WORKSHOP MANUAL KUBOTA EXCAVATOR MANUEL D’ENTRETIEN EXCAVATEUR KUBOTA WERKSTATTANLEITUNG BAGGER KUBOTA U-10,20,35,45 KibotaRecord of Revisions Rapport de Révision Inspektionsaufzeichnungen ‘Symbol Date Main Revised Points & Corrective Measures Person-in-charge Symboles Date Principaux points de révision et mesures correctives | Personne responsable ‘Symbol Datum Hauptpumkte der Inspektion und korrektive Ma@nahmen | __Verantwortlicher ‘June 1988 1. Addition of U-10, 45 M. Katayama 2. Design change information on U-20, 35.Additional Contents : U-10a [1] Major change points 1-1 List of major change points 1-2 Paint color; EU-version 1-3 Rubber track; Upgraded anti-wear characteristic ~ 1-4 System pressure and control valve section sequence - 1-5 Noise level -~ 1-6 Control device 1-7 Oilhose list ARRON [2] Hydraulic components 4. Control valve ~~ 1-1 Outline of control valve 1-2 Structure and funetion’ 2. Hydraulic pump ~ 2-1 Disassembly and reassembly ~~ 3. List of hydrauiic components and circu diagram 3-1 List of hydraulic components 3-2 Hydraulic circuit diagram 3-3 Hydraulic components and layout [3] Electric system 3-1 Engine starting device . 7 3-2 Generating and charging system ~ 3-3 Engine stop device 3-4 Others; oil, fuel, glow plug ~~ 3-5 Electric circuit diagram So — on 3-6 Electric components and layout “ senna [4] Attachment interchangeability[1] Major change points 1-1 List of major change points roo? EEO] ( Basket dong Tree Photo 1 Photo21-2 Paint color; EU-version acm Blue 7 XQ \ track frame Blue 24 Blue 24 Color ‘Spot color | Lacquer (1k can) | Lacquer (4k can) | Super lacquer (4k can) [Super lacquer (16k can) Blue 19 | 07936-50075 | 07913-01098 | 07913-04099 (07913-44099 07913-16010 Blue 24 | 07935-50097 | 07913-01107 | _o7913-04111 (07919-44104 = Black 4 | 07935-50064 | 07919-01006 | 07913-04098 = = Yellow 21 | 07996-50038 | 07913-01108 | 07919-04112 = = 1-3 Rubber track; Upgraded anti-wear characteristic u-10 U-100 Remarks Thickness [mm (inch) 18.0 (0.71) 21.0 (0.89) ‘Total upgrade Iron core width| mm (inch) 140.0 (6.51) 160.0 (6.3) ‘Steel cord ay 36 40 tensile strength Is upgraded Hardness of | Rug side 6025" rubber _| Tread side 7325 Rug pattern T L — ii ‘Same as U-10 100 21-4 System pressure and control valve section sequence 1. Pressure setting Unit : Mpa (kgtfom), psi Usoa v-10 Test condition Main rele valve Actuator Bucket Bucket Engine Max. rpm a Bench set pressure | __17.7(180), 2560, 17.2(175), 2468 At pump dovery por Retuator ‘arm arm Oil temp. 50 = 5° re Bench set pressure 17.7(180), 2560 17.2(175), 2489 122 24°F ‘Overload relief valve Boom up | Bench set pressure |22.5(290 = 3), 3271 x 42.7 [22.5(280 = 9), 271 = 42.7 Swivel, ight | Bench set pressure | 7.1(72=3), 1024 427 | 7.1(72 23), 1024+ 427 ‘Swivel, let_ | Bench set pressure | 7.1(72 =), 1024+ 42.7 | 7.1(72 +8), 1024+ 42.7 Relief pressure testing procedure 1. Remove the plug and install pressure testing quick coupler and gauge. Start engine and confirm the testing circuit. With engine max. RPM, control the leverto relieve the testing cylinder. 4, Repeat 2-3 time to get correct data. 5. Testing oil temp, 50 + 5 °C (122 + 41 °F) EU-version BI ‘Swivel R 82 ‘Arm crowed 83 Travel Forward Ba Dozer down’ 85 Service por, IN BS ‘Travel R Forward 87 Swing L 88 Bucket crowed Bo Boom down Al ‘Swivel L 22 ‘Arm extend AS Travel L Reverse Ad Dozer up AS Service por, out 46 Travel R Reverse aT. Swing R | 48 Bucket dump 49 Boom up.1-5 Noise level Unit U-t00 U-10 ‘Noise level at ear (UR) BIA) 73 73 Noise level, around | Conventional method (7m,39.4" away) | dB(A) 62 63 New method (Sound power level) BIA) 20. S 1-6 Control device 1. Control rod layout Rod end jin tightening torque 235 ~27.5Nm (24-28 kgtm Apply screw locktte 33RE®S SES * Gg 8 2. Adjusting procedure of travel levers ‘Align the rods and valve spools so that the pins can fit just sideway into their connections. Tighten up the lock nuts. * If pins are not fit in at right angles, the operating load may be excessive, damaging the spools. Rod length (For your information) No. Function —_| Length mm (inch) 1 Boom 334 (13.1) Z 2 ‘Arm 255 (10.0) a C) Yeoteneat) 3 Bucket 440 (17.3) / reer 4 ‘Swivel 260 (10.2) 5 Travel, R 334 (13.1) Travel, 334 (13.1) 6 Dozer__| 236-238 (9.3-9.4)1-7 Oil hose list Hose ont a) Location mminch 1 | raoressi-2 [2 : site | 200,79 | Gra | Gv4 | Dozoroyinder-Rid 2 | Rataressea| 2 v4 [380,150 | Gua | G14 | Ru-dozer oyiinder 3 | RAITT-6347-1 1 res | v4 | 10,161 | ava | awe | civ Riraveluppery-R, A 4 | panteoe2 [+ Bue | v4 [450,177 | ava | Gis [CWA tavel(ower-Ais, | 5 | AANT-6940-1 1 Green | 14 | 465,185 | Gta | Gila [GIL travol(uppery AM, B 6 | RANIT-6960-1 1 wa [465,183 | Gta | G14 [CNV L trave\(ower-AW. C 7 [Rares | t write [site | sto,201 | ava | Gua | cx-Pump (Pt) @ | RArzi-62424 Gray | sie [535.211 | ova | aus [ovrume ra) 9 | atzresss2 | t write | 18 [650,256 | Gra | Gv _| CIV swing(upperiL-swing cyinder(bottom) to | ravar-e662 [1 va | 670,264 | Gta | G4 90° | CIV swing(lower)A-swing eylinder(od) ai] pantese1 | 1 Brown | 14 | 425,167 | Gia | Gus | Swivel motor LCN upper 12| Ranites6s-1 | 1 Pak | 4 | as5.180 | Gi | G14 _ | Swivel motor R-GN loner 13| mantress7-1 | 1 wite | 14 [1700,670| avs | Gv | Boom oytinder botom-CiV upper v4| Ranttesset | 1 va _[1610,684] Gv | Gis | Boom cylinder rod-GNV ower 35| Ranivesss1 | 4 : wa [660,260 | Gus | a1 _| Travel motor hs 16| Ranitese52 | 1 : va [365,144 | Gua | G4 90° | Truck cylinder rod-FLU upper F a7] Ranteseet | 1 : v4 | 460,181 | Gwe | G4 90° | Trick cyinder botiom-RW lower ve] Raizresa54 | 1 ua _[ 405.101 | awa | Gv490° | ON dozeriowerRIJH ra] Ranveos | 4 - ‘va_| 060,260 | ave | Gv4 90" | Rid G-change vane A 20] raviesea1 | 1 : va [460,181 | Gua | Gia | Ril F-change vate 8 _ at] rataresort | 1 2 v4 | 695,274 | Gv _| G4 90" | GV dozer lower-change valve P, conter 22| patties732[ 1 Bue | 1/4 [2150,e46| Gu | Gv _| Armeylinder od-C/V lower 2s] Ranivesre2 | 1 Red | 14 [2160,046| Gi | G14 _| Armoylinder bottom-CIV upper ae] Rativesrs2 | 1 Green| 14 2010, 1146] G14 | _G1i4 _| Bucket cylinder bottom-CIV upper as| pattiea7e2 [1 Yellow | 118 [200,146] a1 | Gt _| Bucket cylinder rod-CiV lower 26 27 28 20 [0] Note: G means straight type screw, previously indicated by PF. In a same way, F is equal to PS and Ris PT.[2] Hydraulic components 1. Control valve 1-1 Outline of control valve 1. Hydraulic circuit diagram cf ffowet ft gt to | tom) toe * | Hemf ff oF |] ment one fp Lo tem alps —selfesolfa—_adha ej, fa Relief pressure P1: 17.7 Mpa (180 kgficm), 2560 psi P2: 17.7 Mpa (180 kgtiom?), 2560 psi P3: 7.1 Mpa (72 kgf/cm?), 1024 psi 4: 7.1 Mpa (72 katicm?), 1024 psi P5 : 22.5 Mpa (230 kgf/om?), 3271 psi 6 : Anti-cavitation valve (Sample photo) ef P3 6 ys () Tye (OP OV NSC10-9 KA (2) Maker Naboo (2) Weight ‘Approx. 10.5kg (28. bs) (@) Tie-rod tightening torque(Hex. nut M8) 18.7-14.7Nem (1.4-1.5kgtm) 10.1-10.8ftibs (6) Relief valve tightening torque 39.2N.m (4kgh-m) 28.9ft1bs3. Pressure adjusting procedure (1) Loosen lock nut of relief vaive. Adjust the pressure valve by turning the ad- justing screw with allen wrench After setting, tightening lock nut. To increase pressure, turn to clockwise and vise versa, (2) Finally check pressure setting with max. en- gine RPM.1-2. Structure and function 1. Relief valve function (Operating mechanism of the relief valve) ‘The higher the working load rises, the higher the circuit pressure goes up. At a preset pressure level, however, the relief valve gets activated. When the circuit pressure has reached the setting of the pilot valve spring (D), the oil flows through the orifice of the main poppet (A) into the main poppet spring chamber (E). This pushes up the pilot poppet (C) and lets the oil flow into the tank. Now a pressure difference takes place across the orifice of the main Poppet (A), and the main poppet (A) gets released from the main poppet spring (B) and pushed up off the seat. In this way, the pressure oll starts flowing Out of the circuit to the tank, which keeps the circuit pressure at a preset level. Inner parts, relief valve =—-— 3 —<@ 2. Anti-cavitation valve function if the pressure (8) at the cylinder causes cavitation, the anti-void valve opens itself, feeding the oil from the tank and filing the space. (1) The oylinder port pressure (3) is applied over the large area at the back of the O-ring, which activates the poppet (3) and its seat. (2) When the pressure (3) drops below the atmo- spheric pressure, the tank pressure (4) applies Upon the circular area between At and A2. This pressure will overcome the cylinder port pres- sure and the force of the spring (2), thereby ‘opening the poppet (1). (3) With the space full of oil, the spring forces back the poppet and the cylinder port pressure (3) works tightly upon the seat. Inner parts, anti-void valve 7 (Gample photo) (1) To see if the relief vaive itself is in trouble, re- place it wth new one of the same pressure level and check for similar symptom, (2) The relief valve malfunctions probably due to foreign matters that are caught in between the Poppet (A or C) and the seat. Carefully check these parts for dust, metal chippings and the like. Check also the seat for dents and repair it as required. (3) Check the springs for looseness and the seals for degrading. (1) Check the poppet seat for scratches, the springs for looseness and the seals for degrad- ing.3. Load check valve function For smooth movement and easy inching adjustment of the spool, the passages of the hydraulic source, working section and tank are all interconnected while the spool is switched over. Let's suppose that there is no check valve installed and that the working load keeps on forcing the working section in the opposite direction. In such situation, the working section passage, pump passage and tank pas~ sage are all interconnected while the spool is switched over. This causes a pressure drop and the working load invites a back flow. This is very hazardous, With this reaon, the check vaive is added in halfway along the working section passage. Even if the passage pressure drops too low, the working section's oil is blocked by the check valve and the working load is safely maintained. This function therefore provides for some advantages. The spool switches over smoothly, and the working section does not suffer any reverse motion. What's more, if the spools are activated at once with different working section pressures, the oil flows back from the high-pressure side to the low-pressure one. This design leads to ease of operation. Inner parts, boom section Boom section _ (109(7) (9X8) (9) S + Load creck valve | i eneneneneniares (1) — (A) 66) —sB (1) Vave body (2a) Spoot (7) Check valve (8) Spring —— (9) Oring (10) Retainer (11) Cap (18) Overload lit valve (1) Check the poppet (check valve) seat for soratches, the springs for looseness, and the seals for degrading. (2) Check the spool for scratches, and heavy or unsteady motion along the valve body. If the outer surface of the spool is found scratched by foreign matters, smoothen the surface using fine sandpaper. Be careful not to polish it leaving no scratch marks, but to deburr around the scratch mark. (3) Use a flashlight or a fiberscope to check the valve body for scratches. If burrs are found in the holes, remove them using a nylon brush or oilstone. (4) Check the spools throttle hole for dust deposits 4. Fail symptom causes by control valve ‘Symptom ‘Suspected causes Remedy All functions fal ‘Main relief valve malfunctions ‘Adjust or replace Weak power, slow speed ‘Main relief valve malfunctions Adjust or replace Oil temp. rises. ‘Main relief valve malfunctions ‘Adjust or replace Cylinder has weak power and | 1. Spool stroke is not enough. 