Kubota U55-5 Workshop Manual
Overview
This is the Kubota Workshop Manual for the U55-5 (document code RY911-28117, 2024 edition). It provides service and repair procedures for Kubota U55-5 excavator. Powered by the Kubota V2607 engine.
Manual Details and Coverage
- Manufacturer
- Kubota
- Models
- U55-5
- Equipment type
- Excavator
- Manual type
- Workshop Manual
- Document code
- RY911-28117
- Publication year
- 2024
- Language
- English
- Page count
- 846
- Format
Contents
The manual is structured as follows. Page references correspond to the original PDF pagination.
1. SAFETY
- SAFETY FIRST (1-1)
- SAFETY LABELS (1-5)
2. GENERAL
- GENERAL WORKING INSTRUCTIONS (2-1)
- PRELIMINARY WORKING INSTRUCTIONS (2-11)
- CONCLUDING WORKING INSTRUCTIONS (2-19)
- TIGHTENING TORQUES (2-23)
- GENERAL MACHINE INFORMATION (2-27)
- GENERAL ELECTRICAL INFORMATION (2-37)
- Electrical circuit diagram description (2-37)
- Electrical circuit diagram unit symbol (2-37)
- Electrical wir
- Electrical wiring color coding (2-38)
- Electrical wiring clamp (2-38)
- Bus description (2-39)
- Composite terminal description (2-39)
- Connector handling precaution (2-39)
- Connector diagram description (2-39)
- TRANSPORTING THE MACHINE (2-41)
- SPECIAL TOOLS (2-43)
- Engine compression pressure measuring kit (2-43)
- Overload relief valve measuring kit (2-45)
- Universal joint tightening jig
- Universal joint tightening jig (2-46)
- Hydraulic cylinder special jigs (2-47)
- Manifold gauge (2-50)
- Charging hoses (2-51)
- Refrigerant gas vacuum machine (2-51)
- Refrigerant gas leak tester (2-51)
- Refrigerant gas canister (2-51)
3. MAINTENANCE
- MAINTENANCE INTERVALS TABLE (3-1)
- LUBRICANT QUANTITY (3-5)
- RECOMMENDED LUBRICANTS (3-7)
- DAILY CHECK (3-9)
- EVERY 50 HOURS (3-17)
- EVERY 150 HOURS (3-23)
- EVERY 200 HOURS (3-25)
- EVERY 250 HOURS (3-29)
- EVERY 500 HOURS (3-31)
- EVERY 600 HOURS (3-37)
- EVERY 1000 HOURS (3-39)
- EVERY 1500 HOURS (3-49)
- EVERY 2000 HOURS (3-51)
- EVERY 3000 HOURS (3-55)
- EVERY 6000 HOURS (3-57)
- EVERY 1 YEAR (3-59)
- EVERY 2 YEARS (3-63)
- SERVICE AS REQUIRED (3-69)
4. MACHINE BODY
- MECHANISM (4-1)
- Bucket dimensions (4-3)
- Arm dimensions (4-5)
- Boom dimensions (4-7)
- Blade dimensions (4-9)
- Rubber track dimensions (4-10)
- Steel track dimensions (4-10)
- Front idler dimensions (4-11)
- Sprocket dimensions (4-11)
- Track roller dimensions (4-11)
- Carrier roller dimensions (4-12)
- Pin, bushing, and shim dimensions (4-13)
- SERVICING (4-13)
- SERVICING (4-19)
- Service specifications for the machine body (4-19)
- Measuring the front attachment horizontal play (4-22)
- Measuring the swivel bearing vertical play (4-23)
- Measuring the swing bracket vertical clearance (4-24)
- Measuring the operating force for levers and pedals (4-24)
- Bucket (4-25)
- Removing the bucket (4-25)
- Arm (4-25)
- Removing the arm (4-25)
- Boom (4-27)
- Removing the boom (4-27)
- Blade (4-27)
- Blade (4-30)
- Removing the blade (4-30)
- Removing the angle blade (4-31)
- Swing bracket (4-32)
- Removing the swing bracket (4-32)
- Counterweight (4-33)
- Removing and installing the counterweight (4-33)
- Seat (4-34)
- Removing and installing the seat (4-34)
- Canopy (4-36)
- Removing and installing the canopy (4-36)
- Cabin (4-39)
- Removing and installing the cabin (4-39)
- Lever lock (4-43)
- Removing and installing the lever lock (4-43)
- Swivel bearing (4-47)
- Removing and installing the swivel bearing (4-47)
- Rubber track (4-49)
- Removing and installing the rubber track (4-49)
- Steel track (4-50)
- Removing and installing the steel track (4-50)
- Front idler (4-54)
- Removing the front idler (4-54)
- Front idler components (4-55)
- Disassembling the front idler (4-55)
- Assembling the front idler (4-56)
- Tension spring (4-57)
- Removing and installing the tension spring (4-57)
- Grease cylinder (4-57)
- Grease cylinder (4-58)
- Removing the grease cylinder (4-58)
- Track roller (4-59)
