Kubota K008-3 U10-3 Excavator Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kubota K008-3 U10-3 Excavator Workshop Manual – PDF DOWNLOAD
Safty precautions for servicing, disassembly and reassembly
Safty precautions for servicing
Most accidents during servicing arise from carelessness. Please remember that safty involves both the welfare
of the employees and improved work efficiency.
Safty precautions for Disassembly and reassembly
Machines must be diassembled and assembled efficiently and safely.
It is very important to thoroughly understand the construction and function of the machine, to make all appropriate
preparations, and start operations according to the specified working procedures.
a. Safty measures before starting work
(1)Work clothes
1. Wear specified work cap and clothed.
(Under no circumstances may workers wear
undershirts only.)
Cuffs must be kept buttoned, and any tears
must be mended.)
2. Wear safety shoes.
3. Do not wear cotton gloves when working on
the internal section of engine, reduction
gears or hydrauricunits for repair or others,
or when using a hammer. Wear leather
gloves, however, when hoisting wires.
(2)Inspecting equipment and tools
1. Prepare equipment (cranes, fork lifts, tool,
etc.) required for servicing and inspect for
any problems before starting work.
2. Hammer heads (metal parts) must be firmly
secured to their handles.
3. Check hosting tools (wire ropes, hoisting
chains, etc.) before use.
(3)Keep workshop in order
1. Secure appropriate space needed for disassembly
to the job.
2. Secure a clean, safe place for arranging disassembled
parts.
3. Store volatile substances (gasoline, light oil,
thinner, oily articles, etc.) in appropriate containers
at selected locations to prevent fire
hazards.
TABLE OF CONTENTS:
Kubota K008-3 U10-3 Excavator Workshop Manual – PDF DOWNLOAD
WSM_K008-3_U15-3………………………………………………………………………………………….. 1
CONTENTS……………………………………………………………………………………………… 3
I. General……………………………………………………………………………………………. 5
A. Body and engine identification marks………………………………………………………………. 6
B. Safty precautions for servicing, disassembly and reassembly………………………………………….. 8
a. Safty measures before starting work……………………………………………………………. 8
(1) Work clothes……………………………………………………………………………. 8
(2) Inspecting equipment and tools……………………………………………………………. 8
(3) Keep workshop in order…………………………………………………………………… 8
b. Safty measures during work……………………………………………………………………. 8
(1) Protectors……………………………………………………………………………… 8
(2) Team work………………………………………………………………………………. 8
(3) Disassembly and assembly…………………………………………………………………. 8
(4) Cranes…………………………………………………………………………………. 8
(5) Others…………………………………………………………………………………. 8
c. Preparation for disassembly…………………………………………………………………… 9
(1) Cleaning……………………………………………………………………………….. 9
(2) Acceptance inspection……………………………………………………………………. 9
(3) Equipment and tools……………………………………………………………………… 9
d. Precautions for disassembly and reassembly……………………………………………………… 9
(1) Disassembly…………………………………………………………………………….. 9
(2) Reassembly……………………………………………………………………………… 9
C. IMPORTANT SAFTY PROCESS AND CRITICAL FUNCTIONAL PROCESS……………………………………………… 10
a. Essential Adhesives………………………………………………………………………….. 10
b. Important Safety Process …………………………………………………………………….. 10
c. Important Critical Functional Process …………………………………………………………. 10
D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING………………………………………………………. 10
a Operate the Machine and check for Unusual Noise and Vibrations…………………………………….. 10
b Make Sure the Safety decals and Wireharness Clamps are in their Specified Positions………………….. 10
c With the Machine Front in a Specified Posture, Check the Amount of Hydrauric Oil…………………….. 10
E. SERVICING FUNDAMENTALS…………………………………………………………………………… 11
a. Items for Servicing………………………………………………………………………….. 11
b. O-ring, Oil seal, Circlip and Roll Pin…………………………………………………………. 13
c. Piping……………………………………………………………………………………… 15
(1) General precautions……………………………………………………………………… 15
(2) Hydraulic hose………………………………………………………………………….. 15
