Kubota U35 Excavator Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kubota U35 Excavator Workshop Manual – PDF DOWNLOAD
a. Safty measures before starting work
(1)Work clothes
1. Wear specified work cap and clothed.
(Under no circumstances may workers wear
undershirts only.)
Cuffs must be kept buttoned, and any tears
must be mended.)
2. Wear safety shoes.
3. Do not wear cotton gloves when working on
the internal section of engine, reduction
gears or hydrauricunits for repair or others,
or when using a hammer. Wear leather
gloves, however, when hoisting wires.
(2)Inspecting equipment and tools
1. Prepare equipment (cranes, fork lifts, tool,
etc.) required for servicing and inspect for
any problems before starting work.
2. Hammer heads (metal parts) must be firmly
secured to their handles.
3. Check hosting tools (wire ropes, hoisting
chains, etc.) before use.
(3)Keep workshop in order
1. Secure appropriate space needed for disassembly
to the job.
2. Secure a clean, safe place for arranging disassembled
parts.
3. Store volatile substances (gasoline, light oil,
thinner, oily articles, etc.) in appropriate containers
at selected locations to prevent fire
hazards.
TABLE OF CONTENTS:
Kubota U35 Excavator Workshop Manual – PDF DOWNLOAD
WSM_U35………………………………………………………………………………………………. 1
CONTENTS………………………………………………………………………………………….. 3
I. General………………………………………………………………………………………… 4
A. Body and engine identification marks…………………………………………………………… 5
B. Safty precautions for servicing, disassembly and reassembly………………………………………. 6
a. Safty measures before starting work………………………………………………………… 6
(1) Work clothes………………………………………………………………………… 6
(2) Inspecting equipment and tools………………………………………………………… 6
(3) Keep workshop in order……………………………………………………………….. 6
b. Safty measures during work………………………………………………………………… 6
(1) Protectors………………………………………………………………………….. 6
(2) Team work…………………………………………………………………………… 6
(3) Disassembly and assembly……………………………………………………………… 6
(4) Cranes……………………………………………………………………………… 6
(5) Others……………………………………………………………………………… 6
c. Preparation for disassembly……………………………………………………………….. 7
(1) Cleaning……………………………………………………………………………. 7
(2) Acceptance inspection………………………………………………………………… 7
(3) Equipment and tools………………………………………………………………….. 7
d. Precautions for disassembly and reassembly………………………………………………….. 7
(1) Disassembly…………………………………………………………………………. 7
(2) Reassembly………………………………………………………………………….. 7
C. IMPORTANT SAFTY PROCESS AND CRITICAL FUNCTIONAL PROCESS………………………………………….. 8
a. Essential Adhesives………………………………………………………………………. 8
b. Important Safety Process …………………………………………………………………. 8
c. Important Critical Functional Process ……………………………………………………… 8
D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING…………………………………………………… 8
F. Maintenance intervals………………………………………………………………………… 9
a. KTC, KCL, KTA-version…………………………………………………………………….. 9
b. EU(KE, KDG, KUK)-version………………………………………………………………….. 10
c. Hydraulic Oil Check for machines with Hydraulic Breakers……………………………………… 11
G. Water and oil quantity……………………………………………………………………….. 12
H. Recommended oil……………………………………………………………………………… 13
I. Filters…………………………………………………………………………………….. 14
J. Tightening torque……………………………………………………………………………. 15
a. Hose screw………………………………………………………………………………. 15
Metric Size Hose………………………………………………………………………… 15
b. Joint bodies…………………………………………………………………………….. 15
c. Tightening torque table for hose clamp (Screw type)………………………………………….. 16
d. Nuts for piping………………………………………………………………………….. 16
e. Tightening torque of bolts and nuts………………………………………………………… 17
f. Types and materials of bolts and nuts………………………………………………………. 17
g. Washer-equipped elbow…………………………………………………………………….. 18
K. Machine Quality Specifications………………………………………………………………… 19
II. Machine body(Mechanism section)………………………………………………………………….. 29
A. Front attachment…………………………………………………………………………….. 31
a. Greasing points………………………………………………………………………….. 8
b. Component interchangeability………………………………………………………………. 32
B. Component interchangeability………………………………………………………………….. 33
a. Bucket interchangeability…………………………………………………………………. 33
b. Arm…………………………………………………………………………………….. 35
c. Installing direction of dust seal………………………………………………………….. 36
d. Installation of bushing and thrust collar on the swing bracket………………………………… 36
e. Installing pin, bush and shim (1):U35………………………………………………………. 37
f. Installing pin, bush and shim (2):U35………………………………………………………. 38
