Kubota U25S U20-3α U25-3α Excavator Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kubota U25S U20-3α U25-3α Excavator Workshop Manual – PDF DOWNLOAD
Safety precautions for servicing, disassembly and
reassembly
Safety precautions for servicing
Most accidents during servicing arise from carelessness. Please remember that Safety involves both the
welfare of the employees and improved work efficiency.
Safety precautions for Disassembly and reassembly
Machines must be disassembled 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. Safety 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
hydrauric units 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 U25S U20-3α U25-3α Excavator Workshop Manual – PDF DOWNLOAD
U20-3a
U25-3a
U25S
Service Chapter……………………………………………. 1
CONTENTS………………………………………………………………….. 3
I General……………………………………………………………… 5
A.Body and engine identification marks………………………………… 7
B.Safety precautions for servicing, disassembly and
reassembly………….. 8
C.IMPORTANT SAFETY PROCESS AND CRITICAL
FUNCTIONAL PROCESS……………… 10
D.IMPORTANT INSPECTION ITEMS AFTER
REASSEMBLING……………………….. 10
E.SERVICING FUNDAMENTALS…………………………………………….. 11
F. Maintenance intervals…………………………………………….. 20
a. Maintenance intervals chart : EU-version………………………… 20
b.Maintenance intervals chart : PP-version…………………………. 21
c.Water and oil quantity…………………………………………. 23
d.Recommended oil……………………………………………….. 24
e Hydraulic Oil Check for machines with Hydraulic Breakers…………… 25
f. Periodic replacement of important parts…………………………. 27
II Machine Body………………………………………………………… 29
A.Specifications……………………………………………………. 31
a. Machine weight……………………………………………….. 31
b. Machine specifications………………………………………… 32
c. Lever stroke and operating force……………………………….. 33
d. Dimensions of parts…………………………………………… 34
[1] Front pins………………………………………………. 34
[2] Bucket………………………………………………….. 35
[3] Rubber crawler…………………………………………… 37
[4] Iron crawler…………………………………………….. 37
[5] Track roller, idler, and sprockett…………………………. 38
[6] Dozerr………………………………………………….. 39
[7] Parts weight…………………………………………….. 40
[8] Water and oil quantity……………………………………. 41
B.Front attachment………………………………………………….. 42
a. Parts designation…………………………………………….. 42
b. Exchange of bucket (Kubota
Japan Bucket)……………………….. 45
c. Exchange of bucket teeth and
side cutters [JPN bucket version]……. 46
d. Installing of dust seal and thrust
collar………………………. 47
e. Installation of pin and bush…………………………………… 48
[1] Pin bush………………………………………………… 48
[2] Pin, bush-(2)……………………………………………. 50
[3] Front bucket mounting instruction (PP-version)………………. 52
f. Front hose…………………………………………………… 53
[1] Front hose assembly (U20-3α)………………………………. 53
[2]Front hose assembly (U25-3α, U25S)………………………….. 54
[3] Hose clamp………………………………………………. 55
[4] Front hose control valve side……………………………… 55
C.Upper structure…………………………………………………… 56
a. Lever and pedal………………………………………………. 56
[1] Travel lever…………………………………………….. 56
[2] Acceleration lever……………………………………….. 61
[3] Blade lever……………………………………………… 65
[4] Swing pedal……………………………………………… 66
[5]Service port pedal………………………………………… 67
[6] Limit switch…………………………………………….. 69
b Counterweight…………………………………………………. 70
D.Cab / canopy installation………………………………………….. 71
a. Installing the cabin or canopy…………………………………. 71
[1] Installing the cabin……………………………………… 71
[2] Canopy installation………………………………………. 73
[3]Floor Mat………………………………………………… 74
[4] Heater setup…………………………………………….. 75
[5]Defroster setup…………………………………………… 76
[6] Thermal insulation and sound
absorber……………………… 77
[7] Seat and seat belt……………………………………….. 86
FYI (For your information)……………………………………. 87
[8] Boom cylinder for cab type………………………………… 89
[9] Outlook of covers………………………………………… 90
E. Under carriage…………………………………………………… 91
a Swivel bearing………………………………………………… 91
b Grease tube…………………………………………………… 91
c Track tension device…………………………………………… 92
d Upper roller and track roller…………………………………… 94
e. Crawler replacement and tension adjustment procedure……………… 98
F. Variable track (U20-3α)……………………………………………101
a. Dimensional view………………………………………………101
b.Service data…………………………………………………..102
c. Track frame…………………………………………………..103
d. Blade………………………………………………………..105
e. Track cylinder………………………………………………..107
f. Blade cylinder………………………………………………..109
g. Hydraulic hose………………………………………………..110
h. Control valve…………………………………………………114
i. Swivel joint………………………………………………….115
j. Track control lever……………………………………………117
k. Counterweight…………………………………………………118
G. Label……………………………………………………………119
III Engine……………………………………………………………..129
III-1 Engine specifications for construction machinery…………………..131
