Kubota WSM U35-4 Manual

GENERAL

CHECKING EXCAVATOR IDENTIFICATION

When consulting with your local KUBOTA dealer about this machine, please provide the model of the machine, its frame and engine numbers and the number of hours on the hour meter.

1. Machine Nameplate (Model, Frame Number, Engine Number)
   
   1. Model Nameplate
      
2. Frame Number
   
3. Engine Number
   

ENGINE IDENTIFICATION

1. MODEL NAME AND SERIAL NUMBER
   Be sure to check the engine nameplate and serial number when you wish to consult about the engine.
   The model and serial number of the engine need to be checked prior to servicing the engine or replacing any of its parts.

Engine Serial No.
The engine serial number is the numerical ID of the engine and is printed after the engine's model number.
The year and month of manufacture are indicated as follows.

Engine Series

Production Year

1. Engine Model Name and Serial Number

Production Month and Lot Number

* Alphabetical letters "I" and "O" are not used.

1. D1703: Engine Model Name
2. 7: Engine Series (03 series)
3. C: Production Year (2012)
4. U: Production Month (October)
5. 1237: Lot Number: (0001 to 9999 or A001 to Z999)

1. EU regulation engine output classification category
2. "E4B" engines are identified with "EF" at the end of the Model designation, on the US EPA label.
   "E4B" designates some Interim Tier 4 / Tier 4 models, depending on engine output classification.

3. CYLINDER NUMBER
   You can see the cylinder numbers of KUBOTA diesel engine in the figure.
   The sequence of cylinder numbers is No.1, No.2 and No.3 and it starts from the gear case side.
   

GENERAL PRECAUTIONS

Whenever performing maintenance on the machine, always read the Safety Precautions in this manual and the Operator's Manual carefully, become familiar with them and perform the work safely.
Before performing any maintenance on the machine, make sure it is sufficiently clean and choose a sufficiently clean location to perform any disassembly.
Before performing maintenance on the machine, always disconnect the negative battery cable first.
Whenever a special tool is required, use the special tool that KUBOTA recommends. Make any special tools that are not used very frequently according to the diagrams in this manual.
Always use genuine KUBOTA parts to maintain the performance and safety characteristics of the machine.

Plumber's Tape

• Wrap plumber's tape on the threads before tightening taper couplings. After wrapping (2 wraps) the plumber's tape, tighten to the specified torque. Once the coupling is tightened, do not loosen it as this will cause an oil leak.

1. Plumber's Tape
2. External Thread
3. Internal Thread
4. Gap
5. Leave 1 to 2 Threads

O-Ring

• Clean the groove the O-ring goes in and remove any burrs. Apply grease on the O-ring when inserting it in the groove. (Except floating seals)
• When putting the O-ring in the groove, be careful as it is easy at the very end to twist the O-ring against the inside of the groove. If it gets twisted, roll it gently with your fingertip to untwist it.

1. O-Ring Groove
2. O-Ring Will Twist
3. Check for Burrs
4. If the Ring Touches This Corner, It

Oil Seal

1. Do not face the lip of the oil seal in the wrong direction. Face the main lip toward the material to be sealed.
2. After oil seals are replaced, apply grease to the moving parts around the lip to prevent the dry surfaces from wearing against each other when the engine is started. If the seal has a dust lip, fill the gap between the lips with grease.
3. As a general rule, use a press to insert the oil seal in place. If that is not possible, use an appropriate tool to gently and evenly tap it into place, taking care that it does not go in at a slant. Press the seal all the way so it seats in the boss.

1. Gasket
2. Metal Ring
3. Spring
4. Main Lip
5. Grease
6. Dust Lip

1. Air (Outside)
2. Hydraulic Chamber (Inside)

Floating Seal

• Be sure to wipe off any oil from the O-ring or surfaces that touch the O-ring. (For wheel motors, apply a light film)
• When putting an O-ring into a floating seal, make sure the O-ring does not twist.
• Apply a light film of oil to surrounding surfaces when working to get the floating seal with O-ring in place; take care that the surrounding surfaces, O-ring and housing are parallel with each other.
• After getting the seal in place, turn the engine over 2 or 3 revolutions, to both create a film of oil on surrounding surfaces and to properly seat the face of the seal.

1. Surrounding Surfaces
2. O-Ring

Snap Ring Related

• When installing external or internal snap rings, orient them as shown in the diagram so the angled side faces the direction of force.

1. Position so the Angled Part Receives the Force

1. External
2. Internal

Spring Pins

• When driving a spring pin, face the split in the direction that receives the force, as shown in the diagram.

