1989–1991 Kubota KH-36, KH-41, KH-51, KH-61, KH-66, KH-91, KH-101, KH-151 Excavator Workshop Manual (P/N 97899-60062)

The 1989–1991 Kubota Excavator Workshop Manual, P/N 97899-60062, covers the KH-36, KH-41, KH-51, KH-61, KH-66, KH-91, KH-101, and KH-151. Its revision record dates the KH-91 specification and rubber-track removal updates to June 28, 1989, and the service-bulletin additions to September 30, 1991.

• Routine service: Periodic inspection schedules, lubrication charts, fluid references, structural dimensions, and tightening torques for piping and fasteners.
• Front attachment: Bucket, arm, boom, swing bracket, and dozer removal, pin-and-bushing inspection, shim selection, and reassembly.
• Upper structure and undercarriage: Swivel reduction gear, swivel bearing, control levers, cab removal and installation, travel reduction gears, front idlers, tension devices, upper and bottom rollers, and track shoes.
• Hydraulic repair: Troubleshooting, gear-pump inspection, control-valve servicing, relief-valve checks, cylinder resealing, hydraulic-motor inspection, and rotary-joint overhaul.
• Electrical diagnosis: Starting and charging faults, Easy Checker warning circuits, switches, sensors, fuse-box connections, and model-specific wiring diagrams.
• Engine service: Engine removal from the machine, engine specifications, internal-component inspection standards, and important tightening torques.

The procedures suit experienced equipment technicians with lifting equipment, hydraulic test instruments, and precision measuring tools. Owners undertaking repairs need comparable workshop skills and facilities.

Attachment Wear, Track Assemblies, and Service Updates

Wear assessment: Front-attachment pin-and-bushing measurement views distinguish pin wear, bushing wear, and assembled clearance. Reference dimensions and allowable limits help determine whether a loose joint needs replacement parts or whether bucket side play can be corrected with shims.

Undercarriage work: Upper-roller sectional drawings support roller inspection, while the track procedures cover the idler, grease-operated tension device, and track assembly. The workshop manual distinguishes iron and rubber crawlers and identifies component changes required when converting between them.

Assembly precautions: The bottom-roller instructions warn that inserting the shaft too far into its bracket can damage the O-ring. Service bulletin CM89-010 addresses axle-cap bolt breakage caused by loads transmitted from the sprocket and specifies a revised bolt-and-shim arrangement.

Further service information covers the grease-nipple change, rubber-crawler adjustment, bucket-pipe clamping, and hydraulic-tank breather leakage. The bulletins identify applicable models and serial numbers for selecting the correct replacement components.

Hydraulic Tests and Circuit Tracing

Fault isolation: Symptom-and-cause tables lead into pump delivery checks, cylinder drift tests, motor leakage checks, and travel-performance inspection. Comparing these tests helps narrow a weak hydraulic function to the pump, valve, cylinder, or motor before dismantling components.

Component repair: Separate instructions cover KVS30 and Husco 5000 control valves, cylinder seals, swivel and travel motors, and rotary-joint seals. Rotary-joint hose-routing drawings help identify connections, while hydraulic circuit diagrams show how pumps, valves, motors, and cylinders connect.

The hydraulic reference distinguishes relief-valve settings measured on the bench from settings measured with the valve installed. Follow the manual's machine-support and hydraulic-pressure release precautions before repair work.

Electrical Diagnosis and Engine Inspection

Wiring and warning circuits: Model-specific electrical diagrams identify connectors, wire colors, and components. Easy Checker test illustrations support diagnosis of fuel, coolant, oil-pressure, and air-filter warnings, alongside starting, charging, and engine-stop faults.

Engine coverage: Removal instructions address the machine connections and lifting arrangements. Wear-limit tables cover cylinder-head distortion, piston clearance, crankshaft bearings, and valve components. The engine section does not provide a complete internal-engine overhaul sequence.

Selected Pin-Clearance and Pump-Wear Specifications

The following values are a small selection from the manual's inspection standards.

Across the covered models, front-attachment pin-to-bushing clearance has a reference range of 0.1–0.25 mm and an allowable limit of 2.0 mm.

The gear-pump inspection specifies 0.05 mm as the reference value and 0.15 mm as the allowable limit for gear-track wear, evaluated from the difference between housing measurements at gear-contact and noncontact areas.

PDF Navigation, Wiring Detail, and Download Contents

Viewing and navigation: PDF text search and embedded bookmarks are not available. Use the printed contents and section numbering to navigate; rotate and enlarge circuit sheets to read small labels, with some densely printed wire markings remaining soft.

The download contains one printable PDF in English, French, and German, totaling 334 pages. That total includes 24 integrated service-information pages, one front cover, one revision-record page, one blank page, and one publisher-imprint page.