Kubota Workshop Manual
Kubota U35 Workshop Manual
Document number 97899-60640 · English PDF edition · 273 pages
About this manual
Kubota published this Workshop Manual for the U35 excavator models. It brings the documented service and technical-reference material for those named excavators into a single publication.
The manual is especially useful for work that crosses electrical and hydraulic systems: it includes electrical troubleshooting, alongside hydraulic diagrams, pressure-test evidence, and valve-adjustment information.
Use the Manual Contents below to check that the exact repair, inspection, or maintenance procedure you need is included in this publication.
Manual details
- Manufacturer
- Kubota
- Manual type
- Workshop Manual
- Models
- U35
- Document number
- 97899-60640
- Language
- English
- Page count
- 273
Product highlights
Electrical systems
The manual includes wiring diagrams and electrical troubleshooting.
Hydraulic systems
The manual includes hydraulic circuit diagrams, hydraulic pressure-test material, and hydraulic valve-adjustment material.
Special tools
A special-tools section is included.
Maintenance
The manual includes a lubrication chart.
Manual contents
Use these source headings to locate the task or system you need in the PDF.
- CONTENTS — p. 2
- I. General — p. 3
- A. Body and engine identification marks — p. 4
- B. Safty precautions for servicing, disassembly and reassembly — p. 5
- a. Safty measures before starting work — p. 5
- (1) Work clothes — p. 5
- (2) Inspecting equipment and tools — p. 5
- (3) Keep workshop in order — p. 5
- b. Safty measures during work — p. 5
- (1) Protectors — p. 5
- (2) Team work — p. 5
- (3) Disassembly and assembly — p. 5
- (4) Cranes — p. 5
- (5) Others — p. 5
- c. Preparation for disassembly — p. 6
- (1) Cleaning — p. 6
- (2) Acceptance inspection — p. 6
- (3) Equipment and tools — p. 6
- d. Precautions for disassembly and reassembly — p. 6
- (1) Disassembly — p. 6
- (2) Reassembly — p. 6
- a. Safty measures before starting work — p. 5
- C. IMPORTANT SAFTY PROCESS AND CRITICAL FUNCTIONAL PROCESS — p. 7
- a. Essential Adhesives — p. 7
- b. Important Safety Process . — p. 7
- c. Important Critical Functional Process . — p. 7
- D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING — p. 7
- F. Maintenance intervals — p. 8
- a. KTC, KCL, KTA-version — p. 8
- b. EU(KE, KDG, KUK)-version — p. 9
- c. Hydraulic Oil Check for machines with Hydraulic Breakers — p. 10
- G. Water and oil quantity — p. 11
- H. Recommended oil — p. 12
- I. Filters — p. 13
- J. Tightening torque — p. 14
- a. Hose screw — p. 14
- Metric Size Hose — p. 14
- b. Joint bodies — p. 14
- c. Tightening torque table for hose clamp (Screw type) — p. 15
- d. Nuts for piping — p. 15
- e. Tightening torque of bolts and nuts — p. 16
- f. Types and materials of bolts and nuts — p. 16
- g. Washer-equipped elbow — p. 17
- a. Hose screw — p. 14
- K. Machine Quality Specifications — p. 18
- II. Machine body(Mechanism section) — p. 28
- A. Front attachment — p. 30
- a. Greasing points — p. 7
- b. Component interchangeability — p. 31
- B. Component interchangeability — p. 32
- a. Bucket interchangeability — p. 32
- b. Arm — p. 34
- c. Installing direction of dust seal — p. 35
- d. Installation of bushing and thrust collar on the swing bracket — p. 35
- e. Installing pin, bush and shim (1):U35 — p. 36
- f. Installing pin, bush and shim (2):U35 — p. 37
- g. Installing pin, bush and shim of bucket : U35 — p. 38
- h. Installing local bucket : U35 — p. 39
