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WORKSHOP MANUAL

KUBOTA EXCAVATOR

U35-4

KiSC issued 10, 2022 A

CONTENTS TO THE READER TO THE READER I INFORMATION CONTENTS INFORMATION 1. SAFETY FIRST ............................................ I-1 2. IN THE INTEREST OF WORK SAFETY........................................................ I-2 3. LABELS DISPLAYED TO PROMOTE WORK SAFETY............................................ I-5 4. MAIN SPECIFICATIONS............................ I-12 5. DIMENSIONS ............................................. I-14 G GENERAL CONTENTS GENERAL 1. CHECKING EXCAVATOR IDENTIFICATION ........................................G-1 2. ENGINE IDENTIFICATION .........................G-2 3. GENERAL PRECAUTIONS.........................G-5 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING...........G-9 5. TYPES OF OIL ..........................................G-13 6. TIGHTENING TORQUES..........................G-14 7. MAINTENANCE.........................................G-19 1 MACHINE BODY CONTENTS SERVICING 1. FRONT EQUIPMENT ................................ 1-S1 2. UPPER SWIVEL...................................... 1-S12 3. TRACK FRAME ....................................... 1-S33 2 ENGINE CONTENTS GENERAL 1. SPECIFICATIONS.....................................2-G1 2. EXTERNAL DIMENSIONS ........................2-G2 3. PERFORMANCE CURVE .........................2-G3 3 HYDRAULIC SYSTEM CONTENTS MECHANISM 1. DIGRAM OF HYDRAULIC CIRCUIT ........ 3-M1 2. HYDRAULIC DEVICE LAYOUT ............... 3-M5 3. PUMP ....................................................... 3-M7 4. CONTROL VALVE.................................. 3-M15 5. SWIVEL MOTOR.................................... 3-M24 6. TRAVEL MOTOR ................................... 3-M29 7. HYDRAULIC CYLINDER........................ 3-M40 8. PILOT VALVE......................................... 3-M47 9. UNLOAD VALVE .................................... 3-M55 10. AUX SOLENOID VALVE ........................ 3-M59 11. PROPORTIONAL VALVE FOR ANGLE BLADE CONTROL .................... 3-M62 12. PROPORTIONAL VALVE FOR AC MODE CONTROL .................................. 3-M64 SERVICING 1. PUMP ........................................................ 3-S1 2. CONTROL VALVE................................... 3-S13

3. SWIVEL MOTOR ..................................... 3-S30 4. SWIVEL JOINT ........................................ 3-S41 5. TRAVEL MOTOR..................................... 3-S45 6. HYDRAULIC CYLINDER ......................... 3-S69 7. PILOT VALVE (CONTROL) ..................... 3-S80 8. PILOT VALVE (TRAVEL)......................... 3-S89 9. UNLOAD VALVE ..................................... 3-S99 10. TPSS VALVE ......................................... 3-S104 11. AUX SOLENOID VALVE ....................... 3-S106 12. ANGLE SOLENOID VALVE................... 3-S108 13. THIRD LINE VALVE ASSEMBLY .......... 3-S109 14. ROUTING OF HYDRAULIC HOSES ..... 3-S110 15. MEASURING THE PERFORMANCE OF HYDRAULIC DEVICES ................... 3-S122 16. TROUBLESHOOTING........................... 3-S140 4 ELECTRICAL SYSTEM CONTENTS SERVICING 1. READING THE ELECTRICAL CIRCUIT DIAGRAMS ................................ 4-S1 2. ELECTRONIC DEVICE LAYOUT .............. 4-S8 3. WIRING CIRCUIT .................................... 4-S12 4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION) ......................... 4-S15 5. CHECKS .................................................. 4-S16 6. METER PANEL OPERATING PROCEDURE .......................................... 4-S23 7. TROUBLESHOOTING (METER PANEL EDITION) .................................... 4-S69 8. DEALER SETTING MODE FLOWCHART ........................................ 4-S132 5 CABIN CONTENTS MECHANISM 1. AIR CONDITIONING SYSTEM................. 5-M1 2. WIPER .................................................... 5-M19 SERVICING 1. TROUBLESHOOTING............................... 5-S1 2. MAINTENANCE AND SERVICE RELATED SPECIFICATIO NS .............................................................. 5-S4 3. TORQUE.................................................... 5-S5 4. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM ................. 5-S6 5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM ....................... 5-S12 6. INSPECTION AND DISASSEMBLY ........ 5-S21 7. CABIN REMOVAL AND MOUNTING ...... 5-S41 8. WINDOW WASHER ................................ 5-S43 9. LIGHTING DEVICES (CAB WORK LIGHT, INTERIOR LIGHT) ...................... 5-S46 10. REMOVAL AND INSTALLATION OF GLASS ..................................................... 5-S49 11. FRONT WINDOW.................................... 5-S54

KiSC issued 10, 2022 A

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

IMPORTANT • Please refer to the "Workshop Manual" below for information about the engine. Workshop manual title: Diesel engine D1703-M-DI-E4 WEB PDF code: 9Y111-07830 Booklet print code: 9Y121-07830 CD-ROM code: 9Y131-07830 March 2013 © KUBOTA Corporation 2013

KiSC issued 10, 2022 A

Record of Revisions Last digit of the Code No.

Date

2013.07.01

2013.09.20

2015.05.13

2021.09

2022.03

Page

Main Revised Point and Corrective Measures

I-13

• Description of Main specifications for AU-version added.

G-21

• Description of Maintenance for AU-version added.

1-S35

• Measured values for Measuring swivel bearing play added.

3-M3 to 3-M4

• Description of Diagram hydraulic circuit for AU-version added.

3-M14 3-M22 to 3-M23 3-M34 to 3-M36

• Description of Mechanism for Hydraulic system added.

3-S124

• Measuring the main pump flow (When measuring the combined flow of P1 and P2)

3-S136

• Measured values for pump flow added.

3-S137

• Measured values for AUX discharge flow added.

3-S139

• Measured values for swivel motor drain volume added. • Measured values for travel motor drain volume added.

4-S131 to 4-S133

• Description of Dealer setting mode flowchart added.

G-13

• Type of engine oil is corrected.

4-S26

• Periodic Check Items List added.

I-12

• Operating weight.

1-S5 R-1

• Corrected the pin dimensions.

1-S12, 1-S15, 3-S1 R-2 to R-4

• Corrected the dimensions of the left bonnet mounting bolt.

3-S111 to 3-S113, 3-S116 R-5 to R-8

• Corrected the hydraulic hose dimensions.

1-S17 R-9

• Changed the fuel hose to new type.

2-G1 R-10

• Corrected the compression pressure.

3-S31 R-11

• Corrected the angle of swivel motor adapter.

3-S43 R-12

• Corrected the angle of swivel joint adapter.

3-S139 R-13

• Corrected the swivel block performance.

4-S58 R-14

• Added a descriptive text about arm control.

KiSC issued 10, 2022 A

TO THE READER

U35-4 (NA), WSM

Last digit of the Code No.

Date

2022.10

Page

Main Revised Point and Corrective Measures

1-S6 R-15

• Bushing ID tolerance values for FRONT BUSHING DIMENSIONS added. • Wear limit values for FRONT BUSHING DIMENSIONS added.

1-S35 R-16 to R-17

• Measuring Swivel Gear Backlash added.

1-S39 R-18

• Corrected the Rubber track spec table.

3-M8 to 3-M9 R19 to R-20

• Corrected the Piston Pump Horsepower Control Curve spec table.

R-1

• Diameter tolerance values for FRONT PIN DIMENSIONS added. • Wear limit values for FRONT PIN DIMENSIONS added.

KiSC issued 10, 2022 A

I INFORMATION

KiSC issued 10, 2022 A

INFORMATION CONTENTS 1. SAFETY FIRST .............................................................................................................................. I-1 2. IN THE INTEREST OF WORK SAFETY ........................................................................................ I-2 [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS:......................................................................................................... I-2 (1) Precautions Before Working on the Mini-Excavator ........................................................... I-2 (2) Precautions Before Working on the Equipment.................................................................. I-3 3. LABELS DISPLAYED TO PROMOTE WORK SAFETY................................................................. I-5 [1] LOCATIONS ............................................................................................................................. I-5 [2] LABEL MAINTENANCE ......................................................................................................... I-11 4. MAIN SPECIFICATIONS.............................................................................................................. I-12 [1] US, CA SPECIFICATION ....................................................................................................... I-12 [2] AU SPECIFICATOION ........................................................................................................... I-13 5. DIMENSIONS ............................................................................................................................... I-14

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

1. SAFETY FIRST SAFETY FIRST • This "Safety Alert Symbol" is used in this manual and on labels on equipment to indicate important issues and warn of the danger of personal injury. Read and follow these warnings carefully. • It is important that you thoroughly read these instructions and safety rules prior to working on the equipment and that you always follow them. DANGER • Indicates that failure to follow the warning will result in serious injury or death. WARNING • Indicates that failure to follow the warning may result in serious injury or death. CAUTION • Indicates that failure to follow the warning may result in injury. IMPORTANT • Indicates that failure to follow the warning may result in damage to or a breakdown of the equipment. NOTE • Indicates supplementary explanations that will be helpful when using the equipment. [NOTE] • Indicates other supplementary information to take note of. RY9212001INI0001US0

I-1

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

2. IN THE INTEREST OF WORK SAFETY [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS: (1) 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. RY9212001INI0002US0

• 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. RY9212001INI0003US0

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. RY9212001INI0004US0

• 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. RY9212001INI0005US0

I-2

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

(2) 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. RY9212001INI0006US0

• 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. CAUTION • 3-point support means using both legs and one hand or both hands and one leg as you climb up/down. RY9212001INI0007US0

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. RY9212001INI0008US0

• 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. RY9212001INI0009US0

I-3

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

• 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. RY9212001INI0016US0

• 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. RY9212001INI0011US0

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. RY9212001INI0012US0

• 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. RY9212001INI0013US0

I-4

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

3. LABELS DISPLAYED TO PROMOTE WORK SAFETY [1] LOCATIONS

RY9212182INI0004US0

I-5

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

RY9212182INI0005US0

I-6

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

RY9212182INI0006US0

I-7

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

RY9212182INI0007US0

I-8

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

RY9212182INI0008US0

I-9

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

RY9212182INI0009US0

I-10

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

RY9212182INI0010US0

[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. RY9212001INI0018US0

I-11

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

4. MAIN SPECIFICATIONS [1] US, CA SPECIFICATION KUBOTA EXCAVATOR Model name

U35-4 Angle Blade Type

Type

Canopy

CAB

Operating weight (including operator's)

3687 kg 8129 lbs

3833 kg 8451 lbs

Type

Blade

18.5 kW (25 HP)

Rated speed

2200 rpm

Low idle speed

1300 to 1350 rpm

Unit swing speed

8.9 rpm

Fast

4.6 km/h (2.9 mph)

Slow

3.0 km/h (1.9 mph)

Ground pressure (With operator)

35.1 kPa 0.36 kgf/cm2 5.0 psi

33.7 kPa 0.34 kgf/cm2 4.8 psi

35.2 kPa 0.36 kgf/cm2 5.1 psi

Climbing angle

36 % (20 deg)

Angle in case of crossing slope

27 % (15 deg)

Width × Height

1700 × 343 mm 66.9 × 13.5 in.

Max. swing angle

36.5 kPa 0.37 kgf/cm2 5.3 psi

Left

–

25 deg

Right

–

25 deg

Left

1.22 rad (70 deg)

Right

0.87 rad (50 deg)

Max. displacement (Theoretical)

60.5 L/min (15.9 U.S.gals/min) 17.2 MPa 175 kgf/cm2 2494 psi

Max. pressure

Fuel tank capacity • • ∗ ∗ ∗ ∗ ∗

3991 kg 8800 lbs

1647 cc (100.5 cu.in)

Engine power SAE gross

Boom swing angle Pressure connection for attachments

3845 kg 8478 lbs

D1703-M-DI-E4

Total displacement

Travel speed Performance

CAB

Water cooled 4 cycle diesel engine with 3 cylinder

Model name Engine

Canopy

45.1 L (11.9 U.S.gals)

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) RY9212182INI0003US0

I-12

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

[2] AU SPECIFICATOION KUBOTA EXCAVATOR Model name

U35-4

Type

Canopy

CAB

Operating weight (including operator's)

3685 kg 8124 lbs

3835 kg 8455 lbs

Type

Water cooled 4 cycle diesel engine with 3 cylinder

Model name Engine

Total displacement

Blade

18.5 kW (25 HP)

Rated speed

2200 rpm

Low idle speed

1300 to 1350 rpm

Unit swing speed

8.9 rpm

Fast

4.6 km/h (2.9 mph)

Slow

3.0 km/h (1.9 mph)

Climbing angle

36 % (20 deg)

Angle in case of crossing slope

27 % (15 deg)

Width × Height

1700 × 343 mm 66.9 × 13.5 in.

Max. swing angle

Left

–

Right

–

Left

1.22 rad (70 deg)

Right

0.87 rad (50 deg)

Max. displacement (Theoretical)

60.5 L/min (15.9 U.S.gals/min) 17.2 MPa 175 kgf/cm2 2494 psi

Max. pressure

Fuel tank capacity • • ∗ ∗ ∗ ∗

35.1 kPa 0.36 kgf/cm2 5.0 psi

33.7 kPa 0.34 kgf/cm2 4.8 psi

Ground pressure (With operator)

Boom swing angle Pressure connection for attachments

1647 cc (100.5 cu.in.)

Engine power SAE gross

Travel speed Performance

D1703-M-DI-E4

45.1 L (11.9 U.S.gals)

I-13

KiSC issued 10, 2022 A

INFORMATION

U35-4, WSM

5. DIMENSIONS

(A)

(B)

(C)

(D)

(E)

(F)

(G)

(H)

(I)

(J)

U35-4

789 mm 31.1 in.

481 mm 18.9 in.

1700 mm 66.9 in.

4844 mm 190.7 in.

3397 mm 133.7 in.

3007 mm 118.4 in.

2013 mm 79.2 in.

900 mm 35.4 in.

3735 mm 147 in.

5281 mm 207.9 in.

(K)

(L)

U35-4

371 mm 14.6 in.

369 mm 14.5 in.

(M) 2470 mm 97.2 in.

2480 mm 97.6 in.

(N)

(O)

(P)

(Q)

(R)

1700 mm 66.9 in.

5165 mm 203.3 in.

4635 mm 182.5 in.

1479 mm 58.2 in.

2222 mm 87.5 in.

