Kubota U15, U15-3 Excavator Repair Service Workshop Manual

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This complete service repair workshop manual PDF download for the U15, U15-3 Kubota Excavator has easy-to-read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes.


APPLICABLE MODELS :

KUBOTA U15
KUBOTA U15-3


TABLE OF CONTENTS :

Mechanism Chapter (97899-61482)
    I Product engineering section
    II Service engineering section
    ConversionTable
    
Service Chapter (97899-61282)
    I General
    II Machine Body
    III Engine
    IV Hydraulic System
    V Electrical system


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Code No. : 97899-61482 + 97899-61282
Total Pages : 766


This (OEM) manual pdf download has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the  machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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WSM_U15-3_Mechanism
    CONTENTS
    I Product engineering section
        A. Developing concept and feature
            a. Objective and Concept of Development
                1. Objective of Development
                2. Product Concept
            b. Main Specifications
            c. U15-3 vs U15
                1. Comparison between EU and PP-version
                2. Comparison of Main Specifications for U15 (KTC-version)
            d. Major Selling Points and Improvements
                1. Quick chart : U15-3, EU - version
                2. Quick chart : U15-3, KTC - version
                3. Main feature points
            e. Evaluation of Competitive Power with Competitors
                1. Workability
                2. Durability
                3. Operability
                4. Comfort
                5. Maintainability
                6. Safety
                7. Working Range
                8. Outline of Hydraulic System (Travel straight function)
            f. Actual performance comparison
                1. On-site Excavation Test
                2. Comparison of Operating Speed
                3. Comparison of Stability
            g. U15 featured points
        B. Machine specifications
            a. Major dimensions and working range (with rubber crawler)
            b. Dimensional drawings : U15-3
            c. Performance and lifting capacity
                1. Performance
                2. Lifting capacity
    II Service engineering section
        A. Maintenance specifications
            a. List of oil and water quantities
            b. Tightening torque
                1. Machine
                2. General bolt/nut tightening torque
                3. Hydraulic pipe tightening torque
                4. Hydraulic hose tightening torque
                5. Engine
            c. Quality specifications
            d. Operating noise
            e. Machine weight and parts weight
        B. Machine body structure and function
            a. Overall Arrangement
                2. Arrangement of Control Levers
                3. Press-fitting of Bushes
                4. Front Equipment
                5. Greasing (1)
                6. Greasing (2)
                7. Cleaning and greasing the Track Frame Slide Pipes
            b. Front attachment
                1. Bucket dimensions
                2. Bucket fixture dimensions
                3. Bucket link pin
                4. Front pins and bush
                5. Swing bracket
            c. Control levers and linkage
                1. Lever strokes and operating forces
                2. Accelerator Lever
                3. Dozer Lever
                4. Dozer Cables (Route)
                5. Swing Pedal
                6. Service port Pedal
            d. Under carriage components
                1. Swivel bearing
                2. Truck Frame (Adjustment of Play)
                3. Structure of Track Roller
                4. Tension Device
                5. Idler and tension spring
                6. Idler and sprocket
                7. Rubber track
                8. Track shoe
                9. Steel track shoe
                10. Dozer
        C. Engine
            a. Main specification
            b. Performance curves
            c. Engine electrical data
            d. Engine servicing data
            e. Engine Mount
            f. Fuel System
                1. Fuel System (1)
                2. Fuel System (2)
                3. Fuel tank
            g. Cooling system
                1. Structure
                2. Radiator data
            h. Air cleaner
        D. Hydraulic system
            a. Main pump
                1. Outer view
                2. Pump coupling
                3. Pump hose adapter
                4. structure
                5. P-Q performance curve
                6. Pump Specifications, Type : PVD-00B-14P-5G3-4552A, code NO. : RA221-6111
                7. Discharge rate
                8. Function
            b. Control valve
                1. Relief valve specifications
                2. Control Valve (1)
                3. Control Valve (2)
                4.Control Valve (3)
                5. Control Valve (4)
                6. Control valve sectional view
                7. Inner sectional view
                8. Function of inlet section
            c. Swivel motor
                1. Swivel system specifications
                2. Component of swivel motor
                3. Cross-sectional View of Swivel Motor
                4. Swivel Motor fittings
                5. Function
            d. Travel motor (Wheel motor)
                1. Overview (RA221-61291)
                2. Specifications
                3. Piston motor installation
                4. Structure
                4. Principle of operation