- Removing and installing the track roller (4-59)
- Track roller components (4-60)
- Disassembling the track roller (4-60)
- Assembling the track roller (4-61)
- Carrier roller (4-61)
- Removing and installing the carrier roller (4-61)
5. ENGINE
- MECHANISM (5-1)
- Lubricating system general description (5-10)
- Lubricating system general description (5-12)
- Cooling system general description (5-12)
- Intake air system general description (5-13)
- EGR system general description (5-14)
- Common rail system general description (5-15)
- Aftertreatment system general description (5-16)
- DPF regeneration control (5-17)
- SERVICING (5-21)
- Engine troubleshooting (5-21)
- Service specifications for the engine (5-23)
- Measuring engine compression pressure (5-23)
- Measuring engine oil pressure (5-23)
- Fuel hose and tank (5-24)
- Removing and installing the fuel tank (5-24)
- Fuel hose routing (5-28)
- Engine (5-33)
- Removing and installing the engine (5-33)
- Removing the alternator (5-41)
- Removing the starter motor (5-42)
- Removing and installing the rail (5-42)
- Removing and installing the supply pump (5-44)
- Removing and installing the injector (5-46)
- Removing the EGR valve (5-52)
- Removing the EGR cooler (5-53)
- Removing the throttle valve (5-54)
- Radiator (5-56)
- Removing and installing the radiator (5-56)
- DPF muffler (5-60)
- Removing and installing the DPF muffler (5-60)
6. HYDRAULIC SYSTEM
- MECHANISM (6-1)
- Load sensing system general description (6-1)
- Load sensing system general description (6-2)
- Pilot control system general description (6-4)
- Hydraulic pump specifications (6-6)
- Hydraulic pump hydraulic circuit (6-7)
- Piston pump P-Q performance (6-8)
- Hydraulic pump function and structure (6-9)
- Piston pump working principles (6-9)
- Horsepower control (6-10)
- Flow control (load sensing control) (6-12)
- Standby flow (6-14)
- Gain control (6-15)
- Control valve specifications (6-17)
- Control valve hydraulic circuit (6-23)
- Control valve spool shift performance (6-17)
- Control valve spool shift performance (6-24)
- Control valve function and structure (6-25)
- Main relief valve (6-25)
- Overload relief valve (6-25)
- Boom lowering valve (6-27)
- Unload valve (6-28)
- High pressure selector function (6-30)
- Pressure compensator valve (6-32)
- Arm regeneration (6-34)
- Independent travel valve (6-35)
- Auto-idle signal circuit (6-39)
- Swivel motor specifications (6-40)
- Swivel motor hydraulic circuit (6-41)
- Swivel motor function and structure (6-41)
- Swivel motor working principles (6-41)
- Shockless function
- Shockless function (6-42)
- Swivel motor parking brake (6-42)
- Make-up circuit (6-43)
- Travel motor specifications (6-44)
- Travel motor hydraulic circuit (6-45)
- Travel motor function and structure (6-46)
- Travel motor working principles (6-46)
- Counterbalance valve (6-46)
- Anti-cavitation valve (6-48)
- Automatic deceleration (6-50)
- Travel motor parking brake (6-52)
- Hydraulic cylinder specifications (6-53)
- Swivel joint specifications (6-54)
- Pilot control valve specifications (6-58)
- Pilot control valve performance diagram (6-59)
- Pilot control valve function and structure (6-60)
- Travel control valve specifications (6-60)
- Travel control valve performance diagram (6-61)
- Travel control valve function and structure (6-61)
- Swing control valve specific
- Swing control valve specifications (6-62)
- Swing control valve performance diagram (6-62)
- Swing control valve function and structure (6-63)
- Blade control valve specifications (6-63)
- Blade control valve performance diagram (6-64)
- Blade control valve function and structure (6-65)
- Unload valve specifications (6-67)
- Unload valve function and structure (6-68)
- Unload valve working principles (6-68)
- Proportional valve specifications (6-69)
- Proportional valve performance diagram (6-70)
- Proportional valve function and structure (6-70)
