Kubota K008-3 Workshop Manual
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Kubota K008-3 Workshop Manual

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WORKSHOP MANUAL
KUBOTA EXCAVATOR
K008-3
U10-3
Code No.97899-60730
Courtesy of Machine.Market

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vegas
January 17, 2025

l would like detail content on the hydraulic system for kubota k038 excavator model

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Summary of Contents for Kubota K008-3

  • Page 1 WORKSHOP MANUAL KUBOTA EXCAVATOR K008-3 U10-3 Code No.97899-60730 Courtesy of Machine.Market...
  • Page 2 Record of Revisions Symbol Date Main Revised Points & Corrective Measures Person-in-charge Courtesy of Machine.Market...
  • Page 3 CONTENTS I General II Machine body Mechanism Section ......II -M-1 Service Section .

  • Page 4: Table Of Contents

    K008-3 KTC KCL, KTA - Version ........

  • Page 5: Body And Engine Identification Marks

    A.Body and engine identification marks K008-3, U10-3 EU-Version Your KUBOTA dealer is always ready to help so that your excavator offers the best performance. After having carefully read this manual, you will realize that much of the routine maintenance can be done by yourself.
  • Page 6 K008-3 KTC, KCL, KTA-Version The model name, machine number and engine num- ber of this product are described in their respective positions, as shown below. Note that their positions may be different depending on the specifications. Chech the specification of the product.

  • Page 7: Safty Precautions For Servicing, Disassembly And Reassembly

    B.Safty precautions for servicing, disassembly and reassembly Safty precautions for servicing Most accidents during servicing arise from carelessness. Please remember that safty involves both the wel- fare of the employees and improved work efficiency. Safty precautions for Disassembly and reassembly Machines must be diassembled and assembled efficiently and safely.

  • Page 8: Preparation For Disassembly

    c. Preparation for disassembly (1)Cleaning Remove mud and dirt from the body before disassembly. (2)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 •...

  • Page 9: Important Safty Process And Critical Functional Process

    C.IMPORTANT SAFTY PROCESS AND CRITICAL FUNCTIONAL PROCESS The following instructions are related to essential adhesives, important safety process and critical func- tional process .Pay special attention in servicing these process. (Pay also close attention in reconnecting the electrical cables.) a. Essential Adhesives Type of screw adhesive •...

  • Page 10: Servicing Fundamentals

    E.SERVICING FUNDAMENTALS a.Items for Servicing Locking adhesive 1) Tighten bolts, nuts, adapters,and similar parts to their specified torques which are given in the list of tightening torques and adhesive as well as in this manual. Be sure to observe the specified torques for important tightened parts and components.
  • Page 11 4) Precautions in tightening hoses and pipes. • Flexible hoses have a slight natural bend of their own. Utilize the natural bend. Be also careful not to twist them. • Be careful not to confuse the routes of the hoses. •...

  • Page 12: O-Ring, Oil Seal, Circlip And Roll Pin

    b.O-ring, Oil seal, Circlip and Roll Pin (1) General precautions • Make sure the O-ring and the oil seal are free of anything unusual (uneven surface, scratches, chipping, etc.). • Check the O-ring groove for burrs. Correct, if any, using an oil stone or the like. •...
  • Page 13 (4) Oil seal • Do not confuse the orientation of the oil seal lips. Direct the main lip toward the oil cham- ber; in other word, toward what is to be sealed. Packing Dustproof lip Metal ring Atmosphere (outside) Spring Grease Main lip Oil chamber (inside)

  • Page 14: Piping

    c. Piping (1)General precautions • Tightening the pipe socket to the specified torque. If too tight, the socket itself or a hydraulic component may get damaged. It too loose, an oil leak may result. • In connecting a new hose or pipe, tighten its nut first to the specified torque and then turn it back (about 45°).
  • Page 15 (4)Hose screw Metric Size Hose Tightening torque Torque N·m Thread size N·m kgf·m (piping screw) kgf·m Thread size Wrench size ft·lbf ft·lbf (piping screw) (reference) Taper thread 20 ~ 30 Union nut section × section 2.0 ~ 3.1 14.75 ~ 22.13 ·...
  • Page 16 (6)Tightening torque table for hose clamp (Screw type) Tightening torque N·m Dia. (mm) Code No. kgf·m ft·lbf Ø12 ~ 16 09318-89016 2.5 ~ 3.4 Ø19 ~ 25 09318-89024 25 ~ 35 Ø31 ~ 40 09318-89039 1.84 ~ 2.51 Ø36 ~ 46 09318-89045 Ø15 ~ 25 RC101-64580...
  • Page 17 (8)Tightening torque of bolts and nuts Refer to the tightness torque table below. Bolts, Nuts Nomial Dia. SS41 S40C, S45C SCr4 7.8 ~ 9.3 N·m 9.8 ~ 11.3 N·m 12.3 ~ 14.2 N·m 0.80 ~ 0.95 kgf·m 1.00 ~ 1.15 kgf·m 1.25 ~ 1.45 kgf·m 5.8 ~ 6.9 ft·lbf 7.2 ~ 8.3 ft·lbf...
  • Page 18 (10)Washer-equipped elbow Tightening torque Size N·m kgf·m ft·lbs G1/4 25 ~ 30 2.5 ~ 3.0 18 ~ 22 G3/8 49 ~ 54 5.0 ~ 5.5 36 ~ 40 G1/2 59 ~ 64 6.0 ~ 6.5 43 ~ 47 G3/4 118 ~ 127 12.0 ~ 13.0 87 ~ 94 Tightening procedure...

  • Page 19: F Machine Quality Specifications

    F Machine Quality Specifications a. K008-3, U10-3 EU-Version Machine specification:Service port, Wrist rest, STD-arm, KBT-cab, KBT-bucket Specifications Items Unit K008-3 U10-3 Remarks Main Spec. JIS A8404 Machine size Total length (Trans- 2750 ± 55 2985 ± 60 port) Total width 860 ±...
  • Page 20 Specifications Items Unit K008-3 U10-3 Remarks Main Specs JIS A8404 Bucket tooth slag- 50> 50> F - 30 kgf gish Front digger's tilt- 10> 10> down Dozer's declination 5> 5> Min. clearance 50 ± 25 47 ± 25 between boom and...
  • Page 21 Specifications Items Unit K008-3 U10-3 Remarks Max. digging height Canopy 1302 ± 130 1468 ± 146 radius Max. dump height Canopy 1183 ± 71 1619 ± 162 at bucket pin radius Bucket wrist angle degree 186 ~ 192 186 ~ 192...
  • Page 22 Specifications Items Unit K008-3 U10-3 Remarks Bucket lever crowd 1.5 ± 0.5 1.5 ± 0.5 Dump & crowd 14.7 ± 5 14.7 ± 5 extend 1.5 ± 0.5 1.5 ± 0.5 14.7 ± 5 14.7 ± 5 Swivel (Swing) lever 1.5 ±...
  • Page 23 Specifications Items Unit K008-3 U10-3 Remarks Stability Standard arm, static Bucket load to tip Side 83< 85< Arm extend, limited load fully bucket crowd oil 812< 833< [track frame : extended] temp.50 ± 5 °C (122 ± 41 °F) Front 108<...

  • Page 24: K008-3 Ktc Kcl, Kta - Version

    K008-3 KTC KCL, KTA - Version Machine specification: Service port, Wrist rest, STD-arm, KBT-cab, KBT-bucket Specificatios Items Unit K008-3 Remarks Main Speed JIS A8404 Machine size Total length 2750 ± 55 (Transport) inch 108.3 ± 2.2 Total width 860 ± 17...
  • Page 25 Specificatios Items Unit K008-3 Remarks Front attachment Max. vertical dig- 1375 ± 28 ging depth inch 54.1 ± 1.1 Max. digging height 2870 ± 57 inch 113.0 ± 2.2 Max. dump height 2035 ± 57 inch 80.1 ± 1.6 Mini. turning radius 1120 ±...
  • Page 26 Specificatios Items Unit K008-3 Remarks Work performance Boom lifting capacity 91.8< Front end, Arm extend bucket 0.9< crowd, at tooth" 202< Arm digging force Bucket tooth root 4.3< 1113 Bucket digging force 1000 Machine stance to JIS bucket tooth root 9.3<...
  • Page 27 Specificatios Items Unit K008-3 Remarks Hydraulic performance Relief pressure set- 170 ± 5.0 At pump delivery kgf/cm ting 50 ± 5 °C 16.7 ± 0.5 2418 ± 71 170 ± 5.0 kgf/cm 16.7 ± 0.5 2418 ± 71 Cylinder oil sealing Boom 50 ±...
  • Page 28 Specificatios Items Unit K008-3 Remarks Dozer lever kgf·m 2.0 ± 0.5 Up & down N·m 19.6 ± 5.0 ft·lbs 14.5 ± 3.6 down kgf·m 2.0 ± 0.5 N·m 19.6 ± 5.0 ft·lbs 14.5 ± 3.6 Travel lever Forward kgf·m 1.1 ± 0.5 N·m...
  • Page 29 Specificatios Items Unit K008-3 Remarks Boom lever stroke 80 ± 10 inch 3.15 ± 0.39 down 80 ± 10 inch 3.15 ± 0.39 Arm lever stroke crowd 80 ± 10 inch 3.15 ± 0.39 extend 80 ± 10 inch 3.15 ± 0.39...

  • Page 30: Maintenance Intervals

    G.Maintenance intervals S-27 Courtesy of Machine.Market...
  • Page 31 To ensure safty in operation, you are strongly required to inspect and service the machine at regular inter- vals. For added safety, ask your KUBOTA dealer to replace the following impotant component parts. These parts are prone to degradation in material or subject to wear and tear with time. It is difficult to judge how much they have been affected at regular inspection.

  • Page 32: Hydraulic Oil Check For Machines With Hydraulic Breakers

    a. Hydraulic Oil Check for machines with Hydraulic Breakers The Hydraulic oil change after 1000 operating hours in the operator’s manual is based on the type of work done. Following inspection measure are valid when hydraulic breakers are used: 1. Changing and filling up of hydraulic oil 1) The hydraulic oil must be changed more often when breakers are used because the machine is subject to harder conditions than at normal...
  • Page 33 . Machine body(Mechanism section) A. Specifications............II-M-3 a.
  • Page 34 II-M-2 Courtesy of Machine.Market...

  • Page 35: Specifications

    A.Specifications a. EU - version 700/ 700/ K008-3 245 2870 2030 1720 1380 1120 1420 1940 200 180 2000 750 2750 3020 3070 750/ 750/ U10-3 3050 2210 1800 1550 1250 1420 2100 215 190 2310 670 2980 3330 3380 II-M-3 Courtesy of Machine.Market...

  • Page 36: Ktc, Kcl, Kta - Version

    0.8’ 1’ 3’ 2’11’’ 2’8’’ 2’7’’ 9’5’’ 6’8’’ 5’8’’ 4’6’’ 3’8’’ 7’4’’ 6’5’’ 0.7’ 0.6’ 6’7’’ 2’7’’ 9’2’’ 9’11’’ 10’1’ K008-3 (2450) (300) (700/ (880) (825) (800) (2870) (2035) (1715) (1375) (1120) (2230) (1945) (200) (180) (2000) (790) (2790) (3025) ’(3075)

  • Page 37: Bucket

    Bucket can be mounted between K-008 and K008-3new series in each local bucket as shown in the below table. Also below dimensions are for your reference to process local bucket in your place. Still bucket size and weight should be considered for safety, stability and performance. K-008 K008-3 Bucket Unit:mm K008...