g. Installing pin, bush and shim of bucket : U35……………………………………………….. 39
h. Installing local bucket : U35……………………………………………………………… 40
II. Machine body(Service section)……………………………………………………………………. 41
A. Specifications………………………………………………………………………………. 43
a. Machine Weight…………………………………………………………………………… 43
(1) KE, KDG, KUK version…………………………………………………………………. 43
(2) KTC, KCL, KTA version………………………………………………………………… 43
b. Machine specifications……………………………………………………………………. 44
(1) KE, KDG, KUK version…………………………………………………………………. 44
(2) KTC, KCL, KTA version………………………………………………………………… 45
c. Lever stroke and operating force…………………………………………………………… 46
d. Dimensions of Parts………………………………………………………………………. 47
(1) Front pins………………………………………………………………………….. 47
(2) Bucket……………………………………………………………………………… 48
(3) Rubber crawler………………………………………………………………………. 51
(4) Iron crawler………………………………………………………………………… 51
(5) Track toller, idler, sprocket…………………………………………………………. 52
(6) Dozer………………………………………………………………………………. 53
(7) Parts weight………………………………………………………………………… 54
B. Front attachment…………………………………………………………………………….. 57
a. Parts designation………………………………………………………………………… 57
C. Upper structure……………………………………………………………………………… 58
a. Swivel frame : U35, U35-3…………………………………………………………………. 58
b. Swivel bearing…………………………………………………………………………… 59
c. Swivel bearing installation……………………………………………………………….. 60
d. Traveling lever………………………………………………………………………….. 61
e. Traveling lever adjustment………………………………………………………………… 62
f. Traveling lever lock……………………………………………………………………… 63
Adjusting the lever’s neutral position…………………………………………………….. 63
g. Accel lever (Non AI-version)………………………………………………………………. 64
(3) AI motor side(AI-version)…………………………………………………………….. 65
(4) Engine side…………………………………………………………………………. 65
(5) Accel cable…………………………………………………………………………. 66
h. Swing pedal……………………………………………………………………………… 67
i. Auxiliary port pedal……………………………………………………………………… 68
j. Limit switch installation…………………………………………………………………. 69
k. Hour meter cable, engine stop cable………………………………………………………… 70
l. Cab installation : KTC, KCL, KTA-version……………………………………………………. 71
m. Heater hose……………………………………………………………………………… 72
n. Cab glass replacement procedure……………………………………………………………. 73
(1) Application Procedure if SIKAFLEX (ULTRA-FAST)………………………………………….. 74
(2) ULTRA-FAST application manual…………………………………………………………. 75
(3) 255 EXTRA application manual………………………………………………………….. 77
(4) H-rubber replacement procedure………………………………………………………… 80
(5) Broken glass repairing procedure (for adhered glass KX-2 Series made by KBT)……………….. 81
o. Seat belt……………………………………………………………………………….. 83
p. Weight installation………………………………………………………………………. 84
D. Under carriage………………………………………………………………………………. 85
a. Tension spring pre-set length……………………………………………………………… 85
b. Additional parts to change from rubber track to iron track……………………………………. 85
c. Track Roller and Upper Roller installation………………………………………………….. 86
d. Track tension adjustment………………………………………………………………….. 87
e. Grease tension cylinder, L………………………………………………………………… 88
f. Drive sprocket…………………………………………………………………………… 89
g. Rubber track…………………………………………………………………………….. 90
h. Iron track………………………………………………………………………………. 91
III. Engine……………………………………………………………………………………….. 93
A. Engine mount………………………………………………………………………………… 95
B. Radiator……………………………………………………………………………………. 97
C. Muffler…………………………………………………………………………………….. 98
D. Pump coupling……………………………………………………………………………….. 99
E. Fuel hoses…………………………………………………………………………………..100
IV. Hydraulic system(Mechanism section)……………………………………………………………….103
A. Features of hydraulic system…………………………………………………………………..105
B. Hydraulic system specifications………………………………………………………………..106
C. Main pump……………………………………………………………………………………107
a. Structure & specifications…………………………………………………………………107
b. Performance curve…………………………………………………………………………108
Variable displacement pump………………………………………………………………..108
D. Control valve………………………………………………………………………………..109
a. Specifications……………………………………………………………………………109
e. Arm regeneration circuit…………………………………………………………………..110
(1) Arm dump…………………………………………………………………………….110
(2) Arm Crowd……………………………………………………………………………110
f. Oil flow of lock valve…………………………………………………………………….111
(1) Operation of lock valve……………………………………………………………….111
(2) Boom operation……………………………………………………………………….113
g. Function of lock valve (Anti-drift valve)……………………………………………………115
(1) Boom cylinder holding function…………………………………………………………115
(2) Boom up function……………………………………………………………………..115