(3) Precautions in tightening the bolts and nuts……………………………………………….. 15
(4) Hose screw……………………………………………………………………………… 16
Metric Size Hose……………………………………………………………………………. 16
(5) Joint bodies……………………………………………………………………………. 16
(6) Tightening torque table for hose clamp (Screw type)…………………………………………. 17
(7) Nuts for piping…………………………………………………………………………. 17
(8) Tightening torque of bolts and nuts……………………………………………………….. 18
(9) Types and materials of bolts and nuts……………………………………………………… 18
(10) Washer-equipped elbow…………………………………………………………………… 19
F Machine Quality Specifications…………………………………………………………………….. 20
a. K008-3, U10-3 EU-Version……………………………………………………………………… 20
b. K008-3 KTC KCL, KTA – Version…………………………………………………………………. 25
G. Maintenance intervals……………………………………………………………………………. 31
a. Hydraulic Oil Check for machines with Hydraulic Breakers…………………………………………. 33
II. Machine body(Mechanism section)……………………………………………………………………… 34
A. Specifications………………………………………………………………………………….. 36
a. EU – version………………………………………………………………………………… 36
b. KTC, KCL, KTA – version………………………………………………………………………. 37
B. Component interchangeability……………………………………………………………………… 38
a. Bucket……………………………………………………………………………………… 38
C. Machine structure……………………………………………………………………………….. 39
a. Control linkage……………………………………………………………………………… 39
(1) Operating lever lock (K008-3)…………………………………………………………….. 39
(2) Traveling lever…………………………………………………………………………. 39
(3) Operating lever…………………………………………………………………………. 40
(4) Dozer (K008-3)………………………………………………………………………….. 41
(5) Swing and Service port (K008-3)…………………………………………………………… 42
(6) Accelerator lever……………………………………………………………………….. 43
(7) Change lever for retracting track frame……………………………………………………. 43
b. Engine mount………………………………………………………………………………… 44
c. Under carriage………………………………………………………………………………. 45
(1) Crawler Tension…………………………………………………………………………. 45
(2) Track roller……………………………………………………………………………. 45
(3) Retractable undercarriage………………………………………………………………… 45
(4) Rubber Crawler………………………………………………………………………….. 46
II. Machine body(Service section)……………………………………………………………………….. 48
A. Specifications………………………………………………………………………………….. 50
a. Machine Weight………………………………………………………………………………. 50
(1) K008-3, U10-3 EU – version……………………………………………………………….. 50
(2) K008-3 KTC, KCL , KTA – version…………………………………………………………… 50
b. Machine specifications……………………………………………………………………….. 51
(1) K008-3, U10-3 EU version…………………………………………………………………. 51
(2) K008-3 KTC, KCL, KTA version……………………………………………………………… 52
c. Lever stroke and operating force………………………………………………………………. 53
(1) K008-3, U10-3 EU version…………………………………………………………………. 53
(2) K008-3 KTC, KCL, KTA version……………………………………………………………… 54
d. Dimensions of Parts………………………………………………………………………….. 55
(1) Front pins……………………………………………………………………………… 55
(2) Bucket…………………………………………………………………………………. 56
(3) Rubber crawler………………………………………………………………………….. 58
(4) Track toller, idler, sprocket…………………………………………………………….. 59
(6) Dozer………………………………………………………………………………….. 60
(7) Parts weight……………………………………………………………………………. 61
(7) Water and Oil Quantity…………………………………………………………………… 63
B. Front attachment………………………………………………………………………………… 64
a. Front attachment assembly procedure……………………………………………………………. 64
b. Greasing points……………………………………………………………………………… 67
C. Upper Structure…………………………………………………………………………………. 68
a. Operating unit………………………………………………………………………………. 68
(1) K800-3 mechanical operating unit………………………………………………………….. 68
(2) Accelerator lever……………………………………………………………………….. 72
b. Dozer lever…………………………………………………………………………………. 74
c. Swing pedal…………………………………………………………………………………. 76
d. Service port pedal…………………………………………………………………………… 78
e. Tank……………………………………………………………………………………….. 80
(1) Oil tank……………………………………………………………………………….. 80
f. Weight……………………………………………………………………………………… 84
D. Under carriage………………………………………………………………………………….. 86
a. Swivel bearing………………………………………………………………………………. 86
(1) Assembly sketch of swivel bearing (K008-3)…………………………………………………. 86
(2) Exploded view of swivel bearing (K008-3)…………………………………………………… 87