  • Page 38: Machine Structure

    Control linkage (1)Operating lever lock (K008-3) Operating lever lock Unlock position Lock position (2)Traveling lever 1. Single speed system (K008-3:EU version) Traveling lever LH Traveling lever RH Rod for traveling LH Rod for traveling LH II-M-6 Courtesy of Machine.Market...
  • Page 39 2. Too speed system (K008-3:KTC, KCL, KTA version) Traveling lever LH Traveling lever RH Rod for traveling LH Rod for traveling LH High traveling speed pedal (3)Operating lever 1. K008-3:EU version Operating lever LH Operating lever RH Boom Bucket Swivel II-M-7 Courtesy of Machine.Market...
  • Page 40 2. K008-3:KTC, KCL, KTA version Operating lever LH Operating lever RH Bucket Boom Swivel (4) Dozer (K008-3) Dozer lever II-M-8 Courtesy of Machine.Market...
  • Page 41 (5) Swing and Service port (K008-3) Rod for swing Swing pedal Rod for service port Service port pedal II-M-9 Courtesy of Machine.Market...
  • Page 42 (6)Accelerator lever Accelerator lever Accelerator Cable Governor lever (7)Change lever for retracting track frame Change lever II-M-10 Courtesy of Machine.Market...

  • Page 43: Engine Mount

    b. Engine mount Starter moter Alternator Accelerator cable Air clearner Inlet hose Exhaust manifold Radiator Rubber mount Muffler II-M-11 Courtesy of Machine.Market...

  • Page 44: Under Carriage

    c. Under carriage (1)Crawler Tension Idler Idler support Bolt Plate Cylinder, grease (2)Track roller Track roller Bolt (3)Retractable undercarriage Track, LH Track, Center Track, RH Track, Cylinder Blade, LH Blade, Center Blade, RH II-M-12 Courtesy of Machine.Market...
  • Page 45 Rubber thickness / Endress 19 mm / 22.5 mm 19 mm / 22.5 mm 0.75 in. / 0.89 in. Robber Strength 13.7 MPa 13.7 MPa 140 kg / cm 140 kg / cm 1990 psi 2. K008-3 II-M-13 Courtesy of Machine.Market...
  • Page 46 3. U10-3 II-M-14 Courtesy of Machine.Market...
  • Page 47 . Machine body(Service section) A. Specifications............II-S-3 a.
  • Page 48 II-S-2 Courtesy of Machine.Market...

  • Page 49: Machine Weight

    A.Specifications a. Machine Weight (1)K008-3, U10-3 EU - version unit K008-3 U10-3 Machine weight (2)K008-3 KTC, KCL , KTA - version unit K008-3 Machine weight 2028 II-S-3 Courtesy of Machine.Market...

  • Page 50: Machine Specifications

    Machine specifications (1)K008-3, U10-3 EU version NOTE: • Above dimensions are based on the machine with JPN bucket. JPN = made in Japan II-S-4 Courtesy of Machine.Market...
  • Page 51 (2)K008-3 KTC, KCL, KTA version NOTE: • Above dimensions are based on the machine with JPN bucket. JPN = made in Japan II-S-5 Courtesy of Machine.Market...

  • Page 52: Lever Stroke And Operating Force

    Lever stroke and operating force (1)K008-3, U10-3 EU version Unit K008-3 U10-3 Remarks Stroke Up / Down Boom 14.7 / 14.7 14.7 / 14.7 Force Up / Down 1.5 / 1.5 1.5 / 1.5 Stroke Crowd / Dump 14.7 / 14.7 14.7 / 14.7...
  • Page 53 (2)K008-3 KTC, KCL, KTA version Unit K008-3 Remarks Stroke Up / Down Boom 14.7 / 14.7 Force 1.5 / 1.5 Up / Down 3.3 / 3.3 Stroke Crowd / Dump 14.7 / 14.7 Force 1.5 / 1.5 Crowd / Dump 3.3 / 3.3...

  • Page 54: Dimensions Of Parts

    Dimensions of Parts (1)Front pins Unit K008-3 U10-3 Allowable wear limit 30 × 98.5 Pin diameter × length 1.18 × 3.88 30 × 218 Pin diameter × length 1.18 × 8.58 30 × 106 Pin diameter × length 1.18 × 4.17 30 ×...
  • Page 55 (2)Bucket 1) Bucket dimensions Unit K008-3 U10-3 Remarks Lip outer width 11.8 13.8 Side cutter outer width 12.5 14.5 51 × 6 51 × 6 × t 3.01 × 0.24 2.01 × 0.24 0.47 0.47 0.47 0.47 0.79 0.79 0.98 0.98...
  • Page 56 2. Bucket installation relevant dimensions Unit K008-3 U10-3 Remarks 27.6 32.3 191.5 27.6 II-S-10 Courtesy of Machine.Market...
  • Page 57 (3)Rubber crawler Unit K008-3 U10-3 Remarks Crawler assy code No. RA021-2221 RA131-2221 Identification mark (Core steel rapping position) A : Lug height B : Link height C : Crawler width 10 ~ 15 D : Crawler sag distance 0.4 ~ 0.6...
  • Page 58 (4)Track toller, idler, sprocket Unit K008-3 U10-3 Remarks 60.5 / 56.5 A : Guide width (A)/(B) 2.4 / 2.2 124 / 120 B : Outer diameter (A)/(B) 4.9 / 4.7 11 / 7 C : Roller width (A)/(B) 0.4 / 0.3...
  • Page 59 (6)Dozer Unit K008-3 U10-3 Remarks Assy code No 30 × 70 30 × 70 : Pin diameter × length 1.2 × 2.8 30 × 70 30 × 70 : Pin diameter × length 1.2 × 2.8 30 × 70 30 × 70 : Pin diameter ×...
  • Page 60 (7)Parts weight 1) K008-3, U10-3 EU version Unit K008-3 U10-3 Remarks wide (left) Track frame wide (right) Track frame center Swivel frame Boom Bucket Dozer Weight (rear) Weight (left) Weight (right) Gear pump Control valve Swivel motor Travel motor Swivel bearing...
  • Page 61 2) K008-3 KTC, KCL, KTA version Unit K008-3 Remarks Track frame Side (left) 14.5 Side (right) 14.5 Center 21.3 Swivel frame 37.2 Boom 18.1 Bucket Dozer 13.6 Weight (rear) 33.6 Weight (left) 13.2 Weight (right) 12.7 Gear pump Control valve...
  • Page 62 Unit K008-3 Remarks Bucket cylinder Swing cylinder Dozer cylinder Rotary joint The weights listed above are based on calculations and slightly different from actual ones. (7)Water and Oil Quantity Unit K008-3 U10-3 Remarks Radiator Canopy / Cab 0.74 Kubota LLC-N-50F Reserve tank 0.13...

  • Page 63: Front Attachment Assembly Procedure

    1) Apply grease sparingly to pins before assembling them (ALBANIA EP2, MOBIL PLEX or equivalent ) 2) Tightening torque of pin lock bolts : 48~56N·m (4.9~5.7kgf·m) 3) Do not tighten the lock nuts firmly. Front hose : K008-3 K008-3 Parts name Q’ty...
  • Page 64 Front hose : U10-3 U10-3 Parts name Q’ty Hose (High pressure, 1/4) Hose (High pressure, 1/4) Hose (High pressure, 1/4) Hose (High pressure, 1/4) Hose (High pressure, 1/4) Hose (High pressure, 1/4) SP specification only Hose (High pressure, 3/8) Hose (High pressure, 1/2) White tape attached Service port hose to be lowermost for SP spec.
  • Page 65 Installing direction of dust seal Install the dust seals in the direction as shown at left. If in the wrong direction, the sealing effect is adversely affected, which may get the pins worn out earlier. (Enlarged view of dust seal) Bush Toward the Bushing Dust Seal...

  • Page 66: Greasing Points

    b. Greasing points G : Greasing points (Apply grease to such an extent that it should not run off the pins.) *Note: Balls and teeth of the swivel bearing may be greased before assembly. II-S-20 Courtesy of Machine.Market...

  • Page 67: Upper Structure

    C.Upper Structure a. Operating unit (1) K800-3 mechanical operating unit Assembly procedure Mount pins so that 1) Mount the pins so that they are set abeam to the they are set abeam connection of rod and valve spool and tighten and lock them.
  • Page 68 5) Assembling the bracket Tightening torque bolts at G : 48.1~55.9N·m (4.9~5.7kgf·m) * Apply screw lock agent. Assembling the grip (R)(K008-3) 6) Assembling the grip (R) 1. Assemble the grip (R) after turning it coun- terclockwise 8 or 9 times.
  • Page 69 Assembling the handrail 7) Assembling the hand rail 1. Assemble the handrail, reclining it forward and tighten. 2. Tightening torque of hand rail: 48~56N·m (4.9~5.7kgf·m) Provide clearance. More than 10 mm Assemble it, reclining forward. Assembling the covers (front) and (rear) 8) Assembling the covers (front) and (rear) 1.
  • Page 70 Adjusting the operating levers and lever (travel) (U10-3) 9) Adjusting the operating levers and lever (travel) 1. Adjusting the operating levers Assemble the operating levers so that the lever holes should be parallel to the front side of the operating panel and that the left lever should be set at approx.
  • Page 71 Assembling the grip (U10-3) 11) Mounting direction of the grip lock nut Direct the dented part (by processing) down- ward. Lock nut tightening torque: Plain washer Tube (1) Tube (1) Tube (2) Larger opening Larger opening (2)Accelerator lever Adjusting the accelerator Assembly procedure 1) Adjusting to the maximum rotating speed Adjust the engine governor so that the...
  • Page 72 Governor lever side 4) Connection with engine Connect the lever with engine governor at its outside. Routing of accelerator wire 5) Routing of accelerator wire Pass the wire along the route shown in the left figure. Cord clamp Cover (suction tank) II-S-26 Courtesy of Machine.Market...

  • Page 73: Dozer Lever

    Dozer lever K008-3 Link Pin, Spring Washer, Plain Shaft, Brade Fig No. Pin, Snap Bush D504 Pin, Joint Washer, Plane Fig No. Pin, Snap Lever, Blade D502 Lever, Blade Pin, Spring Grip RA028-060-10 U10-3 Link, Blade Bolt Plate, Blade...
  • Page 74 Track width change/dozer select lever Operation of the Dozer 1. To raise the dozer, pull back the control lever. Pushing the control lever forwards, lowers the dozer. Track width change/dozer select lever Push the control lever forward..The track width reduces [from 860mm to 700mm] Push the control lever backward.

  • Page 75: Swing Pedal

    Swing pedal K008-3 Link Shaft, Swing Washer, Plain Pedal, Swing Pin, Snap Pedal, Swing Pin, Joint Bolt Pin, Snap Washer, Plain RA028-059-10 U10-3 Link Pedal, Swing Washer, Plain Bolt Pin, Snap Washer, Plain Shaft, Swing Pin, Joint Pedal, Swing...
  • Page 76 Boom swing operation 1. Step on the front of the pedal to swing the WARNING boom to the left. To avoid personal injury or death: 2. Step on the rear of the pedal to swing the • Always keep your toes within boom to the right.