III-2 Engine mount on the construction machinery………………………..133
A. Engine bracket………………………………………………..133
B. Radiator……………………………………………………..134
[1] Detaching the radiator…………………………………….134
[2] Reassembling the radiator………………………………….135
C. Muffler………………………………………………………138
[1] Reassembling procedure…………………………………….138
D. Fan belt……………………………………………………..139
E. Air cleaner…………………………………………………..140
F. Fuel tank and hose…………………………………………….141
III-3. 05-M Series Engine WSM-General………………………………….149
III-4. Engine WSM (Mechanism section)………………………………….153
A.Feature……………………………………………………….155
B.Engine body……………………………………………………156
[1]Cylinder block…………………………………………….156
[2]Cylinder head……………………………………………..156
[3]Crankshaft………………………………………………..157
[4]Piston and piston rings…………………………………….157
[5]Connecting rod…………………………………………….158
[6]Rocker arm………………………………………………..158
[7]Camshaft………………………………………………….158
[8]Fuel camshaft……………………………………………..159
[9]Flywheel………………………………………………….159
C.Lubricating system……………………………………………..160
[1]General…………………………………………………..160
[2]Oil pump………………………………………………….161
[3]Relief valve………………………………………………161
[4]Oil filter cartridge……………………………………….162
[5]Oil pressure switch………………………………………..162
D.Cooling system…………………………………………………163
[1]General…………………………………………………..163
[2]Water pump………………………………………………..163
[3]Thermostat………………………………………………..164
[4]Radiator (not included in the basic engine)…………………..164
[5]Radiator cap………………………………………………165
E.Intake / exhaust system…………………………………………166
[1]Air cleaner (not included in the basic engine)………………..166
[2]Muffler (not included in the basic engine)……………………166
F. Fuel system…………………………………………………..167
[1]General…………………………………………………..167
[2] Injection pump……………………………………………167
[3] Injection nozzle………………………………………….170
[4]Fuel filter (not included in the basic model)…………………170
[5]Governor………………………………………………….171
G.Electrical system………………………………………………173
[1]Charging system……………………………………………173
III-5. Engine WSM (Service section)……………………………………175
A.Engine mount on the machine……………………………………..175
B.General……………………………………………………….177
[1]Engine identification………………………………………177
[2]General precaution…………………………………………178
[3]Tightening torques…………………………………………179
[4]Troubleshooting……………………………………………180
[5]Servicing specifications……………………………………183
[6]Maintenance check list……………………………………..192
[7]Check and maintenance………………………………………193
C.Engine body……………………………………………………206
CHECKING AND ADJUSTING………………………………………..206
DISASSEMBLING AND ASSEMBLING…………………………………..207
[1]Draining water and oil………………………………….208
[2]External components…………………………………….208
[3]Cylinder head and valves………………………………..209
[4]Gear case……………………………………………..211
[5]Piston and connecting rod……………………………….217
[6]Flywheel and crankshaft…………………………………220
SERVICING……………………………………………………222
[1]Cylinder head………………………………………….222
[2]Timing gear and camshaft………………………………..227
[3]Piston and connecting rod……………………………….229
[4]Crankshaft…………………………………………….232
[5]Cylinder………………………………………………238
D.Lubricating system……………………………………………..240
CHECKING…………………………………………………….240
SERVICING……………………………………………………240
[1]Oil pump………………………………………………240
E.Cooling system…………………………………………………242
CHECKING…………………………………………………….242
[1]Fan belt………………………………………………242
[2]Radiator………………………………………………242
DISASSEMBLING AND ASSEMBLING…………………………………..243
F. Fuel system…………………………………………………..245
CHECKING AND ADJUSTING………………………………………..245
[1] Injection pump………………………………………..245
[2] Injection nozzle………………………………………247
DISASSEMBLING AND ASSEMBLING…………………………………..248
[1] Injection pump………………………………………..248
[2] Injection nozzle………………………………………249
G.Electrical system………………………………………………250
CHECKING…………………………………………………….250
[1]Starter……………………………………………….250
[2]Glow plug……………………………………………..251
DISASSEMBLING AND ASSEMBLING…………………………………..251
[1]Starter……………………………………………….251
[2]Alternator…………………………………………….252
SERVICING……………………………………………………255
[1]Starter……………………………………………….255
[2]Alternator…………………………………………….257
H.Turbo charger system……………………………………………260
CHECKING…………………………………………………….260
DISASSEMBLING AND ASSEMBLING…………………………………..262
IV.Hydraulic system (Service section)……………………………………..265
A.Troubleshooting……………………………………………………267
a. Common Circuit………………………………………………..267
b. Hydraulic system and front attachment……………………………269
c. Pump…………………………………………………………271
d. Motor………………………………………………………..272
e. Swivel performance…………………………………………….273
f. Traveling performance………………………………………….279
B.Specifications…………………………………………………….283
a. Pump…………………………………………………………283
[1] Specifications……………………………………………283
[2] Piston pump P-Q performance curve (Theoretical)………………285