* 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. RY9212182INI0011US0

I-14

KiSC issued 10, 2022 A

G GENERAL

KiSC issued 10, 2022 A

GENERAL CONTENTS 1. CHECKING EXCAVATOR IDENTIFICATION .............................................................................. G-1 2. ENGINE IDENTIFICATION .......................................................................................................... G-2 [1] MODEL NAME AND SERIAL NUMBER ................................................................................ G-2 [2] E4B ENGINE .......................................................................................................................... G-4 [3] CYLINDER NUMBER ............................................................................................................. G-4 3. GENERAL PRECAUTIONS.......................................................................................................... G-5 4. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................... G-9 [1] WIRING .................................................................................................................................. G-9 [2] FUSES.................................................................................................................................. G-11 [3] CONNECTOR ...................................................................................................................... G-11 [4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER ..................................... G-12 5. TYPES OF OIL ........................................................................................................................... G-13 [1] TABLE OF OIL AND FLUID CAPACITIES ........................................................................... G-13 [2] CHECKING AND FILLING HYDRAULIC OIL ....................................................................... G-13 6. TIGHTENING TORQUES........................................................................................................... G-14 [1] GENERAL USE SCREWS, BOLTS AND NUTS .................................................................. G-14 [2] STUD BOLTS ....................................................................................................................... G-14 [3] TORQUE FOR HYDRAULIC HOSE FITTINGS ................................................................... G-15 (1) Torque for Hydraulic Hose Fittings ................................................................................. G-15 (2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings (Straight Threads)........................................................................................................... G-16 (3) Torque for Tapering Adaptors ........................................................................................ G-16 [4] HOSE CLAMP SCREW TORQUE ....................................................................................... G-17 7. MAINTENANCE.......................................................................................................................... G-19 [1] MAINTENANCE INTERVALS (US, CA SPECIFICATION)................................................... G-19 [2] MAINTENANCE INTERVALS (AU SPECIFICATION) ......................................................... G-21

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

1. 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) (2) Frame Number (3) Engine Number

(a) Model Nameplate

RY9212182GEG0001US0

G-1

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

2. 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 Number or Alphabet

Series

Number or Alphabet

Series

05 (include: WG)

GZ, OC, AC, EA, E

SM (include: WG)

EA, RK

Air Cooled Gasoline

03 (KET Production)

Alphabet or Number

Year

Alphabet or Number

Year

2001

2015

2002

2016

Production Year

2003

2017

2004

2018

2005

2019

2006

2020

2007

2021

2008

2022

2009

2023

2010

2024

2011

2025

2012

2026

2013

2027

2014

(1) Engine Model Name and Serial Number

(To be continued)

G-2

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

(Continued) Production Month and Lot Number Month

Engine Lot Number

January

A0001 to A9999

from B0001

February

C0001 to C9999

from D0001

March

E0001 to E9999

from F0001

April

G0001 to G9999

from H0001

May

J0001 to J9999

from K0001

June

L0001 to L9999

from M0001

July

N0001 to N9999

from P0001

August

Q0001 to Q9999

from R0001

September

S0001 to S9999

from T0001

October

U0001 to U9999

from V0001

November

W0001 to W9999

from X0001

December

Y0001 to Y9999

from Z0001

* Alphabetical letters "I" and "O" are not used. (a)

(b)(c)(d) (e)

e.g. D1703 - 7 C U 1237 (a) (b) (c) (d) (e)

D1703: Engine Model Name 7: Engine Series (03 series) C: Production Year (2012) U: Production Month (October) 1237: Lot Number: (0001 to 9999 or A001 to Z999) RY9212182GEG0009US0

G-3

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

[2] E4B ENGINE [Example: Engine Model Name D1703-M-DI-E4] The emission controls previously implemented in various countries to prevent air pollution will be stepped up as Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission regulations depends on the engine output classification. Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the respective countries affected by Nonroad Emission regulations. For KUBOTA Engines, E4B will be the designation that identifies engine models affected by the next emission phase (See the table below). When servicing or repairing ###-E4B series engines, use only replacement parts for that specific E4B engine, designated by the appropriate E4B KUBOTA Parts List and perform all maintenance services listed in the appropriate KUBOTA Operator's Manual or in the appropriate E4B KUBOTA Workshop Manual. Use of incorrect replacement parts or replacement parts from other emission level engines (for example: E3B engines), may result in emission levels out of compliance with the original E4B design and EPA or other applicable regulations.Please refer to the emission label located on the engine head cover to identify Output classification and Emission Control Information. E4B engines are identified with "EF" at the end of the Model designation, on the US EPA label. Please note: E4B is not marked on the engine. Category (1)

Engine output classification

EU regulation

From 19 to 37 kW

STAGE IIIB

From 37 to less than 56 kW

STAGE IIIB

From 56 to less than 75 kW

STAGE IIIB

From 75 to less than 130 kW

STAGE IIIB

Category (2)

Engine output classification

EPA regulation

Less than 19 kW

Tier 4

From 19 to less than 56 kW

Interim Tier 4

From 56 to less than 75 kW

Interim Tier 4

From 75 to less than 130 kW

Interim Tier 4

(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. RY9212182GEG0011US0

[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. RY9212174GEG0003US0

G-4

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

3. 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. RY9212001GEG0011US0

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 RY9212001GEG0012US0

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 (3) Check for Burrs

(4) If the Ring Touches This Corner, It Will Twist RY9212001GEG0013US0

Oil Seal • Do not face the lip of the oil seal in the wrong direction. Face the main lip toward the material to be sealed. • 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. • 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) (2) (3) (4) (5) (6)

Gasket Metal Ring Spring Main Lip Grease Dust Lip

A : Air (Outside) B : Hydraulic Chamber (Inside)

RY9212001GEG0014US0

G-5

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

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 RY9212001GEG0015US0

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

(A) External (B) Internal RY9212001GEG0016US0

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 RY9212001GEG0017US0

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. (A) Bolt Through-Hole (Nut) (B) Pocket Bolt Hold (Capsule Shape, etc.)

(a) Apply Here (b) Do Not Apply (c) Drip On RY9212001GEG0018US0

G-6

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

Tightening Bolts and Nuts • 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. (A) Top/Bottom Alternately (B) Across Diagonally

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. RY9212001GEG0020US0

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 RY9212001GEG0021US0

G-7

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

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 RY9212001GEG0022US0

G-8

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

4. 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. IMPORTANT • 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 RY9212001GEG0023US0

[1] WIRING • Tighten wiring terminals securely. (1) Correct (Tightened Securely)

(2) Incorrect (Poor Contact if Loose) RY9212001GEG0024US0

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

(3) Wiring Position (Right) (4) Hazardous Position RY9212001GEG0025US0

• Immediately repair or replace old or damaged wiring. (1) Damaged (2) Torn

(3) Electrical Tape RY9212001GEG0026US0

G-9

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

• Insert grommet securely. (1) Grommet

(A) Correct (B) Incorrect RY9212001GEG0027US0

• Clamp wiring securely but do not damage wires with the clamp. (1) Clamp (Spiral Clamp Around Wire) (3) Clamp (2) Wire (4) Welding Mark RY9212001GEG0028US0

• 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

(A) Correct (B) Incorrect RY9212001GEG0029US0

• Do not pinch or bind wiring when installing parts. (1) Wire

(A) Incorrect RY9212001GEG0030US0

• After wiring, double-check terminal protectors and clamps before connecting battery cables. (1) Cover (Install Covers Securely) RY9212001GEG0031US0

G-10

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

[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 RY9212001GEG0032US0

[3] CONNECTOR • Press the lock to disconnect locking connectors. (A) Push RY9212001GEG0033US0

• Hold the connectors when separating them. • Do not pull on the wire harness to separate the connectors. (A) Correct

(B) Incorrect RY9212001GEG0034US0

• 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 RY9212001GEG0035US0

• Female connectors must not be spread too far open (A) Correct

(B) Incorrect RY9212001GEG0036US0

G-11

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

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

(A) Correct (B) Incorrect RY9212001GEG0037US0

[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. CAUTION • 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. (Ex.) (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

(A) (B) (C) (D)

Blasting Wide Spray Less Than 2 m (80 in.) Over 2 m (80 in.) RY9212001GEG0038US0

G-12

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

5. TYPES OF OIL [1] TABLE OF OIL AND FLUID CAPACITIES Item

U35-4

Engine oil (when replacing filter) Radiator coolant (not including coolant in reserve tank)

5.3 L (1.4 U.S.gals) Canopy spec. Cabin spec.

Reserve tank coolant

Hydraulic oil

Notes API class CF/CF-4 or CI-4

4.3 L (1.1 U.S.gals) 4.7 L (1.2 U.S.gals)

KUBOTA LLC-N-50F 50%

0.85 L (0.22 U.S.gals) Total amount of oil

62 L (16 U.S.gals)

In tank (gauge centre)

35.7 L (9.43 U.S.gals)

• ISO 46 (In summer or with high ambient temperatures.) • ISO 32 (In summer or with low ambient temperatures.)

Fuel tank capacity when full

45.1 L (11.9 U.S.gals)

• Diesel Fuel No.2-DS15 • Diesel Fuel No.1-DS15 [Fuel under -5 °C (23 °F)]

Wheel motor

0.6 L (0.16 U.S.gals)

SAE90 (AP1, GL-4, GL-5)

Track rollers

80 ml (4.88 cu. in.)

Carrier roller (Top track roller)

60 ml (3.66 cu. in.)

Front idler

80 ml (4.88 cu. in.)

Engine oil SAE #30CD

RY9212182GEG0003US0

[2] 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

(a) Normal range of hydraulic oil RY9212182GEG0004US0

G-13

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

6. TIGHTENING TORQUES [1] 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. Indication on top of bolt

No-grade or 4T

Indication on top of nut

No-grade or 4T 6T

Material of opponent part

Ordinariness

Aluminum

Ordinariness

Aluminum

Unit

N·m kgf·m lbf·ft

7.9 to 9.3

0.8 to 0.95

5.8 to 6.8

18 to 20

1.8 to 2.1

N·m kgf·m lbf·ft

7.9 to 8.8

0.8 to 0.9

5.8 to 6.5

9.81 to 11.2

1.0 to 1.15

7.24 to 8.31

7.9 to 8.8

0.8 to 0.9

5.8 to 6.5

12.3 to 14.2

1.25 to 1.45

9.05 to 10.4

13 to 15

17 to 19

4.0 to 4.6 6.4 to 7.4

29 to 33

32 to 34

1.7 to 2.0 3.2 to 3.5

13 to 14 24 to 25

24 to 27 48 to 55

2.4 to 2.8 4.9 to 5.7

18 to 20 36 to 41

18 to 20 40 to 44

1.8 to 2.1 4.0 to 4.5

13 to 15 29 to 32

30 to 34 61 to 70

3.0 to 3.5 6.2 to 7.2

22 to 25 45 to 52

40 to 45 63 to 72

47 to 53

–

78 to 90

7.9 to 9.2

58 to 66

63 to 72

6.4 to 7.4

47 to 53

103 to 117

10.5 to 12

76 to 86.7

M14

108 to 125

11 to 12.8

79.6 to 92.5

–

124 to 147

12.6 to 15

91.2 to 108

–

167 to 196

17 to 20

123 to 144

M16

167 to 191

17 to 19.5

123 to 141

–

197 to 225

20 to 23

145 to 166

–

260 to 304

26.5 to 31

192 to 224

M18

246 to 284

25 to 29

181 to 209

–

275 to 318

28 to 32.5

203 to 235

–

344 to 402

35 to 41

254 to 296

M20

334 to 392

34 to 40

246 to 289

–

368 to 431

37.5 to 44

272 to 318

–

491 to 568

50 to 58

362 to 419

M10

M12

Ordinariness

RY9212032GEG0001US0

[2] STUD BOLTS Material of opponent part

Ordinariness

Aluminum

Unit

N·m kgf·m lbf·ft

12 to 15

1.2 to 1.6

8.7 to 11

8.9 to 11

0.90 to 1.2

6.5 to 8.6

M10

25 to 31

2.5 to 3.2

18 to 23

20 to 25

2.0 to 2.6

15 to 18

M12

30 to 49

3.0 to 5.0

22 to 36

3.2

M14

62 to 73

6.3 to 7.5

46 to 54

–

M16

98.1 to 112

10.0 to 11.5

72.4 to 83.1

–

M18

172 to 201

17.5 to 20.5

127 to 148

–

– RY9212032GEG0002US0

G-14

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

[3] 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

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 RY9212001GEG0041US0

Tapered Nuts

Tightening torque

1/8

19.6 to 29.4 N·m 2.0 to 3.0 kgf·m 14.5 to 21.7 lbf·ft

1/4

36.6 to 44.1 N·m 3.7 to 4.5 kgf·m 26.8 to 32.5 lbf·ft

3/8

68.6 to 73.5 N·m 7.0 to 7.5 kgf·m 50.6 to 54.2 lbf·ft

1/2

83.4 to 88.3 N·m 8.5 to 9.0 kgf·m 61.5 to 65.1 lbf·ft

3/4

166.6 to 181.3 N·m 17 to 18.5 kgf·m 123 to 133.8 lbf·ft

(1) Taper RY9212001GEG0042US0

G-15

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

(2) Torques of Lock-Nuts for Elbows with Male Seats and Adaptors with O-rings (Straight Threads) 1/8

15.0 to 16.5 N·m 1.5 to 1.7 kgf·m 11.1 to 12.2 lbf·ft

1/4

24.5 to 29.4 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft

3/8

49.0 to 53.9 N·m 5.0 to 5.5 kgf·m 36.1 to 39.8 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, 1

117.6 to 127.4 N·m 12.0 to 13.0 kgf·m 86.8 to 94.0 lbf·ft

1-1/4

220.5 to 230.3 N·m 22.5 to 23.5 kgf·m 162.8 to 170.0 lbf·ft

Tightening torque

(1) Lock-Nut (2) Washer

(3) Seal (O-Ring) RY9212001GEG0043US0

(3) Torque for Tapering Adaptors

Tightening torque

1/8

19.6 to 29.4 N·m 2.0 to 3.0 kgf·m 14.5 to 21.7 lbf·ft

1/4

36.6 to 44.1 N·m 3.7 to 4.5 kgf·m 26.8 to 32.5 lbf·ft

3/8

68.6 to 73.5 N·m 7.0 to 7.5 kgf·m 50.6 to 54.2 lbf·ft

1/2

83.4 to 88.3 N·m 8.5 to 9.0 kgf·m 61.5 to 65.1 lbf·ft

3/4

166.6 to 181.3 N·m 17 to 18.5 kgf·m 123 to 133.8 lbf·ft

(1) Taper RY9212001GEG0044US0

G-16

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

[4] HOSE CLAMP SCREW TORQUE Type 1 10-

6C040-58721

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

12-

09318-89016

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

19-

09318-89024

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

31-

09318-89039

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

36-

09318-89045

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

44-

09318-89052

3.9 to 4.9 N·m 40 to 50 kgf·cm 2.9 to 3.6 lbf·ft

51-

09318-89058

3.9 to 4.9 N·m 40 to 50 kgf·cm 2.9 to 3.6 lbf·ft

86-

RD809-42241

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

Tightening torque

RY9212001GEG0045US0

G-17

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

Type 2 13-

RB101-63631

2.5 to 3.4 N·m 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft

15-

RC101-64581

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

19-

R1401-63211

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

22-

R1401-63151

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

26-

68311-72821

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

32-

RD411-63821

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

44-

35820-15181

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

50-

RC401-63191

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

58-

36919-04591

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

60-

RD809-63101

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

68-

RD809-63061

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

77-

69284-63171

4.9 to 5.9 N·m 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft

Tightening torque

RY9212001GEG0046US0

G-18

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

7. MAINTENANCE [1] MAINTENANCE INTERVALS (US, CA SPECIFICATION) No.

Check points

Measures check

1 Coolant

Hour meter indicator 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 Daily check

every 2 years

change

2 Fuel 3 Engine oil

check

Daily check

check

Daily check

change check

4 Hydraulic oil



Others



every 500 hrs



every *1 1000 hrs

Daily check

change

Bucket and bucket link pin / Dozer angle pin and Grease front angle cylinder 5 attachments boss Boom swing fulcrum

Interval

–

Daily check

–

Daily check

–

Daily check

6 Radiator and oil cooler

check

Daily check

7 Washer liquid

check

Daily check

8 Engine and electrical wiring

check

Daily check

9 Fuel tank, Water separator

drain



every 50 hrs

10 Battery condition

check



every 50 hrs

–



every 50 hrs

11 Greasing swing bearing teeth

check 12 V-belt tension

Daily check

adjust



every 200 hrs

check



every 200 hrs

13 Radiator hoses and clamps

every 2 years

replace 

every 200 hrs

replace



every *2 @ 1000 hrs

replace



every *2 1000 hrs



every 200 hrs

clean 14

Air filter element



Outer element

Inner element 15 Greasing swing ball bearing

–



16 Fuel filter cartridge

replace



every 500 hrs

17 Engine oil filter

replace



every 500 hrs

18 Drive unit oil

charge



every 500 hrs

19 Breather filter

replace



every 500 hrs

20 Hydraulic return filter element

replace

21 Hydraulic suction filter element

replace



every 1000 hrs

22 Filter in the pilot hydraulic system

replace



every 1000 hrs

Fuel injection nozzle injection pressure

check



every 500 hrs



every *4 @ 1500 hrs

G-19

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

No.