  • Page 77: Service Port Pedal

    Service port pedal K008-3 Link Washer, Plain Washer, Plain Shaft Pin, Snap Washer, Plain Pin, Joint Pin, Spring Pin, Snap Pedal, SP Lever, SP Holder Bolt Pin, Spring RA028-061-10 U10-3 Link Washer, Plain Washer, Plain Shaft Pin, Snap Washer, Plain...
  • Page 78 Service port operation This pedal is used to operate attachments such as breakers. Locking the service port padal Service port pedal The service port pedal can be locked downward Step on the service port pedal and pressured oil in oder to use an attachment such as hand starts following through the “P”...

  • Page 79: Tank

    19.6~29.4 N·m (2.0~3.0 kgf·m) 4) Parts list Bolt Bolt Tank, Oil Gasket Filter return Bolt Plug Washer with rubber Protector, Rear (K008-3) U10-3 weights, Rear Gauge, Oil level Filter, Suction Gasket Bolt Cover, Tank suction Filter, Suction Gauge, Oil level...
  • Page 80 (2)Tank fuel Assembly procedure Swivel frame 1) Assembling the band (fuel tank) When tightening the band, press the fuel tank to the right side, temporarily tighten it and tighten it securely using care not to twist the band. Band (fuel tank) tightening torque: 48~56 N·m (4.9~5.7 kgf·m) 2) Sensor (fuel) tightening torque: 3~4 N·m (0.3~0.4 kgf·m)
  • Page 81 Routing the fuel hose CAUTIONS! • Clamp the fuel hose securely. Do not move the hose after clamped. (Tighten the cord clamp (34150-2939 ) together with the cover (suc- tion tank) (RA021-6213 ). • The fuel hose should not come in contact with sharp edge, high-tem- perature part or rotating part.
  • Page 82 Assy filter, Fuel Band, Filter Bolt Assy pump, Fuel Bolt Bolt Assy filter, Fuel Bolt Washer, Spring Tube, Fuel Joint, Pipe Tube, Fuel Tube Tube, Fuel RA021-007-10 Tube, Fuel Tube, Fuel Tube, Fuel Tube Clip, Pipe Clip, Pipe Bracket Bolt Protection Hose Fuel tank...

  • Page 83: Weight

    Tightening torque of 060 and 130 bolts 77.5~90.2 N·m (7.9~9.2 kgf·m) Tightening torque of 050 nut 62.8~72.6 N·m (6.4~7.4 kgf·m) Tightening torque of 150 nut 107.9~125.5 N·m (11.0~12.8 kgf·m) Exploded view of K008-3 weights (right, left and center) Link Washer, Plain Washer, Plain Shaft...
  • Page 84 Assembly sketch of studs for weights Assembling of stud for weights Studs should be mounted at A, B, C, D and E in above Fig.. Apply screw lock agent. Assembling weights Nut tightening torque A, B, C, D:107.9 125.5 N m 11.0 12.8 kgf m : 62.8...

  • Page 85: Under Carriage

    D.Under carriage a. Swivel bearing (1)Assembly sketch of swivel bearing (K008-3) Assembly procedure 1) Set the screw hole the grease nipple to the right side and attach the stamp mark "S" to the right side. Bolt tightening torque: 107~117.7N·m (10.5~12 kgf·m) 2) Apply and inject grease to the surface of teeth and between balls.
  • Page 86 (2)Exploded view of swivel bearing (K008-3) 3) Parts list 080 040 Bearing, Swivel Bolt Pin, Straight Tube, Grease Tube, Grease Connector Body, Connector Sleeve Nipple, Grease RA028-039-10 Grease tube length Grease tube length 540mm 310mm II-S-40 Courtesy of Machine.Market...
  • Page 87 (3)Assembly sketch of swivel bearing (U10-3) Assembly procedure 1) Set the screw hole the grease nipple to the left side and attach the stamp mark "S" to the left side. Bolt tightening torque: 107~117.7N·m (10.5~12 kgf·m) 2) Apply and inject grease to the surface of teeth and between balls.
  • Page 88 (4)Exploded view of swivel bearing (U10-3) 3) Parts list Bearing, Swivel Bolt Pin, Straight Tube, Grease Tube, Grease Connector Body, Connector Sleeve Nipple, Grease Grease tube length Grease tube length 425mm 290mm II-S-42 Courtesy of Machine.Market...

  • Page 89: Rops

    b. ROPS ASSY FRAME, ROPS FRAME FRAME ASSY PIN LABEL, ROPS WARNING WASHER, PLAIN NUT, SELF-LOCKING PIN, SPLIT BOLT BOLT WASHER, PLAIN WASHER, SPRING Frame (ROPS, top) Pressing the part , tighten up the two bolts (for both sides). Tightening torque (7T): 123.6 147.1 N m (12.6 15.0 kgf m) Install the ROPS onto the stud bolt (Keep the three bolts (090) at...

  • Page 90: Seat Belt Setup Angle

    c. Seat belt setup angle Seat Belt Seat Belt right Left Assembling the seat belt Inside Outside Seat belt Plain washer Frame (rops) Fixture Plain washer Bolt : Tightening Torque 60.8 70.6 N m (6.2 7.2 kgf m) Spring washer II-S-44 Courtesy of Machine.Market...

  • Page 91: Take-Up Unit

    d. Take-up Unit Component parts Idler assembly Track roller Grease cylinder Machine front side (1)Idler assembly Front idler disassembly procedure 1) Remove the rubber rollers and dismount the frond idler in assembly. 2) Pull out the spring pin by means of pin puller. <<At assembly>>...
  • Page 92 3) Remove the plate and dismount the idler sup- port by gear puller. <<At assembly>> Plate tightening torque: 48.0~55.9N·m (4.9~5.7 kgf·m) Apply screw lock agent. 4) Remove the oil seal by screwdriver. <<At assembly>> Apply grease to the lip of oil seal. 5) Remove the circlip.
  • Page 93 Parts Name Idler Idler shaft Idler support Plate Oil seals Ball bearing Collar Circlip Spring pin Bolts (2) Track roller Assembly procedure 1) Bolt (01774-61220) tightening torque: 78.0~90.0N·m (7.9~9.2 kgf·m) * Apply screw lock agent. Bolt Track roller Apply screw lock agent Machine outside Machine inside Parts Name...
  • Page 94 (3) Grease cylinder Assembly procedure 1) Nipple assembly tightening torque: 103.0~108.0N·m (10.0~11.0 kgf·m) "A" * Tighten it twice. 2) Apply oil (NEW UDT, M80B or equivalent) to dust seal, O-ring and backup ring when assem- bling them. *Mount the backup ring so that its mating face should be horizontal.

  • Page 95: Track Frame (Adjustable Leg Specification)

    e. Track Frame (Adjustable Leg Specification) (1)Route of adjustable leg hose Assembly procedure 1) Connection of adjustable leg hose • Pay attention to wrong connection of the hose. • Provide a clearance between the track frame and the hose. • Align the swivel joint lower part with the hose sleeve lower side together with rod and bottom hose of the track frame.
  • Page 96 (2)Exploded view of track frame Parts Name Q’ty Frame, Center Frame, Track LH Frame, Track RH Cover Bolt Base O-ring Bolt Bolt RA028-035-10 Washer, Spring Cover Bolt Bolt Washer, Spring Guide Bolt Washer, Pin Guide, Hose Bolt 3) Mounting the track cylinder •...
  • Page 97 (3)Adjustment of crawlers to15 mm (see illustration) , (In this case, the crawler seam is positioned on the top centre • To loosen the crawlers, follow the following pro- between the idler and the sprocket. cedure: CAUTION DANGER To avoid personal injury: To avoid personal injury or death: •...
  • Page 98 • Additionally the following points are to be observed when adjusting rubber crawlers. 1. If the crawler slackens more than 25 mm, readjust them. 2. Check crawler tansion 30 hours after inistial use and readjust if necessary. Check and adjust there after every 50 service hours. Special information when using rubber crawl- 1.
  • Page 99 .Engine(Mechanism section) A. Safety first ............III-M-3 B.
  • Page 100 In that case, please come to B. Engine specifications for construction machinary. ************************************************************************************************ This Workshop Manual has been prepared to provide servicing personnel with information on the mechanism, service and maintenance of KUBOTA Diesel Engine 03-M Series. It is divided into two parts, “Mechanism” and “Servicing” for each sec- tion.
  • Page 101 A.Safety first This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and decals on the engine itself to warn of the possibility of personal injury. Read these instruc- tions carefully. It is essential that you read the instructions and safety regulations before you attempt to repair or use this unit.
  • Page 102 B.Engine specifications for construction machinery K008-3US K008-3EU U10-3EU Model D722-EBH-3 D722-BH-3 D722-BH-4 No. of cylinder Bore × Stroke 67 × 68 2.64 × 2.68 Displacement 43.9 Max. output/rpm kW/rpm 7.5/2050 PS/rpm 10.2/2050 HP/rpm 10.1/2050 Compression ratio Max.torque N·m 39.3 kgf·m 4.01 ft·lbf Dimensions : L ×...
  • Page 103 C.Engine electric components K008-3US K008-3EU U10-3EU Model D722-EBH-3 D722-BH-3 D722-BH-4 Fuel injection pump type BoschMDtype mini- pump Nozzle type DN4PD62 mini-nozzle Injection pressure 13.7 kgf/cm 1991 Dynamo 12V 150W Manufacturer P/N 15531-6401 Regulator adjusting voltage 12V 14A Battery type 44B19R Normal capacity of 5 hrs rating Specific gravity of electrolite <...
  • Page 104 D.Performance Curve III-M-6 Courtesy of Machine.Market...
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  • Page 129 .Engine(Service section) A. Engine mount on the machine ......... . . III-S-3 B.
  • Page 130 Note: Folowing pages are missing page. 1. From page S1 to S7. 2. From page S10 to S15. 3. From page S22 to S31. 4. From page S33 to S34. 5. Even-numbered pages from pages S35 to S141. III-S-2 Courtesy of Machine.Market...
  • Page 131 A.Engine mount on the machine (1)Engine bracket, vibrationproof rubber Assembly procedure 1) Bracket tightening torque: * Apply screw lock agent. 2) Vibrationproof rubber tightening torque: * Apply screw lock agent. Bracket (rear, engine) Vibrationproof rubber Bracket (front, engine) Engine breather pipe routing 3) Pass the engine breather pipe through this position.
  • Page 132 B.GENERAL [1]ENGINE IDENTIFICATION Model Name and Engine Serial Number When contacting the manufacturer, always specify your engine model name and serial number. Cylinder number The cylinder numbers of 68 mm STROKE SERIES diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2, No.3 starting from the gear case side.
  • Page 133 III-S-5 Courtesy of Machine.Market...
  • Page 134 [3]TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, Several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and at the proper torque. (1)Tightening torques for special use screws, bolts and nuts Note •...
  • Page 135 (3)Main bearing case assembly - Type 1 * The main bearing case and thrust bearing are divided. * This bearing is adopted for the OEM engines (Z482/D662/D722/D782) Tightening torque of main bearing case bolt-1 12.7 to 15.7 N·m/1.3 to 1.6 kg·m Crankshaft side clearance Factory specification:0.15 to 0.31 mm/0.006 to 0.012 in A/Limit: 0.5 mm/0.02 in...
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  • Page 168 Main bearing case assembly 1. Remove the two bearing case screws 1 (4), and remove the main bearing case assembly 1 (3), being careful with the thrust bearing (2) and crank- shaft bearing 2. 2.Remove the main bearing case assembies 2, 3. (When reassembling) •...
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  • Page 199 Hydraulic components layout : K008-3 ....... . . IV-M-58...
  • Page 200 IV M-2 Courtesy of Machine.Market...
  • Page 201 A.Main pump(K008-3, U10-3) Manufacturer KAYABA Type DDG05A55F2H1-R395 Displacement 5.05 × 5.05 cc/rev 0.31 × 0.31 in /rev G3/4 Rot. direction Outlet Inlet Inlet Pump 1, 2 View C Parts Name Q’ty Front cover Body Drive Gear, 1st Drive Gear, 2nd...
  • Page 202 B.Pilot pump( U10-3 2-M10 Parts Name Q’ty Case Cover Gear, Drive Gear METAL, A METAL, B O-ring O-ring O-ring Oil Seal Circlip, Internal Outport Bolt Inport View A Manufacturer KUBOTA Type 56900-26201 Displacement (3.15 l/min) IV-M-4 Courtesy of Machine.Market...
  • Page 203 C.Control valve a. Specifications K008-3 U10-3 Control valve NSC10 NSC10 Section width 24mm 24mm 0.94in Total length 280mm 280mm 11.02in Spool stroke Service port 0.20in Except service port 0.24in Spool operating Dozer, at neutral 58.8N 58.8N force Travel 2nd 6.0kgf 6.0kgf...
  • Page 204 IV-M-6 Courtesy of Machine.Market...