- A. Front attachment — p. 30
- II. Machine body(Service section) — p. 40
- A. Specifications — p. 42
- a. Machine Weight — p. 42
- (1) KE, KDG, KUK version — p. 42
- (2) KTC, KCL, KTA version — p. 42
- b. Machine specifications — p. 43
- (1) KE, KDG, KUK version — p. 43
- (2) KTC, KCL, KTA version — p. 44
- c. Lever stroke and operating force — p. 45
- d. Dimensions of Parts — p. 46
- (1) Front pins — p. 46
- (2) Bucket — p. 47
- (3) Rubber crawler — p. 50
- (4) Iron crawler — p. 50
- (5) Track toller, idler, sprocket — p. 51
- (6) Dozer — p. 52
- (7) Parts weight — p. 53
- a. Machine Weight — p. 42
- B. Front attachment — p. 56
- a. Parts designation — p. 56
- C. Upper structure — p. 57
- a. Swivel frame : U35, U35-3 — p. 57
- b. Swivel bearing — p. 58
- c. Swivel bearing installation — p. 59
- d. Traveling lever — p. 60
- e. Traveling lever adjustment — p. 61
- f. Traveling lever lock — p. 62
- Adjusting the lever's neutral position — p. 62
- g. Accel lever (Non AI-version) — p. 63
- (3) AI motor side(AI-version) — p. 64
- (4) Engine side — p. 64
- (5) Accel cable — p. 65
- h. Swing pedal — p. 66
- i. Auxiliary port pedal — p. 67
- j. Limit switch installation — p. 68
- k. Hour meter cable, engine stop cable — p. 69
- l. Cab installation : KTC, KCL, KTA-version — p. 70
- m. Heater hose — p. 71
- n. Cab glass replacement procedure — p. 72
- (1) Application Procedure if SIKAFLEX (ULTRA-FAST) — p. 73
- (2) ULTRA-FAST application manual — p. 74
- (3) 255 EXTRA application manual — p. 76
- (4) H-rubber replacement procedure — p. 79
- (5) Broken glass repairing procedure (for adhered glass KX-2 Series made by KBT) — p. 80
- o. Seat belt — p. 82
- p. Weight installation — p. 83
- D. Under carriage — p. 84
- a. Tension spring pre-set length — p. 84
- b. Additional parts to change from rubber track to iron track — p. 84
- c. Track Roller and Upper Roller installation — p. 85
- d. Track tension adjustment — p. 86
- e. Grease tension cylinder, L — p. 87
- f. Drive sprocket — p. 88
- g. Rubber track — p. 89
- h. Iron track — p. 90
- A. Specifications — p. 42
- III. Engine — p. 92
- A. Engine mount — p. 94
- B. Radiator — p. 96
- C. Muffler — p. 97
- D. Pump coupling — p. 98
- E. Fuel hoses — p. 99
- IV. Hydraulic system(Mechanism section) — p. 102
- A. Features of hydraulic system — p. 104
- B. Hydraulic system specifications — p. 105
- C. Main pump — p. 106
- a. Structure & specifications — p. 106
- b. Performance curve — p. 107
- Variable displacement pump — p. 107
- D. Control valve — p. 108
- a. Specifications — p. 108
- e. Arm regeneration circuit — p. 109
- (1) Arm dump — p. 109
- (2) Arm Crowd — p. 109
- f. Oil flow of lock valve — p. 110
- (1) Operation of lock valve — p. 110
- (2) Boom operation — p. 112
- g. Function of lock valve (Anti-drift valve) — p. 114
- (1) Boom cylinder holding function — p. 114
- (2) Boom up function — p. 114
- (3) Boom-down function — p. 114
- E. Pilot valve — p. 115
- a. Structure & specifications : U35(KTC, KCL), U35-3(KTA) — p. 115
- b. Pilot valve control diagram : U35(KTC, KCL), U35-3(KTA) — p. 117
- c. KBM-make : Pilot valve : U35-3(EU) — p. 118
- F. Swivel motor — p. 119
- a. Structure & specifications — p. 119
- b. Function of negative brake — p. 122
- (1) Negative brake function(Unload condition) — p. 122
- (2) Negative brake release(On-load condition) — p. 122
- c. Function of valve section — p. 123
- (1)Make-up valve — p. 123
- (2)Function of shockless valve — p. 123
- d. Swivel Performance — p. 124
- (1) KE, KDG, KUK version — p. 124