Check points

Measures

Hour meter indicator 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000

Interval

24 Front idler and track roller oil

change

every 2000 hrs

25 Alternator and starter motor

check

every 2000 hrs

26 Injection pump

check

every *4 @ 3000 hrs

27 Radiator system

rinse

every 2 years

check



28 Fuel line and Intake air line

every 200 hrs every 2 years

replace

@ *3

Air-conditioner No.

Check points

Measures clean

Hour meter indicator 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 



every 200 hrs



every *2 1000 hrs



every 200 hrs

1 Air filter replace 2 Air conditioner condenser

clean



check

every 1 year

replace

every 2 years

check

service as required

3 Air conditioner pipes and hoses

4 Refrigerant (gas)



Interval *2

IMPORTANT •  : First operation • *1 : When using a hydraulic hammer, change hydraulic oil and return filter according to the table on "Hydraulic Oil" Change (Including Exchange of the Suction Filter in the Hydraulic Tank) under "EVERY 1000 SERCVICE HOURS" in the chapter "REGULAR CHECKS AND MAINTENANCE WORK". • *2 : Clean and replace the air filter more frequently if used under dusty conditions. When the filter is very dirty from dusty conditions, replace the filter. • *3 : Replace only if necessary. • *4 : Consult your local KUBOTA dealer for this service. • The items listed above (@ mark) are registered as emission related critical parts by KUBOTA in the U.S.EPA non-road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the instruction. Please see the warranty Statement in detail. RY9212182GEG0008US0

G-20

KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

[2] MAINTENANCE INTERVALS (AU SPECIFICATION) No.

Check points

Measures check

1 Coolant

Hour meter indicator 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 Daily check

every 2 years

change

2 Fuel 3 Engine oil

4 Hydraulic oil

check

Daily check

check

Daily check

change



check

Daily check



Others

–

Daily check

–

Daily check

every 250 hrs



change

Bucket and bucket link pin / Dozer angle pin and Grease front angle cylinder 5 attachments boss Boom swing fulcrum

Interval



every *1 1000 hrs

–

Daily check

6 Radiator and oil cooler

check

Daily check

7 Washer liquid

check

Daily check

8 Engine and electrical wiring

check

Daily check

9 Fuel tank, Water separator

drain



every 50 hrs

10 Battery condition

check



every 50 hrs

–



every 50 hrs

11 Greasing swing bearing teeth

check 12 V-belt tension

Daily check

adjust



every 200 hrs

check



every 200 hrs

13 Radiator hoses and clamps

every 2 years

replace 

every 200 hrs

replace



every *2 @ 1000 hrs

replace



every *2 1000 hrs



every 200 hrs



every 500 hrs

clean 14

Air filter element



Outer element

Inner element 15 Greasing swing ball bearing

–



16 Fuel filter cartridge

replace

17 Engine oil filter

replace



18 Drive unit oil

charge



19 Breather filter

replace

20 Hydraulic return filter element

replace

21 Hydraulic suction filter element

replace



every 1000 hrs

22 Filter in the pilot hydraulic system

replace



every 1000 hrs

Fuel injection nozzle injection pressure

check

every *4 @ 1500 hrs

24 Front idler and track roller oil

change

every 2000 hrs

 



G-21



every 250 hrs



every 500 hrs



every 500 hrs every 500 hrs



KiSC issued 10, 2022 A

GENERAL

U35-4, WSM

No.

Check points

Measures

Hour meter indicator 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000

Interval

25 Alternator and starter motor

check

every 2000 hrs

26 Injection pump

check

every *4 @ 3000 hrs

27 Radiator system

rinse

every 2 years

check



28 Fuel line and Intake air line

every 200 hrs every 2 years

replace

@ *3

Air-conditioner No.

Check points

Measures clean

Hour meter indicator 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 



every 200 hrs



every *2 1000 hrs



every 200 hrs

1 Air filter replace 2 Air conditioner condenser

clean



check

every 1 year

replace

every 2 years

check

service as required

3 Air conditioner pipes and hoses

4 Refrigerant (gas)



Interval *2

G-22

KiSC issued 10, 2022 A

1 MACHINE BODY

KiSC issued 10, 2022 A

SERVICING CONTENTS 1. FRONT EQUIPMENT ..................................................................................................................1-S1 [1] MACHINE STRUCTURE .......................................................................................................1-S1 [2] ARM ASSEMBLY/DISASSEMBLY ........................................................................................1-S2 [3] RELATIVE DIMENSIONS OF BUCKET INSTALLATION JOINTS........................................1-S3 [4] BOOM ASSEMBLY/DISASSEMBLY .....................................................................................1-S4 [5] FRONT PIN DIMENSIONS ...................................................................................................1-S5 [6] FRONT BUSHING DIMENSIONS .........................................................................................1-S6 [7] BLADE DISASSEMBLY/ASSEMBLY ....................................................................................1-S8 [8] BLADE DEMENSIONS........................................................................................................1-S11 2. UPPER SWIVEL........................................................................................................................1-S12 [1] WEIGHT ..............................................................................................................................1-S12 (1) Weight Disassembly/Assembly .....................................................................................1-S12 [2] CANOPY .............................................................................................................................1-S13 (1) Canopy Assembly/Disassembly ....................................................................................1-S13 [3] FUEL TANK.........................................................................................................................1-S14 (1) Fuel Tank components ..................................................................................................1-S14 (2) Fuel Tank Assembly/Disassembly.................................................................................1-S15 (3) Fuel Hose Routing.........................................................................................................1-S17 [4] HYDRAULIC OIL TANK ......................................................................................................1-S18 (1) Hydraulic oil tank components.......................................................................................1-S18 (2) Hydraulic Oil Tank Assembly/Disassembly ...................................................................1-S19 [5] ENGINE...............................................................................................................................1-S20 (1) Engine Assembly/Disassembly .....................................................................................1-S20 (2) Engine Mounts...............................................................................................................1-S23 (3) Muffler............................................................................................................................1-S24 (4) Arch, Air Cleaner ...........................................................................................................1-S25 (5) Radiator .........................................................................................................................1-S26 (6) Accelerator Cable ..........................................................................................................1-S27 [6] OPERATING LEVER, PEDAL .............................................................................................1-S28 (1) Steering pilot lever.........................................................................................................1-S28 (2) Travel Lever...................................................................................................................1-S29 (3) Blade Lever ...................................................................................................................1-S30 (4) Swing pedal ...................................................................................................................1-S31 3. TRACK FRAME .........................................................................................................................1-S33 [1] SWIVEL BEARING ..............................................................................................................1-S33 [2] CRAWLER...........................................................................................................................1-S36 (1) Rubber Track Assembly/Disassembly...........................................................................1-S36 (2) Iron Track Assembly/Disassembly ................................................................................1-S37 (3) Track Dimensions..........................................................................................................1-S39 [3] FRONT IDLER.....................................................................................................................1-S40 (1) Front Idler Assembly/Disassembly ................................................................................1-S40 (2) Front Idler Components.................................................................................................1-S40 (3) Assembly/Disassembly of the Front Idler ......................................................................1-S41 [4] SPRING ASSY ....................................................................................................................1-S44 (1) Spring Assy Assembly/Disassembly .............................................................................1-S44 [5] CYLINDER ASSY ................................................................................................................1-S45 (1) Cylinder assy Assembly/Disassembly ..........................................................................1-S45 [6] TRACK ROLLER .................................................................................................................1-S46 (1) Assembly/Disassembly of Track Roller .........................................................................1-S46 KiSC issued 10, 2022 A

(2) Mounting the track roller ................................................................................................1-S47 (3) Track roller structural components ................................................................................1-S47 (4) Assembly/Disassembly of the Track Roller ...................................................................1-S48 [7] CARRIER ROLLER .............................................................................................................1-S50 (1) Assembly/Disassembly of Carrier Roller .......................................................................1-S50 (2) Mounting the carrier roller..............................................................................................1-S51 (3) Carrier roller structural components ..............................................................................1-S51

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

1. FRONT EQUIPMENT [1] MACHINE STRUCTURE

(a) Standard Spec (A) Front equipment

(B) Upper swivel unit

(1)

Bucket

(5)

Weight

(13)

Swivel bearing

(2)

Arm

(6)

Canopy

(14)

Track

(3)

Boom

(7)

Fuel tank

(15)

Front idler

(4)

Blade

(8)

Hydraulic oil tank

(16)

Track rollers

(9)

Engine

(17)

Carrier rollers

(10)

Travel lever

(11)

Blade lever

(12)

Steering pilot lever RY9212182MBS0001US0

1-S1

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[2] ARM ASSEMBLY/DISASSEMBLY Grounding the arm 1. Fully compress the bucket cylinder and set the arm on the ground. (1) Bucket Cylinder

(2) Arm RY9212182MBS0002US0

Attaching the vacuum pump 1. Shut off the air intake/exhaust port of the breather filter on the top of the hydraulic fuel tank to seal the hydraulic oil tank. Replace the hydraulic oil tank filler cap with a vacuuming plug.

2. Attach a vacuum pump to the vacuuming plug and create a negative pressure inside the hydraulic oil tank. (1) Vinyl tape (2) Plug

(3) Vacuum pump (air) RY9212182MBS0014US0

Removing the bucket cylinder 1. Attach a nylon sling to the bucket cylinder and suspend. Remove the hydraulic hoses. Take out the bottom pin of the bucket cylinder and remove the bucket cylinder. (1) Bucket Cylinder (2) Nylon sling

(3) Hydraulic hoses (4) Pin RY9212182MBS0004US0

Removing the arm 1. Place a supporting block under the arm cylinder. Attach a nylon sling to the arm and suspend. Take out the rod pin and remove the rod part of the arm cylinder. Take out the boom linkage pin and remove the arm. • Weight of arm : approx. 65 kg. (140 lbs.) (1) Block (2) Arm Cylinder (3) Arm

(4) Nylon sling (5) Boom linkage pin RY9212182MBS0112US0

1-S2

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Assembling the Arm The assembly procedure is the reverse of the disassembly procedure. RY9212001MBS0031US0

[3] RELATIVE DIMENSIONS OF BUCKET INSTALLATION JOINTS

(A) Arm Tip

(B) Bucket, Link 1

(1)

175 mm 6.89 in.

(5)

275 mm 10.8 in.

(9)

10 mm 0.39 in.

(13)

46 mm 1.6 in.

(17)

40 mm 1.6 in.

(2)

1150 mm 45.28 in.

(6)

1230 mm 48.43 in.

(10)

134 mm 5.28 in.

(14)

134 mm 5.28 in.

(18)

40 mm 1.6 in.

(3)

276 mm 10.9 in.

(7)

310 mm 12.2 in.

(11)

134 mm 5.28 in.

(15)

134 mm 5.28 in.

(4)

196 mm 7.72 in.

(8)

310 mm 12.2 in.

(12)

40 mm 1.6 in.

(16)

51 mm 2.0 in. RY9212182MBS0006US0

1-S3

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[4] BOOM ASSEMBLY/DISASSEMBLY Removing the arm cylinder 1. Place the boom end on the ground. 2. Attach a nylon sling to the arm cylinder and detach the hydraulic hoses from the arm cylinder. 3. Take out the bottom pin of the arm cylinder and remove the arm cylinder. (1) Arm Cylinder (2) Nylon sling

(3) Pin RY9212182MBS0007US0

Removing the arm cylinder 1. Remove the slide cover from the boom cylinder. 2. Attach a nylon sling to the boom cylinder and detach the hydraulic hoses from the boom cylinder. 3. Take out the pin and remove the boom cylinder. (1) Boom Cylinder

(2) Nylon sling RY9212182MBS0008US0

Removing the front hydraulic hoses 1. Disconnect the whole worklight harness and all of the hydraulic hoses at the boom base. (1) Hydraulic hoses RY9212182MBS0009US0

Removing the boom 1. Attach a nylon sling to the boom, suspend the boom, remove the bolts, take out the pins and then remove the boom. • Weight of boom : approx. 130 kg. (287 lbs.) RY9212182MBS0010US0

Assembling the Boom The assembly procedure is the reverse of the disassembly procedure. RY9212001MBS0036US0

1-S4

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[5] FRONT PIN DIMENSIONS

(a) Pin diameter No.

(b) Length Pin dia. × length

No.

Pin dia. × length

(1)

70 × 147 mm (2.8 × 5.79 in.)

(9)

45 × 185 mm (1.8 × 7.28 in.)

(2)

70 × 135 mm (2.8 × 5.31 in.)

(10)

45 × 162 mm (1.8 × 6.38 in.)

(3)

40 × 132 mm (1.6 × 5.2 in.)

(11)

40 × 162 mm (1.8 × 6.38 in.)

(4)

40 × 107 mm (1.6 × 4.21 in.)

(12)

40 × 193 mm (1.8 × 7.6 in.)

(5)

50 × 286 mm (2.0 × 11.3 in.)

(13)

40 × 193 mm (1.8 × 7.6 in.)

(6)

45 × 157 mm (1.8 × 6.18 in.)

(14)

40 × 161 mm (1.8 × 6.34 in.)

(7)

45 × 193 mm (1.8 × 7.6 in.)

(15)

45 × 131 mm (1.8 × 5.16 in.)

(8)

40 × 230 mm (1.6 × 9.06 in.) RY9212182MBS0072US0

1-S5

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[6] FRONT BUSHING DIMENSIONS Item

U35-4

Material

<1>

70 × 82 × 41 mm (2.8 × 3.2 × 1.6 in.)

STKM16A, S43C, S45C

<2>

70 × 82 × 34 mm (2.8 × 3.2 × 1.3 in.)

STKM16A, S43C, S45C STKM16A, S43C, S45C

<3> 70 × 82 × 34 mm (2.8 × 3.2 × 1.3 in.)

STKM16A, S43C, S45C

<6>

40 × 50 × 50 mm (1.6 × 2.0 × 2.0 in.)

S45C

<7>

40 × 50 × 25 mm (1.6 × 2.0 × 0.98 in.)

STKM16A, S43C, S45C

<8>

50 × 60 × 42 mm (2.0 × 2.4 × 1.7 in.)

STKM16A, S43C, S45C

50 × 60 × 60 mm (2.0 × 2.4 × 2.4 in.)

STK16A, S43C

<10>

45 × 55 × 45 mm (1.8 × 2.2 × 1.8 in.)

STK16A, S43C

<11>

45 × 55 × 45 mm (1.8 × 2.2 × 1.8 in.)

STK16A, S43C

<12>

45 × 55 × 60 mm (1.8 × 2.2 × 2.4 in.)

S45C

<13>

40 × 50 × 60 mm (1.6 × 2.0 × 2.4 in.)

STK16A, S43C

<14>

45 × 55 × 60 mm (1.8 × 2.2 × 2.4 in.)

STKM16A, S45C

<15>

40 × 50 × 50 mm (1.6 × 2.0 × 2.0 in.)

STKM16A, S45C

<16>

40 × 50 × 40 mm (1.6 × 2.0 × 1.6 in.)

STKM16A, S43C

<17>

40 × 50 × 32 mm (1.6 × 2.0 × 1.3 in.)

STKM16A, S43C, S45C

<4> <5>

<9>

(I.D. × O.D. × Length)

(a) I.D. (b) O.D.