(3) Boom-down function……………………………………………………………………115
E. Pilot valve………………………………………………………………………………….116
a. Structure & specifications : U35(KTC, KCL), U35-3(KTA)………………………………………..116
b. Pilot valve control diagram : U35(KTC, KCL), U35-3(KTA)……………………………………….118
c. KBM-make : Pilot valve : U35-3(EU)………………………………………………………….119
F. Swivel motor…………………………………………………………………………………120
a. Structure & specifications…………………………………………………………………120
b. Function of negative brake…………………………………………………………………123
(1) Negative brake function(Unload condition)……………………………………………….123
(2) Negative brake release(On-load condition)……………………………………………….123
c. Function of valve section………………………………………………………………….124
(1)Make-up valve…………………………………………………………………………124
(2)Function of shockless valve…………………………………………………………….124
d. Swivel Performance………………………………………………………………………..125
(1) KE, KDG, KUK version………………………………………………………………….125
(2) KTC, KCL, KTA version…………………………………………………………………125
(3) Inner parts of the swivel motor………………………………………………………..126
G. Rotary joint (Swivel joint)……………………………………………………………………128
H. Travel motor…………………………………………………………………………………129
a. Structure………………………………………………………………………………..129
(1) Relief valve…………………………………………………………………………129
(2) Shockless piston……………………………………………………………………..129
(3) Inner parts of the traveling motor……………………………………………………..130
b. Travel motor specification…………………………………………………………………132
(1) KE, KDG, KUK version………………………………………………………………….132
(2) KTC, KCL, KTA version…………………………………………………………………133
J. Hydraulic circuit diagram……………………………………………………………………..135
a. U35-3 European – version…………………………………………………………………..135
b. U35 : KTC, KCL – version…………………………………………………………………..136
c. U35-3 : KTA – version……………………………………………………………………..137
d. Hydraulic components layout : U35, U35-3…………………………………………………….138
IV. Hydraulic system(Service section)…………………………………………………………………139
A. Troubleshooting………………………………………………………………………………141
a. Common Circuit……………………………………………………………………………141
b. Front Attachment………………………………………………………………………….143
c. Swivel Circuit……………………………………………………………………………146
d. Travel Circuit……………………………………………………………………………148
B. Specifications……………………………………………………………………………….149
a. Relief valve pressure setting………………………………………………………………149
b. Pump…………………………………………………………………………………….151
(1) KE, KDG, KUK version………………………………………………………………….151
(2) KTC, KCL, KTA version…………………………………………………………………152
c. Cylinder…………………………………………………………………………………153
(1) Cylinder operating speed………………………………………………………………153
(2) Cylinder natural fall amount…………………………………………………………..153
(3) Cylinder specifications……………………………………………………………….154
d. Swivel Performance………………………………………………………………………..156
(1) KE, KDG, KUK version………………………………………………………………….156
(2) KTC, KCL, KTA version…………………………………………………………………156
e. Traveling Performance……………………………………………………………………..157
(1) KE, KDG, KUK version………………………………………………………………….157
(2) KTC, KCL, KTA version…………………………………………………………………158
C. Testing……………………………………………………………………………………..159
a. Testing Instruments & special tools…………………………………………………………159
b. Pump flow………………………………………………………………………………..161
c. Pilot pressure……………………………………………………………………………162
(1) Primary pressure……………………………………………………………………..162
(2) Secondary pressure……………………………………………………………………163
d. Main relief valve…………………………………………………………………………164
e. Overload relief valve……………………………………………………………………..166
f. Swivel brake valve pressure………………………………………………………………..168
g. Traveling motor drain amount……………………………………………………………….170
h. Swivel motor drain amount………………………………………………………………….171
i. Swivel motor block performance……………………………………………………………..172
j. Traveling motor block performance…………………………………………………………..173
k. Operating speed…………………………………………………………………………..174
(1) Checking each operating speed………………………………………………………….174
(2) Boom cylinder………………………………………………………………………..174
(3) Arm cylinder…………………………………………………………………………174
(4) Bucket cylinder………………………………………………………………………175
(5) Swing cylinder……………………………………………………………………….175
(6) Dozer cylinder……………………………………………………………………….175
(7) Swivel speed…………………………………………………………………………176
(8) Traveling speed………………………………………………………………………176
l. Straight travel performance………………………………………………………………..176
m. Cylinder natural fall amount……………………………………………………………….177
n. Control and Traveling lever operating force………………………………………………….177
o. Lever stroke……………………………………………………………………………..177
D. Disassembling and assembling…………………………………………………………………..178
