that with European specifications share the same software, but the timing of maintenance varies with the specifications and the size of the system. Therefore, the displayed frequency of each item is changed according to the specifications. Fig. 2 shows an example of the display of the KX41-3 with North American specifications.

Usually, the service hour meter advances in synchronization with the hour meter, thus causing no problems.

If the hour meter is replaced, however, the new hour meter will start with zero hour. In that case, the service hour meter will be asynchronous. Due to ethics reasons, the system cannot incorporate functions that allow the alternation of the hour meter. There are, however, no problems in altering the service hour meter. Therefore, items that can be input for the service hour meter have been prepared.

KX41-3 Service Hour Meter with North American Specifications

Fig. 2 EU - version machine A message appears initial at 50-hour intervals and 250-hour intervals (i.e., every 250, 500, 750, and 1000 hours).

III-33

e. Failure Diagnosis 1. Failure display and diagnosis criteria The following table 1 shows data on failure diagnosis, for operating mode and service mode.

Note: • Display items of the system in service mode can be checked with the fail record.

• In the case of a warning for fuel scarcity, the buzzer will be turned ON for a moment at five-minute intervals.

• No.11 ~ 61 except 31, 32, 51, 52, 53, 54, 55 will be incorporatrd in future version machine, such as auto idle (AI) model, anxilliary port (AUX) model and anti - theft system model.

Table 1. Failure diagnosis Display Operating mode

Buzzer

Lamp

Reset method

Function stop point

service mode

EEPROM address

Method of diagnosis

1 Fuel

-

5-minute intervals

Yellow

Replenish fuel

---

---

Fuel scarcity rate is 90% min. after 60-s sampling

2 Engine oil

2 Engine oil

Continually

Red

Returns to normal

---

66, 86

At 5 V (normal).

The following conditions continue 10 s: oil = L and 800 rpm min.

3 Charge

3 Charge

Momentarily

Red

Returns to normal

---

65, 85

At 5 V (normal).

The following conditions continue 10 s: charge = L and 800 rpm min.

4 High voltage

4 High voltage

Continually

Red

Turn key OFF

AI AUX

67, 87

At 5 V (normal).

A power supply voltage of 18 V min. continues 3 s.

5 Overheat

5 Overheat

Continually

Red

112°C±α max.

AI AUX

77, 97

At 5 V (normal).

The following conditions continue: Engine revolution of 800 rpm min. with overheat warning When the water temperature sensor is normal, a water temperature of (124 ± α) C min. continues 5 s. (α : Adjustable between -10 C and +10 C.)

11 Accel sensor

11 Accel sensor

Momentarily

Red

Turn key OFF

AI

68, 88

At 5 V (normal).

The accelerator sensor for AI specifications at 0.25 V max. or 4.75 V min. continues for 0.2 s.

12 Governor sensor

12 Governor sensor

Momentarily

Red

Turn key OFF

AI

71, 91

At 5 V (normal).

The governor sensor for AI specifications at 0.25 V max. or 4.75 V min. continues for 0.2 s.

13 AI motor short

13 AImotor short

Momentarily

Red

Turn key OFF

AUX

69, 89

At 5 V (normal).

AI specifications.

The specifications are presently under consideration.

14 AI motor short

14 AI motor short

Momentarily

Red

Turn key OFF

AUX

70, 90

At 5 V (normal).

AI specifications.

The specifications are presently under consideration.

III-34

Display Buzzer Operating mode

Lamp

Reset method

service mode

Function stop point

EEPROM address

Method of diagnosis

21 AUX.volum

21 AUX volum

Momentarily

Red

Cancel AUX

AUX

72, 92

At 5 V (normal).

AUX specifications.

AUX mode turns ON. The AUX sensor at 0.25 V max. or 4.75 min. continues for 0.2 s.

22 AUX.Solenoid L short

22 AUX. Solenoid L short

Momentarily

Red

Cancel AUX

AUX

73, 93

At 5 V (normal).

AUX specifications.

AUX mode turns ON. The specifications are presently under consideration.

23 AUX.Solenoid L break

23 AUX.Solenoid L break

Momentarily

Red

Cancel AUX

AUX

74, 94

At 5 V (normal).

AUX specifications.

AUX mode turns ON. The specifications are presently under consideration.

24 AUX.Solenoid R short

24 AUX.Solenoid R short

Momentarily

Red

Cancel AUX

AUX

75, 95

At 5 V (normal).

AUX specifications.

AUX mode turns ON. The specifications are presently under consideration.

25 AUX.Solenoid R short

24 AUX.Solenoid R short

Momentarily

Red

Cancel AUX

AUX

76, 96

At 5 V (normal).

AUX specifications.

AUX mode turns ON. The specifications are presently under consideration.

31 Lift up unload lever

-

Momentarily

Yellow

Wait for 5 s, then disappear

Engine does not start

---

The key is shifted to the start position with the lever lock moved down.

32 Service hour

-

Momentarily

Yellow

Wait for 10 s

---

---

The specified hour meter is set.

33 Key is wrong

-

Momentarily

Yellow

Wait for 3 s

Engine does not start

---

Theft prevention specifications The wrong key is used to start the engine.

The specifications are presently under consideration.

34 Owner tag

-

Momentarily

Yellow

Wait for 3 s

Engine does not start

---

Theft prevention specifications The owner tag is used to start the engine.

The specifications are presently under consideration.

-

51 Coolant sensor

Momentarily

Red

Turn key OFF

---

82, 102

At 5 V (normal).

A water temperature of -30 C max. or 140 C min. continues for 1 s.

-

52 Fuel sensor

Momentarily

Red

Turn key OFF

---

81, 101

At 5 V (normal).

The fuel sensor at 2 V min. continues for 10 s.

53 Sensor supply short 5V

53 Sensor supply short 5V

Momentarily

Red

Turn key OFF

LCD turns OFF 79, 99 AI AUX 5-V output turns OFF

5-V short-circuiting detection terminal at H level continues for 0.1 s.

54 Sensor supply short 12V

54 Sensor supply short 12V

Momentarily

Red

Turn key OFF

AI AUX always 0 rpm

80, 100

At 5 V (normal).

The 12-V short-circuiting detection terminal at H level continues for 0.1 s.

55 Meter controller error

-

Momentarily

Red

Turn key OFF

AI AUX

78, 98

The rightmost 16 bits of the added value of addresses 36 through 50 do not coincide with the value of address 64.

-

61 AI motor retricrd

Momentarily

Red

Press accelerator

---

83, 103

At 5 V (normal).

AI specifications A motor current of 6 A min. continues for 3 s.

III-35

2. Fail record in EEPROM If the sensor or actuator line has an error, the output of the actuator will stop and the LCD will display the contents of the error while the error point is written to the EEPROM. Fig. 2 and fig. 3 show the address allocation of the EEPROM.

2-1 Error Storage Method If an error result, data in a corresponding EEPROM address will be overwritten. The data in the corresponding address has a capacity of 2 x 16 bits. The first address (1 x 16 bits) has an hour meter record for the latest error. The other address (1 x 16 bits) has an hour meter record of the first error along with the total number of errors in the past. The data will be written to the EEPROM after rounding off all hour meter values for less than one hour (see fig.1).

Hour meter data and the number of errors (1) will be written to both addresses if an error occurs for the first time. The last hour meter data will be converted into present hour meter data for errors on and after the second time. The count will remain 15 regardless of whether the actual number of errors exceeds 15, and only data on the last hour meter data will be overwritten.