1. Adjust or repair slow speed. 2. Main relief pressure is low. 2, Adjust or replace 3 Control valve malfunction, 3, Replace Excessive free fall Excessive leakge through control valve. Replace Weak swivel force 1. Overtoad pressure is low. 1. Adjust pressure Speed is low 2. Spool stroke is not enough. 2. Adjust or replace ‘Two much drifting ‘Travel malfunction. Control valve spool malfunction Replace ‘Weak traction force ‘Spool stoke is not enough, ‘Adjust or replace Speed is low. ‘Oblique traveling T. Main relief pressures, RAL are different. ‘Agjust 2. Spool stroke, R&L are diferent Adjust or replace, ° i2. Hydraulic pump 2-1 Disassembly and reassembly 1. Tools Required tools are as shown below. Get ready before repair work. Clean tools, working table and the surround- ing to prevent foreign materials from getting into pump. Tool name Fig, Remarks Torque wrench Socket wrench Socket 14mm (0.55 inch) ‘Snap ring plier (Hole) Resin hammer ATA EH Minus driver 2. Figure of disassembled parts a @ 82 No, Part name ay. No. Part name oy. (01 _| Front cover, 1 50_ | Gasket 4 02 | Body 1 51_| Gasket 2 03 _| First drive gear 1 52 _| Steel ball 4 (04 | 2nd drive gear 1 53 | Bot 4 05 _| Srd drive gear 2 55 | Oillseal 1 06 _| Side plate 4 56 | C-circlip 1 (07 _| Rear cover 1 08 | Bush 8 ae °3. Procedure (1) Before disassemble, put alignment mark on front cover, body and rear cover and remove bolts. Bolt lightening torque : 48.1~51.0 N-m (4.9-5.2 kgf:m) , 35.5-97.6 ftlbs (2) Remove rear cover, gasket, side plate, 2nd drive gear, 2nd driven gear and steel ball. Bush cannot come out. * Watch steel ball not to loose. ‘Stee ball Gasket ‘This groove is inet sido, Inlet port —e\ <——» Delivery port oar sie siding face (Chama sin delivery side, [ Renew seal } ‘When replacing seals, apply grease on seals and fit them in the groove. (3) Remaining oil seal and C-circlip in the front cover, remove gaskets, side plate, 1st drive gear, 1st driven gear and steel balls. "4. Structural parts (5) and oil seal. Oil seal is difficult to remove, care should be taken not to damage machining surface. Apply grease on oil seal housing. [ Replacement of oil seal ] Apply grease on lips of oil seal. Wound vinyl tape around spline of 1st drive gear. Apply gease on the tape to smooth the oil seal. Press fit the oil seal and set the C-circlip.3. List of hydraulic components and circuit diagram 3-1 List of hydraulic components Applied models Maker Shimazy Type wo fandom gear pump Pump Delivery amount PI 11.091) ure min (Us galimin) P2 11.0291) Control valve Maker Nabuco Main role pressure PI 177 (180), 2560 v0 pattem) ps P2 17,7 (180), 2560 Maker Sumitomo Eaton Type Orbit motor; 1 stage Travel motor Displacement colrev (in) 327 (10-1) ure Relief pressure Mpatkatlon®), psi 177 (100), 2560, Maker Sumitomo Eaton Type Orbit motor uso Swivel motor Displacement colrev (in) 18467) K-08 Relief pressure Mpatkatlon®), psi 7 (72), 1084 Bore dia x Rod da mmm ingh) | __ 60x95 (244-4) v0 Boom Stoke mm (inch) 282 (11.1) K-008 A Bore dia. x Rod da mm (inch) | 55x20 (2.21.1) v0 ™ Stoke mm (inch) 312 (12.3) : [Bore ia. x Rod dia mm (inch) | 50x90 (2.0x4.1) Bucket [stoke ‘mm (inch) 283 (11.1) ue Ct Bore dia. x Rod dia. mim (inch) | __50x25 (20x1.0) uso Swing [siroke mm (inch) 236 0:3) i: Bore da. x Rod da ‘mm (inch) | 55x90 (@2x1.1) Dozer | Stoke ‘mm (inch) 118 (46) oe Bore dia. x Rod dia. mm {inch)| 50x25 (20x1.0) 1 Teck [stoke mm (neh) 15069) ue 13,ean an 3-2. Hydraulic circuit diagram [ wer wy ] "e140 uno > bh SHES 14 woog yng Bulg Ua tle 73-3 Hydraulic components and layout Engine Drea {082000 em Pure 415.57 opm 0:98 wpm 2557 colpm 0.34 pm Gy th.1g umn, 2.94 US gatnin 2:11.14 Um | 294 US gatmin Relet pressure 1180 kgm, 2560 2: 180 flo, 2560 Swivel mater 184 cate, 11.2inrev Travel motor 927 ca, 20.0 wirew ovinder ‘Sh 950 425 x 2968 Boom : 480 935 28st drm 9553 490. 3125, ket 80% 70 » 28st Dozer 955 ¢80 x 183t Track: ¢60% $25 «180s 1st stago vave epood Service portyeturn “cracking pressure (12) 2.0kgHem (28.45) 1g FRotum fiter 151 Pe 150 Mesh[3] Electric system 3-1 Engine starting device 1. Starting principle (1) When starter SW is off : Battery voltage is always applied at B-terminal of starter motor, slow blow fuse and 30-terminal of starter SW. (2) When starter SW is at starting position : Battery current flows 30-terminal to 50-terminal of starter SW and to S-terminal of starter motor. Then pinion gear rotates and starts engine. 2. Five basic principles of troubleshooting in electric circuit (1) Check to see if battery voltage is being applied on positive (+) terminal of electrical components. (2) Continuity test between positive (+) terminal and (-, earth) terminal of electrical components. (3) Continuity test of wire harness. (4) Continuity test of line to ground. (6) Insulation test of each component. 3. Troubleshooting of starting system malfunction + When starter switch is at ‘start position, check if battery voltage is on S-terminal of starter. (Photo 4) + If battery voltage doesn't exist, check the following items. (1) Breakage of slow blow fuse (Photo 3) (2) Starter switch discontinuity (Check continuity between 30 and 50 terminals start position.) (3) Contact failure of coupler or wire hamess (4) Cutting of wire hamess (Check continuity test by circuit tester.) + In case battery voltage exists, check the following items, (8) Contact failure of S-terminal (Check continuity between S-terminal and body earth.) (6) Starter body earth failure (Check continuity between starter and body earth.) (7) Cutting of pullin coil and holding coil (Check continuity test between S-ter I and body.) 4. Troubleshooting of engine starting malfunction * First check battery charging amount and earth line condition. * Second check if battery voltage is on S-terminal of starter when starter switch is at ‘start’ position. (Photo 1) (Photo 2) " Gs(95) a) (2) It battery voltage doesn't exist at B-terminal ; 1. Check continuity of slow blow fuse. 2. Check continuity between 30 and 50 termi- nals when turning on the switch. 3. Coupler or wire harness have failure of con- nection. 4. Check continuity of wire hamess. * Fusible link and 30-terminal of starter SW. * S-terminal of starter motor and 50 termi- nal of starter SW. In case battery voltage exists at B-terminal ; starter motor should be suspected and so check the following. 1. Contact failure of S-terminal. (Check continuity between S-terminal and body earth.) 2. Starter body earth failure. (Check continuity between starter and body earth.) 3. Cutting of pullin coil and holding coil. (Check continuity test between S-terminal and body.)3-2 Generating and charging system 1. Generating principle (1) When engine is running ; Permanent magnet is rotated by the fan belt and generates alternating current at the fixed coils. This alternating current is converted to direct current by the full wave rectification ‘of a diode and charged in the battery. ‘While engine is running and dynamo is generating , the current doesn't flow from regulator to charge lamp and the lamp turns off. (2) When engine stops ; Dynamo stops and no current is generated. 2. Dynamo. This dynamo is an 6-6 pole rotating magnet type ‘generator. It is simple in construction, consisting of a stator and rotor. The rotor is made up of six per- manent magnet pole pieces assembled on a shaft and rotates on the center of the stator around which six electromagnetic coils are provided for. This dy- namo produces higher voltage in slow speed rota- tion, and charges electric current to the battery during engine idling. The regulator performs rectification and voltage im regulation. The regulator converts AC into DC which flows through the power consuming circuits and the ) battery, and also charges the battery. If however, o) the battery voltage exceeds a certain level, the DC o 1 current is cut off from the charging circuit to pre- 4) Be fo vent overcharging. (1) Regulator (7) Yellow Lead Wire (2), Dynamo (8) Red Lead Wire I (3) Load (9) Green Lead Wire * (4) Charge Lamp (10) Black Lead Wire (5) Battery (6) Blue Lead Wire (A) General Wiring Diagram (0) Features 4. This small-sized regulator can control large out- put current because charging current is supplied and stopped by thyristor (Series system). 2. Built-in AC diode generation detecting circuit permits a charge indication lamp (12 V, 3.4 W) to be easily connected. x51) 3. Protection diode protects regulator when battery 4 is wrongly connected (1) Blue Lead Wire (4) Green Lead Wire (axe) (2) Yellow Lead Wire (5) Black Lead Wire (3) Red Lead Wire . a4. Inspection method when charging system malfunctions : (1) Check points (Suspected causes) 4. Dynamo's failure 2. Regulators failure 3. Improper connection of coupler wire harness. 4, Improper connection of charge lamp line. (Check continuity between charge lamp and regulator) (2) Dynamo No-load Voltage 1. Disconnect the lead wire from the dynamo. 2. Start the engine and measure the voltage generated by the dynamo. 3. Measure the output voltage with a voltme- ter. Ifthe measurement is not within the fac- tory specifications, replace the dynamo. [No load dynamo votage | Factory spec. | AC 20¥ or mere at 5200 mpm : (yer) sxaay (3) Continuity across Regulator's Terminals 1, Measure with a circuit tester according to the list below. NOTE * For this test, use only Analog Meter ad do not Use a high voltage tester such as a MO meter. * This check sheet shows the results of the test conducted by using the "Sanwa-made testers SP-10 and SP-15D" (Analog Meter) * Use of other testers than those above may show different measured results. 2 shall be used as the unit for the measuring range. * The judgement shoule be as below table. ‘ON’ if the indicator moves, otherwise "OFF". Check Table —__ Tester Card ca eres bie [ be | 104 [retow aren | back Be OF [ON | OF [oF | OF ive [OFF (ON [OFF | OFF | OFF Cord Fred | OFF [OFF oF | oF [OF colors Fellow] ON [ON | ON OFF | oN green | OFF_[OFF_[ OFF | OFF OFF tack [ OFF | OFF | OFF | OFF | OFF (1) Blue (4) Yellow (2) Blue (5) Green (3) Red (6) Black (2) Timer relay (3) Regulator3-3 Engine stop device a | Sa is oon ) ~eeéi am Lene e Functional model: U-15 1. Engine stop circuit line (1) With the starter switch at ON: Whether the starter switch is at ON or OFF, the battery voltage is constantly applied to the timer relay terminal (4) (Photo 1). When the starter switch is tured on, the current starts flowing to the timer relay terminal (3), which electrically charges the timer relay capacitor. (2) With the starter switch at OFF: When the starter switch is turned off, the AC power is cut off and the electrical charge is no longer stored Up in the timer relay capacitor through the terminal (3). By so doing, an electrical discharge occurs from the capacitor and the relay gets activated for a discharge time of 10 seconds. Now the line between the terminals (1) and (4) is made, which allows the current into the engine stop solenoid and stops the engine. 