  • Page 205: General View Of Control Valve

    General view of Control valve K008-3 EU - version : P/N RA021-61160 Tightning Torgue Thread depth 2 IV-M-7 Courtesy of Machine.Market...
  • Page 206 K008-3 KTC, KCL, KTA - version : P/N RA021-61130 Tightning Torgue Thread depth 12 Plug IV-M-8 Courtesy of Machine.Market...
  • Page 207 U10-3 : P/N RA131-61160 Tightning Torgue Thread depth 12 Plug IV-M-9 Courtesy of Machine.Market...
  • Page 208 IV-M-10 Courtesy of Machine.Market...

  • Page 209: Sectional View

    Sectional view (1)K008-3 EU - version : P/N RA021-61160 Inlet Outlet Swivel Travel, L Dozer(Track) Service Travel, R Swing Bucket Boom Inlet Tightening torque=13.7~14.7N·m (1.4~1.5kgf·m) Re-use of the valve rod ends (at 9 positions) is prohibited after disassembled. Drilled hole for identification IV-M-11 Courtesy of Machine.Market...
  • Page 210 Section A-A (Inlet, Outlet) +0.49 Set value: 16.2 MPa (165 kgf/cm At 12L/min Tightening torque=39.2N·m(T=4.0kgf·m) Section B-B (Swivel) +0.49 +0.49 Set value: Set value: 6.86 MPa (70 kgf/cm 6.86 MPa (70 kgf/cm At 12L/min At 12L/min Tightening torque=39.2N·m(T=4.0kgf·m) Tightening torque=39.2N·m(T=4.0kgf·m) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it.
  • Page 211 Section D-D (Travel, Left) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section E-E (Dozer or track) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly Lock tightly by LOCKTIGHT No. 242. observe it. Section F-F (Service) Pay attention not to forget mounting this. Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it.
  • Page 212 Section G-G (Travel, Right) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section H-H (Swing) Tightening torque=39.2N·m (4.0kgf·m) Strictly Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) observe it. Lock tightly by LOCKTIGHT No. 242. Section I-I (Bucket) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No.
  • Page 213 Section J-J (Boom) Tightening torque=39.2N·m (4.0kgf·m) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section K-K (Inlet) +0.49 Set value: 16.2 MPa (165 kgf/cm At 12L/min Tightening torque=39.2N·m(T=4.0kgf·m) IV-M-15 Courtesy of Machine.Market...
  • Page 214 (2)K008-3 KTC, KCL, KTA - version : P/N RA021-61130 Inlet Outlet Travel, Swivel Boom Travel, L Dozer(Tracl) Service Travel, R Swing Bucket Inlet Tightening torque=13.7~14.7N·m (1.4~1.5kgf·m) Re-use of the valve rod ends (at 10 positions) is prohibited after disassembled. Drilled hole for identification IV-M-16 Courtesy of Machine.Market...
  • Page 215 Section A-A (Inlet, Outlet) Refer Section A-A page.IV-S-12 Section B-B (Travel, 2nd) Strictly Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) observe it. Lock tightly by LOCKTIGHT No. 242. Section C-C (Swivel) Refer Section B-B page.IV-S-12 Section D-D (Boom) Refer Section J-J page.IV-S-15 Section E-E (Travel, Left) Refer Section D-D page.IV-S-13 Section F-F (Dozer or track) Refer Section E-E page.IV-S-13...
  • Page 216 (3)U10-3 : P/N RA131-61160 Inlet Outlet Travel Swivel Travel, L Dozer(Tracl) Service Travel, R Swing Bucket Boom Inlet Tightening torque=13.7~14.7N·m (1.4~1.5kgf·m) Re-use of the valve rod ends (at 10 positions) is prohibited after disassembled. Drilled hole for identification IV-M-18 Courtesy of Machine.Market...
  • Page 217 Section A-A (Inlet, Outlet) +0.49 Set value: 17.2 MPa (175 kgf/cm At 12L/min Tightening torque=39.2N·m(T=4.0kgf·m) Section B-B (Travel, 2nd) Strictly Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) observe it. Lock tightly by LOCKTIGHT No. 242. Section C-C (Swivel) +0.49 +0.49 Set value: 6.86 MPa (75 6.86 MPa (75 kgf/cm...
  • Page 218 Section D-D (Arm) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section E-E (Travel, Left) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section F-F (Dozer or Track) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. IV-M-20 Courtesy of Machine.Market...
  • Page 219 Section G-G (Service) Pay attention not to forget mounting this. Strictly Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) observe it. Lock tightly by LOCKTIGHT No. 242. Section H-H (Travel, Right) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section I-I (Swing) Tightening torque=39.2N·m (4.0kgf·m) Strictly Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) observe it.
  • Page 220 Section J-J (Bucket) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section K-K (Boom) Tightening torque=39.2N·m (4.0kgf·m) Tightening torque=3.92~4.90N·m(T=0.4~0.5kgf·m) Strictly observe it. Lock tightly by LOCKTIGHT No. 242. Section L-L (Inlet) +0.49 Set value: 17.2 MPa (175 kgf/cm At 12L/min Tightening torque=39.2N·m(T=4.0kgf·m)

  • Page 221: Structure And Function

    d. 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 sircuit pres- sure 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).
  • Page 222 (3)Load check valve function For smooth movement and easy inching adjustment of the spool, the passages of the hydraulic source, work- ing section and tank are all inter connected while the spool is switched over. Let’s suppose that there is no check valve installed and taht the working load keeps on forcing the working sec- tion in the opposite direction.

  • Page 223: Structure

    D.Pilot valve a. Structure The construction of the pilot valve is as shown in the figure. The casing has a vertical hole where a pressure reducing valve is assembled. The pressure reducing valve is composed of spool (201), secondary pressure setting spring (241), spring seat (216) and washer (217).
  • Page 224 IV-M-26 Courtesy of Machine.Market...

  • Page 225: Pilot Valve Control Diagram

    b. Pilot valve control diagram IV-M-27 Courtesy of Machine.Market...

  • Page 226: Function

    c. Function Hydraulic Symbol View A Identification mark of knob material change. (Screwing depth of lever (323)) Grease is applied on each rotational part of the universal joint. Pay attention to the direction of assembline the universal joint. Grease is applied on each point.
  • Page 227 (3)Operation The operation of the pilot valve is explained hereunder based on the hydraulic pressure circuit diagram (Fig. 1) and the illustrations of operation (Fig. 2 - Fig. 4). Fig. 1 shows a typical example of use of the pilot valve. Fig.
  • Page 228 2) When the steering wheel is inclined (See Fig. 3.) When the steering wheel is inclined to stroke the push rod (212), the (spring seat (216)) spool (201) moves downward, the P port communicates with the ports (2, 4) and oil supplied from the pilot pump flows to the ports (2, 4) to generate pressure.
  • Page 229 IV-M-31 Courtesy of Machine.Market...

  • Page 230: Hydraulic Pilot Circuite

    E.Hydraulic pilot circuite Oil supplied from the pilot pump is guided to the right and left pilot valves. Unload valve and relief valve are installed between them. When the operating lever is manipulated, oil from the right pilot valve is guided directly to the control valve, while the oil from the left pilot valve is guided to the control valve via the change valve.
  • Page 231 a. Control lever lock being at lock position IV-M-33 Courtesy of Machine.Market...

  • Page 232: Flow Of Oil At The Time When The Control Lever Lock Is At Unlock Position (B)

    b. Flow of oil at the time when the control lever lock is at unlock position 1. Hydraulic oil running from the pilot pump passes through the P port and P1 port of the relief valve and guided to the delivery passage of the manifold (1) through the P2 port of the manifold (2).
  • Page 233 b. Control lever lock being at unlock position IV-M-35 Courtesy of Machine.Market...

  • Page 234: Flow Of Oil In Boom Lifting Operation

    c. Flow of oil in boom lifting operation 1. Oil from the pilot pump passes through the relief valve and the manifold is guided up to the P port of the right pilot valve. (Refer to the flow of oil at the times when the control lever lock is locked and when it is unlocked as explained in 1 and 2.) 2.
  • Page 235 c. Flow of oil in boom lifting operation IV-M-37 Courtesy of Machine.Market...

  • Page 236: Flow Of Oil In Bucket Dumping Operation

    d. Flow of oil in bucket dumping operation 1. Hydraulic oil running from the pilot pump flows through the relief valve and manifold up to the P port of the right pilot valve. (Refer to the flow of oil at the times when the control lever lock is locked and when it is unlocked as explained in 1 and 2.) 2.
  • Page 237 d.Flow of oil in bucket dumping operation IV-M-39 Courtesy of Machine.Market...

  • Page 238: Flow Of Oil In Arm Crowding Operation

    e. Flow of oil in arm crowding operation 1. Hydraulic oil running from the pilot pump flows through the relief valve and manifold up to the P port of the left pilot valve. (Refer to the flow of oil at the times when the control lever lock is locked and when it is unlocked as explained in 1 and 2.) 2.
  • Page 239 e.Flow of oil in arm crowding operation IV-M-41 Courtesy of Machine.Market...

  • Page 240: Flow Of Oil In Right Swivel Operation

    f. Flow of oil in right swivel operation 1. Hydraulic oil running from the pilot pump flows through the relief valve and manifold up to the P port of the left pilot valve. (Refer to the flow of oil at the times when the control lever lock is locked and when it is unlocked as explained in 1 and 2.) 2.
  • Page 241 f.Flow of oil in right swivel operation IV-M-43 Courtesy of Machine.Market...