Address sample

(Fig. ___ shows address numbers 85 to 103)

Address sample

(Fig. ___ shows address numbers 65 to 83)

0

A

A

7

:

0 A A 7 H Fig. 1 Error Data Storage Method

2-2 Number of Errors Data is stored in four bits. Therefore, the maximum number of errors is limited to 15. The count increases by one if an error occurs after the key is turned ON. Once the key is turned ON, however, the count increases only by one until the key is turned OFF. (Example) Binary to decimal 1

0

1

0

1

0

1

0

Binary 0 x 20 = 0 1 x 21 = 2 0 x 22 = 0 1 x 23 = 8 0 x 24 = 0 1 x 25 = 32 0 x 26 = 0 +1 x 27 = 128 (decimal) 170 hrs

III-36

2-3 Erasing Method of Error Log The error log will be deleted by selecting Error Log Delete in Diagnosis Mode. In the software, only the 0th to third bits (the accumulated number of errors) in EEPROM addresses 85 through 103 will be zero cleared, but hour meter data will not be zero cleared. Error Log Delete in Diagnosis Mode judges that there is no error log if the number of errors is zero.

Hour meter data will not be deleted after executing Error Log Delete in Diagnosis Mode. Therefore, by dumping the EEPROM, hour meter data for errors will be known. This will make troubleshooting possible if the LCD meter is returned to the factory due to a failure after shipping.

The contents of addresses 65 through 103 are zero cleared with the PC before shipping.

Address No.

Contents & purpose to use

~

0 Hour meter

35 36

Machine model (Ref.1)

37

Optional item (Ref.2)

~

38 AI control data

44

~

45 Thumb control data

50 51 52

Overheat control data

53

Language (Ref.3)

~

54 Machine hours & times

63

~

64 Machine failure warning

104

~

105 127

Original manufacturer use Address No. 118 : Machine serial No.

Fig.2.Address and contents of EEPROM Ref.1 : 0:KX41-3, 1:KX61-3, 2:KC71-3, KX91-3, 4:KX101-3, 5:KX-121-3, 6:KX161-3, ··· Ref.2 : bit No : 8 7 6 5 4 3 2 1 0 0 : Made in Japan, 1 : made in Germany 1 : Chinese - version 0 : Non AI, 1 : AI - version 1 : Thumb - version 1 : Anti - theft - version 0 : Canopy, 1 : Cab 1 : K or U - version 1 : Japanese - version, 0 : Oversea’s - version 1 : Long arm

III-37

Address No.

Contents of failure

65

3 Charge

66

2 Engine oil

67

4 High voltage

68

11 Accel sensor

69

13 AI motor short

70

14 AI motor break

71

12 Governor sensor

72

21 Aux.volume

73

22 Aux.solenoid L short

74

23 Aux.solenoid L break

75

24 Aux.solenoid R short

76

25 Aux.solenoid R break

77

5 Overheat

78

55 Meter controller error

79

54 Sensor supply short 5V

80

53 Sensor supply short 12V

81

52 Fuel sensor

82

51 Coolant sensor

83

61 AI motor retricted

Data bit

The leftmost 12 bits display the hour meter value of the last error. The rightmost four bits display the accumulated number of errors.

84

reserve

85

3 Charge

86

2 Engine oil

87

4 High voltage

88

11 Accel sensor

89

13 AI motor short

90

14 AI motor break

91

12 Governor sensor

92

21 Aux.volume

93

22 Aux.solenoid L short

94

23 Aux.solenoid L break

95

24 Aux.solenoid R short

96

25 Aux.solenoid R break

97

5 Overheat

98

55 Meter controller error

99

54 Sensor supply short 5V

100

53 Sensor supply short 12V

101

52 Fuel sensor

102

51 Coolant sensor

103

61 AI motor retricted

The leftmost 12 bits display the hour meter value of the last error. The rightmost four bits are dummy bits.

Fig.3 EEPROM Addresses for Error Log

III-38

3. self-diagnosis of controller unit 3-1 Purpose The error diagnosis of the meter is possible by using the self-diagnostic harness. The self-diagnostic function of a conventional model provided with a microcontroller can detect failures in the microcontroller only after all the failure diagnosis of the electrical devices other than the microcontroller is made. This kind of method requires time. Furthermore, there is a fear in the accuracy of the diagnosis.

By connecting the self-diagnostic harness to the meter and applying voltage from the battery, the selfdiagnostic program built into the meter will run, thus making the self-diagnosis of the incorporated hardware of the meter possible with the inputs and outputs of the meter automatically activated and checked.

Note: It is not 100% possible to make the perfect self-diagnosis of the hardware of the meter, however, because not all hardware components built into the meter are checked.

3-2 Operation Procedure 1. Dismount the meter from the main harness of the equipment and connect the meter to the self-diagnostic harness.

2. Connect the 12-V terminal and negative terminal of the self-diagnostic harness to the battery.

3. Self-diagnosis starts automatically.

III-39

The red and yellow lamps flash alternately.

The LCD of the meter flashes black and white alternately.

The lamp as shown in the illustration on the right-hand side turns ON and OFF repeatedly.

The buzzer beeps.

The backlight of the meter turns ON and OFF repeatedly.

4. If the following message appears in approximately one minute, the hardware in the meter is considered normal.

Finish key off

5. If any one out of numbers 2 through number 15 specified in table 2 is displayed, the meter has a failure.

6. If the lamp is kept turned ON while the three switches as shown in the illustration on the right-hand side are pressed, the switches and lamp are in normal condition.

III-40

3-3 Failure Display Number of Self-diagnostic Function Table 2. Self - diagnosis of controller, items and methods Check item 2

Check parts

Check methods

Check sum

CPU ROM

Implement self-checksum.

Input & output

Glow relay output RS-485 (negative) (positive) flash TXD, RXD input

Turn OFF the glow relay and make sure that pin 29 (RXD2 power 7.1) is set to low level.

Turn OFF the glow relay and make sure that flash RXD TXD input is set to high level.

Input & output

Glow relay output RS-485 (negative) (positive) flash TXD, RXD input

Turn ON the glow relay and make sure that pin 29 (RXD2 port 7.1) is set to low level.

Turn ON the glow relay and make sure that the flash RXD TXD input is set to low level.

Input & output

Auto release relay output, lever lock switch input

Turn OFF the auto release relay and make sure that the lever lock switch is set to high level.

Input & output

Auto release relay output, lever lock switch input

Turn ON the auto release relay and make sure that the lever lock switch is set to low level.

Input & output

Working lamp relay output, start switch input

Turn OFF the working lamp relay and make sure that the start switch is set to high level.

Input & output

Working lamp relay output, start switch input

Turn ON the working lamp relay and make sure that the start switch is set to low level.

Input & output

Compressor clutch relay output, engine rpm input

Turn OFF the compressor clutch relay and make sure that the engine rpm is set to low level.

Input & output

Compressor clutch relay output, engine rpm input

Set the compressor clutch relay to high level and make sure that the engine rpm is set to high level.

Input & output

AUX LED output, charge input

Turn OFF the AUX LED and make sure that the aircon switch is set to high level.

Input & output

AUX LED output, charge input

Turn ON the AUX LED and make sure that the aircon switch is set to low level.

Input & output

AI LED output, oil input

Turn OFF the AI LED and make sure that the oil is set to low level.

Input & output

AI LED output, oil input

Turn ON the AI LED and make sure that the oil is set to low high level.

Input & output

Travel sol output, aircon switch input

Turn OFF the travel sol and make sure that the charge is set to low level.

Input & output

Travel sol output, aircon switch input

Turn ON the travel sol and make sure that the charge is set to high level.