2. Checkup if the engine fails to stop (1) Tum off the starter switch and check to see if a voltage (12 V) is being applied to the engine stop solenoid terminal for 10 seconds (Photo 3). (2). Ifno voltage is being applied 1. Checking the timer relay 15A fuse (Photo 4) (Visually check the fuse for blowout and the leads for short-circuit.) 2. Checking the timer relay (Apply voltage between terminals (3) and (4). Tur the power off at the terminal 3 to see if a voltage is. applied to the terminal (1) for 10 seconds. Be careful not to allow short-circuit between these narrowly spaced terminals.) 3. Checking the leads (1) and (5) (Using a circuit tester, see if there is continuity.) 4. Checking the coupler and leads for poor contact, * } U-100.(3) When the voltage is being applied 1. Checking the engine stop solenoid (Photo 5). (Check for continuity at the solenoid itself. Or apply 12V voltage to see if the solenoid functions.) 2. Checking the engine stop solenoid coupler for poor contact. 3. Checking the engine stop solenoid body for poor grounding (Photo 6). (Check continuity between the engine stop solenoid terminal and the body.) Timer relay coupler terminal (3) Fuse (AC) RL (4) Fuse RE (1) Stop solenoid W (2) Earth B When starter switch is off, is battery voltage on for approx. 10 seconds? (Photo 3) Apply the battery voltage to the engine stop sole- Continuity check between solenoid terminal and noid terminal and make sure the injection rack body earth. (Photo 6) bar is drawn in. Shut off the voltage and be sure that the rack bar retums. (Photo 5) 100 23-4 Others; oil, fuel, glow plug ‘Wire pamess 1 ‘agua Wie ames 2 Functional model: U-15 T. Charge lamp, oil lamp and fuel lamp light-up circuit lines. (1) With the starter switch at ON and engine at OFF: 1, The dynamo is not running, which means that no electricity is generated. The regulator feeds current to the charge lamp that will light up. 2. No engine oil pressure is applied upon the oil switch. The switch contacts are kept closed to ground the oll lamp that will light up. 3. The thermistor on the fuel sensor gets selt-heated by a very small current. By this heat-up, the thermistors internal resistance drops and a large current is allowed to flow. When the thermistor cools down again, the internal resistance rises and less current is let flow. Such behavior is utilized here. When the ther- tor is out of the fuel, it heats up and the current starts flowing from the fuel lamp, which wil light up. While the thermistor is in the fuel, the heat is absorbed by the fuel. Then the thermistor cools down and its internal resistance rises to put out the fuel lamp. 2. Checkup if a lamp fails to light up (with the starter switch at ON) (1) Check the charge lamp and oil lamp while the engine is off. To check the fuel lamp, empty the fuel tank and see if the lamp bulb is broken. Check also to see if the voltage is applied to the coupler of each lamp. (2) Ino voltage is not being applied: (Charge lamp) 1. Checking the regulator for malfunction 2. Checking the coupler and leads for poor contact 3. Checking the charge lamp wiring for breakage. (Check for continuity between the charge lamp and regulator.) (Cillamp) 1. Checking the fuse (10) (Visually check the fuse for blowout and the leads for short-circuit.) 2. Checking the oil switch (Check continuity at the switch itselt.) (Photo 4) 3. Checking the oil lamp wiring for breakage. (Check for continuity between the starter switch AC terminal and oil switch terminal.) (Fuel lamp) 1. Checking the fuse (10) (Visually check the fuse for blowout and the leads for short-circuit.) 2. Checking the fuel sensor (thermistor) (Measure the current with the fuel and that without the fuel.) (Photo 2) 3. Checking the fuel lamp wiring for breakage. (Check for continuity between the starter switch AC terminal and fuel sensor terminal. * Goa (Photo 3) 3. Oil switch (1). In normal condition When the engine lube oil pressure goes up, the contact of oil switch 6 opens to tum off the lamp. (2) In trouble When the above pressure comes down, the contact of oi switch 6 closes to turn on the lamp. Operating pressure of oil switch Ref. value : 0.5 kgf/om?, 7.1 psi, 0.05 MPa (1) Turminal ~ (5) Contact revet (2) Insulator (6) Contact (3) Spring (7) Body (4) Rubber 4. Glow plug (1) Disconnect the leads from the glow plugs. (2) Measure the resistance with a circuit tester across the grow plug terminal and the hous- ing. (3) If0 ohmis indicated, the screw at the tip of the glow plug and the housing are short-circuited. (4) Ifthe reference value is not indicated, the glow plug is faulty, replace the glow plug. (5) Resistance of glow plug - Ref. value : Approx. 0.9 ohm at 20-30 °C. (68-86 °F) (Photo 4) Low oil pressure; Normal ol pressure Below 0.5 kom (7.1 si) (a8) 245. Horn a) Structure (1) Diaphram (5) Stop screw (2) Point (6) Stay (8) Hom coil (7) Air gap (4) Nut ‘The horn consists of acoustic diaphragm, point, hom coll and other parts. It comes in spiral, flat and other types in construction. Currently, the flat type is most widely used. A typical flat horn is shown at right. (1) Battery (2) Hom switch (3) Hom relay (4) Diaphram (5) Core (©) Coil (7) Moving bott (8) Adjust nut (9) Moving plate (2) Function ‘Shown above is the horn drive circuit. When the hom switch is pressed, current flows to the horn relay to get its contact P1 closed. The current from the battery now flows directly through the horn coil and the Contact P2, which magnetizes the core and attracts the moving plate. Then the contact P2 opens itself and the current is interrupted. The magnetic force then disappears and the spring-loaded diaphragm comes back to the original position. The contact P2 closes itself, and the current flows again through the coil to attract the moving plate. The above series of actions are repeated to keep the diaphragm vibrating, pro- ducing sound. 25(3) Current flow (1) Battery (2) Horn switch (3) Horn relay (4) Diaphram (6) Core (6) Coit (7) Moving bolt (8) Adjust nut (9) Moving plate For your information 1. Function of diode: Prevention of hom switch by absorbing the surge current Inductive type of load, such as solenoid valve generates arc spark at switch point. This diode installed parallel to solenoid valve let the surge current energy flow back to coil to consume as a joule heat. In this way, surge current won't flow to horn switch(Horn SW is off position) Hom sw * When horn switch is off, current doesn't flow through relay. So relay remains off condition and horn doesn't sound. (Horn SW is on position) 1g + When horn switch is on position, current flows through relay, mag netizes it and activates horn.283-5 Electric circuit diagram Rar TeS318 RATT “3921 i i 4 man Lea ans Ta 5 elo 4 ed rn 1) oes ae, Jj ost aye j ae oon oy a oe} i & — gote ' To] Sehr ont Ft 4 9 orto une ol =a | Gos ar | 3 , os Lee gs Wreharess 4 ch r TAT oo3004 | | Tohom i i J 1 — tonne 7) | F al emma | | a = i a * alan f f | 1av Wehanese(Etersion) Ln ‘oe ere { i ison a | a — faley any sie =3-6 Electric components and layoutpebETe upeo np 1 : 1 ve poppe ol peomjay| OT —O—+—O--—© | SuiBe01 np won | (ee00) sz0%0 | raso-rz1VH| oo¥ fose o¥onG | AHH opi Fpabveyo 1960 YaxONG 200% : Ho 6u86ppre1eve9 | (1200) vev0 | osge-tzives| o8e Asse oxong | (PON) uo poppe ted paaio4 puepuers (g00-y) °. © | subsip weve | (6200) zzvo | 0909-110 | ose Asse roxona verona prepuas Bupop sous | ese exon | wpm maue uo pappe e1eid peosojujou| oO O Pp »D (¥20'0) 810°0 €899-1L0Vu | 008 yeyong | WPL N WALEYIP 40100°L00-H|__O- oO. ‘MOEN (8100) v0.0 2899-16169 | Osz Asse eyong | uipjm mouEN spewoy joo] |Ee0e ROL ORE0En) yddy [04 a Asode» SECPEH O So09 owen ent watt ‘siePOW ads AyjiqeaBueyoeju! yuouyoeyny [7 31GENERAL GENERALITES ALLGEMEINESfet) Contents: P age: Development concept - -G-M1-4 Feature summary ~---- GMB Application pictures - - G-M6 U-10 features and performance G-M7~15 U-20 features and performance - --- G-M16~25 U-35 features and performance - G-M26~30 U-45 features and performance G-M31~38 U-35,45 features and performance __ - G-M39~48 Development Concept Almost quarter century have passed since first mini-excavator had been manufatured in Hirakata Factory. Since then mini-excavator has been used in construction and civil engineering applications throughout Japan and worldwide. Nowadays, mini-excavator as a construction machinery is the indispensable equipment in construction work same as large shovel machine. Mini-excavator has basically the downsized structure derived from large excavator, but from its first R & D it had boom swing function and dozer blade as the standard unit That is why mini-excavator in Japan had uniquely expanded its versatile applications in tight urban job site. In the course of market creation, Kubota had been developing the original functions and structures (as shown below), taking the lead in other competitors. 1.Dozer blade 2.Cab/canopy 3.Rubber track 4.Bolt on iron track 5.Pilot operated control 6.Breaker application 7.Shockless valve 8.Boom anti fall valve In this way, mini-excavator has been further multi-functional and downsized to less than one ton class machine. In pararell with struggling with competitors and responding to market needs, Kubota has been seeking the ideal concept of mini-excavator in tight working job site. That is the standard mini-excavator that doesn't worry about its rear end. Here we present new series, U-10,U-20,U-35 and U-45, which have five basic features. 1.Rear end swiveling radius within the machine width. 2.Equivalent stability to standard type. 3.Digging performance and easy operation similar to standard type. 4.Easy maintenace 5.Environmental friendly Above features will be well accepted by standard type machine customers as well as rental yard. Therefore, we will highly expect to create the market and increase its market share by understanding those concepts and features that are illustrated in the following pages. Good luck ! GuiaU-series and its Future Trend ? (Below data was compiled according to the CS survey in Japan.) What are the benefits of Zero turr sto U-type = U-series ? +kNo need to worry about tail end. stand keMore stabilized than zero turn type. : > Easier maintenance than zero turn ‘Equivalent working performance to standard type. Trend and Prospect of machine type ‘Type and Classwise prospect in Japan * Tasha dass oo 8 3 2 aul] 2a 61 |Zero turn type}—} xq | am 10% om \ ° 87 or \ 38 standard type| “982 ees Fete prospect market survey in Japan y an | ow oe o% (és the ratio of min-excavator in Japan) I Even in overseas market, U-series will find its optimum application and well be accepted. Because : 1.Mini-excavator is basically urban use machine and job site is usually very close to houses,walls etc. 2.Job quality often requires precise finishing. 3.In urban job site, machine works beside the traffic and pedestrians. 4.Versatile and miscellaneous job require man and machine combination job. So helpers usually working around the machine. 5.Mini-excavator suits for inside building job, such as demolition and remodeling job. For this reasons, mini-excavator with zero tail turn machine is best suited. Furthermore, we can say that zero tail turn is the one essential concept of mini-excavator.Seeking the ideal mini-excavator, Standard type is working widely for versatile application. But standard type has long hanging tail and can't turn within the machine width. 