  • Page 242: Swing Motor (K008-3, U10-3)

    F. Swing motor (K008-3, U10-3) a. Structure and specifications O-ring groove 2-G1/4-19 O-ring port W3/32” x 103 1/4” Available spline length B port Min. 42 Masking area Specifications Model S-190SS2S-K2880 Displacement 184cc/rev 11.5in /rev Rotaiting direction A port right (To see from output shaft side )
  • Page 243 Part Name Q’ty Part Name Q’ty Part Name Q’ty Hex. socket head bolt Shaft output O-ring End gap metal Housing Oil seal O-ring O-ring Backup washer Geroller bearing assem- Ball check sub-assembly Flange Spacer plate Needle bearing Dust seal Drive Bearing race Hex.

  • Page 244: Operating Principle

    b. Operating principle When high-pressure oil is supplied to the A port side of the housing, this high-pressure oil passes through the oil hole provided in the housing and flows into the flange side groove selectively among the grooves pro- vided around the shaft output periphery.
  • Page 245 G.Rotary joint (Swivel Joint) K008-3 Single speed travel (Retractable track) Part Name. Q’ty Assy joint, Swivel Shaft, Swivel joint O-ring O-ring Rng, Backup Collar Plug Plug Joint Joint, Pipe brank Joint Plug Collar Circlip, External Joint Plug Stopper Pin, Straight...
  • Page 246 U10-3 Two Speed travel (Retractable Track) Part Name. Q’ty Assy joint, Swivel Shaft, Swivel joint O-ring O-ring Rng, Backup Collar Plug Joint Joint Joint Joint Joint Collar Circlip, External Joint Joint Joint Stopper Pin, Straight Bolt Bolt Travel, drain Travel, 2nd Track, ectend Travel left, foreward Travel raight, backward...

  • Page 247: Single Speed Motor (K008, Eu-Version)

    Single speed motor (K008, Eu-version) (1)Structure & Specifications B port G 1/4 O-ring port Drain A port G 1/4 O-ring port A, B port (2)Specifications K008-3 EU - version Speed Range Model TR BF31C1101-A Displacement 311 cc/rev · Theoretical max. output torque 874N ·...
  • Page 248 Tightening torque above 0.2kgf·m Tightening torque 15kgf·m Tightening torque 0.6kgf·m Tightening torque 0.8kgf·m Tightening torque 3kgf·m Tightening torque 6kgf·m Tightening torque 3.0kgf·m Tightening torque 3.5kgf·m Apply loctite.(#242) Gear oil: 55 cc Tightening torque 5.7kgf·m Tightening torque 3kgf·m SHELL SPILAX EP90 Apply loctite.(#242) Customer’s part Part Name...
  • Page 249 Customer’s part Part Name Q’ty Part Number Remarks number Hex. socket head bolt AA0033A M8 × 50 01311-10850 O-ring 1BP 10A HS90 Name plate Rivet Plug DW0128A RA021-70311 Valve housing Single connector 2-speed plug O-ring AS568-908, HS90 Orifice M4 ( 0.4 orifice) Spool Poppet Main spring...

  • Page 250: Two Speed Motor

    G 1/4 O-ring port A port G 1/4 O-ring port Pilot port G 1/8 O-ring port Drain port A, B port Pilot port (2)Specifications K008-3 U10-3 KTC, KCL, KTA version EU - version Speed Range Model TR BV31C1101-A Displacement 311 cc/rev 19.0in...
  • Page 251 Tightening torque above 0.2kgf·m Tightening torque 15kgf·m Tightening torque 0.6kgf·m Tightening torque 0.8kgf·m Tightening torque 3kgf·m Tightening torque 1kgf·m Tightening torque 6kgf·m Tightening torque 0.8kgf·m Tightening torque 3.0kgf·m Tightening torque 3.5kgf·m Apply loctite.(#242) Gear oil: 55 cc Tightening torque 5.7kgf·m Tightening torque 3kgf·m SHELL SPILAX EP90 Apply loctite.(#242)
  • Page 252 Customer’s part Q’ty Part Number Remarks number Hex. socket head bolt AA0033A M8 × 50 01311-10850 O-ring 1BP 10A HS90 Name plate Rivet Plug DW0128A RA021-70311 Valve housing 2-speed spool 2-speed spring 2-speed plug O-ring AS568-908, HS90 Orifice M4 ( 0.4 orifice) Spool Poppet Main spring...

  • Page 253: Hydraulic Circuit

    I. Hydraulic circuit a. K008-3 : EU - version IV-M-55 Courtesy of Machine.Market...

  • Page 254: K008-3 : Ktc, Kcl, Kta - Version

    K008-3 : KTC, KCL, KTA - version IV-M-56 Courtesy of Machine.Market...

  • Page 255: U10-3 : Eu - Version

    c. U10-3 : EU - version IV-M-57 Courtesy of Machine.Market...

  • Page 256: Hydraulic Components Layout : K008-3

    Hydraulic components layout : K008-3 Main pump Control valve Swivel motor Rotary joint Travel motor (L) Travel motor (R) Charge valve (Track <-> Dozer) Hydraulic Tank Suction filter Return filter Swing cylinder Dozer cylinder Boom cylinder Arm cylinder Bucket cylinder IV-M-58 Courtesy of Machine.Market...
  • Page 257 .Hydraulic system(Service section) A. Troubleshooting ............IV-S-3 a.
  • Page 258 IV-S-2 Courtesy of Machine.Market...

  • Page 259: Machine General

    A.Troubleshooting a. Machine general Engine System Engine does not start. Starter does not rotate normally. Check electric system. Starter rotates normally but engine does not start. Check engine system. Check hydraulic system. Engine starts but not Engine does not stop. normally.
  • Page 260 Hydraulic system Engine starts but whole Whole hydraulic system does not operate. Check hydraulic system. hydraulic system does not operate. Cylinder of any of boom, arm, bucket, Swing or dozer does not work. Check front attachment. Swivel operation is impossible. Check swivel bearing system.
  • Page 261 Hydraulic system(cont.) Temperature of Trouble with engine system: cooling water, oil or Check engine system. hydraulic oil tank rises. combustion system Check application and Loose application of heat insulating material to attaching of heat engine hood insulating material and covers. Educate and train operator.

  • Page 262: Hydraulic System

    Only boom does not (1) Boom lever link system is sticking or removed. Adjust or replace link system. operate. Speed is slow. (K008-3). Output power is weak. (2) Malfunction of control valve or spool of boom Check and repair spool.
  • Page 263 Troubles Causes Remedies Remarks Only Swing does not (1) Maladjustment of Swing pedal and link Check and adjust pedal and link. operate. Speed is slow. (2) Malfunction of control valve or spool of swivel Check and repair spool. Output power is weak. section.
  • Page 264 (2)Swivel system Prior to checking, confirm that trouble lies only in the swivel system. Troubles Causes Remedies Remarks Both right and left swiv- (1) Malfunction of charge valve (U10-3) Check operation, and disassem- els do not operate. ble or replace. (2) Malfunction of spool of pilot valve (U10-3) Check operation, and disassem- ble and clean.
  • Page 265 Troubles Causes Remedies Remarks Shock at start and stop (1) Malfunction of spool of pilot valve (U10-3) Check operation, and disassem- is remarkable. Inching ble and clean. operation is impossible. (2) Malfunction or sticking of spool of control valve Check pressure, and disassem- ble and clean.
  • Page 266 (3)Travel system Prior to checking, confirm that trouble lies only in the travel system. Troubles Causes Remedies Remarks Track does not travel. (1) Travel lever link system is sticking or removed. Adjust and replace link system. (2) Stick of spool of control valve Disassemble clean replace control valve.
  • Page 267 8.93 85% of theoretical discharge L/min(gal\min) 2.64 P1, P2 L/min(gal\min) 8.4(2.2) 80% of theoretical discharge L/min(gal\min) 2.48 (S) SHIMAZU CORPORATION, (K) KUBOTA CORPORATION (2)List of pressures Unit K008-3 U10-3 Remarks Main relief valve Actual measured value 16.7 17.7 kgf/cm 2421...
  • Page 268 Unit K008-3 U10-3 Remarks Actual measured value kgf/cm Operating part Independent set pressure kgf/cm Secondary pressure 22.5 kgf/cm Overload relief valve Boom rod/Bottom kgf/cm Arm rod/Bottom kgf/cm Dozer rod/Bottom kgf/cm Swivel system kgf/cm Bucket rod/Bottom kgf/cm IV-S-12 Courtesy of Machine.Market...
  • Page 269 (1) Mounting position:U10-3 Valve type:CP CV NSC-K110 Valve type:CP CV NSC-K110 Name of maker: Nabco Ltd. Name of maker: Nabco Ltd. K008-3 EU version U10-3 K008-3 KTC, KCL, KTA version Part Name Unit K008-3 U10-3 Remarks Main relief valve 16.7 17.7...

  • Page 270: Noise

    Noise Unit K008-3 U10-3 Remarks Noise near ears dB(A) Sound power level (Noise near ears is represented by actual mean energy value measured at max. engine rotating speed with- out load. 80 dB (A) Baby starts crying. 60 dB (A) Baby sleeps peacefully.
  • Page 271 Swivel system (A) Standard values for new vehicles Unit K008-3 U10-3 Remarks Maker Eaton Fluid Power Eaton Fluid Power Ltd. Ltd. Type S-190SS2S-K2880 S-190SS2S-K2880 Capacity cc/rev Brake V pressure kgf/cm Standard value At locking L/min of drain volume gal/min...

  • Page 272: Traveling System

    Lift up the machine, put a mark to the crawler, perform traveling about a half turn and conduct measurement more than twice. Note: The K008-3's 2-speed type is available only on the KTC, KCL and KTA versions. IV-S-16 Courtesy of Machine.Market...

  • Page 273: Cylinder System

    Cylinder system (1)Cylinder speed (A) Standard values for new vehicle (B) Limit value of uses Unit K008-3 U10-3 Remarks Extension (A/B) Sec. 1.9~2.5/3.0 2.2~2.8/3.4 Ground to top Boom cylinder Retraction (A/B) Sec. 2.4~3.0/3.6 2.5~3.1/3.7 Top to ground cushion(Boom) Empty bucket, 50°...
  • Page 274 (3)Boom/Arm/Bucket/Swing/Blade Specification Unit K008-3 U10-3 Remarks 70 × 60 × 35 Tube O.D. × I.D. × rod O.D. 70 × 60 × 35 2.76 × 2.36 × 1.37 Stroke 11.97 Max. length after retraction 23.19 Part No. of seal kit...
  • Page 275 Unit K008-3 U10-3 Remarks 60 × 50 × 30 60 × 50 × 30 Tube O.D. × I.D. × rod O.D. 2.36 × 1.97 × 1.18 Stroke 3.74 Max. length after retraction 14.02 Part No. of seal kit 69191-72401 69191-72401 N·m...

  • Page 276: Pump Flow Test

    C.Testing a. Pump flow test 1. Connect the tester to the pump discharge side. Be careful not to connect the wrongpipes. 2. Open the loading valve of the tester to start the engine. 3. increase the engine speed to the maximum speed.