3

4

5

6

7

8

9

III-41

Fail indication No. 1

2

3

4

5

6

7

Check item

Check parts

Check methods

Input & output

Motor Tr1, Tr2, Tr3, and Tr4 output AI operation switch input, travel switch input

Motor Tr1, Tr2, Tr3, and Tr4 are set to low output level.

The AI operation switch is set to low level. The travel switch is set to low level.

Input & output

Motor Tr1, Tr2, Tr3, and Tr4 output AI operation switch input, travel switch input

Motor Tr1 is set to high output level and Tr2, Tr3, and Tr4 are set to low output level.

The AI operation switch is set to high level. The travel switch is set to high level.

Input & output

Motor Tr1, Tr2, Tr3, and Tr4 output AI operation switch input, travel switch input

Motor Tr1 and Tr4 are set to high output level and Tr2 and Tr3 are set to low output level.

The AI operation switch is set to high level. The travel switch is set to low level.

Input & output

Motor Tr1, Tr2, Tr3, and Tr4 output AI operation switch input, travel switch input

Motor Tr2 is set to high output level and Tr1, Tr3, and Tr4 are set to low output level.

The AI operation switch is set to high level. The travel switch is set to high level.

Input & output

Motor Tr1, Tr2, Tr3, and Tr4 output AI operation switch input, travel switch input

Motor Tr2 and Tr3 are set to high output level and Tr1 and Tr4 are set to low output level.

The AI operation switch is set to low level. The travel switch is set to high level.

Input & output

AUX sol (positive) (R) output, compressor clutch switch input

Turn OFF the AUX sol (positive) (R) and make sure that the compressor clutch switch is set to low level.

Input & output

AUX sol (positive) (R) output, compressor clutch switch input AN2_7 input

Turn ON the AUX sol (positive) (R) and make sure that the compressor clutch switch is set to high level.

The AN2_7 AD value varies more by 25 mV or more from the value with the input turned OFF. From theoretical values, 12 V and 240 Ω: 50 mA Voltage fluctuation corresponding to 50 mA: 50 mV

Input & output

AUX sol (negative) (L) output, AI pressure switch input

Turn OFF the AUX sol (negative) (L) and make sure that the AI pressure switch is set to low level.

Input & output

AUX sol (negative) (L) output, AI pressure switch input

Turn ON the AUX sol (negative) (L) and make sure that the AI pressure switch is set to high level.

Input & output

AI self-hold relay output, breaker switch and AUX switch input

Turn OFF the AI self-hold relay and make sure that the breaker switch and AUX switch are set to low level.

Input & output

AI self-hold relay output, breaker switch and AUX switch input

Turn ON the AI self-hold relay and make sure that the breaker switch and AUX switch are set to high level.

14

AD (Analog and digital conversion)

fuel sensor

Check with the microcomputer that the AD value is 1.8 V ± 0.15.

15

AD (Analog and digital conversion)

water temp sensor

Check with the microcomputer that the AD value is 2.5 V ± 0.15.

16

AD (Analog and digital conversion)

motor potention sensor

Check with the microcomputer that the AD value is 3.75 V ± 0.15.

17

AD (Analog and digital conversion)

accel potention sensor

Check with the microcomputer that the AD value is 2.5 V ± 0.15.

18

AD (Analog and digital conversion)

AUX potention sensor

Check with the microcomputer that the AD value is 1.25 V ± 0.15.

10

11

12

13

III-42

Fail indication No.

8

9

10

11

12

FYI (For your information) Check Sum Error 1. A check sum error is checked to see if the contents of the program for microcomputer control are corrupted.

2. The control program is saved in the ROM of the CPU. Once data is written to the ROM and shipped to the market, the data cannot be written in the market.

3. The total sum of the data in each address of the control program is obtained in advance and stored as check sum data prepared while in normal operation.

4. When the key is ON, the microcomputer calculates the total sum of the data in each address of the control program in self-control of the microcomputer. The microcomputer checks if the results coincide with the check sum data prepared while in normal operation (i.e., at the time of writing the program).

The microcomputer will go to the next step after the microcomputer checks if the results are found normal.

5. If the data does not coincide, the microcontroller judges that the program is illegal. In that case, a check sum data error will result and an error alarm will be output. Error No. = 55 6. The program data can be reversed if the LSI in the controller partly fails to operate due to external environmental factors, such as abnormal temperatures or excessive shock. That is the reason the microcomputer makes this check when the key is turned ON, thus preventing the microcomputer resulting in out-of-control conditions due to program failures.

III-43

3-4 Functions of Self-diagnostic Harness The harness short-circuits the input and output terminals of the meter in advance, switches the respective inputs of the meter ON and OFF in sequence, and checks if the data on the output side is normal.

Self-diagnosis Yazaki I/O

Check if the signal changes in synchronization with the output when the power is turned ON. Goes into aging mode.

Yazaki aging

Always select input mode.

Check that the input potential is inverted with the transistor turned ON and OFF.

III-44

4. Electrical component layout (2) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Main key SW Hi - Low SW Meter coupler Hi - Low lamp Selector SW Coil commander Work lamp SW Fuel pump Engine emergency stop (Fusible link) Engine stop solenoid Glow piug Fusible link Alternator Starter Motor Engine lock SW Lever lock SW

(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31)

(1)

Couper Cab relay Light relay Horn relay Starter relay Glow relay Fuse box Fusible link (50A) Battery Ground Travel Hi - Low solenoid Unload solenoid Power outlet Horn Working lamp

(4)

(3)

(5)

(8)

(9)

(6) (10) (11) (12) (13)

(4)

(29) (30)

(31)

(17) (16) (15)

(21) (20) (19) (18)

(25) (24) (23) (22) (28) (27) (26)

III-45

III-46

5. Service Mode KX41-3(Non-AI Non- anti-theft Non-S/P) ver 1.13

2.

push switch for long time

Note: 1. push switch for short time

f. Circuit wiring diagram 1. KX36-3 EU

III-47

2. KX-41-3 Export (EU) (US)

III-48

3. KX-41-3 Export standard type

III-49

4. Main electrical compornents

III-50

5. Covering circuit by controller

III-51

III-52

g. Electrical component 1. Battery Code NO.

RB238-53231

Type

75D23L

Capacity, 5RH

52 Ah

Discharge, 300A at -15 °C

8.9 V after 5 sec

Weigh, wet

17.0 kg

Specific gravity

1.280

Size L x W x H

230 x 171 x 225 mm

(3)

(2)

(1)

2. Fuel sensor

KX36-3

(1)

(2)

(3)

99.8

188.3

240.2

KX41-3

EU

99.3

189.6

241.6

KX41-3

US

38.6

99.0

143.0

• Flange bolt tightening torque :98.1 ~ 196 N·cm (10.0 ~ 20.0 kg·cm) (0.72 ~ 1.45 ft·lbs) • Insulation : 3M Ω or more (D500V megatester) III-53

KX36-3 (1)

(1) Meter (2) Fuel gauge

(2)

(3) Sender

(5)

(4) Thermistor (4)

(3)

(5) Warning lamp

(6)

(6) Fuel sender (7) tank earth (7)

3. Fuse box KX41-3 : EU - version

III-54

Sender resistance Level

Ω

Full

3.0 ± 2

1/2

(32.5)

Empty

110.0 ± 2

4. Heater : EU - version 1.

1-1 Structure, Maker : Siroco (1)

(1) Electric cable exit (2) Fuse 5 Amps (3) Motor side (4) Duct, (5) Duct,

1-2 Specifications Heating capacity : 4.1 kw Nominal air flow : 239 m3/h Rated voltage : 13 V Consumption current : 5.6 A

(2)

(3)

(4) (5)

(1)

Connector (1) 12 V (Black)

(3)

(2)

(2) HIgh speed (red) Low speed (3) (orange)

III-55

III-56

IV.Hydraulic System . . . . . . . . . . . . . . . . . . IV-2 a. Hydraulic components Specifications . . . . . . . . . . . . . . . . . . . . . . . .IV-2 b. Hydraulic circuit diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-5 c. Main pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-9 d. Control valve assy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-13 e. Pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-19 f. Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-20 g. Swivel motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-29 h. Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-30 i. Rotary joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-34 j. Unload valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-37 k. Selector valve : KX41-3V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-39 l. Accessaries of hydraulic compornents . . . . . . . . . . . . . . . . . . . . . .IV-40 m. Service port performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV-41

IV-1

IV-2

Swing Motor

Rubber Track

Travel Motor

Pump

1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Supplier Parts No. type Motor cap.