1. With Lateral Movement
2. With Rotational Movement

Adhesive

• Clean and dry the area where adhesive will be applied with a solvent so it is free of moisture, oil and dirt.
• Apply adhesive all around the threads of the bolt except the first set of threads at the tip and fill the grooves between the threads. If the threads or the grooves are large, adjust the amount of adhesive accordingly and apply it all around the bolt hole as well.

1. Bolt Through-Hole (Nut)
2. Pocket Bolt Hold
   (Capsule Shape, etc.)

1. Apply Here
2. Do Not Apply
3. Drip On

• Tighten bolts and nuts to their specified torque.
• Tighten nuts and bolts alternately top/bottom(a) (b), left/right so the torque is distributed evenly.

1. Top/Bottom Alternately
2. Across Diagonally
3. Diagonally Across the Center

Assembling Hydraulic Hoses

• Tighten to their specified torque.
• Before assembling, wipe the inside of metal fittings clean of any dirt.
• After assembly, put the fitting under normal pressure and check that it does not leak.

Elbow with Male Seat Assembly Procedure
When assembling an elbow with male seat, adhere to the following procedures to prevent deformation of O-rings and leaks.

1. Connecting to Valves
   
   • Clean the blow with male seat and the surface of the seal opposite and mount with the lock-nut on top.
   • Finger tighten till it touches the washer.
2. Positioning
   
   • Turn the mouth of the elbow back so it faces the right direction. (not back over 1 turn)
3. Fasten
   • Tighten the lock-nut to the specified torque with a wrench.
     
   1. Lock-Nut
   2. Washer
   3. Seal (O-Ring)
   4. Wrench for Holding
   5. Hose
   6. Torque Wrench for Tightening

Installing and Removing Quick Couplings

• To remove a quick hose coupling, push the fitting (2) in the direction of the arrow and pull on the plastic part (1) in the opposite direction.
• To attach a quick coupler, push it in firmly in the direction of the arrow. Then check that it will not pull off.

1. Plastic Part
2. Fitting

HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING

Follow the precautions below for handling electrical parts and wiring to ensure safety and prevent damage to the machine and nearby equipment.

• Inspect electrical wiring for damage and/or loose connections.
• Do not alter or rewire any electrical parts or wiring.
• Always remove the negative battery cable first when disconnecting the battery and attach the positive cable first when connecting it.

1. Battery Cable (-) Side
2. Battery Cable (+) Side

1. WIRING

• Tighten wiring terminals securely.
  
  1. Correct (Tightened Securely)
  2. Incorrect (Poor Contact if Loose)

• Keep wiring away from hazards.
  
  1. Hazardous Positioning
  2. Wiring Position (Wrong)
  3. Wiring Position (Right)
  4. Hazardous Position

• Immediately repair or replace old or damaged wiring.
  
  1. Damaged
  2. Torn
  3. Electrical Tape

• Insert grommet securely.
  
  1. Grommet

1. Correct
2. Incorrect

• Clamp wiring securely but do not damage wires with the clamp.
  
  1. Clamp (Spiral Clamp Around Wire)
  2. Wire
  3. Clamp
  4. Welding Mark

• Clamp wiring so it is not twisted, pulled too tight or sag too much. However, moving parts may require play in the wiring.
  
  1. Wire
  2. Clamp

1. Correct
2. Incorrect

1. Incorrect

• After wiring, double-check terminal protectors and clamps before connecting battery cables.
  
  1. Cover (Install Covers Securely)

2. FUSES
   • Always use fuses of the specified capacity. Never use over or undersized fuses.
   • Never use copper or steel wire in place of a fuse.
   • Do not install accessories such as work lights, radios, etc., if your machine does not have an auxiliary circuit.
   • Do not install accessories as they will exceed the capacity of fuses.
     
   1. Fuse
   2. Fusible Link
   3. Slow-Blow Fuse

3. CONNECTOR

• Press the lock to disconnect locking connectors.
  
  1. Push

• Hold the connectors when separating them.
• Do not pull on the wire harness to separate the connectors.
  
  1. Correct
  2. Incorrect

• Straighten bent prongs and make sure none are sticking out or missing.
• Remove corrosion from terminals with sandpaper.
  
  1. Missing Terminal
  2. Bent Prong
  3. Sandpaper
  4. Corrosion

• Female connectors must not be spread too far open
  
  1. Correct
  2. Incorrect

• The plastic covers of connectors must cover them completely.
  
  1. Cover

1. Correct
2. Incorrect

4. WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER
   Using a high-pressure washer incorrectly can lead to personal injury and/or damage, break or cause parts of the machine to fail, so use the power washer properly according to its operator's manual and labels.
   