b. Relief valve………………………………………………….287
[1] Location…………………………………………………287
[2]Main relief valve (bench data)………………………………288
[3]Main relief valve (at the measurement port on the machine)
……288
[4]Pilot system pressure………………………………………288
[5]Overload relief valve (bench data)…………………………..289
[6]Overload relief valve (at the measurement port on the machine)….289
c.Swivel performance……………………………………………..290
d.Traveling performance…………………………………………..291
e. Cylinder……………………………………………………..293
[1] Specifications and dimensions listt…………………………293
[2] Speed……………………………………………………295
[3] Natural fall……………………………………………..295
[4] Cylinder list…………………………………………….296
C.Testing…………………………………………………………..304
a. Pump flow…………………………………………………….304
b. Pressure measurement…………………………………………..305
[1] Pilot pressure……………………………………………305
[2] Main relief valve pressure…………………………………306
[3] Overload relief pressure…………………………………..308
[4] Swivel brake pressure……………………………………..309
[5] Swivel brake release valve…………………………………310
[6] Travel two-speed selector pressure………………………….310
c. Drain measurement……………………………………………..311
[1] Travel motor……………………………………………..311
[2] Swivel motor……………………………………………..312
d. Measurement of block performance………………………………..313
[1] Swivel…………………………………………………..313
[2] Travel…………………………………………………..313
e. Operating speed……………………………………………….314
[1] Checking procedure of each speed……………………………314
f. Straight travel performance…………………………………….316
g. Control and traveling lever operating force………………………316
h. Control and traveling lever stroke………………………………316
i. Cylinder natural fall amount……………………………………316
D.Disassembling and Assembling………………………………………..317
a. Pump…………………………………………………………317
[1] Pump coupling…………………………………………….317
[2] Mounting and dismounting the pump…………………………..319
[3]Component parts of pump…………………………………….321
[4]Disassembling and reassembling the pump………………………322
[5]Troubleshooting of pump…………………………………….328
b. Control valve…………………………………………………329
[1]Mounting and dismounting the valve…………………………..329
[2] Disassembling and reassembling
the valve …………………..332
[3] Component parts of sections………………………………..333
C. Pilot valve…………………………………………………..340
[1] Mounting and dismounting the pilot
valve
1) ……………….340
[2] Disassembling and reassembling the pilot valve……………….344
d. Swivel motor………………………………………………….356
[1] Mounting and dismounting the swivel motor……………………356
[2] Swivel motor mounting/dismounting component parts…………….358
[3] Disassembling and reassembling
the swivel motor……………..363
e. Rotary joint (Swivel joint)…………………………………….373
f. Traveling motor……………………………………………….377
[1] Mounting and dismounting the wheel motor…………………….377
[2] List of adapter hoses……………………………………..378
[3] Component parts of wheel motor (Kayaba-make)…………………379
[4] Disassembling and reassembling the wheel motor……………….382
g.Cylinder………………………………………………………408
h. Hydraulic hose………………………………………………..413
[1] Delivery hose…………………………………………….413
[2] Delivery hose routing……………………………………..414
[3] Blade / travel hose……………………………………….417
[4] Pilot hose……………………………………………….420
i. Other hydraulic valve………………………………………….425
[1] Selector valve……………………………………………425
[2] Pilot filter……………………………………………..428
[3] TPSS valve, PP-version…………………………………….429
[4] Accumulator………………………………………………431
[5] Third line valve………………………………………….433
V.Electrical system (Service section)……………………………………..435
A.Specifications…………………………………………………….437
B Troubleshooting……………………………………………………440
a Engine………………………………………………………..440
b Meter panel……………………………………………………441
c Others………………………………………………………..443
d Check instructions……………………………………………..444
[1] Fuse…………………………………………………….444
[2] Battery voltage…………………………………………..445
[3] Automatic release relay……………………………………445
[4] Release controller……………………………………….446
[5] Starter motor…………………………………………….446
[6] Key switch……………………………………………….447
[7] Fuel pump coupler…………………………………………447
[8] Engine stop solenoid………………………………………448
[9] Glow relay……………………………………………….448
[10] Charge and engine oil lamp………………………………..450
[11] Water temperature gauge…………………………………..451
[12]Fuel sensor………………………………………………451
[13]Solenoid valve……………………………………………452
[14]Horn…………………………………………………….455
[15]working light…………………………………………….456
C Wireharness installation……………………………………………457
a Front wireharness………………………………………………458
b Wireharness around engine……………………………………….459
C Swivel frame wireharness………………………………………..463
d. Wireharness around battery……………………………………..466
e Wireharness around seat…………………………………………468
Conversion Tables…………………………………………………………..474
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