Brake pressure Motor torque Motor rev.

Teeth Pinion Teeth S race Swivel Torque Swivel Speed

Wire distance Tangential force Wire qty Wire strength Strength ratio

Supplier GB Reduction ratio Equivalent cap.

Output torque Schaft rev.

PCD sprocket fixing pitch Sprocket teeth Pitch rubber tracks.

Travel speed

Supplier Parts No. type Motor cap.

Motor torque Motor rev.

Engine model rated rev rated output relief q1 q2 q3 q4 C/V supplier

Supplier Parts No. type q1 q2 q3 q4

cc/rev kgf/cm2 kgf䍃m rpm pcs pcs kgf䍃m rpm

kg >20

mm kgf

cc/rev kgf䍃m rpm mm mm pcs mm km/h

cc/rev kgf䍃m rpm

kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2

rpm

cc/rev cc/rev cc/rev cc/rev

1. EU - version; KX36-3,

BS Bilbao RG038-2232-1 230x32x96 146.4 905.9 48 400 21.2

AVON RG001-2231-0 200x30x96 146.4 792.8 30(36) 580(670) 21.9(30.4) Sumitomo Eaton RG138-6128-1 Orbit 195 135 41.9 53.1 12 73 254.9 8.7

155 19 96 2.23

157 19 96 2.15

Sumitomo Eaton RG008-6128-2 Orbit 195 135 41.9 51.7 12 73 254.9 8.5

Trasmital B 37.22 406.4 132.6 40.7

Trasmital B RG038-6129-1 MAG10V 10.92 3.56 1516

205 205 205 40 Hydrocontrol

D782-BH 2300

KX36-3 Nachi RG038-6111-1 2Vp+Gear 7.2 7.2 4.5 2.7

Trasmital B 31.8 347.3 116.1 39.3

Trasmital B RG008-6129-1 MAG10V 10.92 3.65 1250

210 210 210 46 KYB

D1105-BH-8 2100

KX36-2 Casappa RG108-6111-2 Gear 6.5 6.5 4.5 supply unit

a. Hydraulic components Specifications

IV.Hydraulic System

3.96

Sumitomo Eaton RG008-6128-2 Orbit 195 135 41.9 58.7 12 73 254.9 9.6

BS Bilbao RG108-2232-2 230x32x96 146.4 792.8 40 400 20.2

2.50

157 19 96

Trasmital B 31.8 347.3 218.8 116.1 73.12 45.6 72.4

Trasmital B RG108-6127-1 MAG10V 10.92 6.88 3.65 2.30 1451 2302

210 210 210 46 KYB

D782-BH 2200

KX41-2㱍 Nachi RG118-6111-1 2Vp+Gear 7.2 7.2 5.2 supply unit

2.03

Sumitomo Eaton RG138-6128-1 Orbit 195 135 41.9 53.1 12 73 254.9 8.7

BS Bilbao RG038-2232-1 230x32x96 146.4 947.7 48 400 20.3

2.38

155 19 96

Trasmital B 31.8 396.2 218.8 138.7 76.61 43.54 78.84

Trasmital B RG138-6127-1 MAG12V 12.46 6.88 4.36 2.41 1384 2507

Nachi

4.26 BS Bilbao RG038-2232-1 230x32x96 146.4 965.4 48 400 19.9

2.03

155 19 96

Nachi 36.96 403.6 221.8 141.3 77.6 42.7 77.8

PHV-120 10.92 6.0 3.82 2.10 1580 2875

220 220 210 40 Hydrocontrol

D902 2300

KX41-3 Nachi RG138-6111-1 2Vp+Gear 7.5 7.5 4.5 2.7

4.04

Sumitomo Eaton RG008-6128-2 Orbit 195 135 41.9 58.7 12 73 254.9 9.6

BS JPN RA211-2231-0 230x32x96 146.4 972.9 48 400 19.7

2.03

157 19 96

Trasmital B 34.2 426.1 214.4 142.4 71.7 37.2 73.9

Trasmital B RG108-6129-1 MAG12V-2 12.46 6.27 4.16 2.10 1271 2526

210 210 210 46 KYB

D782-BH 2200

KX41-2V㱍 Nachi RG118-6111-1 2Vp+Gear 7.2 7.2 5.2 supply unit

4.01

Sumitomo Eaton RG138-6128-1 Orbit 195 135 41.9 53.1 12 73 254.9 8.7

BS Bilbao RG136-2231-1 230x32x96 146.4 1019 48 400 18.8

2.22

155 19 96

Trasmital B 34.2 426.1 235.3 149.2 82.4 40.5 73.3

Trasmital B RG138-6129-1 MAG12V 12.46 6.88 4.36 2.41 1384 2507

Nachi

4.11 BS Bilbao RG136-2231-1 230x32x96 146.4 1004 48 400 19.1

2.25

155 19 96

Nachi 36.96 419.9 229.5 147 80.4 41.1 75.2

PHV-120 11.36 6.21 3.98 2.17 1518 2778

220 220 210 40 Hydrocontrol

D902 2300

Nachi RG138-6111-1 2Vp+Gear 7.5 7.5 4.5 2.7

KX41-3V

IV-3

KX41-3V

KX41-3

KX36-3

parts No. bore rod stroke S length supplier parts No. bore rod stroke S length supplier parts No. bore rod stroke S length supplier

㹣

RG138-67701 60 30 469 675 Pacoma

㹡

㱢 mm 㱢 mm mm mm

㱢 mm 㱢 mm mm mm

㱢 mm 㱢 mm mm mm

㹡

RG038-67601 55 30 343.5 588.5 Pacoma RG138-67601 60 35 335.5 589 Pacoma

2. Cylinder Specifications; EU - version

㹡

RG038-67801 55 30 276.5 529 Pacoma RG138-67801 60 35 276.5 529 Pacoma

㹡

RG138-75101 60 30 111 348 Pacoma

㹣

㹡

RG138-67401 55 30 340 610 Pacoma

㹣

RG138-22301 55 30 310 528 Pacoma

IV-4

b. Hydraulic circuit diagram 1. KX36-3: EU - version

IV-5

2. KX41-3: EU - version

IV-6

3. KX41-3V: EU - version

IV-7

4. KX41-3V: North America & Oceania - version (1) Running left (2) Running left (3) Flexible leg and dozer switching valve (4) Left (5) Right (6) Ascent (7) Decent (8) Right (9) Left (10) Low (11) High (12) Bolting (13) Dump (14) Forward (15) Backward (16) Forward (17) Backward (18) Decent (19) Ascent (20) Bolting (21) Dump (22) Swing (23) Dozer flexible leg (24) Rotation (25) Interflow valve (26) Service port (27) Arm (28) Running right (29) Inlet (30) Running left (31) Boom (32) Bucket (33) Arm bolting (34) Arm dump (35) Rotation left (36) Rotation right (37) Boom ascent (38) Boom descent (39) Bucket bolting (40) Bucket dump