1-S6

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(1) Swivel frame - Swing bracket (upper) (2) Swivel frame - Swing bracket (lower) (3) Swivel frame - Swing cylinder (bottom) (4) Swing bracket - Swing cylinder (rod) (5) Swing bracket - Boom (6) Swing bracket - Boom cylinder (bottom) (7) Boom - Boom cylinder (rod) (8) Boom - Arm (9) Boom - Arm cylinder (bottom) (10) Arm cylinder - Arm cylinder (rod) (11) Arm - Bucket cylinder (bottom) (12) Arm - Bucket link (2, 3) (13) Bucket link (1, 2, 3) - Bucket cylinder (rod)

RY9212182MBS0011US0

1-S7

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[7] BLADE DISASSEMBLY/ASSEMBLY

(1) (2) (3) (4)

U Frame Cover (1, angle) Cover (angle cylinder) Cylinder, ASSY (angle)

(5) (6) (7) (8)

Cover Pin Pin Blade

(9) Hydraulic hose (blade cylinder (11) Hydraulic hose (angle cylinder rod side) rod side) (10) Hydraulic hose (angle cylinder (12) Hydraulic hose (blade cylinder bottom side) bottom side) RY9212182MBS0074US0

1-S8

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Grounding the front equipment 1. Put the front equipment to the position shown in the photograph, set the machine on flat level ground, and set the bucket and blade assembly on the ground. (1) Blade ASSY RY9212182MBS0012US0

Removing the blade cylider bottom pin 1. Place a support block under the blade cylinder and remove the bottom pin. (1) Bottom pin RY9212182MBS0013US0

2. Attach a vacuum pump to the vacuuming plug and create a negative pressure inside the hydraulic oil tank. (1) Vinyl tape (2) Plug

(3) Vacuum pump (air) RY9212182MBS0014US0

Removing the blade assembly 1. Remove the angle cylinder hoses from the track frame. IMPORTANT • Plug the disconnected hoses and adapters. (1) Angle cylinder hose RY9212182MBS0015US0

1-S9

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

2. Attach a nylon sling to the blade assembly at three points and suspend. Take out the pin and remove the blade assembly. • Weight of angle blade assembly : approx. 263 kg. (580 lbs.) (1) Nylon sling RY9212182MBS0016US0

Removing the U frame Attach a nylon sling at two points and raise up the blade assembly. (1) Nylon sling RY9212182MBS0019US0

Remove the angle cylinder bottom pin and the centre pin. Operate the crane and remove the U frame. (1) Pin (2) Centre pin

(3) U Frame RY9212182MBS0020US0

1-S10

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[8] BLADE DEMENSIONS Blade Dimensions Item

U35-4

(1)

Blade width

1700 mm (66.93 in.)

(2)

Blade height

378 mm (14.9 in.)

(3)

Blade length

1374 mm (54.1 in.)

(4)

Length between blade arms

483 mm (19.0 in.)

(A) Cutting Edge RY9212182MBS0021US0

Cutting Edge Dimensions No.

U35-4

(1)

849 mm (33.4 in.)

(2)

735 mm (28.9 in.)

(3)

57 mm (2.2 in.)

(4)

490 mm (19.3 in.)

(5)

24.5 mm (9.65 in.)

(6)

100 mm (3.94 in.)

(7)

50 mm (2.0 in.)

(8)

1.2 mm (0.47 in.) RY9212182MBS0022US0

Pin Dimensions Item (1) (2) (3)

U35-4 30 × 115.5 mm (1.2 × 4.547 in.)

Pin Diameter x Length

(4)

55 × 194 mm (2.2 × 7.64 in.) 45 × 131 mm (1.8 × 5.16 in.) 40 × 161 mm (1.6 × 6.34 in.)

(a) Pin Diameter

(b) Pin Length RY9212182MBS0023US0

1-S11

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

2. UPPER SWIVEL [1] WEIGHT (1) Weight Disassembly/Assembly Removing the rear bonnet 1. Remove the bolts and then the rear bonnet. (1) Rear bonnet

(2) Bolt (M10 × 20) RY9212182MBS0026US0

Removing the left bonnet 1. Remove the four mounting bolts of the left bonnet and the fuel tank cap, and then take off the left bonnet. (1) Cap, ASSY (2) Bolt (M8 × 16)

(3) Left bonnet RY9212182MBS0025US0

Removing the bracket and the partition plate 1. Detach the rear bonnet fixing bracket and the partition plate. (1) Bracket

(2) Partition plate RY9212182MBS0024US0

Removing the weight 1. Attach two eyebolts to the weight, connect a nylon sling to these and support the weight using a crane. (1) Weight (2) Eyebolt (M24 × P3)

(3) Nylon sling (4) Bolts (M20 × 90 × P2.5) RY9212182MBS0027US0

2. Remove the three mounting bolts of the weight, lift slightly with the crane, slide the weight to the rear, lift the weight and remove it from the frame. • Weight of boom : approx. 650 kg. (1430 lbs.) Tightening torque

Weight (1)

367.7 to 431.5 N·m 37.5 to 44.0 kgf·m 271.2 to 318.2 lbf·ft

Apply thread lock (Loctite 271). RY9212182MBS0028US0

1-S12

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[2] CANOPY (1) Canopy Assembly/Disassembly Removing the canopy 1. Put the bucket on the ground and stop the engine. Remove the three bolts and the handrail. (1) Handrail RY9212182MBS0126US0

2. Attach a nylon sling to the canopy and support with a crane. Remove the four canopy mounting bolts. Tightening torque

Canopy mounting bolts (3)

196.1 to 225.6 N·m 20.0 to 23.0 kgf·m 144.6 to 166.4 lbf·ft

3. Operate the crane and remove the canopy. (2) Canopy (3) Bolt (M16 × 50 P1.5 9T)

(4) Nylon sling RY9212182MBS0127US0

1-S13

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[3] FUEL TANK (1) Fuel Tank components

(1) (2) (3) (4) (5) (6) (7)

Fuel tank Fuel sensor Spring washer Nut Cap, ASSY (fuel) Fuel pipe Filter

(8) Fuel hose (9) Hose clamp (10) Grommet (11) Fuel tube (12) Base (drain) (13) Plug (14) Sealing washer

(15) Hose clamp (with spring) (16) Fuel tube (17) Tube (18) Pipe clip (19) Fuel tube (20) Tube (21) Pipe clip

(22) Band ASSY (23) Flat metal washer (24) Lock nut (25) Plate (26) Flange bolt (M10 × 20) (27) Flange bolt (M10 × 20) (28) Bolt (M10 × 20)

Assembly of fuel sensor Tightening torque

Nut (4)

Assembly of fuel hose and fuel pipe

RY9212182MBS0075US0

3 to 4 N·m 0.3 to 0.4 kgf·m 2 to 3 lbf·ft RY9212182MBS0076US0

Hose clamp (9) (fuel pipe side)

4.9 to 5.9 N·m 0.5 to 0.6 kgf·m 3.6 to 4.4 lbf·ft

Hose clamp (9) (fuel tank side)

2.9 to 3.9 N·m 0.3 to 0.4 kgf·m 2.1 to 2.9 lbf·ft

Tightening torque

RY9212182MBS0077US0

1-S14

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Fuel Tank Assembly/Disassembly Removing the left bonnet 1. Remove the four mounting bolts of the left bonnet and the fuel tank cap, and then take off the left bonnet. (1) Cap, ASSY (2) Bolt (M8 × 16)

(3) Left bonnet RY9212182MBS0029US0

Removing the side cover 1. Remove the five bolts and the side cover. (1) Bolt (M10 × 25) (2) Bolt (M10 × 25)

(3) Side cover RY9212182MBS0030US0

Removing the fuel tank 1. Remove the two bolts and the blade 1. Remove the two bolts and the blade 2. (1) Blade 1 (2) Blade 2

(3) Bolt (M10 × 20) RY9212182MBS0032US0

2. Take off the lock nuts of the band assembly. Remove the two bolts and the blade assembly and band assembly. Take out the fuel drain plug, drain the fuel from the fuel tank, and then detach the two bolts and remove the fuel drain main body. (1) Band ASSY (2) Lock nut

(3) Bolt (4) Fuel drain main body RY9212182MBS0033US0

3. Detach the fuel sensor harness connector. RY9212182MBS0114US0

1-S15

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

4. Remove the fuel tank assembly and detach the fuel hose on the tank side. • Weight of fuel tank : approx. 5 kg (10 lbs) (1) Fuel tank ASSY RY9212182MBS0115US0

1-S16

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(3) Fuel Hose Routing

(1) Drain Cock (2) Fuel Tank

(3) Water Separator (4) Fuel Pump

(5) Fuel Filter

Fuel tube Part No.

(6) Engine

Protective tube Length

Part No.

Hose clamp Length

IN / OUT side

(A)

RC788-51331

150 mm (5.91 in.)

–

09318-88125

(B)

09664-81600

1600 mm (62.99 in.)

RC788-51441

1500 mm (59.06 in.)

14911-42751

(C)

09664-80400

400 mm (15.7 in.)

RC788-51451

300 mm (11.8 in.)

14911-42751

(D)

RC788-51411

–

14911-42751

(E)

09664-80220

220 mm (8.66 in.)

–

14911-42751

(F)

RB238-51362

–

14911-42751

(G)

09664-40550

550 mm (21.7 in.)

RC461-51641

45 mm (17.7 in.)

14971-42751

(H)

09664-41650

1650 mm (64.96 in.)

RC788-51461

1550 mm (61.02 in.)

14911-42751

RY9212182MBS0078US0

1-S17

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[4] HYDRAULIC OIL TANK (1) Hydraulic oil tank components

(1) (2) (3) (4) (5) (6)

Hydraulic oil tank Tank cover O-ring Bolt (M10 × 16) Suction strainer Oil supply plug

(7) O-ring (8) Plug (9) Sealing washer (10) Oil gauge (11) Return filter (12) Bolt (M6 × 20)

(13) Nut (14) Breather filter (15) Metal washer (16) Sealing washer (17) Flange bolt (18) Pipe joint

(19) Pipe joint (20) Pipe joint (21) Pipe joint (22) Bolt (M12 × 25)

RY9212182MBS0079US0

Assembly of the tank cover Tightening torque

Bolt (4)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft RY9212182MBS0080US0

Assembly of the return filter (When assembling) • The opposite sides of the filter must be parallel with the locking bolt mounting area. Tightening torque

Return filter (11)

68.6 to 78.4 N·m 7.0 to 8.0 kgf·m 50.6 to 57.8 lbf·ft RY9212182MBS0081US0

Assembly of the hydraulic tank (When assembling) • Apply thread locking compound (Loctite 271) and tighten using the specified torque. Tightening torque

Bolt (22)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft RY9212182MBS0082US0

1-S18

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Hydraulic Oil Tank Assembly/Disassembly Removing the control valve 1. Remove the control valve and assembly. (Refer to the chapter "Control Valve Assembly/Disassembly".) 2. Take out the drain plug from the hydraulic oil tank and drain out the hydraulic oil. • Amount of hydraulic oil: 35.7 L (9.43 U.S.gals) RY9212182MBS0120US0

Removing the hydraulic oil tank 1. Detach the reserve tank and the battery. 2. Loosen the hose clamp and remove the suction hose from the tank. (1) Hose clamp

(2) Suction hose RY9212182MBS0121US0

3. Remove the hydraulic hose from the hydraulic oil tank cover and the unload valve. (3) Tank cover

(4) Unload valve RY9212182MBS0122US0

4. Take out the mounting bolts of the hydraulic oil tank and remove the hydraulic oil tank. Tightening torque

Hydraulic oil tank mounting bolts

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Apply thread lock (Loctite 271). (5) Hydraulic oil tank

(6) Bolt (M12 × 25) RY9212182MBS0123US0

5. Attach an eyebolt to the hydraulic oil tank, connect a shackle and nylon sling, raise with a crane and remove. (7) Eyebolt (M10 × P1.25)

(7) Nylon sling RY9212182MBS0124US0

1-S19

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[5] ENGINE (1) Engine Assembly/Disassembly Removing the Canopy 1. Put the bucket on the ground and stop the engine. Remove the canopy. (Refer to the chapter "Canopy Removal and Installation".) RY9212182MBS0043US0

Removing the Weight 1. Remove the weight. (Refer to the chapter "Weight Removal and Installation".) (1) Weight RY9212182MBS0044US0

Removing the centre bonnet 1. Remove the seat support mounting bolts, shift the seat support towards the front of the machine, and then remove the centre bonnet. (1) Centre bonnet RY9212182MBS0046US0

Removing the fuel tank bracket 1. Remove the two bolts and take the bracket off the arch. (1) Bolt (M10 × 20)

(2) Bracket RY9212182MBS0045US0

Removing the fuel hose, wire harness and air cleaner hose 1. Remove the fuel hose from both filters. (2 places) 2. Detach the wire harness from the arch. 3. Loosen the hose clamp on the air cleaner and detach the air intake hose from the intake manifold. 4. Remove the accelerator cable linkage from the engine. 5. Detach the pilot filter from the arch. (1) Fuel tube (2) Fuel tube (3) Wire harness

(4) Inlet hose (5) Accelerator cable (6) Pilot filter RY9212182MBS0047US0

1-S20

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Removing the arch 1. Remove the arch mounting bolts (6 bolts). Connect a nylon sling about the arch and hoist with a crane.

Tightening torque

103.0 to 117.1 N·m 10.5 to 12.0 kgf·m 76.0 to 86.8 lbf·ft

Arch mounting bolts (1)

Apply thread lock (Loctite 271). (1) Arch

(2) Nylon sling RY9212182MBS0049US0

Removing the pump 1. Remove the pump mounting bolts and disconnect from the pump connector. Rest the pump on a block.

Tightening torque

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Pump, ASSY mounting bolts (1)

(1) Pump, ASSY

(2) Block RY9212182MBS0050US0

Removing the radiator hoses 1. Take out the radiator drain plug and drain the coolant. Amount of coolant

Canopy

4.3 L (1.1 U.S.gals)

Cabin

4.5 L (1.2 U.S.gals)

2. Loosen the hose clamps on the upper and lower coolant hoses and detach the hoses from the engine. (1) Hose clamp (upper hose)

(2) Hose clamp (lower hose) RY9212182MBS0051US0

Removing the engine support bolts 1. Remove the engine suport fixing bolts. Tightening torque

Engine support mounting bolts (1)

48.1 to 55.9 N·m 4.9 to 5.5 kgf·m 35.5 to 41.2 lbf·ft

Apply thread lock (Loctite 271). 2. Remove the mounting nuts of the engine anti-vibration rubbers. Tightening torque

Engine anti-vibration rubber mounting nuts (2)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Apply thread lock (Loctite 271). (1) Bolt (M10 × 25)

(2) Nut RY9212182MBS0053US0

1-S21

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Removing the engine assembly 1. Attach two shackles to the engine, connect a nylon sling to these and support the engine using a crane. (1) Nylon sling RY9212182MBS0054US0

1-S22

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Engine Mounts [A] Engine mount structural components

(1) Anti-vibration rubber (2) Bracket (3) Stopper

(4) Bracket (5) Stopper (6) Stopper

(7) Bracket (8) Bracket

(9) Stopper

• Fastening torque of support mounting bolts Tightening torque

Bolt (M10)

48.1 to 55.9 N·m 4.9 to 5.5 kgf·m 35.5 to 41.2 lbf·ft

Apply thread lock (Loctite 271). • Fastening torque of bracket mounting bolts Tightening torque

Bolt (M12)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Apply thread lock (Loctite 271). • Fastening torque of anti-vibration rubber mounting bolts Tightening torque

Nut

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Apply thread lock (Loctite 271). RY9212182MBS0083US0

1-S23

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(3) Muffler [A] Muffler Assembly Fastening the pipe (muffler) clamp Being careful not to dent or deform the pipe (muffler), fasten with the following torque. Tightening torque

3.9 to 5.9 N·m 0.4 to 0.6 kgf·m 2.9 to 4.4 lbf·ft

Exhaust pipe band (6)

Muffler assembly installation procedure 1. Lightly tighten the bolts (a), (b), (c). IMPORTANT • Ensure there are no gaps on the X, Y and Z surfaces. 2. Tighten the (a) bolt. 3. Tighten the (b) bolt. (Apply Locktite) (ThreeBond 1324) 4. Tighten the (c) bolt. 5. Tighten the U bolt (5). Bolt (a) (c)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt (b)

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.3 to 20.3 lbf·ft

Tightening torque

(1) (2) (3) (4) (5) (6)

Muffler Pipe (muffler) Bracket (muffler) Stay (muffler pipe) U bolt Exhaust pipe band

(a) Bolt (b) Bolt (c) Bolt X: Y: Z:

X surface Y surface Z surface RY9212182MBS0085US0

Ensuring gaps between pipe (muffler) outlet and weight hole. (1) Pipe (muffler) (2) Weight

(A) gap no less than 20 mm (0.79 in.) (B) Pipe (muffler) does not project from end of weight. RY9212004MBS0112US0

1-S24

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(4) Arch, Air Cleaner [A] Assembling the Arch and Air Cleaner

(1) Frame arch (2) Bolt (M12 × 30)

(3) Air cleaner, ASSY

(4) Inlet hose 1

(5) Inlet hose 2 RY9212182MBS0087US0

Assembling the Arch Tightening torque

Bolt (M12 x 30) (2)

103.0 to 117.1 N·m 10.5 to 12.0 kgf·m 76.0 to 86.8 lbf·ft

Apply thread lock compound (Loctite 271). (1) Frame Arch (2) Bolt (M12 x 30) (3) Air Cleaner, Assy

(4) Inlet Hose 1 (5) Inlet Hose 2 RY9212182MBS0055US0

1-S25

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(5) Radiator [A] Radiator Assembly

(1) Radiator, ASSY

• • • •

(2) Fan surround

(3) Cushion (radiator)

(4) Bolt (M6 × 16)

NOTE (a): Gap between radiator core (fan) and fan (b): Gap between fan and fan surround (c): Fit cushion clips securely into the holes in the bracket. (d): Band fastening direction RY9212182MBS0088US0

Fastening torque of fan surround mounting bolts Tightening torque

Bolt (4)

4.5 to 5.5 N·m 0.46 to 0.56 kgf·m 3.3 to 4.1 lbf·ft

Gap between radiator core (fan) and fan Gap between radiator core (fan) and fan (a)

Factory Specification

76 to 82 mm 3.0 to 3.2 in.