- Proportional valve working principles (6-70)
- Proportional valve working principles (6-70)
- Angle blade solenoid valve specifications (6-71)
- Angle blade solenoid valve function and structure (6-71)
- Angle blade solenoid valve working principles (6-71)
- TPSS valve specifications (6-73)
- Hydraulic third line valve specifications (6-74)
- Third line solenoid valve specifications (6-74)
- Third line solenoid valve control diagram (6-75)
- Third line solenoid valve function and structure (6-75)
- Third line solenoid valve working principles (6-75)
- Travel motor working principles (6-46)
- SERVICING (6-77)
- Hydraulic troubleshooting for front attach (6-77)
- Hydraulic troubleshooting for front attachment (6-77)
- Hydraulic troubleshooting for swivel (6-79)
- Hydraulic troubleshooting for traveling (6-80)
- Service specifications for the hydraulic system (6-81)
- Measuring the hydraulic devices (6-84)
- Measuring the boom cylinder speed (6-84)
- Measuring the arm cylinder speed (6-84)
- Measuring the bucket cylinder speed (6-84)
- Measuring the blade cylinder speed (6-85)
- Measuring the swing cylinder speed (6-85)
- Measuring the angle blade cylinder speed (6-85)
- Measuring the swivel speed (6-86)
- Measuring the travel speed (6-86)
- Measuring the cylinder internal leakage (6-87)
- Measuring the travel motor internal leakage (6-88)
- Measuring the swivel motor internal leakage (6-88)
- Testing the travel straightness (6-89)
- Measuring the hydraulic pump (6-90)
- Measuring the piston pump P-Q performance (6-90)
- Measuring the AUX flow rate (6-93)
- Measuring the control valve (6-97)
- Measuring the main relief valve pressure (6-97)
- Measuring the overload relief valve (6-98)
- Measuring the swivel motor (6-100)
- Measuring the swivel motor overload relief valve pressure (6-100)
- Measuring the swivel motor drain (6-102)
- Measuring the travel motor (6-100)
- Measuring the travel motor (6-102)
- Measuring the travel motor drain (6-102)
- Measuring the pilot control valve (6-104)
- Measuring the pilot primary pressure (6-104)
- Measuring the pilot secondary pressure (6-104)
- Hydraulic pump (6-105)
- Removing and installing the hydraulic pump (6-105)
- Hydraulic pump components (6-108)
- Disassembling the piston pump (6-109)
- Assembling the piston pump (6-113)
- Installing adapters for the hydraulic pump (6-121)
- Removing and installing the pump coupling (6-122)
- Control valve (6-123)
- Removing and installing the control valve (6-123)
- Control valve components (6-126)
- Disassembling and assembling the control valve (6-133)
- Installing adapters for the control valve (6-135)
- Swivel motor (6-141)
- Removing and installing the swivel motor (6-141)
- Swivel motor components (6-143)
- Disassembling the swivel motor (6-144)
- Assembling the swivel motor (6-149)
- Installing adapters for the swivel motor (6-156)
- Travel motor (6-156)
- Removing and installing the travel motor (6-156)
- Travel motor components (6-158)
- Disassembling the travel motor (6-159)
- Assembling the travel motor (6-167)
- Hydraulic cylinder (6-181)
- Boom, arm, bucket, and angle blade cylinders (6-181)
- Blade and swing cylinders (6-192)
- Measuring the hydraulic cylinder (6-194)
- Swivel joint
- Swivel joint (6-195)
- Removing and installing the swivel joint (6-195)
- Installing adapters for the swivel joint (6-198)
- Pilot control valve (6-200)
- Removing and installing the pilot control valve (6-200)
- Pilot control valve components (6-204)
- Disassembling the pilot control valve (6-204)
- Assembling the pilot control valve (6-207)
- Installing adapters for the pilot control valve (6-209)
- Travel control valve (6-210)
- Removing and installing the travel control valve (6-210)
- Travel control valve components (6-213)
- Disassembling the travel control valve (6-213)
- Assembling the travel control valve (6-216)
- Installing adapters for the travel control valve (6-220)