  • Page 277: Pilot Pressure (U10-3)

    b. Pilot pressure (U10-3) (1)Primary pressure [Measuring procedure] 1. Remove the cover (front). 2. Disconnect the hose, which connected between the pilot pump and the changeover valve, at the changeover valve side. 3. Mount T-joint and set the pressure gauge. 4.
  • Page 278 (3)Main relief valve pressure [Measuring procedure] 1. Remove the plug (1/8) of the main pump discharge side, and set the pressure gauge. P1 Arm, swivel, travel (L), dozer, leg retraction and service P2 Boom, bucket, swing and travel (R) 2. Start the engine. Check the circuit to be measured for any oil leak.
  • Page 279 Travel straightness measurement test 1. With the engine at full speed, throw the travel control lever by its full stroke, and run the vehi- cle by 10 m (33ft.). 2. Measure the trace error from the straight line. 3. When not within the reference value range, check and repair ad discribed under “Travel cir- cuit”...

  • Page 280: Swivel Motor Block Performance

    5. Load on the bucket should be as follows. KE, KDG, KUK KTC, KCL, KTA version version Brake 5 mm / min K008-3 5 mm / min applied 0.2 in. / min Reference Value Brake 30 mm / min...

  • Page 281: Operating Speed

    Note:The cushioning time is not included. [sec] KE, KDG, KUK KTC, KCL, KTA version version K008-3 Down Reference Value U10-3 Down (3)Arm cylinder 1. Position the boom and arm as showm at left.
  • Page 282 1. Position the boom and arm as showm at left. 2. Measure the bucket cylinder full stroke operating time. [sec] KE, KDG, KUK KTC, KCL, KTA version version Crowd 2.9 ± 0.3 K008-3 Dump 2.0 ± 0.3 Reference Value Crowd 2.9 ± 0.3 U10-3 Dump 2.0 ±...

  • Page 283: Straight Travel Performance

    (7)Swivel speed 1. Position the boom, arm and bucket as showm at left. 2. Measure three times rotation time. [sec/three turns] KE, KDG, KUK KTC, KCL, KTA version version K008-3 19.8 24.0 19.8 24.0 Reference Value U10-3 19.8 24.0 (8)Traveling speed 1.

  • Page 284: Cylinder Natural Fall Amount

    Cylinder natural fall amount 1. Locate the machine on the flat ground, and put the load the bucket. Load on the bucket should be as follows. K008-3: 29kg(64lbs) - exclude bucket weight U10-3: 35kg(77lbs) - exclude bucket weight 2. Arm cylinder must be fully retracted. Bucket cylinder must be fully extended.

  • Page 285: Disassembling And Assembling

    D.Disassembling and Assembling a. Pump coupling Mount the boss having long threaded hole from pump side, and mount the boss having short threaded hole from engine side. Pump side Engine side (1) Pump assembly (Gear) (2) Flange (Pump) (3) Hex. socket head bolt (4) Bolt (5) Hex.

  • Page 286: Pump

    b. Pump Pump (Main) assembly drawing Assembly procedure 1) Pump assembly (gear) mounting torque: 39.2 ~ 45.1 N·m(4.0 ~4.6 kgf·m) * Apply screw lock agent. 2) Mount the adaptor of No.1 pump side 18 deg.- 20 deg. upwards and the adaptor of No. 2 pump side 31 deg.- 33 deg.
  • Page 287 (3)Pump (Pilot) assembly drawing Assembly procedure 1) IN side port pipe joint (L, T3/8-22) tightening torque: 48 ~ 51.5 N·m(4.9 ~ 5.3 kgf·m) OUT side port pipe joint tightening torque :15.1 ~ 30.9 N·m(2.6 ~ 3.2 kgf·m) As viewed from left As viewed from rear Pipe joint(L, T3/8-22) Hydraulic pump assembly...
  • Page 288 (4)Disassembly and reassembly 1) Tools Required tools are as shown below. Get ready before repair work. Clean tools, working table and the sur- rounding 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)
  • Page 289 3) Procedure (1) Before disassemble, put alignment mark on front cover, body and rear cover and remove bolts. Bolt tightening torque : 48.1 ~ 51.0 N·m (4.9 ~ 5.2 kgf·m) , 35.5~37.6 ft·lbs (2) Remove rear cover, gasket, side plate, 2nd drive gear, 2nd driven gear and steel ball.
  • Page 290 (4) Remove C-circlip and oil seal. Oil seal is difficult to remove, care should be taken not to damage machining surface. (5) 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.
  • Page 291 (5)Control valve Assembling the control valve (K008-3) Assembly procedure 1) Tightening torque of control valve: 23.5 ~ 27.5 N·m (2.4 ~ 2.8 kgf·m)(a) * Apply screw lock agent. 2) Tightening torque of bracket (operating): 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m)(b) * Apply screw lock agent.
  • Page 292 Joint, Pipe Joint Joint, Pipe Joint O-ring Joint, Pipe Assy valve, Check Poppet RA028-073-10 Spring K008-3 joint assembly photo Washer Circlip, Internal Joint, Pipe(ST/-) Joint, Pipe Plug Joint, Pipe Assembly procedure Assembling method and tightening torque of the valve adaptor * Apply oil (NEW UDT or M80B, or equiva- lent) to O-rings.
  • Page 293 Exploded view of U10-3 Assy valve, Control Bolt O-ring O-ring Joint, Pipe Joint, Elbow Joint, Pipe Joint Joint, Pipe Joint O-ring Joint, Pipe Assy valve, Check Poppet RA138-003-11 Spring Washer Circlip, Internal U10-3 joint assembly photo Joint, Pipe(ST/-) Joint, Pipe Plug Joint, Pipe O-ring...

  • Page 294: Pilot Valve

    c. Pilot valve Hydraulic operating unit Assembly procedure View from machine front 1) Cautions for routing of pilot hose 1. Hose should not be in tight contact with the cover (front). 2. There should be no tightly contacting parts such as edge near the hose. 3.

  • Page 295: U10-3 Component Parts Of Hydraulic Operating Unit

    d. U10-3 Component parts of hydraulic operating unit Unload valve Super change calve Valve assembly (Relief) Pilot valve (1)Unload valve Unload valve assembly drawing Assembly procedure 1) Tightening valve of hex. socket head bolt (M8 x 1.25): 29.4 N·m (3.0 kgf·m) 2) Parts list Part Name Packing (3)
  • Page 296 Unload valve structural drawing 4) Cautions in assembly Unload valve inside (oil passage) should be especially clean. When assembling the valve, apply antirust LPS- 32 or equivalent to the part which comes in con- tact with spools provided at both sides of machine.
  • Page 297 Exploded view of super change valve 3) Parts list Part Name Valve assembly (SC) O-ring Ring (Backup) O-ring Plug (1) O-ring Plate Bolt Rod (2) Super change valve structural drawing O-ring Ball Spring Plug Rubber-lined washer 4) Hydraulic oil circuit diagram (Swivel left) (Arm raking) (Swivel right)
  • Page 298 (3)Valve assembly (Relief) Valve assembly (Relief) drawing Assembly procedure 1) Parts list Part Name Manifold (1) Packing (1) Plate (1) Manifold (2) Parallel pin Hex. socket head bolt Packing (4) Valve assembly (Relief) Plug (Relief) Shim 0.4 (Relief) Shim 0.2 (Relief) Shim 0.1 (Relief) Plain washer Spring(Relief)
  • Page 299 Route of hydraulic hose 2) Joint mounting • Apply oil (NEW UDT or M80B, or equivalent) to O-rings. • Tightening torque: 15 ~ 16.5 N·m (1.5 ~ 1.7 kgf·m) Pipe (Return) Engine No.3 pump IV-S-43 Courtesy of Machine.Market...
  • Page 300 (4)Pilot valve Exploded view of pilot valve Assembly procedure 1) Parts list Part Name Valve assembly (Pilot) Plate (Port) Seal washer O-ring Hex. socket head bolt Spring pin Bush Plate Plug Push rod Seal O-ring Pilot valve structural drawing Spring(Relief) Washer 2 Spring Spring...

  • Page 301: U10-3 Hydraulic Operating Unit Bleeding Procedure

    e. U10-3 hydraulic operating unit bleeding procedure When air enters the hose for pilot valve or the man- ifold, the attachment may not be operated even when the engine is started and the operating lever Attachment operation lock lever is manipulated. If that is the case, bleed the unit in the procedure as follows.

  • Page 302: Disassembling And Assembling

    f. Disassembling and assembling 1) Tools and tightening torque Tightening torque Tool Size (mm) Part No. Part name Screw size (N·m) Hex wrench Hex socket bolt 20.6 ± 1.5 Adjusting nut Money wrench 68.6 ± 4.9 Disc Special tool (Draw- Joint 47.1 ±...
  • Page 303 3) Disassembling 1. Preparations (1) Prepare a workbench that is spacious enough for the parts handled and strong and stable enough to keep the parts in place. (2) Also have the tools and jigs, discussed in Item 7-1, at hand. 2.
  • Page 304 Procedure Precautions Remove the folding-purpose spring (246) and spring seat (218) from the push rod (212). [Photo 7-16] Draw the push rod (212) out of the plug (211). [Photo 7-17] Remove the O-ring (214) and seal (213) from the plug (211). Use a small bladed screwdriver or the like to take out the seal (213).
  • Page 305 4) Assembling 1. Preparations (1) As in the case of disassembling, prepare the specified workbench, tools and materials. 2. General precautions (1) Take the same general precautions as in disassembling. (2) Before reassembling, remove metal chippings and foreign matters from all the parts. Make sure the parts are free of burrs, hit marks and other problems.
  • Page 306 Procedure Precautions Fit the plug assembly to the casing (101). * Be careful not to pry the spool (201) too hard. Other- When the return spring (221) is weak in force, this assem- wise the casing hole (101) may get damaged. bly is kept in place by the sliding resistance of the O-ring.
  • Page 307 Photo 7-2 Photo 7-1 Photo 7-4 Photo 7-3 Photo 7-5 Photo 7-6 IV-S-51 Courtesy of Machine.Market...
  • Page 308 Photo 7-8 Photo 7-7 Photo 7-9 Photo 7-10 Photo 7-12 Photo 7-11 IV-S-52 Courtesy of Machine.Market...
  • Page 309 Photo 7-13 Photo 7-14 Photo 7-15 Photo 7-16 Photo 7-17 Photo 7-18 IV-S-53 Courtesy of Machine.Market...
  • Page 310 Photo 7-19 Photo 7-20 Photo 7-21 Photo 7-22 Photo 7-24 Photo 7-23 IV-S-54 Courtesy of Machine.Market...
  • Page 311 Photo 7-25 Photo 7-26 Photo 7-27 Photo 7-28 Photo 7-29 Photo 7-30 IV-S-55 Courtesy of Machine.Market...
  • Page 312 Photo 7-32 Photo 7-31 Photo 7-33 Photo 7-34 Photo 7-36 Photo 7-35 IV-S-56 Courtesy of Machine.Market...
  • Page 313 Photo 7-37 Photo 7-38 (4)Trouble shooting It is not easy to pinpoint trouble spots. The table below lists some typical problems, their possible causes and corrections. Before starting repair jobs, refer to the table below. A machine trouble is not necessarily caused by just one part, but by come different parts combined. It should be noted that the corrections listed below might not be enough and additional measures might be needed.