3: This portion is projected. ) Cut and shorten the rear portion, then dramatically change for convenience. \ [ Easy job in tight spot. Suitable for gardening. GM3AJob site necessity is the mother of U-series. Authentic zero tail turn excavator. U-series * No worry about rear end. %* Excellent stability. * Great digging performance. For example; Pipe laying work This machine can easily swivel in urban job site, along with wall or house, It has enough stability for lifting and pipe laying job. Road repair and ditch digging This machine can turn within one lane and so minimum road restriction is required. Housing, civil engineering work Enough lifting capacity and powerful digging force enables to use variety of attachments. Productive rental business This machine can responds to variety type of jobs and so ma- chine's working rate is quite high. * Versatility. | bought this machine for water pipe | and septic tank laying job in tight area. Digging power is great and no need | to worry about rear end. Low noise. Good stability. | won't be fatigued even for a long time work. Customer's responses are; This machine requires minimum road restriction, so urban customers need Ustype, House foundation jobs in urban area are located in narrow space, so mini- mum turning radius and digging pow- er are inevitable performance. With breaker on, U-series are just fit GMas, Easy control and machine balance are well accepted by customer. Rent- al rate is high. Maintenance and repair cost is mini- mum. skThese evalutions were received from U-20's customers in Japan,U-series Feature Summary Zero tail swiveling within machine width @ This machine makes operator free from worrying about rear end. @ U-shape is easy to identify the machine's direction. @ Combination with boom swing upgrades swivel performance. Equivalent stability with standard type machin. © Same stability level with standard type machine. @ ItAfs easy to load and unload from the truck. @ Variable track enables further stability. U-10,20 Equivalent working performance with standard type machine. m © Powerful digging force and fast operating speed. © Wide working range. Variety attachments. Breaker,etc by standard service port line. @ Stable pipe lifting work. © Fast traveling speed. (Hi-Lo speed except U-10) = Easy maintenance. SS @ Full open bonnet for easy access. Double elements air cleaner is standard. @ Hydraulic accumulator is standard in pilot control circuit for safety and service. @ Reliable and durable machine body and components. c Environmental friendly and comfortable to operator. —_— @ Comfort operating space. @ Low noise. @ Emission control type engine. @ Recyclable resin parts. GMbaApplication Pictures Road repair.and ditch digging. engineering work. Machine body can swivel within one side Lifting capacity and digging power are good lane and/so minimum traffic restriction is re- enough for variable attachment use. quired for construction job. i High rental rate. Housing and pipe laying work. For the customers of versatile application. In urban job site, it is easy to turn beside the wall and good stability enables the lifting work smooth. Ges,U-10 Features & Performance Go in small, Work in great ! ic. Value added, small yet authen High-powered engine’ Concept Wide operating range, Variable track width Zero tail swiveling within track width Four Satisfactions Great performance Operational comfort Zero tail turn within track width. Comfort space © Variable track. Functional U-body © Service port and pedal are © Front visibility. standard. Simultaneous operation for © Arm regeneration circuit. | _ swivel and swing. One ton truck loading. High-powered 3 cylinder engine. ‘© Easy machine lifting. Easy maintenance Environmental friendly ‘© Full open bonnet. © Super low noise. ‘Boom cylinder is stored in boom. © Emission controlled engine. Front hoses are stored. ‘New design. © Grease maintenance is free in 6 points. © Grease tension track adjustment, GM7AU-10:Track frame is retractive to 85 cm. Easy going through narrow passage. U-10 can go through narrow passage that competitor's can't. PCOBUU and IX9UX interfer with eaves, Easves height:Approx.1.9m Road width:Approx.1m Eaves of the house Road width: Approx.900m <<” can easily go through with 85cm width. © U-10:U-shape body has narrow width. ss 85cm, : a @8y cutting both sides, machine <—_—> width became narcow. U-st ‘Circular shape} Viot0 Rd PCOBUU ide cut 1S9UX Side cut N47 GMBAActive U-10. ©90 cm width is good enough to go through as shown in Figs. 5 Narrow house inlet. oat Narrow passage to job site. ,co Traveling quietly through ee residential area. WW Tight job site between the house. (mmm Construction goods of 90 cm in Japan. TTT Notice board; Under construction. Detour notice board. 90cmx1m36em, Veneer board. barricade for road construction, ——> ‘Small :75x900m Large : 75x1m20em GMos,U-10:Track frame is retractive to 85 cm. Retractive track. Variable width is 1 m and 85cm. ‘Change lever for dozer blade and track. Variable dozer blade. U-10 adapted variable dozer blade by using pin manually. Dozer pin Zero tail swivelling within machine width. @By extending the track width, operator won't worry about machine's rear end. Precaution ! While digging operation, =" track width should be extended GuoU-10 is the standard version of 1 ton class. Max. digging depth:1780mm_ Max. digging radius:3350mm Difference In comparison with Vio10-R, wider digging radius by 230m bles large working space. t Septic tank for 5~6 persons, Body height:1770mm. Benefits:Septic tank for 5~6 persons is possible to lay down. ‘Competitor's machine can't dig such depth, 0 additional manual digging is required. y \\ uss vio10-F/8120mm Iseuxrac2smm PC0SUUL2880mm Engine output:10.4PS( DIN 70020) Benefits: Efficient root digging work is possible ‘without moving the machine. to4Ps eps 85PS_ es Only machine with 3 cyinder 104 PS engine installed Benefits: Powerul job is guranteed UO. WoIGR — ISBUX — PCOBUU Stability and working amount Dynamic stability(Side direction) Bar graph shows the comparison value, Set Vio10-R is 100, then U-10 is 132. 400 il U0 oro - Testing condtons D0 Woon 0 degrees sve Doser bade up Working amount(45 degrees side ditch digging) Same waht Measure actual digging amount for 1 hour and shows the comparison value. Set Vio10-Ris 100, then U-10 is 116. vito-n v0 @U-10 can lift the weight smoothly. U-10 has excollent stability and working performance, comparing to Vio10-R. Benefits: Efficient working performance enables the high production amount/) >) ( Let's look into the specific features ! J HEFull open bonnet ‘@Full open bonnet widely opens to rear. Benefits: Peer Air cleaner Variety maintenance job from daily inspection to N engine dismantle become easy. Engine. Radiator Reserve tank ‘Operating oil Vio10-R has also a full open bonnet Fuel tank but opening angle is small MMaintenance free at 6 greasing points. @Grease-free type pin is installed in swing cylinder, dozer cylinder and dozer arm Benefits: Reducing the bothering job of grease-up. Pin Dust seal — Cylinder rod Resin bushing—_ Dust seal — GMi24Hiinternal dozer cylinder. uso Vioio-R = @U-10 has adapted the internal dozer cylinder which had a favorable reponse for K-008. Benefits: 1. Boom cylinder is protected by boom frame even if big stone or concrete block were held 5 with bucket and dozer blade. 2.There's nothing to worry about hitting the cylinder with the door stop. 3.There's no fear about scratching the cylinder with breaker point. Front hoses routed inside. Boom,arm and bucket hoses are routed inside. Benefits: There's nothing to worry about hoses for any damage. Grease tension device is installed as standard. Vio10-R has bolt-tightening method. Track tension adjustment became easy. GMI38,HLoading on 1 ton truck. Machine weight is 990 kgf. Dimension of light duty truck vessel:1940x1330 mm (in Japan) \ Benefits: Loading on 1 ton truck to transport to the job site. Machine weight:990 kgf £ Machine size(at transportation) Overall length:2995 mm © Overall height:1370 mm Overall width:850/1000 mm 260mm Service port P,T ports and pedal are installed as a standard. Attachment Model Benefits: [Breaker | KXB20016-25 Umi, 70-100 glen) Service port enables to use variety of attachments. Hand auger | U-10 Service port oil flow amount:22.2 Limin. Service port operating pressure: 175 kgt/om? HBArm regeneration circuit is installed. Even idling speed, arm doesn't fluctuate and levelling work becomes easy. Benefits: This specific circuit displays its great power to the construction work with precise finish, such as U-shape ditch and rain water pipe laying U-shape ditch Rain water pipe ditch ‘Ul lof Precise finish is required. Without arm regeneration circu. Tree points machine lifting. Quick bucket pin. Bi Satet a @Quick bucket pins are fitted same as K-08. fafety precaution | When iting the machine, follow to the safety @Vi010-R has bolt-on type regulations and work procedure. Benefits: | Read the operator's manual. Attachments can be exchanged without using tools. owas@Bo0m swing bracket is mounted at right side to access front bucket easily. . Benefits: It enables the precise digging work easily. Functional U-shape body. — _ 4. Benefits: Cutting the side ot swivel body makes the operator easily notify the direction usto Vio10-R Comfortable operator's surrounding. @Wide foot space, comfortable seat and appropriate lever arrangement present amenity to operator. @Walk through foot floor is adapted to get on and off from either side. Leverlock Swing pedal Simultaneous operation of swivel and swing. ‘Swivel function is controlled by lever and swing by pedal independently. @This enables simultaneous operation of swivel and swing. Benefits: Combination of swivel and swing makes the relocation of bucket position easily. This feature is beneficial to side ditch digging along the wall 1.Start swiveliing and swinging simultaneously. 2.Locating the bucket to appropriate position, ‘stop both functions. In this way, bucket relocation becomes fast KL GMsU-20 Features and Performance This is U-20! Quick feature chart. Clear front visibility. Clear neat rear end. Front view is open and clear to pin point Nothing to worry about interference the bucket position for precise digging work while swiveling. —_| _ / (‘Sr ane can be pon (Sie ) vntimm Front mini, [at ront 7535 : : tuning radius at boom swing) 1160 | Wide operating space. .. Rearend turing radius 685 Specifications u-20 Ros Max. digging height 4230 gx Easy maintenance Max. dumping height meat Full open bonnet enables to Max. cigging depth 2370 . access maintenance items. Fuel system and control valve is easily inspected, Max. vertical digging depth | 1900_| Max. digging radius “4180 Great stability ~ Optimum design of weight balance enables equivalent stability to standard type. Thus pipe lifting and laying jobs become much easier. Fast cycle time yet powerful. Large capacity variable-displacement pump realized fast yet powertul digging. 600mm Extended track Retractile track is to more stability. Large track width is selective to increase stability. Gute,Great stability Comparison of U-20 vs Vio20 U-20 Vio20 Loading and unloading are stable. For safety loading, Vio20 needs to support with bucket Dynamic tipping load. U-20 Vio20 Approx. 