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Kubota U35 Excavator Workshop Repair Manual

Kubota U35 Excavator Workshop Repair Manual

$29.00

🚜 Equipment
Brand	Kubota
Type	Excavator
Model	U35
📄 Documents
Type	Repair Manual
Publication	97899-60640
Language	English
Format	PDF
No of Pages	273

The Kubota U35 Compact Excavator is a zero-tail swing machine engineered for powerful performance, safety, and versatility in confined job sites. Equipped with a Kubota D1703M-DI-E4 diesel engine delivering 40.5 gross horsepower, the U35-4 provides the perfect balance of compact dimensions and mid-sized excavation capability. With an operating weight of approximately 4.4 tonnes and a maximum digging depth of 3.5 meters, it is suited for construction, landscaping, trenching, and utility projects where productivity and maneuverability are essential.

The U35 features advanced hydraulics with an auxiliary flow of up to 15.9 GPM, providing smooth control and compatibility with a wide range of attachments. Strong breakout forces of approximately 8,754 lbs (bucket) and 3,947 lbs (arm) ensure reliable digging performance even in demanding soil conditions. Travel speeds of 1.7–3.1 mph combined with a compact transport width of 1.7 meters and zero-tail swing design allow safe and efficient operation in restricted spaces. Operator comfort and safety are prioritized with an ROPS/TOPS-certified cab, ergonomic controls, and clear visibility. Optional angle dozer blade and rubber or steel track configurations enhance adaptability on diverse job sites.

The workshop repair manual provides detailed service coverage of the U35, including safety precautions, routine maintenance, engine servicing, hydraulic system specifications, swivel and travel motor repair, control valve adjustments, and undercarriage servicing. It also contains electrical schematics, wiring diagrams, hydraulic circuit layouts, torque specifications, lubrication charts, and troubleshooting flow charts. Comprehensive disassembly and reassembly instructions for all major systems—engine, hydraulics, electrics, cab components, and structural elements—ensure accurate maintenance and long-term reliability.

Key Highlights

Kubota D1703M-DI-E4 diesel engine, 40.5 gross hp / 39 net hp
Operating weight: ~9,790 lbs (~4,445 kg)
Maximum digging depth: ~11 ft 6 in (3.5 m)
Bucket breakout force: ~8,754 lbs; Arm breakout force: ~3,947 lbs
Auxiliary hydraulic flow: ~15.9 GPM for attachment use
Zero-tail swing design with 1.7 m width for confined site operation
Travel speeds: 1.7 mph (low) / 3.1 mph (high)
Cab features: ROPS/TOPS certification, ergonomic layout, wide visibility
Manual covers hydraulics, engine, electrics, swivel/travel motors, undercarriage, and cab
Includes wiring diagrams, hydraulic schematics, torque specifications, and lubrication intervals
Angle dozer blade option and interchangeable rubber/steel tracks