- (2) KTC, KCL, KTA version — p. 124
- (3) Inner parts of the swivel motor — p. 125
- G. Rotary joint (Swivel joint) — p. 127
- H. Travel motor — p. 128
- a. Structure — p. 128
- (1) Relief valve — p. 128
- (2) Shockless piston — p. 128
- (3) Inner parts of the traveling motor — p. 129
- b. Travel motor specification — p. 131
- (1) KE, KDG, KUK version — p. 131
- (2) KTC, KCL, KTA version — p. 132
- a. Structure — p. 128
- J. Hydraulic circuit diagram — p. 134
- a. U35-3 European - version — p. 134
- b. U35 : KTC, KCL - version — p. 135
- c. U35-3 : KTA - version — p. 136
- d. Hydraulic components layout : U35, U35-3 — p. 137
- IV. Hydraulic system(Service section) — p. 138
- A. Troubleshooting — p. 140
- a. Common Circuit — p. 140
- b. Front Attachment — p. 142
- c. Swivel Circuit — p. 145
- d. Travel Circuit — p. 147
- B. Specifications — p. 148
- a. Relief valve pressure setting — p. 148
- b. Pump — p. 150
- (1) KE, KDG, KUK version — p. 150
- (2) KTC, KCL, KTA version — p. 151
- c. Cylinder — p. 152
- (1) Cylinder operating speed — p. 152
- (2) Cylinder natural fall amount — p. 152
- (3) Cylinder specifications — p. 153
- d. Swivel Performance — p. 155
- (1) KE, KDG, KUK version — p. 155
- (2) KTC, KCL, KTA version — p. 155
- e. Traveling Performance — p. 156
- (1) KE, KDG, KUK version — p. 156
- (2) KTC, KCL, KTA version — p. 157
- C. Testing — p. 158
- a. Testing Instruments & special tools — p. 158
- b. Pump flow — p. 160
- c. Pilot pressure — p. 161
- (1) Primary pressure — p. 161
- (2) Secondary pressure — p. 162
- d. Main relief valve — p. 163
- e. Overload relief valve — p. 165
- f. Swivel brake valve pressure — p. 167
- g. Traveling motor drain amount — p. 169
- h. Swivel motor drain amount — p. 170
- i. Swivel motor block performance — p. 171
- j. Traveling motor block performance — p. 172
- k. Operating speed — p. 173
- (1) Checking each operating speed. — p. 173
- (2) Boom cylinder — p. 173
- (3) Arm cylinder — p. 173
- (4) Bucket cylinder — p. 174
- (5) Swing cylinder — p. 174
- (6) Dozer cylinder — p. 174
- (7) Swivel speed — p. 175
- (8) Traveling speed — p. 175
- l. Straight travel performance — p. 175
- m. Cylinder natural fall amount — p. 176
- n. Control and Traveling lever operating force — p. 176
- o. Lever stroke — p. 176
- D. Disassembling and assembling — p. 177
- e. Swivel motor (KTC, KCL, KTA-version) — p. 177
- g. Rotary joint — p. 178
- (1) Inner parts of the rotary joint — p. 178
- (2) Assembling of the rotary joint — p. 179
- (3) Rotary joint seal installing procedure — p. 180
- (4) Jig picture — p. 181
- (5) Jig drawing — p. 182
- (6) Adaptor installation on the rotary joint (KTC, KCL, KTA version) — p. 183
- h. Cylinder (EU-version) — p. 184
- (3) Disassembling and assembling : EU-version — p. 184
- j. Hoses — p. 187
- (1) Pilot hose(1) — p. 187
- (2) Pilot hose(2) — p. 188
- (3) Pilot hose(3) — p. 189
- A. Troubleshooting — p. 140
- V. Electrical system(Mechanism section) — p. 190
- a. Components and harness layout : U35, U35-3 — p. 192
- b. Electric Circuit Diagram — p. 194
- c. Electric wiring Diagram — p. 196
- V. Electrical system(Service section) — p. 200
- A. Electrical Equipment Specifications — p. 202
- B. Wire harness installation — p. 205
- a. Precautions — p. 205
- b. Engine earth, starter switch — p. 206
- c. Main harness — p. 208
- d. Coupler insertion — p. 209
- e. Control box harness — p. 210
- f. Engine harness — p. 211
- g. Front harness — p. 212
- C. Troubleshooting — p. 214
- a. General — p. 214