            e. Pilot valve (Remote control valve)
                1. Structure
                2. Sectional view
                3. Adaptors
                4. Function
            f. Cylinders
                1. Cylinder speed
                2. Gravity fall
                3. Specifications and part codes of boom, arm, bucket and swing cylinder
                4. List of cylinder dimensions
                5. Cylinders’ section view
            g. Swivel Joint (Rotary joint)
                1. Swivel Joint (1)
                2. Swivel Joint (2)
                3. Route of Hose (Travel, blade)
                4. Route of Hose (Track Cylinder Hose)
            h. Unload valve
                1. Structure
                3. Adaptor installation
            i. Selector valve
                1. Structure
                2. Function
                3. Specifications
            j. Accessaries of hydraulic compornents
                1. Check valve assy
                2. Hydraulic filter
                3. Oil Tank
                4. Oil cooler
                5. Accumlator (EU - version)
            k. Hydraulic system flow
                1. Hydraulic Pressure Hose Circuit (High-pressure)
                2. Hydraulic Pressure Hose Circuit (Low-pressure)
                3. Pilot system circuit : EU - version
                4. Travel Unloading function
                5. Boom Confluence
                6. Service port Confluence
                7. Straight Travel Circuit
            l. Service port system
                1. Component layout
                2. 1-way or 2-way valve (EU - version)
            m. TPSS (Two Pattern Selection System) : PP - version
                1. Location and overview
                2. Hose connection
                3. TPSS port connection
                4. Technical data
                5. TPSS function circuit
            n. Hydraulic components layout : U15-3, U15
            o. Hydraulic circuit diagram
                1. U15-3, EU - version
                2. U15-3, EU - version : Track extention
                3. U15-3, EU - version, Service port flow
                4. U15, PP - version
                5. U15, PP - version : Three operation : boom up, arm extend, swivel R, A(JD)-pattern
                6. U15, PP - version : Travel forward, high speed and boom down, B(ISO, Kubota)-pattern
        E. Electrical system
            a. New Functions of Electric System
                1. Starter automatic release function
                2. Auto-glow
                3. Theft-proof Specification
            b. Battery circuit
            c. Key switch (Engine starter switch)
            d. Safety lever lock switch
                (2) Safety lever lock circuit malfunction
            e. Solenoid valve
                1. Structure
                3. Solenoid test method
            f. Travel hi-speed control circuit
                1. Hi - Low switch and circuit diagram
                2. Troubleshooting: Travel hi-speed malfunction
                3. Testing Hi - Low SW
                4. Hi - Low self hold circuit
            g. Meter panel
                1. Installation view
                3. Warning lamps indication
                4. Meter structure
                5. Meter panel circuit diagram
                6. Fuel gauge coil resistance test
                7. Hour meter function test LED and stepping motor function check.
            h. Fuses
                1. Replacing Fuses
                2. Fuse Capacities and Circuits
            i. Auto glow circuit
                1. Function
                2. Auto glow control circuit diagram
                3. Auto glow controller
                4. Auto glow circuit
            j. Auto release control system
                1. Outline
                2. Auto relase control, structure and function
                3. Key SW to engine start position
                4. Key SW to AC position
                5. When the Key SW is stucked at the start position
                6. Key to the start position while engine is running
                7. Function of low-voltage detection
                8. Auto release and auto glow circuit combined
            k. Water temp. sensor & gauge
                1. Water temp. sensor circuit malfunction
            l. Fuel control circuit
                (1) Function)
            m. Engine stop solenoid and coil commander
                1. Location
                2. Circuit diagram
                3. Function
                4. Inspeetion & troubleshooting
            n. Fuel sensor
                1. Fuel sensor
                2. Fuel sensor testing
            o. Engine oil pressure sensor circuit
                Oil switch
            p. Engine electrical system
                1. Engine oil pressure failure
            q. Horn circuit
                1. Structure
                2. Function
                3. Current flow
                4. Horn circuit
            r. Charging system (Alternator)
                1) Alternator structure (Code No. 16678-64012)
                2) Circuit diagram
                4. Charging system malfunction
            s. Relay
                1. Relays location
                2. Purpose of relays
                3. Structure of relay
                4. Specifications
                5. Checking relays
            t. Route of Electric Wiring
                1. Unloading, horn
                2 Route of Electric Wiring (Engine Rear)
                3. Route of Electric Wiring (Engine Upper Side)
                4. Route of Electric Wiring (Starter Motor, Body Grounding)
                5. Route of Electric Wiring (Right Side of the Operation Stand)
            u. Electrical component layout