40 kgf difference at front direction.(Dozer up) At side direction, approx. 20 kgf differences, Note: Measurement was taken by wide track condition and using weight in the bucket. GMI7AU-20 : High working capacity Operating space is equivalent to standard type machine. Large capacity variable displacement pump and horsepower control realizes superb digging performance. Powerful yet fast digging speed. High working efficiency leads to shorten the construction time. Therefore, wide operating range enables to dig the hole for septic tank Square hole digging of septic tank for 7-10 persons is easily possible. Guia,U-20 Vio20 Max. digging depth 2350mm 2120mm Result -—— U-20:11.6m Vio20:10.8m U-20 has almost same working capacity as standard type, KX-2 type and is superior Start line to Vio20. When dumping the soil onto 2-ton truck, U-20 has enough room but Vio20 interferes with doorstop. Sait U-20 Vio 20 Doorstop height of ‘2m tuck: 1350mm _ Septic tank for 7-10 persons Septic tank for 15-21 persons GMI94,U-20 is Authentic Versatile functions are incorporated. Basic concepts are: Great working performance Easy operation and Easy maintenance Following pages illustrated the features of U-20. Great Working Performance ! Hydraulic retractile track frame. With one lever operation, track width can be shifted in two ways. Control lever 600mm With wide track, wide ditch digging is easy. (mm rack wiath [Track tength | u-20 | 1400/1600 | 1660 vio2o | 1340 1790 WiQuick change dozer blade width Dozer blade width can be changed quickly by only removing and i reinstalling the pins as shown below. Dozer blade width:1400mm Remove pin. Remove the extra blade. Install it inside. Dozer blade width:1600mm G-M204,WiCompact body for 2-ton truck. Machine size is just fit in 2-ton truck. Simultaneous operation of Hi-Low travel speed boom and bucket High speed of 5 km/h enables fast job site Throttle valve is installed in bucket circuit, moving. which enables simultaneous operation of boom and bucket. Long arm ; optional attachment Long arm,300mm longer, enables wider operating space. HPowerful engine Displacement Output ; (a) (KWIPSY*pm) Milron track: factory option v20 1.128 13.8(18.7/2200 Rubber track can be possible by using the Vio20 0.784 9.6(13)/2250 holes of iron track. Breaker application: Double acting service port ~Maker_[ Model Spees Rammer | KXB400 | 20-50L/min, 97~122kaffem® Krupp | HM75 | 20-40L/min, 100-130kgt/om® U-20 service port capacity Flow rate 35.8 Limin, Operating pressure: 20.6 Mpa(210 kgf/cm?) GaiaComfortable operating space Comfortable operating condition by great stability and smooth working performance realized less fatigue and amenity operating surrounding, afety lock lever Control levers are arranged optimum in ergonomics. Safety lock lever is one-touch lifting type. Vio20 Clear front visibility enables operator to dig To check the bucket teeth, operator needs in relaxed posture. to shift his head. MiTravel straight circuit This specific circuit enables straight traveling while operating the front attachments. This feature is beneficial for easy truck loading and pipe laying work. Travel straight circuit Yes Yes No Vio20 obliques to left by operating boom and right direction by arm. Vie20 u-20 M228Arm regeneration circuit This specific circuit accelerates the arm crowding speed and prevents arm from fluctuating even at engine's idling speed. Benefits: Leveling work becomes easy. u-20 Without arm regeneration Shock absorbing function on travel and swivel circuit Shock absorbing valves functions at start and stop of travel and swivel to moderate the excessive shock. Perfect stop! Front levers with pilot valve Feather-touch lever control. T aT Front lever operation enables digging work neatly near if the machine body. ee Sai: Hydraulic accumulator is installed to get down front attachment without engine power. (U-20,35,45) Boom, arm and bucket can get down within 1 minute by using the accumulated pressure. To utilize accumulator pressure, starter key should be at AC position and safety lock lever should be down to release Reversible starter key Engine starter key is reversible like automobile. a) G-M23.4.Same as KX-2 series, U-20 has also a full open bonnet. This enables to access maintenance items easily. Check items of fuel system are located in one side and control valve is visible by opening the side cover. Therefore, Daily and periodical inspections are easy. Ordinary repair job is also possible by opening the side cover. This is easy to access. Vio20 is as shown below. Almost impossible to reach. GM24,Bucket hoses are routed inside. Bucket hoses are routed inside the arm. It enables clear front view and prevents hose damage. Bucket hoses Vio20 Nothing to worry about. Hoses can be scratched by trees or rock, WiKubota bucket : Bucket side HiLock pin type bucket teeth clearance is adjustable. This type tooth is replaceable when worn out. Kubota Japan made bucket only. Remove the shims and retighten. That's all. WAngle-shape track frame Soil won't pile up on track frame. Soil removing is also easy. Soil can easily pile up on flat-shape track frame. M25Feature & Performance Quick Chart U-35 [Boom free fall prevention device Big digging force Simultaneous operation of boom and bucket Wide working space WiBucket hoses routed inside Great stability HiLong arm, optional attachment HiLamp guard, newly adapted Functional body design New slide door type cab WClear front visibility BiAmenity operating surrounding iNew type bucket Full open bonnet MiCollected check items of fuel system MiLarge capacity variable displacement piston pump WBreaker application . Super low noise and clean MiTravel straight circuit ‘emission engine st travel speed BlAngle track frame ilron track with holes, option GM264,U-35 vs Competitors SELL U-36 can lift the weight smoothly. Both Vio30 and 30JX couldn't lift up. Measuring condition: Upper frame is in side way. Dozer biade is up. ‘Same amount weight is placed in the bucket and lifts it up, 30UX Benefit @U-35 has a lower gravity center to increase the stability. @U-35 has a wider track to upgrade the stability @U-35 has a longer track length than Vio30, thus enables big difference of stability in F and R direction. Soe width U-35 300 v0 2300 100 Vio30 370 130 S0UX sou aoa sosr (zo Os 30SR 300 100 GMa7,Working Performance Test condition: Ditch digging and 45-degree side dump. +Below bar graph shows the digging amount for one hour. *#Data are actually measured, 124 100 o 7 Ugo U3 Viosd SO0x Benefits: U-35's front speed is upgraded and total balance of digging has been improved. U-35 has the equivalent working capability to the standard type. Travel performance (Travel speed) (Travel straightness) ‘4.6xanih , 27kmih yo sees sam) 43kmih aoux , Zak U-35 has travel straight performance. Vio30 has oblique traveling. 30JX is same as U-35. (Theoretical traction force) Benefits: — High | Low’ U-35 exceeds in travel speed to competitors. u-35 | 27.9(2229) 36.98767) Great traction force enables powerful dozing work. G28Arm vertical bucket bottom height This dimension is vital for actual dumping work. ‘Competitors /\ C \e wh CS 4-ton truck Doorstop height : 1500~1560mm ‘Arm vertical | bucket bottom height! 1 | In case of competitor's 4-ton truck Unit: mm doorstop height | 1825, saan 1435 2:ton truck | doorstop height 1500-1560 [9 1190-1400 U-35 Vio30_—-S0UX Comparison of arm vertical bucket bottom height *#Precaution! Here, bucket hits the doorstop Doorstop height varies to the type of truck. and so need to rise up. Long arm: 200-mm longer arm is available as an optional attachment. Unitmm Cab(canopy) STD ‘Long Max. digging hight | 4650(5005) | _4780(5160) ‘Max. dump hight | 3220(3555) | 3350(3710) Max.digging depth 2950, 3150 Max. digging radius] 5135: 5330. U-35 GM298,Working capacity Max. digging force 2715 2700 21002475 _kaf(At tooth root) For your information. 7) New JIS spec. New JIS spec. | ofheapes capacity OldIS spec. Old IS spec. U-35 Vio30—«30JX “30SR ot heaped capacty Benefits: U-35 has superior digging force to the competitors. Large capacity variable displacement piston pump U-35 has approx. 30% more pump discharge rate. Benefits: ae - - : Thanks to the big capacity pump, a8 301 304 | U-35 enables speedy yet powerful digging operation. | | Umin U-35 Vio30 30UX Four cylinders powerful diesel engine 16.2kW || t6.2Kw || 169K Benefits: 22PS 22PS ad i 7 Acencell ricical U-35 has 4-cylinder engine that = enables tenacious construction job. 3../3..|3.. Vios0——S0JX—*30SR G-M308,U-45 Development concept : For general construction work. U-45 has achieved five essential requirements. 1.Wide operating space in combination with 11 ton-truck. 2.Excellent digging performance to general digging job. 3.Great stability for versatile application like breaker work. 4.Big traction force for dozer work and high speed for mov- ing in job site. 5.Reliable durability for heavy-duty construction work. @Equivalent stability, working performance, controllability, and maintenance to KX-2 series are well incorporated in U-45. LOS Teatro emo MTA Lae Responding to the market needs and further upgraded. @ Advanced loading performance onto 11 -ton truck. @ Just fit to repair work of asphalt road. Authentic machine for coming age! G-M31 4Sales. Feature Quick.Chart U-45 Great stability equivalent to standard type. Excellent working performance. Boom cylinder free fall prevention device. Simultaneous operation of boom and bucket. WiShock absorbing functions in boom cylinder, swivel motor and travel motor. xs \ Functional and comfortable operating space. WiTops/Fops cab with slide door. WlEasy asphalt Se breaking Easy maintenance HEFull open bonnet WDouble element air cleaner Powerful, speedy travel Reliable, durable rigid X-shape track frame Reinforced dozer blade. BPilot control system with accumulator GazU-45 Evaluate the value! Wide — a Bucket bottom height is one of the vital specifications in actual loading work. Unitsmm - men ------------------8 /1965(Canopy) 4 l1850(Cab) | 1880 ey | 1780 +1630] U-45— Viod0 40JX SK40SR. Digging job near the dozer blade @ Distance of 190 mm of U-45 enables to break asphalt smoothly. @ Also ditch digging near the dozer blade is easy. [Distance between dozer blade and bucket tip U4 190 Vio40 490 40IX 310 SK40SR 350 ‘Above data are actually measured. Unitmm sk40sR, M330Digging space ‘Max. digging height A 5770 BE, ei0~ soso | Max. dump height 5300 5260 a E Max. vertical digging depth “Max. digging depth U-45 Long'Srm i040 40JX _SK40SR Kubota’ soptic tank for 25-80 persons Dept:2400mm Units 3300 ARE 3400 34003880 Max. digging radius —u-45 —— U-45 Long arm Vioao —-— 40x sss SKAOSR Unitmm 58505810 5520 O45 | U8 Viosd A0IK SKAOSA ‘ong arm Long arm: Optional attachment Arm length: Standard arm=1350mm, Long arm=1650mm_ U-a5 STD | U-85 Long aim Max.digging height 5545/5310 ‘57015510 Benefits: eden seoorsra0 | 42186880 | | @Equivalent to KX-2 series, U-45 can afford [Beit ote atom ria] es se __| | to versatile works. = — = = = = Great stability enables one rank higher job. ——— @Long arm is good for deeper ditch digging. ‘Max diggingradius S710 6000 ‘9 b si ae Mintuning rive 215(1685) 2170 (at boom swing) unit: mm G-M34a,Xcellent digging performance eneral construction work Working performance U-45 achieved superior working performance to the competitors. u-45 Vio4o| 404x\ Sk40SR, Above digging comparison has been done for 12 Above bar graph shows the comparison of minutes. actual digging amount for 45-degree side ditch If it were calculated for continuous 6 hours digging, digging. U-45 finished approx. 