Gap between fan and surround Gap between fan and surround (b)

Tightening torque

Factory Specification

Band (d):

No less than 10 mm (0.39 in.) 3.9 to 4.9 N·m 0.4 to 0.5 kgf·m 2.9 to 3.6 lbf·ft RY9212182MBS0089US0

1-S26

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(6) Accelerator Cable Routing of accelerator cable (1) Accelerator cable

(2) AI motor RY9212182MBS0125US0

Engine governor (1) Accelerator cable RY9212182MBS0092US0

AI motor AI motor assembly screw fastening torque Tightening torque

Machine screw (Taptite) (2)

2.45 to 3.92 N·m 0.25 to 0.40 kgf·m 1.81 to 2.89 lbf·ft

Accelerator sensor mounting bolt fastening torque Tightening torque

Screw with washer (4)

1.47 to 1.96 N·m 0.15 to 0.2 kgf·m 1.08 to 1.45 lbf·ft

Apply threadlock (ThreeBond TB1401B or equivalent). (1) (2) (3) (4) (5)

AI motor, ASSY Machine screw Accelerator sensor Machine screw and washer Cable (accelerator, 1274)

(a) Leave gap no less than 1 mm (0.04 in.) at maximum engine RPM.

RY9212182MBS0093US0

1-S27

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[6] OPERATING LEVER, PEDAL (1) Steering pilot lever

(1) Gas damper

(2) Limit switch

(a) 536 mm (21.1 in.) reference (b) 16 mm (0.63 in.) value

NOTE • (A): Eliminate any gaps in part (A) when locked on limit control side.

Tightening torque

Limit switch (2)

3.9 to 4.9 N·m 0.4 to 0.5 kgf·m 2.9 to 3.6 lbf·ft

Apply a thread lock (ThreeBond TB1401B). RY9212182MBS0094US0

1-S28

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Travel Lever (1) (2) (3) (4)

Lever (Travel, Left) Lever (Travel, Right) Bolt (M8 × 20) Grip (Travel)

(a) 193 ± 5 mm (7.6 ± 0.2 in.) (b) When in Neutral (c) To-and-fro Difference between Left and Right Levers should be within 2.0 mm (0.08 in.) (d) Gap between Left and Right Levers : 11 to 22 mm (0.43 to 0.87 in.) RY9212032MBS0031US0

Lever (travel, left), lever (travel, right) assembly The pilot valve side is aluminum die cast so be careful not to over tighten; tighten to the torques indicated below. Tightening torque

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Bolt (3)

Lever (Travel, Left) Lever (Travel, Right) Bolt (M8 × 20) Grip (Travel) Washer Head Bolt Valve, Assy (PV, Travel) Damper (HST) Headed Pin Snap Pin 8

17.7 to 20.6 N·m 1.8 to 2.1 kgf·m 13.1 to 15.1 lbf·ft (10) Flat Metal Washer (11) Pedal Assy (Travel Left) (12) Pedal (Travel 2) (13) Pedal Assy (Travel Right) (14) Headed Pin (15) Flat Metal Washer (16) Snap Pin (17) Bolt (M10 × 25) RY9212032MBS0032US0

1-S29

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(3) Blade Lever

(1) (2) (3) (4)

Grip Clip (Angle spec.) Blade lever Blade lever (Angle spec.)

(5) Bolt (M10 × 30) (6) Blade cable (7) Bolt (M10 × 25)

A : Without angle B : Angle Specification

Tightening torque

Bolt (5)

(a) (b) (c) (d) (e) (f)

90° (1.57 rad) 142 mm (5.59 in.) 52 mm (2.0 in.) 46 mm (1.8 in.) 53 mm (2.1 in.) 47 mm (1.8 in.) 39.2 to 45.1 N·m 4.0 to 4.6 kgf·m 28.9 to 33.3 lbf·ft RY9212182MBS0095US0

1-S30

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(4) Swing pedal

(1) Swing pedal (2) Pedal bracket assembly

(3) Swing cable bracket (4) Swing cover

(5) Cable (6) Snap pin with retainer

(A) Position the slots towards the front of the machine.

Check points after assembly of swing pedal 1. Set control valve spool to full stroke. 2. Operate control valve spool. Tolerable bend radius of push-pull cable

Factory Spec

no less than 165R RY9212182MBS0096US0

1-S31

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(1) Swing (2) Blade

(a) (b) (c) (d) (e) (f) (g)

37 mm (1.5 in.) 30 mm (1.2 in.) 137 mm (5.39 in.) Reference value 47 mm (1.8 in.) 31 mm (1.2 in.) 38 mm (1.5 in.) 102 mm (4.02 in.) Reference value RY9212182MBS0097US0

1-S32

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

3. TRACK FRAME [1] SWIVEL BEARING No.

Part Name

Q'ty

(1)

Swivel bearing

(2)

Bolt (M16 × 45)

(3)

Diaphragm spring

(4)

Bolt (M16 × 45)

(5)

Diaphragm spring

20 RY9212182MBS0098US0

Swivel bearing assembly procedure 1. Swivel bearing installation position Mount the inner tire soft zone ('S' mark) (a) on the right side of the body. 2. Fastening torque of swivel bearing After lightly tightening, tighten to the torque indicated below from a diagonal angle. Tightening torque

Swivel bearing mounting bolts

259.9 to 304.0 N·m 26.5 to 31.0 kgf·m 191.7 to 224.0 lbf·ft

Apply thread lock (Loctite 271). 3. Apply grease to the tooth surfaces Apply grease so that it covers the entire bearing teeth surfaces. A : Front of machine (c) Port for applying grease to the (a) "S" mark (inner tire soft zone) ball (mate with hole in swivel (b) Ball insert groove (outer tire soft frame) zone) (d) Tooth surface grease application zone RY9212182MBS0099US0

1-S33

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Swivel bearing structural components 1. Component names No.

Q'ty

Part names

U35-4

(1)

Ball

(2)

Seal A

(3)

Seal B

(4)

Outer race

(5)

Inner race

2. External Dimensions No.

U35-4

45 mm (1.8 in.)

38.5 mm (1.52 in.)

C D E F G H I

599 mm (23.6 in.) P.C.D. 574 mm (P.C.D. 22.6 in.) 527 mm (20.7 in.) P.C.D. 482 mm (P.C.D. 19 in.) 460 mm (18.1 in.) P.C.D. 440 mm (P.C.D. 17.3 in.) 429 mm (16.9 in.) RY9212182MBS0100US0

1-S34

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Measuring Swivel Bearing Play 1. Fasten the dial gauge to the track frame so the probe of the dial gauge touches the swivel frame. 2. Extend the arm all the way and stow the bucket. Zero the dial gauge. 3. Use the attachment to tilt the body of the machine upwards and take a reading on the dial gauge. Take this measurement a number of times and use the average as the final measurement. CAUTION • Perform the measurement 3 times; take the average and use this as the measurement value.

(L): Point 50 mm (2.0 in.) from the swivel race

Factory Spec

U35-4

1.04 mm 0.04 in.

Allowable limits

U35-4

2.08 mm 0.08 in.

(L) Point to measure RY9212182MBS0130US0

1-S35

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[2] CRAWLER (1) Rubber Track Assembly/Disassembly CAUTION • The pressure in the grease cylinder is high so if loosened quickly, the nipple may pop off and the highly pressurized grease in the cylinder may fly out. Do not put your face near the nipple or place your body in front of the nipple, and be sure to loosen the nipple gradually. • The rubber track is heavy and must be handled with care. RY9212182MBS0071US0

Removing the grease nipple 1. Place a wrench (socket) at the base of the grease nipple and loosen slowly. If there are any rocks or the like caught in the sprocket, remove the rocks first. Tightening torque

Grease nipple (3)

(1) Cover (2) Bolt (M10 x 20)

98.0 to 107.8 N·m 10 to 11 kgf·m 72.0 to 79.5 lbf·ft (3) Grease Nipple RY9212182MBS0116US0

Loosening the track 1. Jack up the body using the front end and blade, expel grease from inside the grease cylinder, and fully loosen the track. When the track becomes loose, attach the grease nipple. RY9212182MBS0058US0

Removing the rubber tracks 1. With the machine lifted slightly, wedge a steel pipe into the track and turn the sprocket backwards in direction A. When the steel pipe reaches halfway up the idler and the track lifts off the idler, stop turning the sprocket and slide the track sideways in direction B to remove it. • Weight of rubber track: approximately 138 kg (304 lbs) A : Backwards

B : Direction to slide RY9212182MBS0101US0

Assembling the rubber tracks 1. Jack up the machine with the front and the blade and with it lifted slightly off the ground, wedge the track onto the sprocket and set it on the frame. 2. Wedge steel pipes into the track and rotate the sprocket backwards in direction A. When a steel pipe reaches halfway up the idler, stop turning the sprocket. Slide the track sideways in direction B and set the track onto the idler. Lower the machine and drive it backwards to make sure the tracks are on securely. Adjust the tension of the track. CAUTION • Be sure to assemble the rubber track the right way round. A : Backwards

B : Direction to Slide RY9212182MBS0102US0

1-S36

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Iron Track Assembly/Disassembly CAUTION • The pressure in the grease cylinder is high so if loosened quickly, the nipple may pop off and the highly pressurized grease in the cylinder may fly out so do not get your face near the nipple nor place your body in front of the nipple and loosen the nipple gradually. RY9212001MBS0008US0

98.0 to 107.8 N·m 10 to 11 kgf·m 72.0 to 79.5 lbf·ft

Grease nipple (3)

(1) Cover (2) Bolt (M10 x 20)

(3) Grease Nipple RY9212182MBS0116US0

Removing the locking pin 1. Turn the track until the master pin (1) is in front of the front idler. 2. Remove the locking pin (3) from the master pin. (1) Master Pin (2) Master Link

(3) Locking Pin RY9212001MBS0103US0

Removing the master pin 1. Place a jig on the master pin and tap it out with a hammer. Use a jig as shown in the diagram to the left for removing the pin. (1) Hammer (2) Jig

(3) Block RY9212001MBS0104US0

1-S37

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Removing the shoe 1. Slowly move the travel lever to the backup position and back up the excavator. 2. Jack up the excavator using the front end and blade and pull off the shoe. DANGER • Do not get your feet under the machine . • Weight of steel crawler: approx. 177 kg (390 lbs) RY9212004MBS0014US0

Mounting an iron track 1. Jack up the mini excavator using the front end and blade and place the track so that the end of the track meshes with the sprocket under the mini excavator. Make sure the track is placed in the correct orientation. (1) Master Link

(a) Sprocket Side (b) Front Idler Side RY9212001MBS0106US0

2. Raise the track using a crane and mesh it with the sprocket teeth. (4) Sprocket RY9212001MBS0107US0

3. Slowly move the travel lever to the forward travel position to mesh the track with the shoe (6). When the track is sufficiently pulled on to where the track link joint is at the front idler, lower the mini-excavator, and place a block (7) under the shoe to support the shoe. Match up both ends of the shoe, insert the master pin from the outside of the body, insert the locking pin and bend the tip. (5) Idler (6) Shoe

(7) Block RY9212001MBS0108US0

1-S38

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(3) Track Dimensions Rubber track Item

U35-4

Crawler ASSY part no.

RC788-2231-1

Manufacturer's name

Sumitomo Rubber (Co., Ltd.)

(1) Lug height

22 mm (0.87 in.)

(2) Roller side height

23.5 mm (0.925 in.)

(3) Track width

295 mm (11.6 in.)

(4) Track height

7.5 mm (3.0 in.)

(5) Track tension

10 to 15 mm (0.39 to 0.59 in.)

Core pins

Track central circumference Pitch between pins

4452 mm (175.3 in.) 53 mm (2.1 in.) RY9212182MBS0103US0

Steel Track Item

U35-4 Std. when new

Usage limit

Crawler ASSY part no.

RC541-2210-2

Manufacturer's name

TOPY Enterprises (Ltd.)

Track width (1) Length

300 mm (11.8 in.) 406.4 mm (16 in.)

416.5 mm (16.4 in.)

(2) Tread height

68 mm (2.7 in.)

63 mm (2.5 in.)

(3) Track height

16.5 mm (0.65 in.)

8 mm (0.3 in.)

(4) Bush length

55 mm (2.2 in.)

–

(5) Bush inner diameter

17 mm (0.67 in.)

19 mm (0.75 in.)

(6) Bush outer diameter

28 mm (1.1 in.)

26.46 mm (1.042 in.)

(7) Master pin length

96.5 mm (3.8 in.)

–

(8) Master pin outer diameter

16.8 mm (0.661 in.)

15.5 mm (0.61 in.)

(9) Pin length

97 mm (3.8 in.)

–

(10) Pin outer diameter

17 mm (0.67 in.)

15.5 mm (0.61 in.)

(11) Track tension No. of links (A) Track (B) Bushing

75 to 80 mm (3.0 to 3.1 in.) 43 (C) Master pin (D) Pin RY9212182MBS0104US0

1-S39

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[3] FRONT IDLER (1) Front Idler Assembly/Disassembly Removing the idler 1. Remove the track. (Refer to the chapter Assembly/Disassembly of the Rubber Track.) Jack up the excavator with the front-end and the blade, and place blocks etc. under the frame.

2. Using a bar, remove the front idler from the track frame along with the yoke. • Weight of front idler assembly : approx. 15 kg. (33 lbs.) (1) Block RY9212182MBS0060US0

(2) Front Idler Components No.

Component names

Q'ty

(1)

Spring Pins

(2)

Bracket (R)

(3)

Shaft (Idler)

(4)

Idler

(5)

Floating Seal

(6)

Bushing

(7)

External Circlip

(8)

O-ring

(9)

Bracket (L)

(10)

Plate (Yoke)

(11)

Bolt

(12)

Plug (R1/8)

1 RY9212182MBS0061US0

1-S40

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(3) Assembly/Disassembly of the Front Idler No.