            v. Electric Circuit
                1. Battery direct line and ground (Earth) line
                2. Key switch ON (AC - position)
                3. Key switch to the start position
                4. Engine running at travel high range
            w. Electrical wiring diagram
                1. Initial type (Lever lock SW isn’t linked)
                2. Modified type (Lever lock SW is wired)
    ConversionTable
WSM_U15-3_Service
    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
                e. Maintenance
                f. Waste Disposal
        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
            a. Operate the Machine and check for Unusual Noise and Vibrations.
            b. Make Sure the Safety decals and Wireharness Clamps are in their Specified Positions.
            c. With the Machine Front in a Specified Posture, Check the Amount of Hydrauric Oil
            d. Piping
                (1) General precautions
                (2) Hydraulic hose
                (3) Precautions in tightening the bolts and nuts
                (4) Hose screw
                Metric Size Hose
                (5) Joint bodies
                (6) Tightening torque table for hose clamp (Screw type)
                (7) Nuts for piping
                (8) Tightening torque of bolts and nuts
                (9) Types and materials of bolts and nuts
                (10) Washer-equipped elbow
                (11) Adhesives
        E. Maintenance intervals
            a. EU version
            b. PP (KTC, KCL)-version
            b-1. KTA-version
            c. Hydraulic Oil Check for Machines with Hydraulic Breakers
            d. Maintenance items
                (1) Drive unit Oil Change(First Oil Change of the 100 hours)
                (2) Inspection and Cleaning of the Air Filter Element
                (3) Cleaning the Track Frame Slide Pipes
            e. Troubleshooting for operators
            f. Periodic replacement of important component parts
            g. Recommend oils
            h. Lifting capacity : U15-3
        F. Specifications
            a. Machine Weight
                (1) KE, KDG, KUK version
                (2) PP (KTC, KCL, KTA) version
            b. Main Specifications
            c. Lever stroke and operating force
            d. Dimensions of Parts
                (1) Front pins and bush
                (2) Bucket fixture dimensions
                (3) Bucket link pin
                (4) Track roller
                (5) Idler and sprocket
                (6) Dozer
                (7) Bucket dimensions
                (8) Machine weight and parts weight
                (9) Water and Oil Quantity
            e. Quality specifications
    II Machine Body
        A. Front attachment
            a. Pin, bush and shim installation
                (1) Swing cylinder, swing bracket, boom
                (2) Arm, bucket link
                (3) Blade, blade cylinder and truck cylinder
                (4) Clearance adjustment
            b. Instruction to press in the bushing
                (1) Bush installation steps
                (2) Installing direction of dust seal
                (3) Installation of thrust collar on the swing bracket
                (4) Swing bracket pin & bush.
                (5) Measuring the swing bracket looseness
                (6) Service tip to ease customer complain
            c. Greasing points
        B. Upper Structure
            a. Swivel bearing
            b. Travel lever
            c. Accelarator lever
            d. Dozer lever
            e. Control link
            f. Swing pedal
            g. Service port pedal
            h. Pilot control valve
            i. Limit switch installation
            j. Seat and Seat belt
            k. Wrist rest
            l. Canopy
            m. Weight
        C. Undercarrige
            a. Track tension device
            b. Track Roller
    III Engine
        A. Engine accessories
            a. Engine mount
            b Air cleaner
            c. Radiator
                (4) Thermostat
            d. Muffler
            e. Pump coupling
            f. Fuel tank
            g. Fuel hoses
            h. Engine outlook
        B. Engine WSM : D782 -B
    IV Hydraulic System
        A. Troubleshooting
            a. Common circuit
            b. Hydraulics
            c. Pump
            d. Motor
            e. Swivel performance
            f. Traveling performance
        B. Testing
            a. Testing Instruments & special tools
            b. Pump flow
            c. Pressure measurement
                (1) Pilot pressure
                (2) Main relief valve
                (3) Overload relief valve
                (4) Swivel brake valve pressure
            d. Drain measurement
                (1) Traveling motor
                (2) Swivel motor
            e. Measurement of block performance
                (1) Swivel
                (2) Traveling
            f. 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
            g. Straight travel performance
            h. Swivel system diagnosis
                (1) Main check points
                (2) Checking the pilot valve spool performance
                (3) Checking the control valve spool performance (stuck)
                (4) Measuring the secondary pressure of pilot valve
                (5) Checking the brake valve pressure
                (6) Checking the anti-void valve movement and seating
                (7) Checking the motor drain amount
            i. Travel system diagnosis
                (1) Diagnosis
                (2) Main points
                (3) Inlet dump spool check