IV-8

c. Main pump 1. Outer view

(1)

(2)

(4)

(3)

(4)

(5)

(4)

(4)

(1) Suction port

(2) 4 - M10

(3) Oil inlet

(5) Rotation direction, Clockwise

IV-9

(4) Discharge port

2. structure

(1) Body S

(10) Swash plate

(21) Rod G

(35) Snap ring

(62) Seal washer

(2) Body H

(11) Needle

(24) Retainer

(39) O - ring

(65) Gear pump

(3) Shaft

(12) Swing pin

(25) Stopper pin

(40) O - ring

(66) Coupling

(4) Cylinder barrel

(13) Packin

(27) Pin

(44) Hex bolt

(67) Collar

(5) Valve plate

(14) Spring C

(30) Ball bearing

(49) Hex plug

(68) Bolt

(6) Piston

(15) Spring T

(31) Needle bearing

(51) Plug

(69) O - ring

(7) Shoe

(18) Spring holder

(32) Oil seal

(56) Spring pin

(70) Washer

(8) Shoe holder

(19) Spring guide

(33) Belleville spring

(60) Hex screw

(71) O - ring

(9) Barrel holder

(20) Pin

(34) Snap ring

(61) Nut

(72) O - ring

IV-10

Discharge: q1=q2 (cc/rev)

3. P-Q performance curve

Pressure: P1+P2 (kgf/cm2) Tedt condition

Remark

Oil

ISOVG46

3.77 kgf·m

Oil temp

50 ± 5 °C

(at P3=5 kgf/cm2)

RPM

2300 rpm

3.98 kgf·m

Direction

Clockwise

q3

4.5 cc/rev

q4

2.7 cc/rev

P4

40 kgf/cm2

Pump intake torque

(at P3=210 kgf/cm2)

4. Pump Specifications, Type : PVD-00B-15P-5G3-4982A 1.Capacity 2.Pressure at bench

P1, P2: 7.5 x 2 cm3/rev

P3: 4.5 cm3/rev

P4: 2.7 cm3/rev

P1, P2: 21.6 MPa

P3: 20.6 MPa

P4: 3.9 MPa

(220

kgf/cm2)

(210

kgf/cm2)

3.Speed

Rated Speed: 2300 min-1 Max. Speed: 2600 min-1

4.Suction pressure

-0.02 ~ ±0.04 MPa (-0.2 ~ ±0.4 kgf/cm2)

5.Oil

ISO VG 32, 46, 68 Anti - Wear hydraulic fluid

6.Oil temp

Temp range : -20 ~ +100 °C

7.Control

Constant torque control

8.Torque

at P3= 0.49 MPa T=37.0 N·m at P3= 20.6 MPa T=39.0 N·m

9.Pump discharge

P1, P2: 17.25 l/min x 2 (4.56 ug gal/min)

IV-11

(40 kgf/cm2)

Rotation Direction: Clockwise

P3: 10.35 l/min (2.73 ug gal/min)

P4: 6.21 l/min (1.64 ug gal/min)

5. Function1 1) Outline

Discharge groove P2

This compact, lightweight hydraulic pump has a mechanism that provides for the performance of two variable pumps. Yet it needs as small a space as for just one conventional pump. This pump is also equipped with a pilot gear pump.

The pump features a constant horsepower control function for making most of the engine power. The greater the pump load becomes, the lesser the discharge rate becomes. As a result, when the pump discharge pressures P1 and P2 have risen and the resultant force of the piston higher, the swash plate exceeds the spring force and tilts from the oscillating center of the oscillating pin. In this way, the discharge rate can be kept low.

Suction groove (1) Suction groove (2)

Discharge groove P1

(a) Valve plate Discharge groove P1 and opening

Discharge groove P2 and opening

6. Function2 An even number of pistons are used in this swash plate variable piston pump. This is to produce the performance of two same-capacity pumps in one pump casing.

Conventional valve plates have one suction groove and one discharge groove, as shown in Fig. 4. The new system, on the other hand, is provided with two suction grooves and two discharge grooves, as shown in Fig. 3. The discharge grooves P1 and P2 are located in the outer and inner sides, respectively. Every other piston chamber of cylinder barrel gets open to either of these discharge grooves in the valve plate. In other words, both the inner and outer suction grooves behave just the same way, whereas the inner and outer discharge grooves work independently from each other.

In this design with an even number of pistons, the same number of pistons gets open outward and inward of the valve plate. Because all the pistons are of the same diameter, located in a same-pitch circle and slide over the same swash plate, the discharge rates of the discharge grooves P1 and P2 are the same.

There is another advantage in employing just a single swash plate. Even though the swash plates tilting angle varies according to the variable control, the discharge rates of P1 and P2 ports change accordingly and equally.

(b) Cylinder barrel Fig. 3 Operating principle

Suction groove Discharge groove

(a) Valve plate

(b) Cylinder barrel Fig. 4 Conventional swash plate piston pump IV-12

d. Control valve assy 1. KX36-3: EU - version, Code No:RG038-61131, Maker: Hydro control

IV-13

2. KX41-3: EU - version, Code No:RG138-61131, Maker: Hydro control

IV-14

3. Control valve section : KX41-3S ; RG138-61131

(Swing section)

IV-15

(Dozer section)

(Slew section)

(Inlet section, P3)

IV-16

(Service section)

(Arm section)

(Travel section, L & R)

IV-17

(Inlet section, P1 & P2)

(Boom section)

(Bucket section)

IV-18

e. Pilot valve 1. EU - version

Maximum permissible operating torque at lever: 8 daN.m

IV-19

f. Travel motor 1. EU - version; KX36-3, KX41-3S, KX41-3V Maker: Transmital Bonfiglioli (1) Structure

P1 P2

T2

G 1/4 19 TPI (JIS B 2351 “0” RING BOSS) DRAIN PORT

1

M10x1 FILLING AND DRAINING OIL PLUG

2

M10x1 OIL LEVEL PLUG

Blue:KX36-3 White:KX41-3 Black:KX41-3V Mark to identify gearbox

T1

IV-20

G 3/8 19 TPI (JIS B 2351 “0” RING BOSS) SERVICE PORT

(2) Circuit diagram : EU

KX36-3

KX41-3S, KX41-3V

(3) Technical data : EU No.