- (1) How to diagnose — p. 214
- (5) CHECKING SWITCHES — p. 218
- (6) Checking fuses — p. 219
- (7) Solenoid test method — p. 220
- (8) Checking relays — p. 221
- (9) Checking cables and wires — p. 222
- b. Troubleshooting flow chart — p. 223
- (1) Starter motor failure to turn on — p. 223
- (2) Auto release malfunction — p. 224
- (3) Electronic accelerator failure — p. 225
- (4) Auto glow failure — p. 226
- (5) AI system failure — p. 227
- c. Front attachment — p. 228
- (1) Working lamp failure — p. 228
- (2) Safety lever lock circuit malfunction — p. 229
- d. Engine electrical system — p. 230
- (1) Engine oil pressure failure — p. 230
- (2) Water temp. sensor circuit malfunction — p. 231
- (3) Fuel sensor circuit — p. 233
- (4) Engine stop solenoid — p. 234
- (5) Charging system malfunction — p. 235
- (6) Auto glow controller — p. 237
- (7) Auto release controller — p. 239
- e. Auto idle system — p. 241
- (1) Troubleshooting outline — p. 241
- (2) AI pressure switch test method — p. 242
- (3) Governer sensor test method — p. 244
- (4) AI motor test method — p. 246
- (5) Engine speed sensor — p. 247
- (6) Auto glow circuit — p. 249
- f. AI version: AI controller (built-in microcomputer) Cases of trouble diagnosis with circuit tester — p. 251
- (1) “Water temperature sensor” line in trouble — p. 251
- (2) Other circuitry layouts and their trouble diagnosis — p. 253
- g. Cases of trouble diagnosis with circuit tester — p. 254
- h. Auto Idle(AI) version: Trouble diagnosis with lamp — p. 255
- (1) General — p. 255
- (2) Display and identification of errors in operating mode — p. 257
- (3) Entering the service mode — p. 258
- (4) Working on the 6 menus in the service mode — p. 259
- (5) Example:Alternation of engine idling speed — p. 261
- (6) Working on the 3 menus in the service mode — p. 262
- (7) Working on the AI motor drive menus in the service mode — p. 263
- (8) Entering the setup mode — p. 264
- (8) Lamp-identified fail symptoms, trouble spots and possible causes — p. 268
- a. General — p. 214
Capabilities
The source outline indexes servicing instructions, disassembly and assembly, maintenance tasks, checking and adjustment, mechanism explanations, and troubleshooting. Use these source-backed headings to locate the applicable task or system in the source PDF, then confirm model-specific notes, specifications, illustrations, and operating conditions at the relevant page before carrying out service work.
Keep the source's safety sequence, prerequisite steps, labels, units, configuration notes, and footnotes with the selected task; do not apply an isolated value outside the conditions stated in the manual.
Technical reference
Reference tables include maintenance schedules and checklists, tightening torques, specification tables, performance and reference values, limits and settings, special-tool reference, and electrical specifications for service checks, adjustment work, and specification lookup. Use the values and conditions in the PDF for the applicable model and procedure.
- Service limits and settings: tightening torques and limits and settings.
- Machine specifications: specification tables and performance and reference values.
- Electrical and emissions: electrical specifications.
- Service planning: maintenance schedules and checklists and special-tool reference.
Delivery
This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.
References
Kubota Workshop Manual for Excavator, document code 97899-60640, PDF edition.
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