Tightening torque

Component names

Q'ty

(1)

Spring Pins

(2)

Bracket (R)

(3)

Shaft (Idler)

(4)

Idler

(5)

Floating Seal

(6)

Bushing

(7)

External Circlip

(8)

O-ring

(9)

Bracket (L)

(10)

Plate (Idler)

(11)

Bolt (M12 x 55)

(12)

Plug (R1/8)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Bolt (11)

Apply thread lock (Loctite 271). RY9212182MBS0105US0

Disassembling the Idler 1. Remove the plug (R1/8) from the bracket (R) and drain the oil. 2. Use a pin punch to extract the left and right spring pins and then remove the bracket (L). (1) (9)

Spring Pin Bracket (L)

(a) Pin Punch RY9212090MBS0064US0

3. Remove the floating seal. (1) (5)

Spring Pin Floating Seal

(9)

Bracket (L) RY9212090MBS0065US0

4. Remove the shaft (idler). (1) (2) (4)

Spring Pin Bracket (R) Idler

(5) (8) (9)

Floating Seal O-ring Bracket (L) RY9212090MBS0066US0

1-S41

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Reassembly of Idler 1. Insert the O ring onto the shaft (idler). IMPORTANT • Apply grease to the O-ring. (3)

Shaft (Idler)

(8)

O-ring RY9212090MBS0067US0

2. Assemble the shaft (idler) on the bracket (R). (2) Bracket (R)

(7)

Wire RY9212090MBS0068US0

3. Assemble one floating seal on the bracker (R). IMPORTANT • Make sure there is no oil or debris on the O-ring or the O-ring seat. • Apply a thin film of oil to the sliding surfaces. • Make sure there are no scratches on the sliding surfaces or the O-rings. (5) Floating Seal

(a) Sliding Surface RY9212090MBS0069US0

4. Place the floating seal on the idler side too, and then assemble the bracket (R). (5) Floating Seal RY9212090MBS0070US0

5. Place the floating seal on the idler and bracket (L). IMPORTANT • Make sure there is no oil or debris on the O-ring or the O-ring seat. • Apply a thin film of oil to the sliding surfaces. • Make sure there are no scratches on the sliding surfaces or the O-rings. (5) Floating Seal RY9212090MBS0071US0

1-S42

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

6. Align the holes in the shaft (idler) and the bracket (L), hold them in place with a clamp, as shown left, and tap in a spring pin. IMPORTANT • Face the split in the spring pin so it is perpendicular to the shaft and tap it in. • After completing reassembly, rotate the roller 2 to 3 turns to form a film of oil on the sliding surface of the floating seals. (1)

Spring Pin

(a) Clamp RY9212090MBS0072US0

7. Fill with engine oil via the plug hole in the bracket (R). Lubricant

Type SAE 30 CD engine oil

80 cc

8. Install the plug (R1/8). Tightening torque

10 N·m 1.0 kgf·m 7.4 lbf·ft

Plug (R1/8) (12)

Apply thread lock (Loctite 503 or equivalent). RY9212182MBS0062US0

Idler / Driver sprocket Item

U35-4 Std. when new

Usage limit

(1) Idler outer diameter

292 mm (11.5 in.)

284 mm (11.2 in.)

(2) Guide width

30 mm (1.2 in.)

24 mm (0.94 in.)

(3) Idler width

72 mm (2.8 in.)

64 mm (2.5 in.)

(4) O.D.

361 mm (14.2 in.)

353 mm (13.9 in.)

(5) Wheel width

30 mm (1.2 in.)

26 mm (1.0 in.)

Idler

Sprocket

(A) Idler

(B) Sprocket RY9212182MBS0106US0

1-S43

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[4] SPRING ASSY (1) Spring Assy Assembly/Disassembly Removing the spring assembly 1. Remove the track, front idler, and cylinder assembly. (Refer to the "Track and Front Idler" chapters for assembly/disassembly of the track, front idler and cylinder assembly.) After removing the cylinder assembly, pull out the spring assembly from the track frame. • Weight of spring assembly : approx. 9.8 kg. (21.6 lbs.) (1) Spring ASSY RY9212182MBS0065US0

Rubber track specification No. (1)

Component names Bolt (spring)

Number 1

(2)

Spring

(3)

Retainer (spring)

(4)

Slotted nut

(5)

Cotter pin

(a) Rubber track set length: 242 mm (c) Setting position for steel track (9.53 in.) specifications (b) Set the cotter pin in the groove of the slotted nut RY9212182MBS0108US0

Steel track specifications No.

Component names

Number

(1)

Bolt (spring)

(2)

Spring

(3)

Retainer (spring)

(4)

Slotted nut

(5)

Cotter pin

(a) Steel track set length: 251 mm (c) Setting position for rubber track (9.88 in.) specification (b) Set the cotter pin in the groove of the slotted nut RY9212182MBS0066US0

1-S44

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[5] CYLINDER ASSY (1) Cylinder assy Assembly/Disassembly Removing the cylinder assembly 1. Remove the track and the front idler. (Refer to the "Front Idler and Spring Assembly" chapters for assembly/disassembly of the track and front idler.) After removing the front idler, pull out the cylinder assembly from the track frame. • Weight of cylinder assembly : approx. 8.5 kg. (18.7 lbs.) (1) Cylinder assembly RY9212182MBS0063US0 No.

Component names

Q'ty

(1)

Rod

(2)

Rod seal

(3)

Backup ring

(4)

O-Ring

(5)

Cylinder tube

(6)

Nipple, assy

Tightening torque

Nipple, assy (6)

98.0 to 107.8 N·m 10 to 11 kgf·m 72.0 to 79.51 lbf·ft RY9212182MBS0064US0

Rubber track specification structural components (1) Idler Assy (2) Spring Assy (3) Cylinder Assembly

(a) 242 mm (9.53 in.)

RY9212182MBS0107US0

Iron track specification structural components (1) Idler Assy (2) Spring Assy (3) Cylinder Assembly

(a) 251 mm (9.88 in.)

RY9212182MBS0070US0

1-S45

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[6] TRACK ROLLER (1) Assembly/Disassembly of Track Roller CAUTION • The pressure in the grease cylinder is high so if loosened quickly, the nipple may pop off and the highly pressurized grease in the cylinder may fly out so do not get your face near the nipple nor place your body in front of the nipple and loosen the nipple gradually. RY9212001MBS0008US0

Grease nipple (3)

(1) Cover (2) Bolt (M10 x 20)

98.0 to 107.8 N·m 10 to 11 kgf·m 72.0 to 79.5 lbf·ft (3) Grease Nipple RY9212182MBS0116US0

Loosen track 1. Jack up the body using the front end and blade, expel grease from inside the grease cylinder, and fully loosen up the track. When the track is loose, attach the grease nipple and place a block under the track frame. RY9212182MBS0117US0

Removing the track roller 1. Loosen the track roller mounting bolt, and remove the track roller. Track roller weight : 7.5 kg (17 lbs) RY9212182MBS0118US0

1-S46

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Mounting the track roller

(1) Track roller, ASSY

Tightening torque

(2) Bolt (M16 × 40)

Track roller, ASSY mounting bolt (2)

(3) Flat metal washer

(a) Less than 1.5 mm (gap between working surfaces)

259.9 to 304.0 N·m 26.4 to 31.0 kgf·m 191 to 224 lbf·ft

Thread locking compound: Three Bond 1305P Apply the thread locking compound to the female threads. RY9212182MBS0109US0

(3) Track roller structural components

No.

Component names

Q'ty

No.

Component names

Q'ty

(1)

Bracket (Track roller)

(6)

Seal (Floating)

(2)

Bracket (Track roller)

(7)

Track roller

(3)

Shaft

(8)

Bushing

(4)

Wire

(9)

Plug (R1/8)

(5)

O-ring

(10)

Shaft assy

1 RY9212182MBS0110US0

1-S47

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(4) Assembly/Disassembly of the Track Roller No.

Component names

Q'ty

(1)

Bracket (1)

(2)

Bracket (2)

(3)

Shaft

(4)

Wire

(5)

O-ring

(6)

Seal (Floating)

(7)

Track roller

(8)

Bushing

(9)

Plug (R1/8)

(10)

Shaft Assy

1 RY9212090MBS0062US0

Disassembling the track roller 1. Remove the plug from the bracket, drain the oil and remove the wire. IMPORTANT • Take care that the wire does not fly off. (4)

Wire

(9) Plug (R1/8) RY9212090MBS0074US0

2. Use a puller to pull the bracket. RY9212090MBS0075US0

3. Remove the O-ring, floating seal and the shaft assembly. CAUTION • Use a press when removing the shaft from the bracket (2). (2) (3) (5)

Bracket (2) Shaft O-ring

(6) Seal (floating) (7) Track rollers (10) Shaft, ASSY RY9212090MBS0076US0

1-S48

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Reassembling the track roller 1. Install floating seals on the shaft assembly and the track roller. IMPORTANT • Make sure there is no oil or debris on the O-ring or the O-ring seat. • Apply a thin film of oil to the sliding surfaces. • Make sure there are no scratches on the sliding surfaces or the O-rings. (6)

Floating seal

(a) Sliding surface RY9212090MBS0077US0

2. Install the shaft ASSY into the track roller. RY9212090MBS0078US0

3. Install the O-ring on the shaft assembly. IMPORTANT • Apply grease to the O-ring. 4. Install floating seals on the bracket (1) and the track roller. (5)

O-ring

(6)

Floating seal RY9212090MBS0079US0

5. Install the bracket (1) on the track roller, clamp it as shown left, and install the wire. IMPORTANT • After completing reassembly, rotate the roller 2 to 3 turns to form a film of oil on the sliding surface of the floating seals. (4)

Wire RY9212090MBS0080US0

6. Fill with engine oil via the plug hole in the bracket (1). Lubricant

Type SAE 30 CD engine oil

80 cc (4.88 cu. in.)

7. Install the plug (R1/8). Tightening torque

Plug (R1/8) (9)

10 N·m 1.0 kgf·m 7.4 lbf·ft

Apply thread lock (Loctite 503 or equivalent). RY9212182MBS0067US0

1-S49

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

[7] CARRIER ROLLER (1) Assembly/Disassembly of Carrier Roller CAUTION • The pressure in the grease cylinder is high so if loosened quickly, the nipple may pop off and the highly pressurized grease in the cylinder may fly out so do not get your face near the nipple nor place your body in front of the nipple and loosen the nipple gradually. RY9212001MBS0008US0

98.0 to 107.8 N·m 10 to 11 kgf·m 72.0 to 79.5 lbf·ft

Grease nipple (3)

(1) Cover (2) Bolt (M10 x 20)

(3) Grease Nipple RY9212182MBS0116US0

Removing the carrier roller 1. Insert a block into the gap between the carrier roller and the track. 2. Loosen the nut and remove the carrier roller. • Carrier weight : approximately 3.0 kg (7.0 lbs) (1) Carrier Roller (2) Block

(3) Nut RY9212182MBS0119US0

1-S50

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

(2) Mounting the carrier roller

(1) Carrier roller, ASSY

Tightening torque

(2) Bolt

Carrier roller, ASSY mounting nut (4)

(3) Spring washer

(4) Nut

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

Apply thread lock (Loctite 271). RY9212182MBS0068US0

(3) Carrier roller structural components

No.

Component names

Q'ty

No.

Component names

Q'ty

(1)

Carrier roller

(5)

External circlip (30)

(2)

Shaft

(6)

Plug

(7)

Spacer

(3)

Oil seal

(4)

Ball bearing

2 RY9212182MBS0069US0

1-S51

KiSC issued 10, 2022 A

MACHINE BODY

U35-4, WSM

Track roller / Carrier roller Item

U35-4 Std. when new

Usage limit

80 mm (3.1 in.)

75 mm (3.0 in.)

(2) O.D.

124 mm (4.88 in.)

121 mm (4.76 in.)

(3) Roller width

175 mm (6.89 in.)

–

(4) Guide width

81 mm (3.2 in.)

76 mm (3.0 in.)

76.3 mm (3.0 in.)

72.3 mm (2.85 in.)

Track roller (1) Guide width

Carrier roller (5) O.D. (A) Track roller

(B) Carrier roller RY9212182MBS0111US0

1-S52

KiSC issued 10, 2022 A

2 ENGINE

KiSC issued 10, 2022 A

GENERAL CONTENTS 1. SPECIFICATIONS...................................................................................................................... 2-G1 2. EXTERNAL DIMENSIONS ......................................................................................................... 2-G2 3. PERFORMANCE CURVE .......................................................................................................... 2-G3

KiSC issued 10, 2022 A

ENGINE

U35-4, WSM

1. SPECIFICATIONS U35-4 Model

D1703-M-DI-E4-BH-US1

No. of cylinders

D1703-M-DI-E4-BH-US2 3

Cylinder Bore × Stroke

87 × 92.4 mm (3.4 × 3.64 in.) 1647 cm3 (100.5 cu.in.)

Total displacement Idling RPM

1300 to 1350 min-1

Rated RPM

2200 min-1

Compression ratio

20.5 : 1 Net

17.8 kW / 2200 min-1 (23.9 HP / 2200 min-1)

Gross

18.5 kW / 2200 min-1 (24.8 HP / 2200 min-1)

Net

95.2 N·m / 1500 min-1 (9.7 kgf·m / 1500 min-1) (70.2 lbf·ft / 1500 min-1 )

Gross

97.4 N·m / 1500 min-1 (9.9 kgf·m / 1500 min-1) (71.8 lbf·ft / 1500 min-1 )

Rated output/RPM

Max torque/RPM

Machine dimensions (LxWxH)

604 × 486 × 679 mm (23.8 × 19.1 × 26.7 in.)

Dry weight

610 × 486 × 679 mm (24 × 19.1 × 26.7 in.)

148 kg (326 lbs)

Valve clearance

0.18 to 0.22 mm (0.0071 to 0.0087 in.)

Fuel injection order

1-2-3

Combustion chamber

Direct injection

Compression pressure

2.9 to 3.2 MPa (29.6 to 32.6 kgf/cm2) (2.1 to 2.3 psi)

Fuel consumption (at rated RPM)

Net

261.3 g/kW·h (192.2 g/HP·h, 0.568 lb/HP·h)

Gross

251.4 g/kW·h (184.9 g/HP·h, 0.564 lb/HP·h) 18.6 MPa (190 kgf/cm2, 13.3 psi)

Fuel injection pressure

294 to 441 kPa (3.0 to 4.5 kgf/cm2) (0.21 to 0.32 psi)

Engine oil pressure (at rated RPM) Engine oil consumption (at rated RPM)

0.68 g/kW·h (0.50 g/PS·h, 0.0015 lb/HPh)

Fan belt Alternator

12 V, 720 W

Charging current

60 A

Regulator adjusted voltage Battery

14.2 to 14.8 V JIS

80D26R

Battery fluid ratio

1.28 ± 0.01

Mol meter

12 V, 1.4 W

Glow plug

0.9 Ω RY9212182END0001US0

2-G1

KiSC issued 10, 2022 A

ENGINE

U35-4, WSM

2. EXTERNAL DIMENSIONS

604 mm (23.8 in.)

238 mm (9.37 in.)

679 mm (26.7 in.)

10 mm (0.39 in.)

486mm (19.1 in.)

225 mm (8.86 in.)