Machine model

KX36-3 Low speed

10.92 cm3/rev

KX41-3S 12.46 cm3/rev

1

Motor Displacement

2

Gearbox ratio

1 : 37.22

1 : 31.8

3

Max, pressure

206 bar

216 bar

4

Max, flow

16.6 l/min

17.3 l/min

5

Max, drain pressure

6

Max, motor output torque (theoretical)

High speed

7

Max, motor output speed (theoretical)

High speed

8

Max, gearbox output torque (theoretical)

High speed

9

Max, gearbox output speed (theoretical)

High speed

10

Counter balance spool opreating pressure

11

Check valve cracking pressure

12

Hydraulic motor oil

13

Gearbox oil type

14

Gearbox oil: quantity

15

Oil temperature

16

Total weight

High speed

Continous

1 bar

Peak

5 bar

Low speed Low speed Low speed Low speed

35.8 Nm at 206 bar 1520 rpm 1333 Nm 40.8 rpm 3 bar

6.88 cm3/rev

428 Nm at 216 bar 2515 rpm 1388 rpm 751 Nm

810 Nm

1361 Nm

1467 Nm

73.4 rpm 40.6 rpm 6 -7 bar

ISO VG 46 ISO VG 150 E.P./SAE 80W90 API GL5/MIL-L-2105

1 lt ± 10 % 17 Kg ± 10%

IV-21

1 : 34.2

273 Nm at 216 bar

less than 0.3 bar

-20 °C / +100 °C

KX41-3V

0.3 lt ± 10 %

2. KTC, KCL, KTA - version : KX41-3V (1) Motor type ID mark

PHV - 120 - 37 - 9 - 8158C R & D No. Paint class Reduction ratio Nominal output torque NACHI travel motor PHV series (2) Specifications Gear box

Motor

Others

Max. output torque

1443 N·m (147 kgf·m)

Max. output speed

41.2 / 75.4 min-1

Reduction ratio

1 / 36.96

Displacement

11.36 / 6.21 cm3/rev

Max. pressure

21.6 MPa (220 kgf/cm2)

Max. speed

1523 / 2786 min-1

Max oil flow

17.3 l/min

Hi - Low change pressure

0.5 MPa (5 kgf/cm2)

Equivalent capacity for one turn of motor assy.

419.9 / 229.5 cm3/rev

Operating oil

ISO - VG46 or equivalent

Temperature

-20 ~ 100 °C

Filtering

10 µm

Gear box oil

SAE -30 -CD

Gear box oil amount

330 cm3

Weight

17 kg

IV-22

3. Structure

(1)

(2)

(3)

(5)

(4)

(1)

(1)

(2)

(5)

(1) Counter balance valve

(4) Selector valve

(2) HI - Lo change valve

(5) Hi - Lo piston

(3) Selector valve

IV-23

(4)

4. Principle of operation (1) Operating principle of wheel motor

(1)

(2)

(6)

(7) (5) (3)

(5) (4)

(1) Stationary part

(5) Hydraulic motor

(2) Rotating part

(6) Symple planetary gear reducer (two - step)

(3) Counter balance valve

(7) Carrier 2 b1 : four planet gears, (8) b2 : three planet gears

(4) Two - speed spool

Description of operation The PHV series travelling motor has a stationary main body composed of a hydraulic motor and hydraulic valve and a rotating main body composed of a simple planetary gear reducer.

IV-24

(2) Reducer 1) Function The PHV series travelling motor reducer, which is a simple two-step planetary gear reducer, converts the high-speed revolution of the hydraulic motor to low-speed high torque to obtain case rotation.

2) Description of operation In the figure shown to the right, the gear S2 is spline-coupled with the hydraulic motor output shaft (or they are combined). The revolution of the gear S2 is single-reduced through the gears (S2, b2, a2). This single-reduced revolution is double-reduced through the gears (S1, b1, a1) spline-coupled with the carrier 2.

The reduced revolution is transmitted to the rotating main body through the annular gears a1 and a2, providing travelling driving force.

The reduction ratio of a simple two-step planetary gear reducer is generally expressed as shown below.

R=

(1)

(2)

(4)

Zs1 Zs2 × Zs1 + Za1 Zs2 + Za2

Where Zs1, Zs2: Number of teeth of gears s1 and s2 Za1, Za2: Number of teeth of gears a1 and a2 Because the PHV series travelling motor is of the main body rotating type, the reduction ratio is expressed as shown below.

1 R’ = 1-1/R

(3)

(1) Stationary part (2) Rotating part (3) Symple planetary gear reducer (two - step) (4) Carrier 2

IV-25

(3) Hydraulic motor 1) Function of motor The hydraulic motor, which is an axial piston motor (rotating cylinder and swash plate type), converts the hydraulic energy supplied from the pump to revolving movement.

2) Structure of motor and operating principle (See the figure below.)

(4) Cylinder barrel

(a) The motor shaft and gear S2 are combined or coupled through splines

(5) Valve plate

(b) Port A

(6) Piston

(c) Port B

(7) Swash plate (8) Shaft

The pressure oil flowing in through the hydraulic valve is supplied to the valve plate (5). When the pressure oil is supplied to the port A, the oil flows into the cylinder port, which corresponds to the port A, in the cylinder barrel (4) and presses the piston (6). This pressing force is converted to turning force through the swash plate (7) and the resulting turning force is transmitted to the shaft (3) splinecoupled with the cylinder barrel (4). The return oil in the cylinder port flows out through the port B of the valve plate (5).

In the case of reverse rotation, the pressure oil flows in through the port B and flows out through the port A.

IV-26

3) Operating principle of two-speed motor The swash plate has two faces I and II on the surface opposite to the shoe-sliding surface and supported by the two balls fixed in the body 2 .

The ball is positioned eccentrically above the central axis. In the 1st speed state, therefore, the face II is pressed against the body 2 by hydraulic oil force applied to the piston and the spring force in the cylinder barrel and the swash plate angle becomes α. At this time, the motor is of large capacity.

When the speed selector lever is switched to the g2nd speed position, the operating pressure is conducted through the two-speed spool to the control room and the control piston moves until the face II of the swash plate touches the body 2, fixing the swash plate angle at β. At this time, the motor is of small capacity.

When the engine is stopped, the control room is connected to the drain port through the two-speed spool and the swash plate is returned to the 1st speed position by the spring force. At the time of starting, therefore, the motor is always in the 1st speed state.

(1) Swash plate

(7) Body 2

(2) Shoe

(8) Face II

(3) Piston

(9) Face I

(4) Spring

(10) Control room

(5) Cylinder barrel

(11) Control piston

(6) Ball

(12) Operating pressure

IV-27

(4) Hydraulic valve (counter balance valve) When the pressure oil is supplied through the port A, the pressure oil pushes open the check valve (3) and flows into the inlet-side port A’ of the hydraulic motor. At the same time, the pressure oil flows through the choke hole C into the room D and slides the spool valve (2) to the right, overcoming the force of spring (4). As a result, the hydraulic motor return oil flows in through the port B’, passes through the opening E of the main body (1) and spool valve (2) and returns to the port B. These processes make the hydraulic motor rotate. When the pressure oil is supplied through the port B, the above-mentioned processes are reversed and the hydraulic motor rotates reversely.

When the pressure oil supplied through the port A is made unpressurized, the spring force works to return the spool valve to the left. At this time, the oil in the room D controls the speed at which the spool valve returns to the left, utilizing the choking effect of the choke hole C. Even if the pressure oil supplied through the port A is made unpressurized, the hydraulic motor continues rotating using an inertial force.

At this time, the return oil is gradually controlled through the sliding speed of the spool valve and the helix shape, thus stopping the hydraulic motor smoothly.