(3) Assembly sketch of swivel bearing (U10-3)………………………………………………….. 88
(4) Exploded view of swivel bearing (U10-3)……………………………………………………. 89
b. ROPS……………………………………………………………………………………….. 90
c. Seat belt setup angle………………………………………………………………………… 91
d. Take-up Unit………………………………………………………………………………… 92
(1) Idler assembly………………………………………………………………………….. 92
(2) Track roller……………………………………………………………………………. 94
(3) Grease cylinder…………………………………………………………………………. 95
e. Track Frame (Adjustable Leg Specification)……………………………………………………… 96
(1) Route of adjustable leg hose……………………………………………………………… 96
(2) Exploded view of track frame……………………………………………………………… 97
(3) Adjustment of crawlers…………………………………………………………………… 98
III. Engine(Mechanism section)…………………………………………………………………………..100
A. Safety first……………………………………………………………………………………. 50
B. Engine specifications for construction machinery…………………………………………………….103
C. Engine electric components………………………………………………………………………..104
D. Performance Curve………………………………………………………………………………..105
E. Dimensions………………………………………………………………………………………106
III. Engine(Service section)…………………………………………………………………………….130
A. Engine mount on the machine……………………………………………………………………….132
(1) Engine bracket, vibrationproof rubber………………………………………………………….132
(2) Muffler…………………………………………………………………………………….132
B. GENERAL…………………………………………………………………………………………133
[1] ENGINE IDENTIFICATION………………………………………………………………………..133
[2] GENERAL PRECAUTION…………………………………………………………………………..133
[3] TIGHTENING TORQUES…………………………………………………………………………..135
(1) Tightening torques for special use screws, bolts and nuts…………………………………….135
(2) Tightening torques for general use screws, bolts and nuts…………………………………….135
(3) Main bearing case assembly – Type 1………………………………………………………..136
(4) Main bearing case assembly – Type 2………………………………………………………..136
IV. Hydraulic system(Mechanism section)…………………………………………………………………..200
A. Main pump(K008-3, U10-3)………………………………………………………………………….202
B. Pilot pump(U10-3)………………………………………………………………………………..203
C. Control valve……………………………………………………………………………………204
a. Specifications……………………………………………………………………………….204
b. General view of Control valve………………………………………………………………….206
c. Sectional view……………………………………………………………………………….210
(1) K008-3 EU – version : P/N RA021-61160………………………………………………………210
(2) K008-3 KTC, KCL, KTA – version : P/N RA021-61130…………………………………………….215
(3) U10-3 : P/N RA131-61160…………………………………………………………………..217
d. Structure and function………………………………………………………………………..222
(1) Relief valve function…………………………………………………………………….222
(2) Anti cavitations valve function……………………………………………………………222
(3) Load check valve function…………………………………………………………………223
D. Pilot valve……………………………………………………………………………………..224
a. Structure……………………………………………………………………………………224
b. Pilot valve control diagram……………………………………………………………………226
c. Function…………………………………………………………………………………….227
(1) Basic function…………………………………………………………………………..227
(2) Functions of major parts………………………………………………………………….227
(3) Operation……………………………………………………………………………….228
E. Hydraulic pilot circuite………………………………………………………………………….231
a. Flow of oil at the time when the control lever lock is at lock position (A)…………………………231
a. Control lever lock being at lock position……………………………………………………232
b. Flow of oil at the time when the control lever lock is at unlock position (B)……………………….233
b. Control lever lock being at unlock position………………………………………………….234
c. Flow of oil in boom lifting operation…………………………………………………………..235
c. Flow of oil in boom lifting operation……………………………………………………….236
d. Flow of oil in bucket dumping operation…………………………………………………………237
d.Flow of oil in bucket dumping operation………………………………………………………238
e. Flow of oil in arm crowding operation…………………………………………………………..239
e.Flow of oil in arm crowding operation………………………………………………………..240
f. Flow of oil in right swivel operation…………………………………………………………..241
f.Flow of oil in right swivel operation………………………………………………………..242
F. Swing motor (K008-3, U10-3)……………………………………………………………………….243