- Swing control valve (6-220)
- Removing and installing the swing control valve (6-220)
- Swing control valve components (6-221)
- Disassembling the swing control valve (6-221)
- Assembling the swing control valve (6-225)
- Installing adapters for the swing control valve (6-228)
- Blade control valve (6-229)
- Removing and installing the blade control valve (6-229)
- Blade control valve components (6-232)
- Disassembling the blade control valve (6-232)
- Assembling the blade control valve (6-232)
- Assembling the blade control valve (6-234)
- Installing adapters for the blade control valve (6-237)
- Unload valve (6-237)
- Removing and installing the unload valve (6-237)
- Unload valve components (6-238)
- Disassembling and assembling the unload valve (6-239)
- Installing adapters for the unload valve (6-241)
- Proportional valve (6-242)
- Removing and installing the proportional valve (6-242)
- Proportional valve components (6-243)
- Disassembling and assembling the proportional valve (6-243)
- Installing adapters for the proportional valve (6-244)
- Angle blade solenoid valve (6-244)
- Removing and installing the angle blade solenoid valve (6-244)
- Angle blade solenoid valve components (6-245)
- Disassembling and assembling the angle blade solenoid valve (6-245)
- Installing adapters for the angle blade solenoid valve (6-246)
- TPSS valve
- TPSS valve (6-246)
- Removing and installing the TPSS valve (6-246)
- TPSS valve components (6-248)
- Disassembling and assembling the TPSS valve (6-248)
- Installing adapters for the TPSS valve (6-248)
- Hydraulic third line valve (6-249)
- Removing and installing the hydraulic third line valve (6-249)
- Disassembling and assembling the hydraulic third line valve (6-249)
- Installing adapters for the hydraulic third line valve (6-250)
- Third line solenoid valve (6-251)
- Removing and installing the third line solenoid valve (6-251)
- Disassembling and assembling the third line solenoid valve (6-251)
- Installing adapters for the third line solenoid valve (6-252)
- Hydraulic oil tank (6-252)
- Removing and installing the hydraulic oil tank (6-252)
- Hydraulic hose (6-259)
- Length description of hydraulic hoses (6-259)
- Metal fittings of hydraulic hoses (6-259)
- Metal fittings of hydraulic hoses (6-260)
- Delivery hose routing (6-261)
- Front hose routing (6-262)
- Swivel and swing hoses routing (6-264)
- Travel and blade hoses routing (6-267)
- Drain hose routing (6-270)
- Pilot hose routing (delivery, drain) (6-272)
- Pilot hose routing (operation) (6-280)
7. ELECTRICAL SYSTEM
- MECHANISM (7-1)
- Electrical device layout (7-1)
- Switch layout (7-3)
- Fuse and relay layout (7-5)
- Slow blow fuse layout (7-7)
- Communication port layout (7-7)
- Ground wiring layout (7-7)
- Power supply electrical circuit diagram (7-8)
- Accessory electrical circuit diagram (7-10)
- Battery charge electrical circuit diagram (7-11)
- Engine start electrical circuit diagram (7-13)
- Lever lock electrical circuit diagram (7-15)
- Travel speed shift electrical circuit diagram (7-13)
- Travel speed shift electrical circuit diagram (7-16)
- AUX operation electrical circuit diagram (7-18)
- Work light electrical circuit diagram (7-19)
- AI electrical circuit diagram (7-21)
- Wiper and washer motors electrical circuit diagram (7-23)
- Beacon electrical circuit diagram (7-25)
- Electric third line electrical circuit diagram (7-27)
- Home screen (7-29)
- Meter panel functions (7-29)
- User setting mode (7-30)
- Periodic check (7-30)
- Log record (7-31)
- Messages (7-32)
- AUX setting (7-32)
- Various settings (7-35)
- Service mode (7-32)
- Service mode (7-37)
- Entering the Service mode (7-37)
- Service mode list (7-38)
- Diagnosis (7-40)
- Setting (7-45)
- Function invalidation (7-63)
- SERVICING (7-65)
- Electrical troubleshooting (7-65)
- Error warning list (Red lamp) (7-66)
- Engine system error (Red lamp) (7-68)
- Handling Engine oil pressure err (7-71)