IV-28

g. Swivel motor 1. EU - version; KX36-3, KX41-3, KX41-3V Maker: Eaton Fluid Power Ltd. (1)Structure

(1) SMOTOR,ASSY(SWING) (2) ADAPTER (3) ADAPTER (4) BOLT

(2)Circuit diagram (3)Specifications

IV-29

h. Cylinder 1. Structure 1-1 EU - version

(2) (1)

(3)

(KX36-3, KX41-3S, KX41-3V, Bucket)

(4)

(1)

(2)

(3)

(4)

KX36-3

65

φ 55

φ 30

62

KX41-3S,V

70

φ 60

φ 35

64

(KX36-3, KX41-3S, KX41-3V, Arm)

(4)

(8)

(6) (5) (7)

(1)

(2)

(3)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

KX36-3

62

62

343.5 ± 2

φ 65

φ 55

φ 30

M22 x 1.5

M58 x 1.5

KX41-3S,V

72.5

60

335.5 ± 2

φ 70

φ 60

φ 35

M27 x 2

M63 x 1.5

(KX36-3, KX41-3S, KX41-3V, Boom)

IV-30

(KX36-3, KX41-3S, KX41-3V, Swing)

(KX36-3, KX41-3S, KX41-3V, Blade)

Retracted length = 348 ± 1.5, Stroke = 111mm (KX41-3V, Truck)

, Length = 34.75 ± 0.25 DU-bushing ; Inner dia = φ 30 +0.09 0

IV-31

1-2 North America and oceanea (KX41-3V, Bucket, Arm) T.T. (21)

(20)

(17) (18) (19) T.T.

(1) Cylinder tube

(6) Backup-ring

(11) DU-bushing

(2) Cylinder rod

(7) Scraper

(12) Piston

(17) Stroke

[mm] Arm

Bucket 276.5

335.5

529 ± 1.5

589 ± 1.5

(3) Bushing

(8) O-ring

(13) Piston seal

(18) Retracted L

(4) Cylinder head

(9) Backup-ring

(14) Wear-ring

(19) Extended L

(5) Packing

(10) O-ring

(15) Lock nut, M24

(20)

328.5

387.5

(16) grease nipple

(21)

75.5

76.5

805.5 ± 2.5 924.5 ± 2.5

(KX41-3V, Boom) T.T.

(3) (1)

(2)

T.T.

(1)Retracted L = 765 ± 1.5 (2)Extended L = 1234 ± 2.5 (3)Stroke = 469 (KX41-3V, Blade) (1) (2) (3)

T.T. T.T.

(1)Retracted L = 348 ± 1.5 (2)Extended L = 460 ± 2.5 (3)Stroke = 112 IV-32

(KX41-3V, Swing) (1)

(2) (3) T.T.

T.T.

(1)Retracted L = 610 ± 1.5 (2)Extended L = 950 ± 2.5 (3)Stroke = 340 (KX41-3V, Truck) (1)

(2)

T.T.

(3)

T.T.

(1)Retracted L = 528 ± 1.5 (2)Extended L = 838 ± 2.5 (3)Stroke = 310 T.T. : Tightening torque [Cylinder essential quality] 1. Seal durability: Must conform to class “A” (0.05 ml / 100m) of “JIS B 8354” under following conditions.

Oil pressure : 21.6 MPa (220 kgf / cm2), Oil temperature : 100 deg, Speed : 16.6 m / min, Sliding distance : 300km 2. Dust Seal properties : Dust enter must be 11 mg or less under following conditions.

Speed : 16.6 m / min, Stroke : 150 mm, Number of repetitions : cycles, Vibration applied to facility : 7.4 Hz 3. Internal oil leakage : Must be within 1 cm3 for 3 min under the condition of the main relife pressure 21.6 MPa (220 kgf / cm2) applied to the stroke end (Oil temperature 50 ± 5 deg).

4. Minimum operating pressure : Must be within 4 % of the main relief pressure 0.86 MPa (8.8 kgf / cm2) applied to the bottom port after 3 or more cycles with full stroke sliding under none load (Oil temperature 50 ± 5 deg).

5. Withstanding pressure : Permanent deformation and oil leakage must not occur after pressure 2 times as high as the main relief pressure 43.1 MPa (440 kgf / cm2) is applied by 40000 time or more.

IV-33

6. Withstanding external force : Any damages, distortions, oil leakage, permanent deformations must not occur in any parts when external force 2 times as high as the main relief pressure 43.1 MPa (440 kgf / cm2) the cylinder thrust force (12240 kgf) is applied by 30000 times or more.

7. Rust prevention of plating : Must be rating number 9 or higher after 4 cycles (64 hour) of CASS testing. Thickness of platinf must be kept more than Ep-ICr30 (0.03 mm) 8. Cushion performance : (Cushion type cylinder only) Cushion facility must be set in bottom side for contraction with following performance.

Oil temperature : 30 deg / cushion time : 2 seconds or less Oil temperature : 50 deg / cushion time : 1 ± 0.3 seconds Oil temperature : 80 deg / cushion time : 0.3 seconds or more 9. Piston rod surface treatment : Piston rod rubbing part : Ni-Hcr or Hcr plating Thickness 9.03 mm or more Hardness HV (25g) 700 or more Induction hardening : HRC 50 to 56, Depth 2 to 3 mm

i. Rotary joint 1. Structure 1-1 KX36-3

(17)

(14)

(15)

(13)

(16)

(17)

(17) (13)

(14) (19)

(18)

(20) (18) (15)

(16) (14)

(1) Shaft

(8) Plug (R 1/8)

(15) F:Travel R, upper

(2) Back-up ring

(9) Collar

(16) D:Travel, drain

(3) D-ring

(10) Circlip

(17) C:Blade, bottom

(4) Back-up ring

(11) O-ring

(18) B:Blade, rod

(5) O-ring

(12) Plug (R 1/8)

(19) I:Travel L, upper

(6) Collar

(13) H:Travel L, lower

(20) Each port must be free from painting

(7) Body

(14) E:Travel R, lower

IV-34

1-2 KX41-3S

(17)

(14)

(15)

(13)

(16) (16)

(21)

(19) (13)

(21) (19)

(17) (18)

(20) (18) (15)

(16) (14) (21)

(1) Shaft

(8) Plug (R 1/8)

(15) F:Travel R, upper

(2) Back-up ring

(9) Collar

(16) D:Travel, drain

(3) D-ring

(10) Circlip

(17) C:Blade, bottom

(4) Back-up ring

(11) O-ring

(18) B:Blade, rod

(5) O-ring

(12) Plug (R 1/8)

(19) I:Travel L, upper

(6) Collar

(13) H:Travel L, lower

(20) Each port must be free from painting

(7) Body

(14) E:Travel R, lower

(21) G:Travel high speed

Note: 1. Applied pressure: B, C, E, F, H, I = 24.5 MPa (250 kgf/cm2) G = 3.9 MPa (40 kgf/cm2) D = 1.5 MPa (15 kgf/cm2) 2. Leakage from ports of both sides is 1 cc or less after pressuring for 2 min.

IV-35

1-3 KX41-3V

(17)

(22) (14)

(15)

(13)

(16) (16)

(21)

(19) (13)

(23) (17) (21) (19)

(18) (22)

(20) (18) (15)

(16) (23)

(14) (21)

(1) Shaft

(8) Plug (R 1/8)

(15) F:Travel R, upper

(2) Back-up ring

(9) Collar

(16) D:Travel, drain

(3) D-ring

(10) Circlip

(17) C:Blade, bottom

(4) Back-up ring

(11) O-ring

(18) B:Blade, rod

(5) O-ring

(12) Plug (R 1/8)

(19) I:Travel L, upper

(6) Collar

(13) H:Travel L, lower

(20) Each port must be free from painting

(7) Body

(14) E:Travel R, lower

(21) G:Travel high speed (22) I:Track cylinder, rod (23) J:Track cylinder, bottom

Note: 1. Proof pressure strength must be 34.3 MPa (350 kgf/cm2).