a. Structure and specifications…………………………………………………………………..243
b. Operating principle…………………………………………………………………………..245
G. Rotary joint (Swivel Joint)……………………………………………………………………….246
H. Travel motor…………………………………………………………………………………….248
a. Single speed motor (K008, Eu-version)…………………………………………………………..248
(1) Structure & Specifications………………………………………………………………..248
b. Two speed motor………………………………………………………………………………251
(1) Structure & Specifications………………………………………………………………..251
(2) Specifications…………………………………………………………………………..251
I. Hydraulic circuit………………………………………………………………………………..254
a. K008-3 : EU – version…………………………………………………………………………254
b. K008-3 : KTC, KCL, KTA – version……………………………………………………………….255
c. U10-3 : EU – version………………………………………………………………………….256
d. Hydraulic components layout : K008-3……………………………………………………………257
IV. Hydraulic system(Service section)…………………………………………………………………….258
A. Troubleshooting………………………………………………………………………………….260
a. Machine general………………………………………………………………………………260
b. Hydraulic System……………………………………………………………………………..263
(1) Hydraulic system…………………………………………………………………………263
(2) Swivel system……………………………………………………………………………265
(3) Travel system……………………………………………………………………………267
B. Specifications…………………………………………………………………………………..268
a. Pump System………………………………………………………………………………….268
(1) Discharge……………………………………………………………………………….268
(2) List of pressures………………………………………………………………………..268
b. List of Relief Valves…………………………………………………………………………270
c. Noise……………………………………………………………………………………….271
d. Swivel system………………………………………………………………………………..272
e. Traveling system……………………………………………………………………………..273
f. Cylinder system………………………………………………………………………………274
(1) Cylinder speed…………………………………………………………………………..274
(2) Degree of free-fall………………………………………………………………………274
(3) Boom/Arm/Bucket/Swing/Blade Specification…………………………………………………..275
(4) Table of dimensions of cylinder parts………………………………………………………276
C. Testing…………………………………………………………………………………………277
a. Pump flow test……………………………………………………………………………….277
b. Pilot pressure (U10-3)………………………………………………………………………..278
(1) Primary pressure…………………………………………………………………………278
(2) Secondary pressure……………………………………………………………………….278
(3) Main relief valve pressure………………………………………………………………..279
c. Swivel motor block performance…………………………………………………………………281
d. Traveling motor block performance………………………………………………………………281
e. Operating speed………………………………………………………………………………282
(1) Checking each operating speed……………………………………………………………..282
(2) Boom cylinder……………………………………………………………………………282
(3) Arm cylinder…………………………………………………………………………….282
(4) Bucket cylinder………………………………………………………………………….283
(5) Swing cylinder…………………………………………………………………………..283
(6) Dozer cylinder…………………………………………………………………………..283
(7) Swivel speed…………………………………………………………………………….284
(8) Traveling speed………………………………………………………………………….284
f. Straight travel performance……………………………………………………………………284
g. Cylinder natural fall amount…………………………………………………………………..285
h. Control and Traveling lever operating force……………………………………………………..285
i. Lever stroke…………………………………………………………………………………285
D. Disassembling and Assembling………………………………………………………………………286
a. Pump coupling………………………………………………………………………………..286
b. Pump………………………………………………………………………………………..287
(1) Pump (Main) assembly drawing………………………………………………………………287
(2) Route of delivery hose……………………………………………………………………287
(3) Pump (Pilot) assembly drawing……………………………………………………………..288
(4) Disassembly and reassembly………………………………………………………………..289
(5) Control valve……………………………………………………………………………292
(6) Control valve joint………………………………………………………………………293
c. Pilot valve………………………………………………………………………………….295
Hydraulic operating unit……………………………………………………………………..295
d. U10-3 Component parts of hydraulic operating unit………………………………………………..296
(1) Unload valve…………………………………………………………………………….296
(2) Super change valve……………………………………………………………………….297
(3) Valve assembly (Relief)…………………………………………………………………..299
(4) Pilot valve……………………………………………………………………………..301
e. U10-3 hydraulic operating unit bleeding procedure………………………………………………..302