350m, Vio did 280m. Know how on excellent digging performance @ U-45 has the integrated combination of big power engine, large capacity pump and digging force. Thus enables excellent digging performance. © Furthermore, simultaneous operation of boom and bucket enables efficient digging, loading and leveling work. Engine A ump capaty Max. digging force | Output | No.of eyinder | Displacement Pipe kG) mes) Unie as 34710584) | 29.16085) 4 2197 Baax2 Vow | 27.0(2750) | 23.5(92.0) 3 1642 ‘65x2 ax 20.8100) | 2501640) 4 502K2 [[seaose | s2.0;3200) | 22.5005) 3 1682 a50x2 Max. digging force Max. digging force ‘SK40SR| Engine output Pump capacity Engine output Pump capacity Engine output — Pump capacity M364| Powerful and speedy traveling > aa») ee Sie rease es Travel straightness vas @Comparison with Vio40 Comparison with 40JX @Comparison with SK40SR Vio40 travels obliquely. 40JX got down the speed. SK40SR got down the speed. Travel speed Pee Traction force ‘Second (km/h) ad Theoretical value unitkN(kaf) uss 0) [aE] st: 48 s1940) 2.3) 1 | U-45 a ag | ‘Second : 30.2(3079) 2.8) | ' 400K z ' 431 27] | ' SSF ae aaa @Short link pitch track transfers traction force efficiently and generates less vibration. Benefits: No oblique travel while loading onto or off the Straight traveling and enough traction force truck. enable to come out of the swamp effectively. G-M364SNe Gieat stability for ~~. °- «= ~~ —_ versatile applications ~— Stability comparison in side way U-45 can lift up the weight. Vi040 couldn't. 40JX couldn't. ‘SK40SR can. G-M37.4.Secret of great stability Low machine gravity design enables overall stability. Wider track enables big stability in side way. ‘Comparison of machine with Viosgy Longer track length enables great stability in front and rear direction. Vioso 2300 Comparison of track length 40NX 2420 Sk40SR 2300 Unitmm IFYI] Litting capacity U45__| Vioso | 40Jx__| SK40SR [815 670 310 | 766 Condition: Machine front direction, blade down ZX For safety, follow the local regulation. Benefits: Pipe lifting work is easy. Smooth digging job for heavy-duty construction work. With great stability, versatile attachments are applicable. Loading onto and off the truck is safe and easy. G38U-35 & U-45 common features and performances Let’s look into the features of U-35 and U-45 YD Working performance Boom free fall prevention device Boom cyli inder Anti-fall valve Control valve Con Engine Breaker application Pipe lifting work becomes easy. — Boom ant-fall valve a | Vioao x 400K x [skaosr_| x Benefits Minimum free fall of boom cylinder enables to utilize machine stockyard more efficiently. Its also useful to jack up the machine for cleaning. @Large capacity pump and oil cooler enables continuous breaker operation. U-35 and u-45 have double acting service port circuit. Vio 30, 40 don’t have oil cooler. Hydraulic oil heat balance condition Ree oes Foor nouearoeeeever rove | vanes | >a, a Gitorarowiumny | aia] ma Operating pressure(kgticm?) 210 210 'U-20,35 and 45 have double acting service port cicult. G-M394,Iron track with holes Rubber pads are possible to install by using the holes of iron track. ‘Track width: U-35=300mm, U-45=400mm No. of link : U-35=43 , U-45=38 Lifting hook is possible to weld on the bucket link. (FYI) According to the Japanese Safety Regulation, formula of max. lifting capacity is as follows. Max. lifting capacity=(Standard bucket struck capacity x 1800) kgf For Example: U-45: 0.084 m3 x 1800=150kgt GMaos,YD Easy operation Cab with slide door Sliding door with round form is newly adapted Lifting up front window and roof window lighten the cab inside. STD Accessories in cab; Heater ashtray,cigar lighter, wiper, window washer Wrist-type control lever Automatic air bleeding circuit and excellent response. Wrist control lever presents comfortable operation. Comfortable seat and optimum lever arrangement. Safety lever lock is very handy. Control lever G-Mai 4,Clear front vi ity =. 24 Front view is open and clear to access the bucket position for precise digging work Smooth leveling work Combination of pilot contro! and optimum hydraulic system enable the smooth leveling work. Benefits: Leveling the ground surface and bottom of the ditch can be finished horizontally. 7 ¢ & uC { Smooth ———> Three shock absorbing functions Boom cylinder cushioning Swiveling shock absorbing valve Reduce shock when boom stops raising Reduce shock and vibration at starting and and so prevent soil spillage. stopping. Travel shock-absorbing valve Benefits; Reduce shock and vibration at starting and stopping. Less soil spillage out of bucket. ‘Smooth operation and less fatigue. One reversible key Engine start key and bonnet key is identical GMaza,| == © Durability and reliability Separated dozer cylinder hose Dozer cylinder hose has been separated into two to easy replacement. ‘4 30JX isn't separated type. ~ ‘Separated dozer hose Kubota U-20-45 ° Vio o 0X x Rigid track frame Frame rigidity and durability is the vital requirement for general digging application. Travel motor hoses are stored inside the frame. X-shape frame guarantees the rigidity and durability. = [Plate thickness Kubota U-20-45 12 Vio’ | 9 30IK 9 Uniram GMaa,New rigid-type bucket } Wide and reinforced plates are welded on the bottom ( of bucket, thus prolong the durability. Reinforced plates Lock pin type bucket teeth Easy replaceable bucket teeth. 18S type : RD101-66861 Rigid type dozer blade Box frame dozer blade is adopted. | Thicker and longer edge. 90 degree dozer angle enables the soil to curl forward. | ! Benefits: ), | | Dozer blade durability has been upgraded. Filling back and dozing work become efficient. Existing type New type Curl to soil Dig in the soit Angle track frame Soil won't pile up on track frame. G-Ma4a,Bucket cylinder hoses are routed inside. Working lamp with protecting guard U-45 Vio40, f ee E ey x Hoses inside Hoses are exposed. Hoses inside Hoses are exposed. Protection guard External frame No protection No protection GMsYD Easy maintenance Full open bonnet:U-45 Full open bonnet with large opening angle ‘alebenek Roses tale Water separator is newly adapted to separate water in the fuel. Double element air cleaner is installed to secure- ly protect the engine. P Radiator parator Vio:Bonnet opening angle is 40JX:Location of oil fter and battery SK40SR:Engine room is too tight narrow. is low and hard to replace. and replacement of air cleaner and oil filter is dificut. Easy maintenance access window x Access window leads easy service. ©§ Control valve Elna U-45 adapted cartridge type pilot fiter. Benefits: Reliability on pilot control system has been up- graded. Easy replacement in every 1000 hours GMEFull open bonnet:U-35 Same as U-45, full open bonnet, water sepa- Air cleaner rator and double element air cleaner are the feature items. Oil tank Radiator G-Ma74,oY Amenity, environmental friendly engine Super low noise engine 1. Inatallation of low speed engine and effective noise restraint measure enable to pass the su- per low noise standard in Japan. 2. Noise band is much moderate to ear. Benefits: Job site is widely allowed even to near the hospi- tal,residential area or construction job during night. Noise level B10) MOdel_[ Uo | U20 | U-35 [U-45Cab LWA, 90 4 | 98 99 TH wpa | 75 [70 | ea | as | 7m away | 62 5 | 65 69 | (FYI) Noise regulation in Japan 1. Low noise standard: 99 dB(A) at noise source. 2. Super low noise standard: 93 dB(A) at noise source. Note: LPA=noise level at operator's ear LWA=Noise level at noise source Emission control engine 1.E-TVCS engine is installed. E-TVCS: E-Three vortex combustion system E: Environmental, ecological, emission controlled 2.Engine type and main specifications Machine model U-10 U-20 U-35 U-45 Engine type D722-BH-2 | D1105-BH-5 | V1505-BH-6 | V2203-BH-6 (ew) 76 13.6 18.4 29.1 ut put 070020 aos (PS) 104 185 25 39.5 Displacement (co) 719 1123 1498 2197 Speed (com) 2000 2200 2200 2200 (gkWh) 292 299 292, 299 Fuel comsumption rat ve tion rate (gipsh) | (215) (220) (215) (220) G-Mas4SERVICE CONTENTS [1] BODY AND ENGINE IDENTIFICATION MARKS ---G-S1 [2] SAFETY PRECAUTIONS FOR SERVICING --------- G-S2 (1) Safety Measures before Starting Work (2) Safety Measures during Work -- [3] PRECAUTIONS FOR DISASSEMBLY AND REASSEMBLY ---- (1) Preparation for Disassembly -- {2) Precautions for Disassembly and Reassembly [4] IMPORTANT SAFETY PARTS AND CRITICAL FUNCTIONAL PARTS (1) Essential Adhesives -- (2) The Following Two points are Included in the Important Safety Process [5] (3) The Following Five Points are Included in the Critical Functional Process [A] --~ G-S7 GST [5] IMPORTANT INSPECTION ITEMS (1) Operate the Machine and Check for Unusual Noise and Vibrations -- (2) Make sure the Nameplate and Grommets are in their Specified Positions (3) With the Machine Front in a Specified Posture, Check the Amount of Hydraulic Oil [6] SERVICING FUNDAMENTAL: (1) Items for Servicing (2) O-Ring, Oil Seal, Circli (3) Piping[7] PERIODIC INSPECTION AND SERVICING TABLE --- (1) Periodic Inspection Standards (For User Guidance) « (2) Hydraulic Oil Check for Machines with Hydraulic Breakers - [8] GENERAL SPECIFICATIONS (1) Quantity Water and Oil- (2) Recommended Oil and Lubrication ~ (3) Tightening Torque and Adhesive - (4) Noise Level --- (5) Approximate Component Weight - (6) Pepair Parts (7) Quality Specifications - (8) Paint Color --- [9] TRANSPORTING & LIFTING (1) Transporting Method --- (2) Machine Hoisting Procedure - (3) Backhoe Hoisting Procedure ~~as TABLE DES MATIERS [1] CORPS ET MARQUES D'IDENTIFICATION DU MOTEUR [2] MESURES DE SECURITE PENDANT L'ENTRETIEN (1) Précautions 4 Prendre Avant de Commencer les Travaux (2) Précautions 4 Prendre pendant les Travaux * [3] PRECAUTIONS PENDANT LE DEMONTAGE ET LE REMONTAGE - (1) Préparation Avant le d'emontage: (2) Précautions Pendant le d’emontage et le Remontage: G-S5 G-S5 G-S6 [4] PIECE IMPORTANTES CONCERNANT LA SECURITE ET PIECES FONCTIONNELLES CRITIQUES ------G-S8 (1) Adhésits Essentiels -- -G-S8 (2) Les Deux Points Suivants sont Inclus dans le Processus de Sécurité Important (3) Les Cing Points Suivants sont Inclus dans le Processus Fonctionnel Critique) ---- “G-S8 “G-S8 [5] ORGANES IMPORTANTS POUR UNE INSPECTION:--- (1) Faire Fonctionner la Machine et Vérifier pour des Bruits Inhabituels et des Vibrations (2) S'assurer que la Plaque du Construteur et les Rondelles soient aux Positions Spécifiées-- “GSB (3) Avec I'avant de la Machine dans une Position Spécifiée, Vérifier la Quantité de I'huile Hydraulique’ GSB “GSB *G-S8[6] DONNEES FONDAMENTALES DE L'ENTRETIEN---G-S11 (1) Piéce d'entretien - “G-S11 (2) Joint torique, joint étanche a I'huile, circlip et tourillon de cylindre “G-S15 (3) Tuyauterie--- -G-S19 [7] VERIFICATION PERIODIQUE ET TABLEAU DE NORMES D'ENTRETIEN (1) Normes d'inspection Périodique (Guide de I'usager)--G-S25 (2) Contréle du Liquide Hydraulique des Engins avec Marteau Piqueur Hydraulique (Braker) -------- G-S29 [8] SPECIFICATIONS - (1) Tableau des Quantités d'eau et d'huile (2) Lubrifiants Recommandés (3) Couple des