   • Stand at least 2 meters from the machine and adjust the nozzle for a wide spray so it does not cause any damage. If you blast the machine with water or wash it from too close a distance,
   1. It may cause a fire due to damaged or cuts in the insulation of electrical wiring.
   2. An injury may result if hydraulic oil gushes out under high pressure, due to damaged hydraulic hoses.
   3. It may damage, break or cause parts of the machine to fail.
      1. Stickers or labels may come off
      2. Electrical parts or the engine may fail due to water in them.
      3. Damage glass, resins, etc. or the rubber of oil seals.
      4. Tear off paint or the film from plating
         
         1. Do Not Blast with Water
         2. Never Wash from Too Close

1. Blasting
2. Wide Spray
3. Less Than 2 m (80 in.)
4. Over 2 m (80 in.)

TYPES OF OIL

TABLE OF OIL AND FLUID CAPACITIES

CHECKING AND FILLING HYDRAULIC OIL
Stop vehicle body on horizontal ground, extend cylinder rods to near central position, and place bucket and blade on the ground.
Check that the oil level is in the centre of the oil level gauge when the hydraulic oil is at room temperature (10 to 30°C).
The level is normal, if the oil is in the range (a) at or above the centre of the level gauge.
If there is insufficient oil, refill via the filler port.

1. Filler port
2. Oil level gauge

1. Normal range of hydraulic oil

TIGHTENING TORQUES

GENERAL USE SCREWS, BOLTS AND NUTS
Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below.

STUD BOLTS

TORQUE FOR HYDRAULIC HOSE FITTINGS

1. Torque for Hydraulic Hose Fittings
   Union Nuts

   Tightening torque	1/8	7.8 to 11.8 N·m 0.8 to 1.2 kgf·m 5.7 to 8.7 lbf·ft
   	1/4	24.5 to 29.2 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft
   	3/8	37.2 to 42.1 N·m 3.8 to 4.3 kgf·m 27.5 to 31.1 lbf·ft
   	1/2	58.8 to 63.7 N·m 6.0 to 6.5 kgf·m 43.4 to 47.0 lbf·ft
   	3/4	117.6 to 127.4 N·m 12.0 to 13.0 kgf·m 86.8 to 94.0 lbf·ft
   	1	181.3 to 191.1 N·m 18.5 to 19.5 kgf·m 133.8 to 141.0 lbf·ft
   	1-1/4	210.7 to 220.5 N·m 21.5 to 22.5 kgf·m 162.7 to 168.0 lbf·ft

   1. Union Nuts

Tapered Nuts

1. Taper

1. Taper

TO THE READER

This Workshop Manual provides service personnel with information about the mechanisms, service and maintenance of the construction machine. The Manual is divided into three sections, General, Mechanisms and Service.

• General
  This section contains information such as engine and equipment ID numbers, general precautions, maintenance schedules, inspections and maintenance items.
• Mechanisms
  This section describes the structure of mechanisms and explains their functions. Be sure that you fully understand this Mechanisms section prior to performing any service work, such as troubleshooting or when performing any disassembly or assembly work.
• Service
  This section contains information and procedures for performing maintenance on the mini-excavator, such as troubleshooting, service specification tables, torque specifications, items to be inspected and adjusted, disassembly and assembly procedures, as well as precautions, maintenance standard values and usage limits.
  All of the illustrations, specifications and other information in this manual were created based on the latest model at the time of publication.
  Please be aware that changes to the content may be made without prior notice.
• NOTE
  • Applicable Models

    Model	Engine
    U35-4	D1703-M-DI-E4-BH

• • Please refer to the "Workshop Manual" below for information about the engine.

INFORMATION

SAFETY FIRST

IN THE INTEREST OF WORK SAFETY

WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS:

Precautions Before Working on the Mini-Excavator
Before starting any service or maintenance work,

• Read all the general and safety instructions in this manual, as well as the decals on your equipment.
• Always stop the engine whenever you leave the driver's seat to inspect or clean the machine or its devices, or to inspect or adjust parts.
• Choose a safe spot for inspecting the equipment-on flat, hard ground.
• When performing maintenance on the equipment, hang the DO NOT OPERATE sign where it will be obvious from and around the driver's seat.

• When performing maintenance or repairs, always lower attachments to the ground, stop the engine and set the brake.
• When performing maintenance on the equipment, always disconnect the negative battery cable.
• Before using tools, make sure you understand how to use them correctly and use tools in good condition and of the right size for the job.

Be Ready for an Emergency

• Keep a first-aid kit and fire extinguisher close at hand so you can use it when needed.
• Keep emergency contact information for doctors, hospitals and ERs handy.

• Wear clothes appropriate for working on equipment. Do not wear loose-fitting clothes as they may catch on the machine controls.
• When working on the equipment, use all safety gear, such as a helmet, safety glasses and shoes, that are required by law or regulation.
• Never perform maintenance while drowsy or under the influence of alcohol or drugs.