2. Turning forgue, without load : 127 Nm (13 kgf·m) or less.

IV-36

j. Unload valve 1. North America and Oceanea version 1-1 Structure Maker : Nishina

Red Black

(1) Shim

(11) Plug

(2) spring

(12) Hollow bolt

(3) Name plate

(13) Washer

(4) Plunger

(14) Screw

(5) Spring

(15)

(6) Spool

(16) O-ring

(7) Body

(17)

(8) Solenoid

(18) Cable clamp

(9) Cover

(19) Protection tube

1-2 Specifications

Red

Black

(1) Alow voltage:

DC 10.8 ~ 14.4V

(2) Current:

1.2 A at 20 °C

(3) Insulation:

JIS C 4003 H

(4) Coil resistance:

Ω

(5) Surge killer:

Diode

(6)

Relief valve set pressure:

+0.2 2 3.9 +0.2 0 MPa (40 0 kgf/cm ) at 6l/min

(7)

Cracking pressure:

(8)

Valve pressure loss:

3.4 MPa (35kgf/cm2) at 2l/min p → A, B 0.5 MPa (5.1 kgf/cm2) or less at 6l/min A, B, G = G 1/4 P, T = G 3/8

(9) Port size:

(19)

IV-37

2. EU - version 2-1 Structure Maker : Hydro control

(1) VALVE,ASSY(UNLOAD)

(6) ADAPTER

(2) VALVE,ASSY(UNLOAD) ONLY FOR KX36-3

(7) ADAPTER

(3) ADAPTER

(8) ADAPTER

ONLY FOR KX41-3

(9) BOLT

M10 x 1.5

(4) ADAPTER

ONLY FOR KX41-3

(5) ADAPTER

2-2 SpecificationsStructure 1.

2.

3.

4.

Pilot oil flow : 6.2 l/min Max. allowable oil flow : 16 l/min Rated voltage and output : 12V - 18W Coil resistance : 8 Ω

IV-38

k. Selector valve : KX41-3V 1. Structure

2. Function This valve is to select the oil flow direction for blade cylinder or track cylinder.

3. Specifications 1) Operating pressure and flow : Main relief pressure (20.6 MPa) at 10.4 l/min.

2) Inside leakage : 8 cc/min at 20.6 Mpa, 50 °C

IV-39

l. Accessaries of hydraulic compornents 1. Check valve assy (6) (7)

(8)

(1) Shim (2) spring (4) Plunger

(10) (11)

(9)

(3) Name plate (5) Spring (6)

(7)

(8)

(9)

KX36-3 KX41-3 EU KX41-3V

67

55

G 1/2 φ26 30.02

KX41-3V US

65

53

G 3/8 φ18.6 25.4

[mm] (11) HEX

(10)

27 22 2

Cracking pressure : 343 ± 29 MPa (3.5 ± 0.3 kgf/cm )

2. Hydraulic filter Specifications items

Suction filter, all models

Return filter : EU

1.Filtration area

1650 cm2

1850 cm2

2.Filtration level

105 µm (150 mesh)

10 µm nominal

3.Oil flow

80 l/min

70 l/min

4.Hex.spanner

41 mm

36 mm

5.Filter dia.

φ 85

φ 90

6.Filter length

105

140

7.Relief opening pressure

0.1MPa

IV-40

m.Service port performance 1. Test sample : KX36-3 GL

IV-41

2. Test sample : KX41-3V GL

IV-42

V.Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-3 a. Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-3 b. Performance curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V-5 c. Function & structure of coil commander . . . . . . . . . . . . . . . . . . . . . . V-7

V-1

V-2

V.Engine a. Engine Specifications Machine model

KX36-3 EU

KX41-3S, V EU

KX41-3V US

Engine Model

D782-BH-3

D902-BH

D902-EBH

3

3

No. of cylinder Bore x Stroke

mm in

67 x 73.6 2.64 x 2.90

72 x 73.6 2.83 x 2.90

Displacement

cc in3

778 47.5

898 54.8

Max. output/rpm

kW/rpm PS/rpm HP/rpm

9.3/2300 12.6/2300 12.5/2300

11.6/2300 15.8/2300 15.5/2300

24

24 > > >

> > >

Compression ratio

41.8 = 4.26 = 30.8 =

49.9 = 5.10 = 36.8 =

Max. torque

N·m kgf·m ft·lbf

Dimensions:L x W x H

mm in.

449 x 402 x 538 17.7 x 15.8 x 21.2

473 x 402 x 546 18.6 x 15.8 x 21.5

Dri weight

kg lbs

64 141

72 159

Valve clearance

mm in.

0.145-0.185 0.0057-0.0073

0.145-0.185 0.0057-0.0073

1-2-3

1-2-3

E-TVCS

E-TVCS

Firing sequence Combustion chamber Compression pressure (A)/(B)

Mpa kgf/cm2 psi

Fan belt

2.84-3.24 29-33 412-469 RPF2325

Fuel consumption ratio

g/kWh g/Psh lbs/Hph

286 210 0.47

286 210 0.47

Fuel consumption

l/h gal/h

3.2 0.85

4.1 1.08

Max.speed without load

rpm

2650 > =

2650 > =

Speed with 2 pumps relief

rpm

2300 =

Speed with idling

rpm

1200--1300

1200--1300

Engine oil pressure with rated engine rpm

kPa kgf/cm2 psi

196-441 2.0-4.5 28.4-64.0

196-441 2.0-4.5 28.4-64.0

Injection pressure

MPa kgf/cm2 psi

13.7 140 1991

>

Pressurized radiator(0.088Mpa, 0.9kgf/cm2), water pump

Cooling system Engine oil consumption ratio

52.6 5.36 38.8

g/kWh g/Psh lbs/Hph

0.95 0.7 0.0016

V-3

Engine electric components Machine model

KX36-3 EU

KX41-3 EU

KX41-3 US

Engine Model

D782-BH-3

D902-BH

D902-EBH

Fuel injection pump type

Bosch MDtype mini-pump

Nozzle type Injection pressure

DN4PD62 mini-nozzle Mpa kgf/cm2 psi

Dynomo

12V480W

Manufacturer P/N Regulator adjusting voltage

13.7 140 1991

V

100211-4730

100211-1670

14.2-14.8

14.2-14.8

12V1.2KW

12V1.4KW

228000-0951

228000-0991

1.5

1.5

Battery type Nominal capacity of 5hrs rating

Ah

Specific gravity of electrolite Starter motor Manufacturer P/N Glow plug

Ω

V-4

b. Performance curve KX36-3; D782-BH-3 Net value;

D1546

V-5

KX41-3S, KX41-3V; D902-EBH(-BH) Net value;

D1545

V-6

c. Function & structure of coil commander 1. Circuit diagram Hold (Red) Pull (white) Pull coil

Hold coil

Timer circuit FE Transistor Gnd (Black) Coil commander

Solenoid (pull in type)

2. Function Under some condition, such as low temp, large current flows to pull coil and may cause to cut the coil.

Coil commander is to regulate the current flow to pull coil by controlling the current time according to the temperature Temperature vs Current Time

V-7

3. Inspeetion & troubleshooting 1) Check the continuity of hold coil.

2) Check pull in coil function after wiring 12V to red and while terminal and ground to black color terminal.

Then engine solenoid functions and pull in the plunger head.

Photo : pull in condition

Photo : hold condition

V-8

KUBOTA Corporation

CONSTRUCTION MACHINERY DIVISION 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN

EDITOR:

CONSTRUCTION MACHINERY MANUFACTURING DEPT. SERVICE SECTION HIRAKATA PLANT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN PHONE :+81-72-840-1195 FAX :+81-72-890-2886

KUBOTA Corporation

Printed in Japan 0403.CMC.e.10

Code No.97899-60810