  • Page 314: Swivel Motor

    Swivel motor (1)K008-3 mounting position Assembly procedure (K008-3) 1) Tightening torque of case (swivel) mounting bolt:60.8 ~ 70.6 N·m (6.2 ~ 7.2 kgf·m) * Apply screw lock agent. 2) Tightening torque of motor assembly (swivel) mounting bolt (b): 78.0 ~ 90.0 N·m (7.9 ~ 9.2 kgf·m) * Apply screw lock agent.
  • Page 315 (2)U10-3 mounting position Assembly procedure (U10-3) 1) Tightening torque of case (swivel) mounting bolt:60.8 ~ 70.6 N·m (6.2 ~ 7.2 kgf·m) * Apply screw lock agent. 2) Tightening torque of motor assembly (swivel) mounting bolt (b): 78.0 ~ 90.0 N·m (7.9 ~ 9.2 kgf·m) * Apply screw lock agent.
  • Page 316 (3)Swivel motor disassembly and assembly procedure. [1] Disassembly and reassembly tools Name of Tool Shape Remarks Torque wrench 44 N·m capacity Hexagon socket Width across flats: wrench 6 mm Screwdriver Slim screwdriver Plastic hammer [2] Preparations for disassembly (1) Place for disassembling the motor should be dust-free and clean. Prepare a plastic parts box. (2) Wash tools and parts necessary for disassembly in advance.
  • Page 317 [3] Exploded view and names of parts Parts Name Q’ty Parts Name Q’ty Parts Name Q’ty Hex. socket head bolt Shaft output O-ring End cap Housing Oil seal O-ring O-ring Backup washer Geroller assembly Ball check sub assembly Flange Spacer plate Needle bearing Dust seal Drive...
  • Page 318 [4]Disassembiy Procedure 1. Before disassembling orbitrol (swivel motor), clean working area and necessary tools should be come to order. Get ready plastic box for removed parts, 2. Before disconnecting hoses, wipe and clean around joint section. (1) Tap out shaft key. Remove bur around shaft key groove by using sand paper or oil stone.
  • Page 319 (6) Take out drive. (7) Take out spacer plate. (8) Take out O-ring from housing. (9) Dismount motor from vise and push out out- put shaft. (10)Take out needle bearing from output shaft. (11) Mount the motor housing by vise as shown in photo, remove 4 pieces of flange mount- ing bolts.
  • Page 320 (12)Take out flange. In case of S-280 and S- (13)Take out bearing. 380, 4 pieces of spring pins are installed, Therefore, remove flange by slightly topping the flange by plastic hammer, then pull out spring pins. (14)Remove O-ring. (15)Remove oil seal. When removing oil seal and dust seal, never get the flange damaged.
  • Page 321 (17)Take out two plugs from housing. (18)Remove O-ring (4 pieces) from the check Inserting throush port hole, push up the plugs. When reassembling, check the plug, plugs. If not in need, never remove check securely replace O-rings with new ones. plug.
  • Page 322 (2) Apply grease on O-ring of check plug and (3) Insert needle bearing and bearing race into push in the housing. output shaft. (3) Install output shaft in housing. (4) Fit dust seal in flange. Use appropriate jig not to damage seal or distort metal plate.
  • Page 323 When press fit the dust seal and oil seal, use (7) Fit O-ring in flange. socket ans tap in with hammer. (8) Thoroughly clean flange mounting screw (9) Mount flange into housing saay. holes of housing, remove grease and apply Care should be taken not to damage seal screw-locktite slightly.
  • Page 324 (12)Attach spacer plate. (13)Insert drive. (14 Fit O-ring (2 pieces) onto geroler. (15)Install geroler. Apply grease on O-ring and securely fit. Care should be taken on the position of out- put shaft, geroler and geroler set. Refer to the figure below. (16)Insert spacer.
  • Page 325 (17)Put end cap onto geroler set, aligning to bolt (18)Tighten 7 pieces of end cap mounting bolts. holes. Model S-380 requires screw locktite #262. (19)Tap in shaft key. Tightening torque Securely check the rotating direction. S-70, S-100 19.6 ~ 22.5N·m (2.0 ~ 2.3kgf·m) See the figure below.

  • Page 326: Assembly And Disassembly

    E.Swivel Joint a. Assembly and Disassembly Assembly procedure 1) Tightening torque of swivel joint assembly mounting bolt: 24.0 ~ 28.0 N·m (2.4 ~ 2.8 kgf·m) * Apply screw lock agent. 2) Tightening torque of stopper mounting bolt: 24.0 ~ 28.0 N·m (2.4 ~ 2.8 kgf·m) * Apply screw lock agent.
  • Page 327 Specifications of K008-3 fixed leg 1 - speed Shaft (Swivel joint) O-ring Ring (Backup) Collar Plug (R1/8) Elbow pipe joint Pipe joint (L, R2-G2) Pipe joint (S, R1/8-G1/4) End cover Pipe joint (L, R1/4-10) Body (Swivel joint) Collar Circlip for shaft...
  • Page 328 Specifications of K008-3 retractable leg 2 - speed Shaft (Swivel joint) O-ring Ring (Backup) Collar Plug (R1/8) Elbow pipe joint Pipe joint (L, R2-G2) Plug (Seal) Pipe joint (S, R1/8-G1/4) Plug (PT1/4) Plug (PT1/4) Body (Swivel joint) Collar Circlip for shaft...
  • Page 329 Specifications of U10-3 retractable leg Shaft (Swivel joint) O-ring Ring (Backup) Collar Plug (R1/8) Elbow pipe joint Pipe joint (L, R2-G2) Adaptor 10 Pipe joint (S, R1/8-G1/4) Plug (L, R1/4-10) Body (Swivel joint) Collar Circlip for shaft Pipe joint (T, R1/4-R1/8) Pipe joint (L, R1/8-Q1/8) Stopper Parallel pin...
  • Page 330 2) Tightening torque of motor-frame fixing bolt: 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) * Apply screw lock agent.(8 bolts for "B") (1)Mounting the wheel motor adaptor K008-3, U10-3 K008-3 Travel 1-speed specification Travel 2-speed specification (Machine left side)
  • Page 331 (2)Route of wheel motor hose K008-3 U10-3 Hose (high pressure, 1/4) Hose (high pressure, 1/4) Route of hose Route of hose K008-3 Hose (high pressure, 1/8) Hose (high pressure, 1/8) (Machine right side) (Machine right side) Hose (high pressure, 1/8)

  • Page 332: Wheel Motor

    c. Wheel Motor (made by Eaton Equipment Co. Ltd.) (1)Wheel motor disassembly and assembly procedure [1] Introduction This instruction manual describes the handling method with a view to prevent possible trouble in handling and maintain the full performance for long period of time when you use this product as mini-shovel travel motor.
  • Page 333 Customar’s Part Customar’s Part Customar ’s Part Part Name Q’ty Part number Remarks Part Name Q’ty Part number Remarks Part Name Q’ty Part number Remarks number number number Ring X-ring Counter-balance check spring Star Hex. socket head bolt DW0024A- M10 × 60 V11.
  • Page 334 [6] Motor disassembly procedure Disassembly procedure Prior to starting disassembly work, clean around the work place and prepare clean plastic box as parts box. Before disconnecting piping hose, clean around the motor and remove paint sticking to connections by means of wire brush. [Caution] Do not disassemble the following assembly.
  • Page 335 3) Remove the geroller (4). 4) Fit an eye bolt to the valve plate (17), hook it on screwdriver and lift the valve plate (17) from the wheel (10) M8 × 1.25 5) Pull out the drive (20). IV-S-79 Courtesy of Machine.Market...
  • Page 336 6) Dismount the valve plate (17) by inserting a screwdriver between the valve plate (17) and the wheel (10). 7) Pull out the valve (19). 8) Insert the plastic bar into the valve hole and push the sleeve (22) out of the valve (19), and remove the spring.
  • Page 337 9) Take out the spacer (21). 10) Fix the wheel and remove four M8 bolts (28) by which the end cover assembly is mounted. 48.1 ~ 55.9 N·m (4.9 ~ 5.7 kgf·m) End cover assembly disassembling procedure [Caution] When clamping the assembly by vice etc., use care not to pinch the copper plate and give damage to the machine finished surface.
  • Page 338 12) Remove the plug (V12) which is fitted to the spool (V7), and remove the spring (V10) and Counter-balance poppet (V8). 13) Remove the orifice (16) which is fitted to the housing. 14) Remove the plug (V4), spring (V3) and spool (V2).
  • Page 339 15) Remove the plug (V19), and then remove the pilot poppet (V20), spring (V21) and orifice plate (V23). Use care not to confuse right and left combination of the pilot poppets. This procedure is not needed for TRBF (1- speed motor). 16) Remove the check plug (V16) and take out the ball (V18).
  • Page 340 2) Mount the orifice plate (V23), spring (V21) and pilot poppet (V20), and tighten the plug (V19) with specified tightening torque. • Tightening torque: 0.8 kgf·m Use care not to confuse right and left combina- tion of the pilot poppets. This procedure is not needed for TRBF (1- speed motor).
  • Page 341 5) Insert the Counter-balance poppet (V8) and spring (V10) into the spool (V7), and tighten the plug (V12). • Apply loctite No.242 to threads. • Tightening torque: 3 kgf·m 6) Insert the spool (V7), washer (V13) and spring (V9) (Mounting direction is free) one by one, and tighten the plug (V11).
  • Page 342 Motor assembly procedure 8) Put in the spacer (21). 9) Apply grease to the X-ring (23) put it in. 10) Insert the spring (15) in the valve and fit in the sleeve (22). If frictional force of sleeve's O-ring is large and the spring which is elongated up to the bottom will not return, push the sleeve slightly out of the valve hole.
  • Page 343 11) Mount the parallel pin (16) to the valve (19). (2 locations) Apply grease to it and put it upside down so that the pin should not drop. Put a mark beforehand by felt pen to the inner side of the position where the pin is mounted to the valve.
  • Page 344 14) Mount the valve plate (17). Phase position can be aligned by matching with the wheel hole. Put a mark by felt pen to the same phase posi- tion as the position where the valve is marked. 15) Put a mark to one of the teeth of the drive (20) and fit it in by matching to the mark of aforesaid hole side.
  • Page 345 17) Clamp and fix the end cover assembly (27) and turn the wheel and valve plate to align it with the bolt holes of the geroller. (There is only one phase position to be able to match all the bolt holes.) Phases of the inside bolts and outsides bolts are matched at one position.
  • Page 346 (2)Troubleshooting Troubles Causes Remedies Motor does not rotate. • Oil volume in tank is insufficient. • Supply hydraulic oil up to appropriate level. • Pump is broken. • Replace pump. • Malfunction of relief valve or low set pres- • Disassembly and wash relief valve, and set sure it at appropriate pressure.