f. Disassembling and assembling…………………………………………………………………..303
(4) Trouble shooting…………………………………………………………………………314
g. Swivel motor…………………………………………………………………………………315
(1) K008-3 mounting position………………………………………………………………….315
(2) U10-3 mounting position…………………………………………………………………..316
(3) Swivel motor disassembly and assembly procedure……………………………………………..317
E. Swivel Joint…………………………………………………………………………………….327
a. Assembly and Disassembly………………………………………………………………………327
(1) Disassembly and assembly of swivel joint……………………………………………………327
b. Wheel Motor………………………………………………………………………………….331
(1) Mounting the wheel motor adaptor…………………………………………………………..331
(2) Route of wheel motor hose…………………………………………………………………332
c. Wheel Motor (made by Eaton Equipment Co. Ltd.)…………………………………………………..333
(1) Wheel motor disassembly and assembly procedure………………………………………………333
(2) Troubleshooting………………………………………………………………………….347
d. Cylinder…………………………………………………………………………………….348
(2) Disassembling and assembling………………………………………………………………351
(3) Inspection………………………………………………………………………………353
F. Route of Hydraulic Hose…………………………………………………………………………..354
(1) Route of control valve hydraulic hose (Fixed leg, 1-speed)……………………………………….354
(2) Route of return hose…………………………………………………………………………355
V. Electrical system(Service section)…………………………………………………………………….360
A. Wireharness……………………………………………………………………………………..362
a. Wireharness(1)……………………………………………………………………………….362
b. Wireharness(2)……………………………………………………………………………….362
c. Wireharness(3)……………………………………………………………………………….362
B. Electric Wiring………………………………………………………………………………….364
a. Cautions on electric wire clamping method……………………………………………………….364
(A) Clamp to valve assembly (check)……………………………………………………………365
(B) Wiring to fuel sensor…………………………………………………………………….365
(C) Clamping to bracket (step)………………………………………………………………..365
(D) Clamping of wire harness (1) and the battery plus cord……………………………………….365
(E) Clamping of wire harness for alternator, oil switch and slow-blow fuse…………………………365
(F) Clamping to the engine breather……………………………………………………………365
(H) Clamping to the support (radiator)…………………………………………………………366
(G) Clamping of the battery plus cord and the wire harness (1) to the swivel frame………………….366
(I) Clamping of the cord (battery plus) and the cord (battery minus) to the wire harness for sole…….366
(J) Assembling the cord (battery)……………………………………………………………..366
Front………………………………………………………………………………………367
(K) Assembling the body ground and the battery minus cord………………………………………..366
(M) Wiring to working light…………………………………………………………………..367
(L) Assembling the cord (battery plus)…………………………………………………………367
C. Troubleshooting of Electric System…………………………………………………………………368
a. Outline pf troubleshooting…………………………………………………………………….368
(1) Procedure……………………………………………………………………………….368
b. Cautions in general…………………………………………………………………………..369
(1) Checking of conductivity and voltage at coupler……………………………………………..369
(2) Checking procedure for removal of pin………………………………………………………369
(3) Checking method………………………………………………………………………….370
(4) Checking of fuse…………………………………………………………………………371
(5) Checking of wire harness………………………………………………………………….372
(6) Handling and checking of battery…………………………………………………………..372
(7) Measuring instrument and special tools……………………………………………………..373
c. Troubleshooting………………………………………………………………………………374
(1) Engine system……………………………………………………………………………374
(2) Panel (key switch: ON)……………………………………………………………………374
(3) Panel (Engine start)……………………………………………………………………..375
(4) Others………………………………………………………………………………….375
d. Checking procedure……………………………………………………………………………376
(1) Starter…………………………………………………………………………………376
(2) Engine stop……………………………………………………………………………..379
(3) Charger…………………………………………………………………………………381
(4) Horn, fuel pump and working light………………………………………………………….384
(5) Charge lamp, oil lamp and fuel lamp………………………………………………………..385
(6) Others………………………………………………………………………………….388
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V