Table of Content

📙 Table of Contents

Wsm_U35

WSM_U35
- CONTENTS
- I. General
  - A. Body and engine identification marks
  - B. Safety precautions for servicing, disassembly and reassembly
    - a. Safety measures before starting work
      - (1) Work clothes
      - (2) Inspecting equipment and tools
      - (3) Keep workshop in order
    - b. Safety measures during work
      - (1) Protectors
      - (2) Team work
      - (3) Disassembly and assembly
      - (4) Cranes
      - (5) Others
    - c. Preparation for disassembly
      - (1) Cleaning
      - (2) Acceptance inspection
      - (3) Equipment and tools
    - d. Precautions for disassembly and reassembly
      - (1) Disassembly
      - (2) Reassembly
  - C. IMPORTANT SAFETY PROCESS AND CRITICAL FUNCTIONAL PROCESS
    - a. Essential Adhesives
    - b. Important Safety Process.
    - c. Important Critical Functional Process.
  - D. IMPORTANT INSPECTION ITEMS AFTER REASSEMBLING
  - F. Maintenance intervals
    - a. KTC, KCL, KTA-version
    - b. EU(KE, KDG, KUK)-version
    - c. Hydraulic Oil Check for machines with Hydraulic Breakers
  - G. Water and oil quantity
  - H. Recommended oil
  - I. Filters
  - J. Tightening torque
    - a. Hose screw
      - Metric Size Hose
    - b. Joint bodies
    - c. Tightening torque table for hose clamp (Screw type)
    - d. Nuts for piping
    - e. Tightening torque of bolts and nuts
    - f. Types and materials of bolts and nuts
    - g. Washer-equipped elbow
  - K. Machine Quality Specifications
- II. Machine body (Mechanism section)
  - A. Front attachment
    - a. Greasing points
    - b. Component interchangeability
  - B. Component interchangeability
    - a. Bucket interchangeability
    - b. Arm
    - c. Installing direction of dust seal
    - d. Installation of bushing and thrust collar on the swing bracket
    - e. Installing pin, bush and shim (1): U35
    - f. Installing pin, bush and shim (2): U35
    - g. Installing pin, bush and shim of bucket: U35
    - h. Installing local bucket: U35
- II. Machine body (Service section)
  - A. Specifications
    - a. Machine Weight
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
    - b. Machine specifications
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
    - c. Lever stroke and operating force
    - d. Dimensions of Parts
      - (1) Front pins
      - (2) Bucket
      - (3) Rubber crawler
      - (4) Iron crawler
      - (5) Track roller, idler, sprocket
      - (6) Dozer
      - (7) Parts weight
  - B. Front attachment
    - a. Parts designation
  - C. Upper structure
    - a. Swivel frame: U35, U35-3
    - b. Swivel bearing
    - c. Swivel bearing installation
    - d. Traveling lever
    - e. Traveling lever adjustment
    - f. Traveling lever lock
      - Adjusting the lever’s neutral position
    - g. Accel lever (Non AI-version)
      - (3) AI motor side (AI-version)
      - (4) Engine side
      - (5) Accel cable
    - h. Swing pedal
    - i. Auxiliary port pedal
    - j. Limit switch installation
    - k. Hour meter cable, engine stop cable
    - l. Cab installation: KTC, KCL, KTA-version
    - m. Heater hose
    - n. Cab glass replacement procedure
      - (1) Application Procedure if SIKAFLEX (ULTRA-FAST)
      - (2) ULTRA-FAST application manual
      - (3) 255 EXTRA application manual
      - (4) H-rubber replacement procedure
      - (5) Broken glass repairing procedure (for adhered glass KX-2 Series made by KBT)
    - o. Seat belt
    - p. Weight installation
  - D. Under carriage
    - a. Tension spring pre-set length
    - b. Additional parts to change from rubber track to iron track
    - c. Track Roller and Upper Roller installation
    - d. Track tension adjustment
    - e. Grease tension cylinder, L
    - f. Drive sprocket
    - g. Rubber track
    - h. Iron track
- III. Engine
  - A. Engine mount
  - B. Radiator
  - C. Muffler
  - D. Pump coupling
  - E. Fuel hoses
- IV. Hydraulic system (Mechanism section)
  - A. Features of hydraulic system
  - B. Hydraulic system specifications
  - C. Main pump
    - a. Structure & specifications
    - b. Performance curve
      - Variable displacement pump
  - D. Control valve
    - a. Specifications
    - e. Arm regeneration circuit
      - (1) Arm dump
      - (2) Arm Crowd
    - f. Oil flow of lock valve
      - (1) Operation of lock valve
      - (2) Boom operation
    - g. Function of lock valve (Anti-drift valve)
      - (1) Boom cylinder holding function
      - (2) Boom up function
      - (3) Boom-down function
  - E. Pilot valve
    - a. Structure & specifications: U35 (KTC, KCL), U35-3 (KTA)
    - b. Pilot valve control diagram: U35 (KTC, KCL), U35-3 (KTA)
    - c. KBM-make: Pilot valve: U35-3 (EU)
  - F. Swivel motor
    - a. Structure & specifications
    - b. Function of negative brake
      - (1) Negative brake function (Unload condition)
      - (2) Negative brake release (On-load condition)
    - c. Function of valve section
      - (1) Make-up valve
      - (2) Function of shockless valve
    - d. Swivel Performance
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
      - (3) Inner parts of the swivel motor
  - G. Rotary joint (Swivel joint)
  - H. Travel motor
    - a. Structure
      - (1) Relief valve
      - (2) Shockless piston
      - (3) Inner parts of the traveling motor
    - b. Travel motor specification
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
  - J. Hydraulic circuit diagram
    - a. U35-3 European – version
    - b. U35: KTC, KCL – version
    - c. U35-3: KTA – version
    - d. Hydraulic components layout: U35, U35-3
- IV. Hydraulic system (Service section)
  - A. Troubleshooting
    - a. Common Circuit
    - b. Front Attachment
    - c. Swivel Circuit
    - d. Travel Circuit
  - B. Specifications
    - a. Relief valve pressure setting
    - b. Pump
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
    - c. Cylinder
      - (1) Cylinder operating speed
      - (2) Cylinder natural fall amount
      - (3) Cylinder specifications
    - d. Swivel Performance
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
    - e. Traveling Performance
      - (1) KE, KDG, KUK version
      - (2) KTC, KCL, KTA version
  - C. Testing
    - a. Testing Instruments & special tools
    - b. Pump flow
    - c. Pilot pressure
      - (1) Primary pressure
      - (2) Secondary pressure
    - d. Main relief valve
    - e. Overload relief valve
    - f. Swivel brake valve pressure
    - g. Traveling motor drain amount
    - h. Swivel motor drain amount
    - i. Swivel motor block performance
    - j. Traveling motor block performance
    - k. Operating speed
      - (1) Checking each operating speed.
      - (2) Boom cylinder
      - (3) Arm cylinder
      - (4) Bucket cylinder
      - (5) Swing cylinder
      - (6) Dozer cylinder
      - (7) Swivel speed
      - (8) Traveling speed
    - l. Straight travel performance
    - m. Cylinder natural fall amount
    - n. Control and Traveling lever operating force
    - o. Lever stroke
  - D. Disassembling and assembling
    - e. Swivel motor (KTC, KCL, KTA-version)
    - g. Rotary joint
      - (1) Inner parts of the rotary joint
      - (2) Assembling of the rotary joint
      - (3) Rotary joint seal installing procedure
      - (4) Jig picture
      - (5) Jig drawing
      - (6) Adaptor installation on the rotary joint (KTC, KCL, KTA version)
    - h. Cylinder (EU-version)
      - (3) Disassembling and assembling: EU-version
    - j. Hoses
      - (1) Pilot hose(1)
      - (2) Pilot hose(2)
      - (3) Pilot hose(3)
- V. Electrical system (Mechanism section)
  - a. Components and harness layout: U35, U35-3
  - b. Electric Circuit Diagram
  - c. Electric wiring Diagram
- V. Electrical system (Service section)
  - A. Electrical Equipment Specifications
  - B. Wire harness installation
    - a. Precautions
    - b. Engine earth, starter switch
    - c. Main harness
    - d. Coupler insertion
    - e. Control box harness
    - f. Engine harness
    - g. Front harness
  - C. Troubleshooting
    - a. General
      - (1) How to diagnose
      - (5) CHECKING SWITCHES
      - (6) Checking fuses
      - (7) Solenoid test method
      - (8) Checking relays
      - (9) Checking cables and wires
    - b. Troubleshooting flow chart
      - (1) Starter motor failure to turn on
      - (2) Auto release malfunction
      - (3) Electronic accelerator failure
      - (4) Auto glow failure
      - (5) AI system failure
    - c. Front attachment
      - (1) Working lamp failure
      - (2) Safety lever lock circuit malfunction
    - d. Engine electrical system
      - (1) Engine oil pressure failure
      - (2) Water temp. sensor circuit malfunction
      - (3) Fuel sensor circuit
      - (4) Engine stop solenoid
      - (5) Charging system malfunction
      - (6) Auto glow controller
      - (7) Auto release controller
    - e. Auto idle system
      - (1) Troubleshooting outline
      - (2) AI pressure switch test method
      - (3) Governer sensor test method
      - (4) AI motor test method
      - (5) Engine speed sensor
      - (6) Auto glow circuit
    - f. AI version: AI controller (built-in microcomputer) Cases of trouble diagnosis with circuit tester
      - (1) “Water temperature sensor” line in trouble
      - (2) Other circuitry layouts and their trouble diagnosis
    - g. Cases of trouble diagnosis with circuit tester
    - h. Auto Idle (AI) version: Trouble diagnosis with lamp
      - (1) General
      - (2) Display and identification of errors in operating mode
      - (3) Entering the service mode
      - (4) Working on the 6 menus in the service mode
      - (5) Example: Alternation of engine idling speed
      - (6) Working on the 3 menus in the service mode
      - (7) Working on the AI motor drive menus in the service mode
      - (8) Entering the setup mode
      - (8) Lamp-identified fail symptoms, trouble spots and possible causes