Serrage et Zidhésits el (4) Bruit 4 Niveau « (5) Poids Approximatits des Organes (6) Piéce de Réparer- (7) Spécification des Qualite (8) Peinture des Corps~ G-S72 [9] TRANSPORT ET LEVAGE DE MACHINE - (1) Méthode de Transport « G-S75 (2) Procédure de Levage de Machine -- G-S79 (3) Precédure de Levage de Pelle Rétrocaveuse “G-S81AUREL VERZEICHNIS [1] KENNZEICHNUNG VON HAUPTEINHEIT UND MOTOR 7 [2] SICHERHEITSVORKEHRUNGEN FUR WARTUNG (1) Sicherheitsma&nahmen vor Beginn der Arb: (2) Sicherheitsma&nahmen wahrend der Arbeit [3] VORSICHTSMARNAHMEN BEI DEMONTAGE UND MONTAGE --- (1) Vorbereitung fiir Demontage (2) Vorsichtsma8nahmen bei Demontage und Montage - [4] WICHTGE BAUTEILE FUR DIE SICHERHEIT UND KRITISCHE FUNKTION (1) Wesentliche Sicherungsmittel (2) Die folgenden beiden Punkte sind Abschnitt “Wichtiger Sicherheitsprozef [S]" enthalten (3) Die folgenden funf Punkte sind im Abschnitt "Kritischer Funktionsproze& [Al" enthalten -~ [5] WICHTIGE PRUFPUNKTE --- (1) Die Maschine betreiben und auf ungewéhnliche Gerausche und Vibration iberpriifen. (2) Sicherstellen, da sich das Namensschild und die Tillen in ihren Vorgeschriebenen Positionen befinden ~ G-S9 (3) Das Vorderteil der Maschine in die spezifizierte Lage bringen, dann die HydraulikéImenge iiberpriifen ---G-S9 “G-S9[6] GRUNDLAGEN FUR DIE WARTUNG (1) Wartunggegenstand ---- (2) O-ring, Oldichtring, Splint und Spannstit (3) Rorhleitungen ---- [7] TABELLE FUR PERIODISCHE INSPEKTION UND WARTUNG - (1) Normen fir Periodische Inspektion (Leitfaden fair Verwender) (2) Uberprittung des Hydraulikéls an Maschinen, Hydraulischem Hammer ausgeriistet sind [8] TECHNISCHE DATEN--- (1) Tabelle der Ausstrémmenge Wasser und OI (2) Empfohiene 61 (3)Anzugsmoment und Klebemitt (4) Schallpegel - (5) Circa-Gewicht der (6) Reparierenteil « (7) Qualitatt Technische Daten (8) Die Farbung elnen Teile [9] TRANSPORT UND ANHEBEN DER MASCHINE ---G-S75 (1) Transportverfahren - (2) Hinweise fiir das Anheben der Machine “G-S79 (3) Vorgehensweise beim Anheben der Muschine ------G-S81[1] BODY AND ENGINE IDENTIFICATION MARKS. [1] CORPS ET MARQUES D'IDENTIFICATION DU MOTEUR [1] KENNZEICHNUNG VON HAUPTEINHEIT UND MOTOR 27 SHOTSU HCAS LCHOME nan OSHKK PAN wooe[—__] sera no [7 ss [ho waconawaanPais | Power kw ae veRT. tomy [aN wowracrnenven =] sate ean (Kuso corp, c€ If troubles should occur during use, or if servicing is necessary, contact the dealer who handles the machine. At the time please inform the deals of @ Model of machine and serial number @ Model of engine and serial number @ Name of parts and code number {Listed in Genuine Parts List) En cas panne sur la pelleteuse ou lorsque le service aprésvente est nécessaire, prendre contact avec nous, en indiquant: D Model et numéro de série de la machine @ Model et numéro de série du moteur © Nomis) et numéro(s) code de la(des) piéce(s) (oir la Liste des piéces détachées d'origine) ‘Treten wahrend des Einsatzes der Maschine ‘Stérungen auf bzw. werden Wartungsarbeiten, fallig, ist der Vertragshandler zu benachri- chtigen. Baggermodell und Seriennummer ‘Motormodoll und Serionnummer @ Bozeichnung des erforderlichen Ersatztils und dio Toilenummer angeben. @ Machine serial number: © Numéro de série de la machine: © Maschinen-Seriennummer:[2] SAFETY PRECAUTIONS FOR SERVICING [2] MESURES DE SECURITE PENDANT L'ENTRETIEN [2] SICHERHEITSVORKEHRUNGEN FUR WARTUNG A Safety Precautions for Servi Most accidents during servi carelessness. Please remember that safety involves both the welfare of the emplyees and improved work efficiency. ng arise from (1) Safety Measures before Starting Work 1. Work clothes 1. Wear specified work cap and clothes. (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 hydraulic units for repair or others, or when using a hammer. Wear leather gloves, however, when pulling hoisting wires. . Inspecting equipment and tools 1. Prepare equipment (cranes, fork lifts, tools 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 hoisting tools (wire ropes, hoisting chains, etc.) before use. A Mesures de Sécurité Pendant L'entretien La plupart des accidents survenant pendant Ventretien sont das la négligence. II faut se souvenir que la sécurité implique @ la fois bien-étre des employés et une meilleure efficacité. (1) Précautions & Prendre Avant de Commencer les Travaux 1. Vétements de travail 1. Porter des vétements et une casquette appropriés. En aucun cas, l'ouvrier ne portera qu'un tee-shirt ou maillot de corps. Les manchettes doivent étre boutonnées et toute partie déchirée doit étre recousue. 2. Porter des chaussures de sécurit. 3. Ne pas porter de gants en coton quand on travaille sur la partie interne du moteure, les engrenages ou les systemes hydrauliques, ou quand on se sert d'un marteau. Porter, en tout cas, des gants de ‘cuir pour tirer les cables de levage. 2. Matériel de vérification et outils 1. Préparer le matériel nécessaire & I’entretion (grues, gerbeuses, outils, etc.) et le vérifier avant d'entreprendre les travaux. 2 Les tétes de marteau doivent étre solidement fixées @ leur manches. 3. Contréler les instruments de levage (cdbies métalliques, chaines de levage, etc.) avant emploi. A Sicherheitsvorkehrungen fir Wartung Die meisten Unfalle wahrend einer Wartung entstehen durch Sorglosigkeit. Bitte denken Sie daran, da von der Sicherheit beides abhangig ist, Wohlergehen der Arbeitnehmer und verbesserte Arbeitseffektivatat, n der 1. Arbeitskleidung 1. Vorgeschriebene Arbeitskleidung und Schutzhelme tragen. Unter gar keinen Umstanden darf der betreffende Arbeitnehmer nur Unterwasche oder ein T- Shirt tragen. Armelaufschlage missen zugeknopft sein und alle Risse geflickt. 2. Sicherheltsschuhe tragen. @s2 3. Keine Baumwothandschuhe wahrend der Arbeit an den inneren Teilen von Motor, Zwischenvorgelege, Hydraulik-baugruppen, zur Reparatur oder anderen Taitigkeiten, oder bei der Verwendung eines Hammers tragen. Jedoch bei der Handhabung von Hubseilen Lederhandschuhe trgen. . Oberprifen von Ausrostung und Werla-eugen Die fur die Wartung erforderliche Ausriistung (Kran, Gabelstapler, Werkzeuge, usw.) vorbereiten und vor Begin der Arbeit auf alle Problempun-kte hin Gberpriifen. 2. Die Hammerképfe (Metaliteile) missen fest. mit dem Stiel verbunden sein. 3. Hebezeug (Drahtseile, Hebeketten, usw.) vor Gebrauch iberpriffen.3. Keep workshop in order 1. Secure appropriate space needed for disassembly according 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. 3. Maintenir atelier en ordre 1. Ménager une place suffisante pour le démontage en fonction du travail 4 effectuer. . Libérer une surface propre pour y déposer les piéces démontées qui devront étre a I'abri. 3.Remiser les matiéres volatiles (essence, huile fluide, solvants, corps gras, etc.) dans des récipients appropriés et & un endroit choisi afin de prévenir les risques d'incendie. Werkstatt in Ordunung halten 1, Ausreichend Platz fiir die Demontage freihalten, je nachdem welche Arbeit durchgefiihrt werden muB. 2. Einen sauberen und sicheren Platz vorbereiten, wo die demontierten Teile abgelegt werden kénnen 3.Fliichtige Substanzen (Benzin, dinnflissiges Ol, dlige Materialien, usw.) passenden Behaltern aufbewahren und an besonders dafiir vorgesehenen Orten abstellen, damit die Brabdgefahr gemindert wird. G-s3 (2) Safety Measures During Work 1. Protectors 1. Wear goggles when using chisels for chipping. 2. Use appropriate protectors during welding 3. Wear a helmet when working with a crane or at elevated locations. 2, Team work 1. When working with two or more people, devide the work and maintain close communication. 2. Crane work must be carried out using predetermined signals. (2) Précautions a Prendre Pendant les Travaux 1. Protecteurs 1. Porter des lunettes de protection si l'on utilise un ébarboi 2. Employer les protecteurs requis pour a soudure. 3. Porter un casque en effectutant des travaux avec une grue ou sur toute position élevée. 2. Travail d'équipe 1. En cas de travail 4 deux ou plus, partager les tches et rester toujours en communication. 2. Déterminer a l'avance les signaux lors de l'utilisation d'une grue. (2) Sicherheitsmaf&nahmen wahrend der Arbeit 1. Schutzvorrichtungen 1. Bei der Arbeit mit einem MeiRel eine Schutzbrille tragen. 2. Bei SchweiBarbeiten entsprechende ‘Schutzvorrichtungen verwenden. 3. Einen Helm bei der Arbeit mit einem Kran oder an erhéhten Orten tragen. 2. Gruppenarbeit 1, Bei der Arbeit mit zwei oder mehr Personen die Zustandigkeitsbereiche eindeutig festlegen und Verstiindigung aufrecht erhalten. 2.Wenn Arbeiten mit einem Kran durchgefiihrt werden miissen, vorher vereinbarte Signale benutzen.3. Disassembly and assembly 1. Do not wear gloves when using hammers. 2. Use rods of the specified soft material for removing pins. Do not use a hammer as @ pad. 3, Do not place fingers in holes when centering. 4, Heavy parts must be adequately supported before removing bolts. 4. Cranes 1. In principle, use a crane for objects heavier than 44lb (20kg.) 2. Crane operation and hoisting must be performed only by qualified personnel. 3, Pay careful attention to the center of gravity when hoisting, and do not stand under the lifted objects. . Others: 1. To work under a jacked-up carrier, be sure to place woodpieces under it. 2. When charging batteries, make sure there are no open flames in the immediate vicinity, 3. All electric tools must be grounded, 4, Before welding the machine, remove the battery, (© When removing the battery, be sure to fisconnect the negative (-) cord first. © When mounting the battery, be sure to connect the positive (+) cord first. 3. Démontage et remontage .. Ne pas porter de gants quand on se sert d'un marteau. 2. Utiliser une tringlerie correspondant aux normes de souplesse requises pour dégager les essieux. Ne pas se servir d'un marteau comme cale de support. 3. Ne pas mettre les doigts dans les trous pendant le centrage. 4. Les piéces pesantes doivent étre calées de maniére adéquate avant d'éter les boutons. 4. Les grues 1. Par principe, utiliser une grue pour les objects dont le poids excéde 20 kg. 2. Les opérations de grutage et de levage doivant étres effectuées par le personnel qualifié uniquement. 3. Faire particuliérement attention au centre de gravité pendant les opération de levage ‘et ne pas stationner sous les charges. . Autres 1. Avant de travailler sous un vérin, s‘assurer que des étais ont bien été placés au- dessous. 2, Avant de recharger les batteries, s'assurer qu'il n'y @ aucune flamme dans le voisinage immédiat 3. Tout loutillage électrique doit étre ralié & la masse. 4. Avant de souder la machine, retirer la batterie. © Lors du retrait de Ja batterie, s‘assurer de bien débrancher d’abord le fil négatif(-). © Au remontage de la batterie, s‘assurer de bien brancher d’abord le fil positif (). 3. Demontage und Montage 1. Keine Handschuhe tragen, wenn ein Hammer benutzt wird, 2. Zum Entfernen von Stiften stets Treiber des vorgeschriebenen weichen Materials verwenden. Keinen Hammer als Polster verwenden, 3. Beim Zentrieren Finger nicht in die Locher stecken. 4, Schwere Teile miissen ordnungsge-maR, adgefangen sein, ehe die Schrauben entfernt werden. 4. Krine 1, Fir Objekte schwerer als 20kg grunds- atalich einen Kran verwenden. 