248 mm (9.76 in.) RY9212182END0002US0

2-G2

KiSC issued 10, 2022 A

ENGINE

U35-4, WSM

3. PERFORMANCE CURVE

(a) Engine RPM (rpm x 100) (b) Output (kW) (c) Torque (N·m)

(d) Fuel Consumption (g/kW·h) (f) Torque (ft·lb) A : SI Unit (e) Output (HP) (g) Fuel Consumption (g/HP·h) B : Industrial Unit of the United States RY9212182END0003US0

2-G3

KiSC issued 10, 2022 A

3 HYDRAULIC SYSTEM

KiSC issued 10, 2022 A

MECHANISM CONTENTS 1. DIGRAM OF HYDRAULIC CIRCUIT .......................................................................................... 3-M1 [1] Diagram of Hydraulic Circuit [U-35-4 Canopy Specification (Angle blade, travel alarm option)] (For US, CA) ............................................................................................................ 3-M1 [2] Diagram of Hydraulic Circuit [U-35-4 Cab Specification (Angle blade, travel alarm option)] (For US, CA) ............................................................................................................ 3-M2 [3] Diagram of Hydraulic Circuit [U35-4 Canopy Specification] (For AU)................................... 3-M3 [4] Diagram of Hydraulic Circuit [U35-4 Cab Specification] (For AU) ........................................ 3-M4 2. HYDRAULIC DEVICE LAYOUT ................................................................................................. 3-M5 3. PUMP ......................................................................................................................................... 3-M7 [1] SPECIFICATIONS................................................................................................................ 3-M7 [2] COMPONENTS (STANDARD VERSION) ......................................................................... 3-M10 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M11 (1) Pump Operating Principles........................................................................................... 3-M11 (2) Pump Hosepower Control Mechanism ......................................................................... 3-M12 (3) A/C mode...................................................................................................................... 3-M13 4. CONTROL VALVE.................................................................................................................... 3-M15 [1] STANDARD VERSION....................................................................................................... 3-M15 [2] ANGLE VERSION .............................................................................................................. 3-M16 [3] DIAGRAM OF HYDRAULIC CIRCUIT ............................................................................... 3-M17 [4] FUNCTION AND STRUCTURE ......................................................................................... 3-M18 (1) Auto-Idle Signal Circuit ................................................................................................. 3-M18 (2) Travel Straight Forward Circuit..................................................................................... 3-M19 (3) Boom-up Operation ...................................................................................................... 3-M20 (4) Boom-down Operation.................................................................................................. 3-M21 (5) P3 Unload Circuit.......................................................................................................... 3-M22 (6) AUX1 Union Circuit....................................................................................................... 3-M23 5. SWIVEL MOTOR...................................................................................................................... 3-M24 [1] SPECIFICATIONS.............................................................................................................. 3-M24 [2] COMPONENTS .................................................................................................................. 3-M25 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M27 (1) Operating Principles ..................................................................................................... 3-M27 (2) Make Up Circuit ............................................................................................................ 3-M27 (3) Shockless Valves ......................................................................................................... 3-M28 (4) Parking Brake ............................................................................................................... 3-M28 6. TRAVEL MOTOR ..................................................................................................................... 3-M29 [1] SPECIFICATIONS.............................................................................................................. 3-M29 [2] COMPONENTS .................................................................................................................. 3-M30 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M32 (1) Operating Principles ..................................................................................................... 3-M32 (2) Counter-balance valve.................................................................................................. 3-M32 (3) Anticaviation Valve ....................................................................................................... 3-M34 (4) Auto-decelerator Function ............................................................................................ 3-M37 (5) Parking Brake ............................................................................................................... 3-M39 (6) Decelerator ................................................................................................................... 3-M39 7. HYDRAULIC CYLINDER.......................................................................................................... 3-M40 [1] BOOM CYLINDER ............................................................................................................. 3-M40 (1) Specifications ............................................................................................................... 3-M40 (2) Components ................................................................................................................. 3-M40 (3) Function and Structure ................................................................................................. 3-M41 KiSC issued 10, 2022 A

[2] ARM CYLINDER................................................................................................................. 3-M42 (1) Specifications................................................................................................................ 3-M42 (2) Components ................................................................................................................. 3-M42 [3] BUCKET CYLINDER .......................................................................................................... 3-M43 (1) Specifications................................................................................................................ 3-M43 (2) Components ................................................................................................................. 3-M43 [4] SWING CYLINDER ............................................................................................................ 3-M44 (1) Specifications................................................................................................................ 3-M44 (2) Components ................................................................................................................. 3-M44 [5] BLADE CYLINDER ............................................................................................................. 3-M45 (1) Specifications................................................................................................................ 3-M45 (2) Components ................................................................................................................. 3-M45 [6] ANGLE CYLINDER ............................................................................................................ 3-M46 (1) Specifications................................................................................................................ 3-M46 (2) Components ................................................................................................................. 3-M46 8. PILOT VALVE ........................................................................................................................... 3-M47 [1] PILOT VALVE (BOOM, ARM, BUCKET, SWIVEL) ........................................................... 3-M47 (1) Specifications................................................................................................................ 3-M47 (2) Components ................................................................................................................. 3-M49 (3) Function and Structure ................................................................................................. 3-M50 [2] PILOT VALVE (TRAVEL) .................................................................................................. 3-M51 (1) Specifications................................................................................................................ 3-M51 (2) Components ................................................................................................................. 3-M52 (3) Function and Structure ................................................................................................. 3-M53 9. UNLOAD VALVE ...................................................................................................................... 3-M55 [1] SPECIFICATIONS .............................................................................................................. 3-M55 [2] COMPONENTS .................................................................................................................. 3-M56 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M57 (1) Function ........................................................................................................................ 3-M57 (2) Operation ...................................................................................................................... 3-M57 10. AUX SOLENOID VALVE ..........................................................................................................3-M59 [1] SPECIFICATIONS .............................................................................................................. 3-M59 [2] COMPONENTS .................................................................................................................. 3-M60 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M61 11. PROPORTIONAL VALVE FOR ANGLE BLADE CONTROL.................................................... 3-M62 [1] SPECIFICATIONS .............................................................................................................. 3-M62 [2] COMPONENTS .................................................................................................................. 3-M62 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M63 12. PROPORTIONAL VALVE FOR AC MODE CONTROL............................................................ 3-M64 [1] SPECIFICATIONS .............................................................................................................. 3-M64 [2] COMPONENTS .................................................................................................................. 3-M64 [3] FUNCTION AND STRUCTURE ......................................................................................... 3-M65 (1) Function ........................................................................................................................ 3-M65 (2) Operation ...................................................................................................................... 3-M65

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

1. DIGRAM OF HYDRAULIC CIRCUIT [1] Diagram of Hydraulic Circuit [U-35-4 Canopy Specification (Angle blade, travel alarm option)] (For US, CA)

3-M1

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] Diagram of Hydraulic Circuit [U-35-4 Cab Specification (Angle blade, travel alarm option)] (For US, CA)

3-M2

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] Diagram of Hydraulic Circuit [U35-4 Canopy Specification] (For AU)

3-M3

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[4] Diagram of Hydraulic Circuit [U35-4 Cab Specification] (For AU)

3-M4

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. HYDRAULIC DEVICE LAYOUT

(1) Pump (2) Control Valve (3) Swivel Motor

(4) Swivel Joint (5) Travel Motor (6) Pilot Valve (Control)

(7) Pilot Valve (Travel) (8) Pilot Valve (AUX1) (9) Unload Valve

(10) Solenoid Valve (Angle Blade) (11) TPSS Valve (12) AC Mode Valve

RY9212182HYM0001US0

3-M5

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM (5) Travel Motor (6) Pilot Valve (Control)

(7) Pilot Valve (Travel) (11) TPSS Valve RY9212182HYM0039US0

3-M6

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

3. PUMP [1] SPECIFICATIONS

(1) P1 discharge port (2) P2 discharge port (3) P3 discharge port

(4) P4 discharge port (5) Piston pump

(6) Gear pump (7) Suction port

Item

U35-4

Maker

Fujikoshi Corp.

Model

PVD-15B-36P-9AG5-5300A (PVD-15B-36PAG-5302A) *1

Rated RPM

Max useful pressure

Max discharge capacity

Notes

*1: A/C Spec.

2200 rpm Piston pump P1+P2

Max displacement

(8) Reduced horsepower port (A/C spec. only)

18 + 18 cc/rev (1.1 + 1.1 cu.in./rev)

Gear pump P3

9.5 cc/rev (0.58 cu.in./rev)

Pilot pump P4

4.5 cc/rev (0.27 cu.in./rev)

Piston pump P1, P2

24.5 MPa (250 kgf/cm2, 3550 psi)

Gear pump P3

19.6 MPa (200 kgf/cm2, 2840 psi)

Pilot pump P4

3.9 MPa (40 kgf/cm2, 570 psi)

Piston pump P1+P2

35.2 + 35.2 L/min. (2150 + 2150 cu.in./min, 9.3 + 9.3 U.S.GPM)

Gear pump P3

20.9 L/min. (1280 cu.in./min, 5.52 U.S.GPM)

Pilot pump P4

9.9 L/min. (600 cu.in./min, 2.6 U.S.GPM) RY9212182HYM0002US0

3-M7

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Piston Pump Horsepower Control Curve

(1) P3 = 0.49 MPa (5.0 kgf/cm2, 71 psi)

(2) P3 = 19.6 MPa (200 kgf/cm2, 2840 psi)

(a) Discharge Flow: q1 = q2 (cc/rev)

(b) Discharge Pressure: P1 + P2 (MPa)

Pump input RPM: 2200 rpm At gear pump pressure: P3 = 0.49 MPa Pressure (MPa)

Delivery flow (cc/rev)

At gear pump pressure: P3 = 19.6 MPa Pressure (MPa)

Delivery flow (cc/rev)

PA0 = 0.0

QA0 = 18.0 (Target value)

PA1 = 17.0

QA1 = 17.5 (Target value)

PB1 = 6.0

QB1 = 17.8 (Target value)

PA2 = 28.6

QA2 = 11.9 (Target value)

PB2 = 23.4

QB2 = 9.0 (Target value)

PA3 = 49.0

QA3 = 6.4 (Target value)

PB3 = 43.2

QB3 = 3.7 (Target value)

PB4 = 49.0

QB4 = 3.4 (Target value) RY9212182HYM0043US0

3-M8

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Piston Pump Horsepower Control Curve (AC Mode Specification)

(a) Discharge Flow: q1 = q2 (cc/rev)

(b) Discharge Pressure: P1 + P2 (MPa)

(1) P3 = 0.49 MPa (5.0 kgf/cm2, 71 psi), Pc = 0 MPa (0 kgf/cm2, 0 psi) (2) P3 = 0.49 MPa (5.0 kgf/cm2, 71 psi), Pc = 3.9 MPa (40 kgf/cm2, 570 psi) (3) P3 = 19.6 MPa (200 kgf/cm2, 2840 psi), Pc = 0 MPa (0 kgf/cm2, 0 psi) (4) P3 = 19.6 MPa (200 kgf/cm2, 2840 psi), Pc = 3.9 MPa (40 kgf/cm2, 570 psi) Pump input RPM: 2200 rpm At gear pump pressure: P3 = 0.49 MPa

At gear pump pressure: P3 = 0.49 MPa

At AC mode pressure: Pc = 0 MPa

At AC mode pressure: Pc = 3.9 MPa

Pressure (MPa)

Delivery flow (cc/rev)

Pressure (MPa)

Delivery flow (cc/rev)

PA0 = 0.0

QA0 = 18.0 (Target value)

PA1 = 17.0 PA2 = 28.6

QA1 = 17.5 (Target value)

PB1 = 10.4

QB1 = 17.7 (Target value)

QA2 = 11.9 (Target value)

PB2 = 23.4

QB2 = 11.0 (Target value)

PA3 = 49.0

QA3 = 6.4 (Target value)

PB3 = 49.0

QB3 = 4.4 (Target value)

Pump input RPM: 2200 rpm At gear pump pressure: P3 = 19.6 MPa

At gear pump pressure: P3 = 19.6 MPa

At AC mode pressure: Pc = 0 MPa

At AC mode pressure: Pc = 3.9 MPa

Pressure (MPa)

Delivery flow (cc/rev)

Pressure (MPa)

Delivery flow (cc/rev)

PA0 = 0.0

QA0 = 18.0 (Target value)

PD0 = 0.0

QD0 = 16.1 (Target value)

PC1 = 3.0

QC1 = 17.9 (Target value)

PD1 = 17.6

QD1 = 6.8 (Target value)

PC2 = 20.8

QC2 = 8.8 (Target value)

PD2 = 30.4

QD2 = 3.4 (Target value)

PC3 = 42.0

QC3 = 3.2 (Target value)

PD3 = 49.0

QD3 = 3.0 (Target value)

PC4 = 49.0

QC4 = 3.0 (Target value) RY9212182HYM0044US0

3-M9

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] COMPONENTS (STANDARD VERSION)

No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Snap ring

(27)

(2)

Seal holder

(28)

Barrel cylinder

(3)

O-ring

(29)

Retainer

(4)

Oil seal

(30)

Spring

(5)

Shaft

(31)

Snap ring

(6)

Ball bearing

(32)

Valve plate

(7)

External circlip

(33)

Needle bearing

(8)

Plug

(34)

Gasket

(9)

O-ring

(35)

Spring pin

(10)

Body S

(36)

Body H

JIS B 2401, 1B, G75

JIS B 2401 1B P11

Notes

(11)

Metal washer

(37)

Seal washer

(12)

Diaphragm spring

(38)

Set screw

(13)

(39)

Hex nut

(14)

O-ring

(40)

Hole pin

(15)

(41)

Hex socket plug

(16)

Plug

(42)

Spring washer

(17)

Rod

(43)

Hex socket bolt

JIS B 1176 M10 × 45

(18)

Ball

(44)

O-ring

JIS B 2401 1B P7

(19)

Swash-plate

(45)

O-ring

JIS B 2401 1B P8

(20)

Spring holder

(46)

O-ring

JIS B 2401, 1B, G55

(21)

Compression spring

(47)

Connector

(22)

Spring guide

(48)

Collar

(23)

Piston, ASSY

(49)

Gear pump

(24)

Shoe holder

(50)

Flat metal washer

(25)

Barrel holder

(51)

Bolt

(26)

Metal washer

JIS B 2401 1B P12

JIS B 1181 1 M8

JIS B 1180 M8 × 25

RY9212182HYM0003US0

3-M10

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE (1) Pump Operating Principles

(1) (2) (3) (4)

Suction Port Discharge Port (P1) Discharge Port (P2) Valve Plate

(5) Cylinder Barrel (6) Piston (7) Swashplate

(a) Intake Cycle (b) Discharge Cycle (c) Top Dead Center

(d) Bottom Dead Center (e) Tilt Angle

• The cylinder barrel of the piston pump is coupled to the shaft via a spline, so it rotates with the shaft. The pistons in the cylinder barrel move in reciprocating motion within the cylinder barrel in line with the swashplate as they slide on the top of the swashplate; the pistons drive the intake and discharge pump operations according to changes in the volume of the cylinder. • During the interval from TDC to BDC, the piston moves in the direction that increases the volume of the cylinder barrel, so oil flows from the intake port via the valve plate and into the bore of the cylinder barrel. (Intake Cycle) • As the drive shaft turns further and the piston goes from BDC to TDC, it moves in the direction that decreases the volume of the cylinder barrel, so the oil inside the cylinder barrel is expelled to the discharge port. (Discharge Cycle) • Because the piston moves in constant contact with the swashplate, as the swashplate's tilt angle changes, the stroke of the piston changes and so does the pump discharge quantity. • As an even number of pistons are used, the number of pistons that open on the outside and the inside of the valve plate is the same; what's more, all the pistons are of the same diameter and are on the same pitch arc and are moving on the same swashplate, so the discharge quantity from the outside (P1) and the inside (P2) of the valve plate is identical. Furthermore, as the swashplate is in one place, even when the swashplate angle changes under variable control, the discharge quantity from ports P1 and P2, both change in the same way, so it does not produce a difference in discharge quantity. RY9212004HYM0006US0

3-M11

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Pump Hosepower Control Mechanism

(1) Swash-plate (2) Ball

(3) Rod G (4) Spring

(5) P3

(a) Load F1 (b) Spring force F2

Constant power variation mechanism The pump capacity is altered by varying the swash-plate angle, and the swash-plate angle can be used to control the pump to a constant power by a simple direct-action variation mechanism based on a spring. The centre of rotation of the swash-plate is the ball on the rear surface, and the load F1 from the piston side acts in the direction shown above and produces a rightward turning moment in the swash-plate. A spring (spring force F2) for setting a constant power is provided to act in the opposite direction to this moment, and is set to a prescribed load. As the pressure rises, the rightward turning moment increases and when it becomes greater than the leftward turning moment created by the force of the spring, the spring warps and the angle of the swash-plate decreases, thus reducing the discharge flow, so that the pump power is kept uniform. When the pressure of P3 acts on the rod, a rightward turning moment proportional to the pressure acts on the swash-plate, and therefore the P-Q characteristics shift and the power is kept uniform, including the gear pump. (Overall power control mechanism) RY9212182HYM0040US0