e. Swivel motor (KTC, KCL, KTA-version)………………………………………………………..178
g. Rotary joint……………………………………………………………………………..179
(1) Inner parts of the rotary joint………………………………………………………..179
(2) Assembling of the rotary joint…………………………………………………………180
(3) Rotary joint seal installing procedure………………………………………………….181
(4) Jig picture………………………………………………………………………….182
(5) Jig drawing………………………………………………………………………….183
(6) Adaptor installation on the rotary joint (KTC, KCL, KTA version)…………………………..184
h. Cylinder (EU-version)……………………………………………………………………..185
(3) Disassembling and assembling : EU-version……………………………………………….185
j. Hoses……………………………………………………………………………………188
(1) Pilot hose(1)………………………………………………………………………..188
(2) Pilot hose(2)………………………………………………………………………..189
(3) Pilot hose(3)………………………………………………………………………..190
V. Electrical system(Mechanism section)……………………………………………………………….191
a. Components and harness layout : U35, U35-3………………………………………………………193
b. Electric Circuit Diagram………………………………………………………………………195
c. Electric wiring Diagram……………………………………………………………………….197
V. Electrical system(Service section)…………………………………………………………………201
A. Electrical Equipment Specifications…………………………………………………………….203
B. Wire harness installation……………………………………………………………………..206
a. Precautions………………………………………………………………………………206
b. Engine earth, starter switch……………………………………………………………….207
c. Main harness……………………………………………………………………………..209
d. Coupler insertion…………………………………………………………………………210
e. Control box harness……………………………………………………………………….211
f. Engine harness……………………………………………………………………………212
g. Front harness…………………………………………………………………………….213
C. Troubleshooting………………………………………………………………………………215
a. General………………………………………………………………………………….215
(1) How to diagnose………………………………………………………………………215
(5) CHECKING SWITCHES…………………………………………………………………….219
(6) Checking fuses……………………………………………………………………….220
(7) Solenoid test method………………………………………………………………….221
(8) Checking relays………………………………………………………………………222
(9) Checking cables and wires……………………………………………………………..223
b. Troubleshooting flow chart…………………………………………………………………224
(1) Starter motor failure to turn on……………………………………………………….224
(2) Auto release malfunction………………………………………………………………225
(3) Electronic accelerator failure…………………………………………………………226
(4) Auto glow failure…………………………………………………………………….227
(5) AI system failure…………………………………………………………………….228
c. Front attachment………………………………………………………………………….229
(1) Working lamp failure………………………………………………………………….229
(2) Safety lever lock circuit malfunction…………………………………………………..230
d. Engine electrical system…………………………………………………………………..231
(1) Engine oil pressure failure……………………………………………………………231
(2) Water temp. sensor circuit malfunction………………………………………………….232
(3) Fuel sensor circuit…………………………………………………………………..234
(4) Engine stop solenoid………………………………………………………………….235
(5) Charging system malfunction……………………………………………………………236
(6) Auto glow controller………………………………………………………………….238
(7) Auto release controller……………………………………………………………….240
e. Auto idle system………………………………………………………………………….242
(1) Troubleshooting outline……………………………………………………………….242
(2) AI pressure switch test method…………………………………………………………243
(3) Governer sensor test method……………………………………………………………245
(4) AI motor test method………………………………………………………………….247
(5) Engine speed sensor…………………………………………………………………..248
(6) Auto glow circuit…………………………………………………………………….250
f. AI version: AI controller (built-in microcomputer) Cases of trouble diagnosis with circuit tester….252
(1) “Water temperature sensor” line in trouble………………………………………………252
(2) Other circuitry layouts and their trouble diagnosis………………………………………254
g. Cases of trouble diagnosis with circuit tester……………………………………………….255
h. Auto Idle(AI) version: Trouble diagnosis with lamp……………………………………………256
(1) General……………………………………………………………………………..256
(2) Display and identification of errors in operating mode……………………………………258
(3) Entering the service mode……………………………………………………………..259
(4) Working on the 6 menus in the service mode………………………………………………260
(5) Example:Alternation of engine idling speed………………………………………………262
(6) Working on the 3 menus in the service mode………………………………………………263
(7) Working on the AI motor drive menus in the service mode…………………………………..264
(8) Entering the setup mode……………………………………………………………….265
(8) Lamp-identified fail symptoms, trouble spots and possible causes…………………………..269
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