- Handling Overheat forced idling (7-73)
- Handling Overheat forced idling (hydraulic oil) (7-74)
- Handling Charging sys. err
- Handling Charging sys. err (7-75)
- Handling Fuel sensor err (7-76)
- Handling CAN communication error (7-78)
- Handling CAN sys. err.ECU (Main) (Serial number: To 014039) (7-78)
- Handling CAN sys. err.ECU (Main) (Serial number: From 014040) (7-82)
- Handling CAN sys. err.ECU (Engine) (Serial number: To 014039) (7-85)
- Handling CAN sys. err.ECU (Engine) (Serial number: From 014040) (7-90)
- Handling CAN sys. err.ECU (Sub) (Serial number: To 014039) (7-93)
- Handling CAN sys. err.ECU (Sub) (Serial number: From 014040) (7-96)
- Handling CAN sys. err. Keypad (Serial number: To 014039) (7-99)
- Handling
- Handling CAN sys. err.ECU (Meter panel) (Serial number: To 014039) (7-103)
- Handling CAN sys. err.ECU (Meter panel) (Serial number: From 014040) (7-107)
- Handling 2-speed sys. err (7-110)
- Handling AUX1 system error (7-111)
- Handling AUX1 sys. err. (AUX1 knob switch) (7-111)
- Handling AUX1 sys. err. (AUX1 proportional solenoids LH and RH) (7-113)
- Handling AUX2 system error (7-114)
- Handling AUX2/Thumb sys. err. (AUX2 thumb knob switch) (7-114)
- Handling AUX2/Thumb sys. err. (AUX2 proportional solenoids LH and RH) (7-116)
- Handling Overvoltage (7-117)
- Handling Auto idle sys. err (7-118)
- Handling Lever lock sys. err (7-120)
- Handling External 5V sys. err (7-121)
- Handling Overload warning err (7-123)
- Handling Hyd. temp. sensor err (7-125)
- Handling 3-way valve sys. err (7-126)
- Handling Dozer angle sys. err (7-128)
- MECHANISM (8-1)
- Compressor specifications (8-4)
- Compressor function and structure (8-5)
- Compressor working principles (8-5)
- Magnetic clutch pulley (8-5)
- Safety valve (8-5)
- Temperature switch (8-6)
- Air conditioning unit specifications (8-7)
- Air conditioning unit function and structure (8-9)
- Evaporator (8-9)
- Heater core (8-9)
- Blower (8-9)
- Blower resistor (8-9)
- Expansion valve (8-10)
- Thermostat (8-10)
- Servomotor (8-11)
- Heater valve (8-11)
- Condenser specifications (8-11)
- Condenser function and structure (8-12)
- Receiver specifications (8-12)
- Receiver function and structure (8-13)
- Pressure switch specifications (8-13)
- Pressure switch function and structure (8-13)
- Pressure switch function and structure (8-13)
- Heater unit specifications (8-15)
- Heater unit function and structure (8-17)
- Heater core (8-17)
- Blower (8-17)
- Blower resistor (8-17)
- Servomotor (8-17)
- Heater valve (8-18)
- VICING (8-19)
- Air conditioning troubleshooting (8-19)
- Service specifications for air conditioning and heater system (8-23)
- Checking the refrigerant liquid (8-23)
- Measuring the refrigerant pressure (8-23)
- Checking the fan switch (8-25)
- Measuring the magnetic clutch pulley air gap (8-26)
- Checking the blower resistor (8-27)
- Vacuuming the refrigerant (8-27)
- Charging the refrigerant (8-28)
- Compressor (8-30)
- Removing and installing the compressor (8-30)
- Ai (8-28)
- Air conditioning unit (8-32)
- Removing and installing the air conditioning unit (8-32)
- Condenser (8-61)
- Removing and installing the condenser (8-61)
- Receiver (8-62)
- Removing and installing the receiver (8-62)
- Air conditioning and heater hoses (8-63)
- Air conditioning and heater hose routing (8-63)
9. APPENDICES
- APPENDICES (9-1)
- Service specifications for the machine body (9-1)
- Service specifications for the engine (9-4)
- Service specifications for the hydraulic system (9-4)
- Piston pump P-Q performance (9-8)
- AUX P-Q performance (9-9)
- Service mode (9-8)
- Service mode (9-12)
- Default settings (9-12)
- ABBREVIATIONS
- DANGER
- WARNING
- CAUTION
- IMPORTANT
- 1-2 U55-5
- 1-4 U55-5
- SAFETY LABELS
- 1-6 U55-5
- 1-8 U55-5
- 1-10 U55-5
- 1-12 U55-5
- 1-14 U55-5
Delivery (Instant Download)
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 RY911-28117, PDF edition.