Specification

Specification	Kubota U35 Compact Excavator
Engine Model & Type	Kubota D1703M-DI-E4, Tier emissions compliant diesel
Gross / Net Power	40.5 hp (gross) / 39.0 hp (net) @ ~2,250 rpm :contentReference[oaicite:0]{index=0}
Operating Weight (including operator)	~9,790 lb (≈ 4,445 kg) :contentReference[oaicite:1]{index=1}
Max Digging Depth	~11 ft 6 in (≈ 3,505 mm) :contentReference[oaicite:2]{index=2}
Auxiliary Hydraulic Flow	Auxiliary flow (AUX1) ≈ 15.9 GPM (60 L/min) :contentReference[oaicite:3]{index=3}
Bucket Breakout Force	≈ 8,754 lb (≈ 3,974 kgf) :contentReference[oaicite:4]{index=4}
Arm Breakout Force	≈ 3,947 lb (≈ 1,792 kgf) :contentReference[oaicite:5]{index=5}
Travel Speed (Low / High)	~1.7 mph / ~3.1 mph :contentReference[oaicite:6]{index=6}
Dimensions (L × W × H)	Length ≈ 15 ft 7 in (4,749 mm) × Width ≈ 5 ft 10.9 in (1,700 mm) × Height ≈ 8 ft 3 in (~2,510 mm) :contentReference[oaicite:7]{index=7}
Track / Blade Details	Rubber tracks (~300 mm shoes); Steel version available; Dozer blade with angle & float options; min ground clearance ~11.34 in (288 mm) :contentReference[oaicite:8]{index=8}

Buyer Questions & Answers

Frequently Asked Questions❔

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