  • Page 347: Cylinder

    d. Cylinder Boom cylinder and component parts Assy cylinder, Boom Bush, Pin Bush, Pin Gasket Ring, Backup Scaraper O-ring Ring, Buckup O-ring Bush Piston SPG Seal Wearing Screw, Set RA028-024-10 Ball Ball Spring Plug, Screw Kit tube, Cylinder Kit rod, Cylinder Kit seal Arm cylinder and component parts Assy cylinder, Arm...
  • Page 348 Bucket cylinder and component parts Assy cylinder, Bucket Bush, Pin Bush, Pin Gasket Ring, Backup Scaraper O-ring Ring, Buckup O-ring Bush Piston ST Seal Wearing Kit tube, Cylinder RA028-026-10 Kit rod, Cylinder Kit seal Blade cylinder and component parts Assy cylinder, Blade Bush, Pin Bush Seal, Dust...
  • Page 349 Swing cylinder and component parts Assy cylinder, Swing Bush Seal, Dust Bush, Pin Gasket Rung, Backup Scraper O-ring Ring, Backup O-ring Bush Piston ST seal Nipple, Grease RA028-028-10 Kit tube, Cylinder Kit rod, Cylinder Kit seal Track cylinder and component parts Assy cylinder, Track Bush Blank...
  • Page 350 (2)Disassembling and assembling 1) Disassembling 1. Place the cylinder on a vise. 2. Let hydraulic oil out of the cylinder. 3. Undo the lock washer. Hammer Chisel Lock washer 4. Loosen the cylinder head screw and detach the cylinder head. Pipe Hook wrench 5.
  • Page 351 6. Apply a wrench to the hex nut of the piston. Loosen the nut. 7. Draw out the piston and remove the shim 8. Remove the cushion bearing. Shim Cushion bearing 9. Draw out the cylinder head. 10.Release the piston rod from the vise. IV-S-95 Courtesy of Machine.Market...
  • Page 352 (3)Inspection 1.Piston rod warp Mount the piston rod on a V-block. Set a dial indicator at the center of the rod. Rotate the piston rod and read the indicator. Warp is one-half of the difference between the maxi- mum and the minimum readings. If the valve exceeds the allowable limit, replace the piston rod.

  • Page 353: Route Of Hydraulic Hose

    F. Route of Hydraulic Hose (1)Route of control valve hydraulic hose (Fixed leg, 1-speed) Swivel motor Swivel motor right side (No tape) Swivel motor left side (Pink) Arm rod side (Red) Arm bottom side (Blue) * Boom bottom side (white) * Boom rod side (No tape) Swivel joint C port (Shaft side) (Green) Swivel joint B port (Shaft side) (Yellow)
  • Page 354 Blade cylinder Tightening torque of blade cylinder hose For blade cylinder side only Swivel joint 29.4 ~ 34.3N·m (3.0 ~ 3.5 kgfm) (Top) B:Straight pipe joint Body 1 P:Pipe joint Leg extending (Changeover valve) A:Straight pipe joint /retracting cylinder (Bottom) (Top) Swivel joint body (Bottom)
  • Page 355 4) Tightening torque of the plug: 58.8 ~ 63.7 N·m (6.0 ~ 6.5 kgf·m) IV-S-99 Courtesy of Machine.Market...
  • Page 356 Route of K008-3 return hose (1-speed) Detail of Provide more than Hose clamp (15-24) 5 mm clearance. Pipe joint (S, T3/8-13.8) Specification with SP Valve ass'y (Check) Elbow pipe joint (G3-G3) Hose (Return, 3) Pass the hose through Pipe (Return)
  • Page 357 Route of U10-3 return hose (2-speed) Avoid contacting swivel frame. Detail of Spec. without SP Specification with SP Provide more than Pass the hose through 5 mm clearance. the lowermost part below hydraulic hoses in the swivel frame. Hose clamp (15-24) Pipe joint (S, T3/8-13.8) Valve ass'y (Check) Elbow pipe joint (G3-G3)
  • Page 358 IV-S-102 Courtesy of Machine.Market...
  • Page 359 . Electrical system(Service section) A. Wireharness............V-S-3 a.
  • Page 360 V-S-2 Courtesy of Machine.Market...

  • Page 361: Wireharness(1)

    A.Wireharness a. Wireharness(1) b. Wireharness(2) c. Wireharness(3) V-S-3 Courtesy of Machine.Market...
  • Page 362 V-S-4 Courtesy of Machine.Market...

  • Page 363: Electric Wiring

    B. Electric Wiring a. Cautions on electric wire clamping method 1. There should be no contact or possible contact with surroundings of wire. There should be no contact of wire at a place where no protective material is provided. 2. Do not clamp electric wire together with fuel hose. 3.
  • Page 364 (A)Clamp to valve assembly (check) (B) Wiring to fuel sensor Cord band Starter switch Set the cord band between the operat- Cord band ing panel and the Bracket (Step) If the cord band is Valve assembly (Check) placed on the bracket (step), it may pinched by the step...
  • Page 365 (G) Clamping of the battery plus cord and (H) Clamping to the support (radiator) the wire harness (1) to the swivel frame. Support (Radiator) To horn Cord (Battery, plus) Cord band Lamp Wire harness of fuel pump Cord band * Clamp the battery plus cord and the wire har- * Clamp the battery plus cord and the wire harness of ness (1) to the swivel frame.
  • Page 366 (L) Assembling the cord (battery plus) (M)Wiring to working light Mount by pressing it to resin. Resin Starter assembly Working light Wire harness (1) Cord band Battery (Plus) * Clamp the wire harness of the working light securely. * Starter terminal tightening torque Front Route should be as shown in the right *Cord band...

  • Page 367: Troubleshooting Of Electric System

    C.Troubleshooting of Electric System a. Outline pf troubleshooting (1)Procedure The most important thing in conducting troubleshooting is "to estimate the cause". It is also essential to nar- row down the checking points and cut out excess checking work by estimation of the cause. The estimation of cause must require the theory and the proof based on facts and must not lean on intuition.

  • Page 368: Cautions In General

    b. Cautions in general (1)Checking of conductivity and voltage at coupler In order to prevent loose connection of coupler and deterioration of waterproofing property of coupler, per- form checking of conductivity and voltage at coupler in the procedure as follows. Checking of ordinary (non-waterproof) coupler 1) Ordinary (Non-waterproof) coupler Carry out checking by inserting the test lead from the...
  • Page 369 (3)Checking method 1) Visual checking and checking by sound Trouble with the machine can be checked by operation of invisible parts such as by operating sound of relay, motor rotating sound and lamp lighting though the flow of electricity is invisible. 2) Summary checking For example, when there is such a trouble that the head lamp does not light up and fuse is considered to...
  • Page 370 (4)Checking of fuse 1) Cautions at blowing of fuse When fuse is blown, two causes are considered. One is the case where fuse is blown by overcurrent of higher than rated value, and the other is the case where fuse is blown by repetition of intermittent cur- rent.
  • Page 371 (5)Checking of wire harness 1. There should be no looseness, rust nor taint dam- age at connections. 2. Terminals or wires should not be corroded by bat- tery electrolyte. 3. There should be no breakage nor half-breakage of terminals and wires. 4.
  • Page 372 (7)Measuring instrument and special tools In proceeding to checking work, use of the tester and special tools will be helpful for safe and speedy work. • HIOKI Digital Hi-tester (3256-01) Characteristics: Measurable of frequency (Hz) • Special tools Use these tools when test lead can not be connected to coupler or connector, or fixed to it. Name of item;...

  • Page 373: Troubleshooting

    c. Troubleshooting (1)Engine system Troubles Checking points Remedies Remarks 1) Starter does not 1. Isn't slow-blow fuse (30A) blown? Check or replace. rotate. 2. Isn't battery terminal loosened? Re-tighten. 3. Is voltage is higher than 10.5 V at battery both ends ((+), Charge or replace.
  • Page 374 (3)Panel (Engine start) Troubles Checking points Remedies Remarks 1) Charge lamp does 1. Isn't fuse (5A) blown? Replace. not go out. 2. Isn't output terminal or coupler of dynamo removed? Repair or replace. 3. Does dynamo work normally? Repair or replace. 2) Oil lamp does not 1.

  • Page 375: Checking Procedure

    d. Checking procedure (1)Starter 1) Flow of electricity Key Switch Circuit Terminal 19 30 17 50 AC 2) Starting principle 1. Starter switch OFF Voltage from the battery is applied at all times to the starter B, slow-blow fuse and starter switch 30 ter- minal.
  • Page 376 3) Checking at the time when starting is impossible When starter switch is at start position, check whether battery voltage is applied to the starter S terminal (1) or not. (Photo 4) • When voltage is not applied: 1. Slow-blow fuse is blown (Photo 3) (Visually check to see whether or not shortcircuit occurs between wires.) 2.
  • Page 377 4) Testing the motor [Cautions] Starter • Starter moves by reaction when it is rotated. There- fore, be sure to fix it firmly by vice. • Use connection cable of diameter large enough for flowing of large electric current (several hundred amperes).
  • Page 378 (2)Engine stop 1) Flow of electricity At engine start At engine stop Key Switch Circuit Terminal 19 30 17 50 AC 2) Engine stop principle At starter SW ON Battery voltage is applied to the timer relay terminal (4) (Photo 1) at all times regardless of opera- tion of the starter switch.
  • Page 379 3) Checking to be done when engine does not stop • At (Immediately after) starter SW OFF, check to see if voltage (12) is applied to the engine stop solenoid terminal for 10 sec. (Photo 3) When voltage is not 1.
  • Page 380 Apply battery voltage to the engine stop sole- Check conductivity between the solenoid ter- noid and check to see whether or not the minal and the body ground. (Photo 6) injection rubber is drawn in and the rack bar returns when the application of voltage is stopped.
  • Page 381 This AC dynamo is so designed as to mount a cooling fan at the shaft end and composed of a rotor and sta- tor. The stator has six magneto coils around which the rotor having (six) permanent magnets rotates to gener- ate alternating current at the stator coils.
  • Page 382 4) Conductivity of regulator [Cautions] Check the conductivity between the connector termi- nals by using resistance range of circuit tester accord- ing to the table. "ON" stands for "Conductive", while "OFF" for "Non-conductive". This regulator is not always normal even if all the items are normal. How- Black ever, should any one of them be abnormal, the regula- Vacant...
  • Page 383 (4)Horn, fuel pump and working light 1) Flow of electricity Key Switch Circuit Terminal 19 30 17 50 AC 2) Operating principle of horn, fuel pump and working light At starter SW ON Battery voltage is applied by the starter switch AC terminal to the working light switch and horn switch, and current flows to the fuel pump.
  • Page 384 (5)Charge lamp, oil lamp and fuel lamp 1) Flow of electricity Key Switch Circuit Terminal 19 30 17 50 AC 2) Operating principle of charge lamp, oil lamp and fuel lamp At engine stop 1. Since the dynamo does not rotate, no electricity is generated and the regulator feeds electric current to the charge lamp to light it up.
  • Page 385 3) Checking to be done when the lamps do not light up Check the charge lamp and oil lamp when the engine is stopped, and check the fuel lamp after depleting the fuel tank to see if the bulb of the lamp is dead. In addition, check to see it voltage is applied to every coupler of the lamps.
  • Page 386 5) Checking of fuel sensor • Dismount the fuel sensor from the fuel tank for checking. • Bring the plus test read into contact with the cou- pler CN23 [3]. • Bring the minus test lead into contact with the plated part to measure the resistance.
  • Page 387 (6)Others Horn SW 1) Checking of horn 1. Measurement of voltage at horn terminal • Key switch: ON • Horn switch: ON 12 V: Normal Check the horn. Other than 12 V: Check the conductivity. Check the horn. 2. Checking of horn switch •...
  • Page 388 V S-30 Courtesy of Machine.Market...
  • Page 389 Courtesy of Machine.Market...
  • Page 390 KUBOTA Corporation CONSTRUCTION MACHINERY DIVISION 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN EDITOR: CONSTRUCTION MACHINERY MANUFACTURING DEPT. SERVICE SECTION HIRAKATA PLANT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN PHONE :+81-72-840-1195 :+81-72-890-2886 KUBOTA Corporation Printed in Japan 0308.CMC.e.12 Code No.97899-60730 Courtesy of Machine.Market...

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