                (4) Checking the counterbalance valve and high/low-speed selector valve (travel motor)
                (5) Checking the swivel joint for internal leak
            j. Cylinder natural fall amount
            k. Control and Traveling lever operating force
            l. Lever stroke
        C. Specifications
            a. Pump specifications
            b. Relief Valve
                (1) Bench set data
                (2) Machine set data (at the pump gauge port)
            c. Swivel performance
            d. Traveling performance
            e. Cylinder
                (1) Speed
                (2) Natural fall
                (3) Cylinder maintenance data
            f. Service port flow amount
            g. Motor oil drain amount test sample
                (1) Travel motor
                (2) Swivel motor
            h. Hydraulic components layout : U15-3, U15
            i. Hydraulic circuit diagram
                1. U15-3, EU - version
                2. U15, PP - version
        D. Disassembling and reassembling
            a. Pump
                (1) Pump coupling
                (2) Adaptor installation
                (3) Component of pump
                (4) Disassembling and reassembling
            b. Control valve
                (1) Control Valve assy
                (2) Adaptor installation
                (3) Adaptor installation
                (4) Inner parts of control valve
                (5) Disassembling and reassembling
            c. Pilot valve
                (1) Installation
                (2) Component of pilot valve
                (3) Inner parts
                (4) Function
                (5) Adaptor installation
                (6) Pilot hose connection
                (7) Pilot hose (Size 1/4)
                (5) Disassembling and assembling
            d. Swivel motor
                (1) Component of swivel motor
                (2) Cross-sectional View of Swivel Motor
                (3) Adaptor Installation
            e. Rotary joint
                (1) Installation
                (2) Adaptors
                (3) Components of Rotary Joint
                (4) Hose connection
                (5) Oil piping
                (6) Assembling of the rotary joint
                (7) Disassembling of the Rotary Joint from machine
            f. Travel motor
                (1) Componet of travel motor
                (2) Adaptor installation
                (3) Hose connection
                (4) Disassembly and reassembly
            g. Cylinder
                (1) Components and specifications
                (2) Disassembling and reassembling
            h. Change valve (Dozer, Track)
                (1) Location and adaptor
                (2) Components of change valve (Dozer, Track)
            i. Unload valve
                (1) Location and adaptor
                (2) Structure and specifications
                (3) Hose connection
            j. Accumulator
                (1) Installation
                (2) Accumulator performance test
            k. Oil tank
                (1) Installation
                (2) Filter element
            l. Third line
            m. TPSS valve
                (1) Dismounting and remounting
                (2) Disassembly and reassembly
                (3) Pilot hose
    V Electrical system
        A. General
            a. New feature on electrical system
                (1) Starter automatic release function
                (2) Auto glow
                (3) Anti-theft type
            b. Electrical component layout
            c. Electric circuit diagram
            d. Electrical wiring diagram, initial version
            e. Electeical wiring diagram, revised version
        B. Troubleshoothing
            a. General
                (1) How to diagnose
            b. Engine
            c. Panel relevant (Key switch: ON)
            d. Panel relevant (Engine starting)
            e. Others
        C. Inspection
            a. Coupler check
            b. Components check
            c. Fuse inspection
            d. Harness check
            e. Battery check
            f. Measuring instruments and special tools
        D. Wire Herness Installation
            a. Precautions in clamping the electrical cabling
            b. Harness layout, overview
            c. Engine's back
            d. Engine's top
            e. Cabling the unload and horn switch
            f. Routing the front electrical cables
            g. High-speed switch, horn and anti-theft unit
        E. Main Components Maintenance
            a. Checking the fuses
                (1) Check points
            b. Checking the battery
                (1) Check points
            c. Checking the meter panel and key switch
                (2) Fuel meter
                (3) Check procedure of the key switch
            d. Checking the working lamp
            e. Checking the horn
            f. Checking the glow relay
            g. Glow plug
            h. Unload safety switch
            i. Hi-Low travel switch
            j. Checking the solenoid valve
            k. Checking the fuel pump
            l. Checking the fuel sensor
            m. Engine stop solenoid and coil commander
            n. Checking the water temperature gauge
            o. Oil switch
            p. Relay
                (1) Location
                (2) Starter lock relay
                (3) Auto release relay
                (4) Auto release stabilizer relay
                (5) Glow relay
                (6) Auto glow controller
                (7) Auto release controller
                (8) Travel high - low circuit relay
            q. Installation of Canopy Light for KTA
            
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