Precautions Before Working on the Equipment

• Stop the machine on a hard and level location and make sure the area around the machine is free of obstacles and hazardous materials. When parking the machine indoors, select a spot that can be properly ventilated.
• When performing work such as with a hammer, fragments may go flying, so make sure only authorized persons are around the machine. Before servicing the machine, clean it off so there is no mud, debris, oil or the like sticking to it.

• Before getting on/off of the machine, clean off around the steps so there is no mud on them. Always give yourself 3-point support when getting on/off the machine.

• 3-point support means using both legs and one hand or both hands and one leg as you climb up/down.

Starting the Machine Safely

• Before starting the engine, always sit in the driver's seat and make sure the area is safe and clear. As it is dangerous, never start the engine from anywhere but the driver's seat.
• Always check and make sure control lever(s) are not engaged before starting the engine.
• Never start the engine by hot-wiring the starter circuit. This is not only dangerous, but may damage the machine.
• Whenever it is necessary to open the engine covers or hood in order to service the machine, always prop them open.
• If it is absolutely necessary to run the engine while working on the machine, make sure you are clear of all rotating or moving parts. Also take care not to leave anything, such as tools or rags, near any moving parts.
  

• The engine, muffler, radiator, hydraulic line, etc., have parts that remain very hot even after the engine has been stopped. Be sure to avoid these parts, as touching them can result in burns. Radiator coolant, hydraulic fluid and oil also remain hot. Therefore, do not attempt to remove caps and plugs, etc., before these fluids have sufficiently cooled.
• Make sure the coolant temperature has dropped sufficiently before opening the radiator cap. Also, since the inside of the radiator is pressurized, when removing the cap, first loosen it to release the pressure before removing the cap completely.

• The pressure in the hydraulic circuit stays at pressure even after the engine stops.
  Before removing parts, such as hydraulic devices from the machine, first release the pressure. Please note that when releasing residual pressure, the machine itself and/or implements may move without warning, so be very careful when releasing the pressure.
• Oil gushing out under pressure is extremely dangerous as it may pierce your skin or your eyes. Similarly, oil leaking out of pinholes is not visible. So when checking for oil leaks, always wear safety glasses and gloves and use a piece of cardboard or a wood block to shield yourself from oil.

No Smoking or Open Flames while Fueling

• Fuel is extremely flammable and dangerous. Never smoke near fuel. If fuel is spilled on the machine, its engine, or electrical parts, it may cause a fire. If fuel is spilled, wipe it all up immediately.
• Never smoke while filling the machine with fuel. And always tighten the fuel cap securely and wipe up any spilled fuel.

• Always wear safety glasses and gloves when handling the battery.
• The gas generated by the battery is flammable. Never weld or use tools like a grinder near the battery. And never smoke near it.
• When disconnecting the battery, always disconnect the negative cable first. When connecting the battery, always connect the positive cable first.

LABELS DISPLAYED TO PROMOTE WORK SAFETY

1. LOCATIONS
   
   
   
   
   
   
   
2. LABEL MAINTENANCE
   Thoroughly Read, Understand and Follow Safety Precautions on Labels

• Always keep labels in a clean, undamaged state.
• If labels get dirty, wipe them off with soapy water and a soft cloth.
  If solvents such as paint thinner or engine oil are used, the text and or figures may fade away.
• When using a pressure washer to clean the equipment, do not spray any labels directly as doing so may make them peel off.
• If a label is damaged or lost, order a new one from your dealer and affix it as before.
• Before affixing a new label, completely wipe off any dirt or grime on the surface, allow it to dry and then affix in the same place.
• When replacing a part that has a label on it, replace the label at the same time.

MAIN SPECIFICATIONS

US, CA SPECIFICATION

NOTE

• Above dimensions are based on the machine with rubber trucks.
• Specifications subject to change without notice.

∗ With unloaded digging bucket. (Q/C BUCKET)
∗ Firm compacted soil.
∗ Operators must exercise extra caution and follow instructions in the operator's manual.
∗ Worse condition or heavier attachment to the above will decrease climbing angle.
∗ Operator's weight: 75 kg (165 lbs)

AU SPECIFICATOION

NOTE

• Above dimensions are based on the machine with rubber trucks.
• Specifications subject to change without notice.

∗ With unloaded digging bucket. (Q/C BUCKET)
∗ Firm compacted soil.
∗ Operators must exercise extra caution and follow instructions in the operator's manual.
∗ Worse condition or heavier attachment to the above will decrease climbing angle.

DIMENSIONS

* Dimensions in parentheses: CANOPY type models

NOTE

• Above dimensions are based on the machine with KUBOTA original bucket.
• Above dimensions are based on the machine with rubber track.
• Specifications subject to change without notice.