2.Die Bedienung des Krans und die Aufhangung an den Seilen darf nur von. qualifizierterm Personal durchg-efihrt werden. esa 3. Beim Anheben sorgfalting auf den ‘Schwerpunkt achten und sich nicht unter die angehobenen Objekte stellen. . Sonstiges 1. Bei der Arbeit unter einem angeh-obenen Trager unbedingt einen Holzklotz darunter stellen, 2.Wenn eine Batterie geladen wird, unbedingt Uberpriifen, da keine offenen Flammen in unmittelbare Nahe gelangen. 3. Alle elektrischen Werkzeuge mussen geerdet sein. 4, Entfernen Sie die Batterie bevor Sie die Maschine schwei8en. Beim Ausbau der Batterie trennen Sie immer zuerst die negative Leitungsschnur (Pol). (© Zur Montage der Batterie, schliessen Sie immer die positive Leitungsschnur (+Po!) zuerst an, °[3] 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. (1) Preparation for Disassembly 1. Cleaning Remove mud and dirt from the body before disassembly. 2 ©0000 Acceptance inspection The machine must be checked before it is disassembled to record existing conditions, such as those listed below. Model, serial number, and hourmeter reading Reason for repair and repair history Element stains Fuel and oil condition Parts damage *(Take photographs if necessary.) 3. Equipment and tools Prepare equipment, tools, cranes and parts storage racks as required. [3] PRECAUTIONS PENDANT LE DEMONTAGE ET LE REMONTAGE Les machines doivent étre démontées et remontées de maniére efficace et sans danger. I est primordial de comprendre parfaitement la construction et le fonctionnement de I'engin, afin d’effectuer toute la préparation nécessaire et d'entreprendre les travaux conformément a la marche-d-suivre, (1) Préparation Avant le démontage 1. Nettoyage Oter la boue et la poussiére collée au corps avant de démonter. 2 000 0 0 » Verification d'admissibilité L’engin doit étre contréié avant le démontage. Prendre note de son état actuel en se référant lla liste ci-dessous. Modale, numéro de série, ‘compteur d'heures. Cause de la réparation - historique des lecture du réparations. Salissures. Combustible et graissage: état. Piéces endommagées (prendre des photographies si nécessaire). . Appareillage et outils Préparer l'apparsillage, les outils, les grues, les casiers d'entreposage des piéces, selon la méthode adéquate. [3] VORSICHTSMARNAHMEN BEI DEMONTAGE UND MONTAGE Maschinen miissen auf effektive Weise und gefahrlos zerlegt werden. Es ist daher auBerordentlich wichtig, Konstruktion, und Funktion der Maschine vollstandig zu verstehen. Nur so kénnen die entsprechenden Vorbereitungen getroffen und die vorgeschriebenen Arbeitsverfahren durchgefihrt werden (1) Vorbereitung fiir Demontage 1. Reiningung Schlamm und Schmutz von der Maschine entfernen, ehe sie demontiert wird. G85 2 e000 0 Annahmeinspektion Vor der Demontage mu8 die Maschine gepriift werden, um den tatsachlichen Zustand wie er in der nachfolgenden Liste beschrieben ist festzustellen. Modell, Seriennummer und Betriebsstu- ndenanzeige Grund fiir die Reparatur und Vorge-schichte Verfarbungen Fallmengen von Kraftstoff und O1 Beschadigte Teile* (fotografieren, falls erforderlich.) ‘Ausriistung und Werkzeuge Ausriistung, Werkzeuge, Krane und Regale zum Lagern der Teile nach den Erfordernissen vorbereiten,(2) Precautions for Disassembly and Reassembly isassembly_ © Follow the specified disassembly procedures. © Make alignment markes to insure correct ° reassembly. Arrange disassembled parts in an orderly way, and attach identification tags or put marks if needed. Assembly, Clean all parts before assembly. Repair any scratches or dents. Take special precautions. against dirt and dust. ox © Parts with rust-preventive coatings must be assembled only after removing the coatings. © Separated parts must be correctly reassembled using alignment marks. © Asa rule, use a press to reassemble bearings, bushings and oil seals. Use pads when using a hammer, (2) Précautions Pendant le démontage et le Remontage 1. Démontage © Se conformer a la marche a suivre © Marquer I'alignement des piéces en vue du remontage © Ranger les piéces démontées dans ordre; au besoin, attacher des étiquettes pour les identifier. Montage Nettoyer chaque piéce avant de la remo-nter. Faire disparaitre toute égratignure ou bosse. Faire particulieérement attention 4 la poussiére et aux impuretés. oN © Les piéces recouvertes d'une couche d'anti- rouille doivent étre décapées avant lo remontage. O Les piéces rapportées doivent étre correctement réassemblées en se servant des ‘marques faites au moment du démontage. © En régle générale, utiliser une presse pour remonter les roulements, les bagues, les disques de retenue d'huile. Utiliser un amortisseur de vibrations pour se servir d'un marteau. (2) Vorsichtsma&nahmen bei Demontage und Montage 1. Demontage © Das vorgeschriebene Demontagever-fahren durchfihren. © Ausrichtmarkierungen anbringen, um eine richtige Montage sicherzustellen. © Die demontierten Teile geordnet ablegen und erforderlichenfalls Kennzeichnungs-fahnen order Marken anbringen. Montage Alle Teile vor der Montage reinigen. Alle Kratzer und Dellen ausbessern. Besondere Vorkehrungen gegen Schmutz und Staub treffen. on Gse © Tele, die mit einem Rostschutz ausgestatten sind, dirfen erst montiert werden, nachdem. der Rostschutz beseitigt wurde. © Auseinandergebaute Teile missen mit Hilfe der Ausrichtmarkierungen richtig wieder zusammengebaut werden. © Grudsatzlich zur Montage von Lagern, Buchsen und Simmerringen eine Presse verwenden. Beim Eintreiben mit einem Hammer eine Zwischelage verwenden.[4] IMPORTANT SAFETY PARTS AND CRITICAL FUNCTIONAL PARTS The following instructions are related to essential adhesives, important safety parts (Process [S]) and critical functional parts (Process [Al). Use special attention in servicing these parts. (Pay also close attention in reconnecting the electrical cables.) (1) Essential Adhesives ‘Type of screw adhesive © Unless otherwise specified, use Three-Bond 1324 adhesive (medium-duty type). x Keep the screw threads free of oil and water. ‘Types of instantaneous adhesives © Use Three-Bond 1733 or Three-Bond 1741E adhe % Keep the bond areas free of oil and water. (2) The Following Two Points are Included in the Important Safety Process [S]. @Reconnecting the fuel hose (clearances, hose routes, clamps, etc.) @Electrical cabling (engine, instrument panel, controls, etc.) (wiring routes, clamps and couplers) (3) The Following Five Points are Included in the Critical Functional Process [Al. © Setting up the travel wheel motor (tightening torque) @Reassembling the rotary joints (joint direction and shaft set-up) @ installing the swivel base bearing and the swivel motor (tightening torque) g the pump couplings (tightening torque) @ Setting the radiator (clearance between fan and shroud) [5] IMPORTANT INSPECTION ITEMS (1) Operate the Machine and Check for Unusual Noises and Vibrations. (2) Make Sure the Nameplate and Grommets are in their Specified Positions. (3) With the Machine Front in a Specified Posture, Check the Amount of Hydraulic Oil. Checking the oil level (For further details, refer to the Operation Manual of each model.) 1. Park the machine on a level ground. 2. Make sure the hydraulic oil temperature is in the range of 10-31 specified zone of the oil level gauge. 3. Keep the machine front in one of the following postures © and ®. Posture ©: Stretch the rods of the arm and bucket cylinders nearly half. Place the bucket on the ground, the offset swing at the center, and the dozer also on the ground. All KH series models as well as Models KX-36 ~ 151, K-008, KX-61-2 ~ 161-2, and U-10 and see if the oil level is within the Posture @: Stretch the boom topmost. Have the arm and bucket tuck in. Place the offset swing at the center and the dozer on the ground. Keep the tracks, if adjustable in width, in their widest position, Models KX36-2, KX41-2, U-20, 35 and U-45 After changing the hydraulic oil for fresh one, take these steps: First keep the machine in Posture @ and run it idle for a while. Then take Posture @, check the oil level and add oil as required. Finally close the tank cap. Note: Never fail to take Posture @ before closing the tank cap. es, the hydraulic oil tank of whit G-s7[4] PIECE IMPORTANTES CONCERNANT LA SECURITE ET PIECES FONCTIONNELLES CRITIQUES Les instructions suivantes se rapportent aux adhésifs essentiels, aux piéces importantes concernant la sécurité (Processus (§]) et aux piéces fonctionnelles critiques (Processus (A)). Faire particuliérement attention lors de l'entretien/dépannage de ces piéces. (Prendre particuliérement garde aussi lors du raccordement des cables électriques.) (1) Adhésifs Essentiels Type d’adhésif pour les vis © Sauf indication différente, utiliser I'adhésif Three-Bond 1324 (type standard). x Préserver le filetage des vis de I'huile et de l'eau, Types d'adhésits instantanés © Utilisr 'adhésif Three-Bond 1733 ou Three-Bond 1741E. 38 Préserver la surface d'adhérence de I'huile et de l'eau. (2) Les Deux Points Suivants sont Inclus dans le Processus de Sécurité Important |S]. @ Raccordement de la durite de carburant (intervalles, parcours des durites, attaches, etc.) @ Céblage électrique (moteur, tableau de bord, commandes, etc.) (parcours des cablages, attaches et coupleurs) (3) Les Cinq Points Suivants sont Inclus dans le Processus Fonctionnel Critique (Al. @ Ajustage du moteur des galets de roulement de translation (couple de serrage) @ Remontage des joints rotatifs (direction des joints et montage de I'arbre) @ Installation du palier de vilebrequin pivotant et du moteur pivot (couple de serrage) @ Montage des accouplements de la pompe (couple deserrage) © Montage du radiateur (intervalle entre ventilateur et envelope de protection) [5] ORGANES IMPORTANTS POUR UNE INSPECTION (1) Faire Fonctionner la Machine et Vérifier pour des Bruits Inhabituels et des Vibrations. (2) S'assurer que la Plaque du Constructeur et les Rondelles soient aux Positions Spécifiées. (3) Avec l'avant de la Machine dans une Position Spécifiée, Vérifier la Quantité de I'huile Hydraulique. Vérification du niveau de huile (Pour plus de détails, se référer au Manuel de Fonctionnement de chaque modéle,) 1. Garerla machine sur un sol plane. 2. S'assurer que la température de Ihuile hydraulique soit dans une plage de 10°C ~ 30°C et verifier si le niveau de Thuile est en deed de la zone spécifiée de lajauge de niveau dhuile 3. Maintenir I'avant de la machine dans une des positions @) ou @) suivantes. Position (1): Etendre les tiges des cylindres du bras et du godet de pelle 4 presque la moitié de leur longueur. Poser le gadet de pelle sur le sol, le pivotement décalé au centre et la tracto-palle aussi sur le sol Tous les modéles de la série KH aussi bien que les modéles KX-36 & 151, K-008, KX-61-2 §-161-2 et U-10. Position: Allonger la she le plus haut possible, avec le bras et le godet de pelle rentrés. Placer le pivotement décalé au centre et la tracto-pello sur le sol. Conserver les chenilles, si elles sont réglables en largeur, dans la position la plus large. Modes KX-36.2, KX-41-2, U-20, -36 ET ~45. Apris le remplacoment de hulle hydraulique par de hulle neuve, Suivre les etapes suivantes: Placer tout d‘abord la machine dans la position (1) et faire tourner le moteur au ralenti pendant un certain temps. Puis, prendre la position ®, vérifier le niveau de I'huile et en ajouter sist nécessaire. Refermer ensuite le bouchon du réservotr. Nota: Ne jamais oublier de suivre la position ® avant de reformer le bouchon du réservoir. ese