P-Q characteristics (A) Discharge flow Q1, Q2 (B) P1 + P2 discharge pressure

(a) Shifted curve

RY9212182HYM0041US0

3-M12

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) A/C mode

(1) Hydraulic pumps

(2) Solenoid valve

1. Overview When using the air-conditioning, the A/C compressor is driven and therefore engine torque is lost. The engine is prevented from cutting out, by reducing the set torque of the hydraulic pumps accordingly, so as to decrease the load on the engine. By adding a power control piston to the variable-capacity pump and supplying a control pilot pressure, it is possible to lower the set torque of the pump. RY9212182HYM0036US0

2. P-Q Characteristics (A) Discharge flow Q1, Q2 (B) P1 + P2 discharge flow

(a) Shifted curve (b) In A/C mode RY9212182HYM0053US0

3-M13

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(1) Swash-plate (2) Ball (3) Rod G

(4) Spring (5) P3

(6) Rod C (7) Pc

(a) Load F1 (b) Spring force F2

3. Control Function When PC port pressure acts on rod C, a clockwise moment is applied to the swash-plate commensurate with the pressure, thus shifting the P-Q characteristics and allowing the power consumption of the pump to be reduced by the amount of power consumed by the AC. RY9212182HYM0045US0

3-M14

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. CONTROL VALVE [1] STANDARD VERSION

(1) (2) (3) (4) (5) (6) (7)

Swivel right (Pa1) Swivel left (Pb1) Swing rod (Pa2) Swing bottom (Pb2) Blade bottom(Pa3) Blade rod (Pb3) AUX return bottom (Pa4)

(8) AUX discharge rod (Pb4) (9) Arm bottom (Pa5) (10) Arm rod (Pb5) (11) Travel forward (Pa6) (12) Travel backward (Pb6) (13) Travel forward (Pa7) (14) Travel backward (Pb7)

(15) Boom rod (Pa8) (16) Boom bottom (Pb8) (17) Bucket rod (Pa10 ) (18) Bucket bottom (Pb10) (19) P1 Port (20) P2 Port (21) P3 Port

Item

(22) T1 Port (23) T2 Port (24) Drain port (25) P1 Main relief valve (26) P2 Main relief valve (27) P3 Main relief valve

U35-4

Maker

Nabtesco (Corp.)

Model

BCV35-DAW10-2

Main relief valve pressures P1, P2

24.5 MPa (250 kgf/cm2, 3550 psi) at 39.6 L/min. (2420 cu.in./min, 10.5 U.S.GPM)

Main relief valve pressure P3

19.6 MPa (200 kgf/cm2, 2840 psi) at 20.9 L/min. (1280 cu.in./min, 5.52 U.S.GPM) Boom (15), (16)

27.5 MPa (280 kgf/cm2, 3990 psi) at 5 L/min. (300 cu.in./min, 1.3 U.S.GPM)

Arm (9) (10) Bucket (18) Over load relief valve Blade (5)

24.0 MPa (240 kgf/cm2, 3500 psi) at 5 L/min. (300 cu.in./min, 1.3 U.S.GPM)

AUX (7) (8)

17.2 MPa (175 kgf/cm2, 2490 psi) at 40 L/min. (2400 cu.in./min, 11 U.S.GPM) RY9212182HYM0004US0

3-M15

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] ANGLE VERSION

(1) (2) (3) (4) (5) (6) (7) (8)

Angle rod (Pa1) Angle bottom (Pb1) Swivel right (Pa2) Swivel left (Pb2) Swing rod (Pa3) Swing bottom (Pb3) Blade bottom (Pa4) Blade rod (Pb4)

(9) AUX return (10) AUX discharge (11) Arm bottom (12) Arm rod (13) Travel forward (Pa7) (14) Travel backward (Pb7) (15) Travel forward (Pa8) (16) Travel backward (Pb8)

(17) Boom rod (18) Boom bottom (19) Bucket rod (Pa10 ) (20) Bucket bottom (Pb10) (21) P1 Port (22) P2 Port (23) P3 Port

Item

(24) T1 Port (25) T2 Port (26) Drain port (27) P1 Main relief valve (28) P2 Main relief valve (29) P3 Main relief valve

U35-4

Maker

Nabtesco (Corp.)

Model

BCV35-DBJ11

Main relief valve pressures P1, P2

24.5 MPa (250 kgf/cm2, 3550 psi) at 35.2 L/min. (2150 cu.in./min, 9.3 U.S.GPM)

Main relief valve pressure P3

19.6 MPa (200 kgf/cm2, 2840 psi) at 20.9 L/min. (1280 cu.in./min, 5.52 U.S.GPM) Boom (17), (18) Arm (11) (12)

27.5 MPa (280 kgf/cm2, 3990 psi) at 5 L/min. (300 cu.in./min, 1.3 U.S.GPM)

Bucket (20) Over load relief valve

Angle (1) 24.0 MPa (240 kgf/cm2, 3500 psi) at 5 L/min. (300 cu.in./min, 1.3 U.S.GPM)

Blade (7) AUX (9) (10)

17.2 MPa (175 kgf/cm2, 2490 psi) at 40 L/min. (2400 cu.in./min, 11 U.S.GPM)

Angle (2)

RY9212182HYM0005US0

3-M16

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] DIAGRAM OF HYDRAULIC CIRCUIT

(1) (2) (3) (4) (5)

Angle Swivel Swing Blade AUX1

(6) Arm (7) Travel left (8) Travel right (9) Boom (10) Bucket

(11) P1 (12) P2 (13) P3 (14) P4

(a) (b) (c) (d)

Auto-idle switch Communication valve Third line valve Selector valve RY9212182HYM0029US0

Pilot pressure characteristics (A) Spool stroke (mm) (B) Pilot pressure (MPa) (a) 0.33 MPa (3.4 kgf/cm2) (b) 0.68 MPa (6.96 kgf/cm2)

0.79 MPa (8.1 kgf/cm2) 1.63 MPa (16.6 kgf/cm2) 2.47 MPa (25.2 kgf/cm2) Communication valve Other RY9212182HYM0030US0

3-M17

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[4] FUNCTION AND STRUCTURE (1) Auto-Idle Signal Circuit

(1) (2) (3) (4) (5)

Angle Swivel Swing Blade AUX1

(6) Arm (7) Travel left (8) Travel right (9) Boom (10) Bucket

(11) P1 (12) P2 (13) P3 (14) P4

(a) Auto-idle switch (b) Communication valve

1. When the actuator spools in (1) to (10) are in neutral, then the oil from P4 passes along the signal circuits of each session and returns to the tank. 2. When the auto-idle switch on the side of the accelerator dial is on and the actuator spools of any of (1) to (10) is operated, then the flow of oil is shut off and the pressure inside the signal circuit is raised. The pressure switch is switched by this pressure, thereby controlling the engine RPM (based on the dial position). 3. When the actuator spool is returned to neutral, the oil returns to the tank, the pressure in the signal circuit also falls, and the engine RPM returns to idling. RY9212182HYM0006US0

3-M18

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Travel Straight Forward Circuit

(1) (2) (3) (4) (5)

Angle Swivel Swing Blade AUX1

(6) Arm (7) Travel left (8) Travel right (9) Boom (10) Bucket

(11) P1 (12) P2 (13) P3 (14) P4

(a) Auto-idle switch (b) Communication valve

1. All sections Neutral. Oil from P4 passes through the AUX1, arm, travel right, travel left, boom and bucket spool sections, and the signal circuit holes other than the spools, and returns to the tank. 2. Travel lever Neutral. Even if the boom, arm, bucket or AUX1 is operated, oil from P4 returns to the tank from the travel right and travel left spools, and therefore the pressure in the signal circuit does not rise. 3. Travel (left/right) + boom, arm, bucket, service operations. If any one of the front devices is operated while the machine is travelling (left/right), then the oil from the P4 is shut off, the pressure inside the signal circuit rises, the spool of the communication valve is operated, and the oil in P3 flows to the front section that has been operated. RY9212182HYM0007US0

3-M19

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) Boom-up Operation (1) (2) (3) (4) (5) (6) (7) (8)

Spool Lock valve Needle valve Piston A Piston B Ball check Orifice Oil cooler

(A) Boom switching section (B) Boom lock valve section (C) Boom lock valve (detailed view) (D) T section (detailed view) (E) Lock valve operation (detailed view) (a) Raise boom pilot pressure (b) Lower boom pilot pressure P/V: Pilot Valve

1. When a Raise boom operation is performed, the oil from the pilot valve enters into part (a), and shifts the main spool to the right. 2. The oil from P1 passes through the hole that links section A to section B, the check valve of the boom lock valve operates, and the oil flow into the boom cylinder. 3. The oil on the cylinder rod side flows from the main spool to the tank port, and the boom rises up. RY9212004HYM0038US0

1. Lock valve operation When the Raise boom operating pressure (P1) in part e becomes greater than the pressure f (lock valve back pressure) plus the spring force, and the lock valve moves to the left. (e) Raise boom operating pressure parts

(f)

Lock valve back pressure RY9212004HYM0039US0

3-M20

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(4) Boom-down Operation (1) (2) (3) (4) (5) (6) (7) (8)

Spool Lock valve Needle valve Piston A Piston B Ball check Orifice Oil cooler

(A) Boom switching section (B) Boom lock valve section (C) Boom lock valve (detailed view) (D) T section (detailed view) (a) Raise boom pilot pressure (b) Lower boom pilot pressure P/V: Pilot Valve

1. When a Lower boom operation is performed, the oil from the pilot valve enters into the boom switching section part (b) and the boom lock valve section part (c). 2. The oil that has entered into the boom switching section part (b) moves the main spool to the let and the oil from P1 is fed to the cylinder rod side. 3. The oil that entered into part (c) of the boom lock valve section movves to the right, successively, from the piston (B) to the piston (A) to the needle valve. When the needle valve moves, the oil inside the piston (A) moves the check valve, and flows into the tank port from the spools of the lock valve section and the spool switching section. 4. Due to the fall in the pressure inside the piston (A), the piston A moves to the left, the oil at the bottom of the cylinder flows to the tank port and the boom is lowered. RY9212004HYM0040US0

1. Lock valve operation Due to the pressure loss in the orifice, the cylinder bottom pressure becomes greater than the pressure f (lock valve back pressure) plus the spring pressure, and the lock valve moves to the left. (7) Orifice

(E) Lock valve operation (detailed view) (f)

Lock valve back pressure RY9212004HYM0041US0

3-M21

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(5) P3 Unload Circuit

(1) P3 Unload Circuit (2) AI Signal Circuit

(3) Forward Travel Signal Circuit (4) AUX1

(5) Communication valve

1. When the unload lever is locked, the oil discharged from the hydraulic pump passes from port P3 through the communication valve inside the control valve and flows directly into the tank line. 2. At such time, oil is not supplied to the actuator ports, even if the control levers for the swing or blade are actuated. CAUTION • If a part of the vehicle is in an attitude in which it is under its own weight, it may operate despite the lever being locked. Never operate a control lever if someone is nearby or if something may be hit by doing so. (Ex.: With the blade raised, trying to lower the blade.) RY9212182HYM0049US0

3-M22

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(6) AUX1 Union Circuit

(1) AUX1 Union Circuit (2) AI Signal Circuit

(3) Forward Travel Signal Circuit (5) Communication valve (4) AUX1

(6) From unload valve

1. When the unload lever is released, the pilot pressure supplied to the communication valve is cut off, so the oil supplied from port P3 flows through the check valve of the P3 supply side and into the passage on the P2 side. 2. As the flow of pumps P2 and P3 are supplied (come together) in the passage on the P2 side, when AUX1 is being used, it allows the use of maximum flow of P2 + P3. RY9212182HYM0050US0

3-M23

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. SWIVEL MOTOR [1] SPECIFICATIONS

(1) Relief valve

(2) Pilot port (parking brake)

(3) Make-up port (4) Port B

Item

(5) Port A (6) Drain port U35-4

Maker

KUBOTA Seiki

Model (Part No.)

RC788-61701

Motor capacity

30.974 cc/rev (1.890 cu.in./rev)

Reduction ratio

9.9

Total displacement Max Flow

306.64 cc/rev (18.712 cu.in./rev) 20.9 L/min. (1280 cu.in./min, 5.52 U.S.GPM)

Theoretical RPM

68.2 rpm

Theoretical ouptut torque

957 N·m (97.6 kgf·m, 706 lbf·ft)

Relief valve brake pressure

20.6 MPa (210 kgf/cm2, 2990 psi)

Mechanical brake torque

957 N·m (97.6 kgf·m, 706 lbf·ft) or above

Parking brake release pressure

1.5 MPa (15 kgf/cm2, 220 psi) or lower RY9212182HYM0008US0

3-M24

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] COMPONENTS

3-M25

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

O-ring

(35)

Piston, ASSY (A)

(2)

Hex socket bolt

(36)

(3)

Motor, valve housing

(37)

Friction plate

(4)

Plug

(38)

Cylinder block

(5)

O-ring

(39)

Spring washer 2

(6)

Compression spring

(40)

Spring (CY)

(7)

Poppet

(41)

Internal circlip

(8)

Plug (G1/2)

(42)

O-ring

(9)

O-ring

(43)

Brake piston

(10)

Shockless piston

(44)

Spring (NB)

(11)

Filter

(45)

O-ring

(12)

O-ring

(46)

Valve plate

(13)

Backup ring

(47)

Ball bearing

(14)

O-ring

(48)

O-ring

(15)

Poppet seat ring

(49)

Parallel pin

(16)

Poppet

(50)

Parallel pin

(17)

Poppet guide

(51)

O-ring

(18)

Spring seat ring

(52)

Parallel pin

(19)

Compression spring

(53)

Plug (R1/4)

(20)

Guide spring

(54)

Motor cover

(21)

O-ring

(55)

Hex socket bolt

(22)

Backup ring

(56)

Pinion shaft

(23)

Backup ring

(57)

Ball bearing

(24)

O-ring

(58)

Gear case

(25)

O-ring

(59)

Oil seal

(26)

Relief housing

(60)

Ball bearing

(27)

Set screw

(61)

External circlip

(28)

Nut

(62)

Holder

(29)

Ball bearing

(63)

Collar

(30)

External circlip

(64)

Needle bearing

(31)

Shaft

(65)

Planetary gear

(32)

Thrust plate

(66)

Thrust plate

(67)

Bolt

(33)

Retainer plate

(34)

Retainer holder

Notes

RY9212182HYM0028US0

3-M26

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE (1) Operating Principles The pressurized oil from port A goes through valve plate, enters the piston inside the cylinder block and presses against the swash-plate. The pistons receive the counterforce from the swash-plate, part of which becomes rotational force and the block rotates due to the sum total of the rotational forces exerted by the pistons which the hydraulic oil entered. The cylinder block and the shaft are linked via a spline, so the rotation is transmitted to the shaft. When operating in reverse, hydraulic oil flows in via port B and is discharged via port A. (1) (2) (3) (4)

Port A Port B Valve plate Cylinder block

(5) Piston (6) Swash-plate (7) Shaft RY9212004HYM0009US0

(2) Make Up Circuit If the swivel is decelerated with the pressurized oil supplied via port A, the motor rotates due to the inertia of the swiveling equipment, and the motor drives the pump. As a result, the load shifts to the port A side. In order to prevent this, the oil on the cylinder side passes through the poppet in the make up circuit and is supplied to the port A side. (1) Poppet

(a) To motor MA circuit RY9212004HYM0010US0

3-M27

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) Shockless Valves • At start up and shutdown, the oil that has flowed into port A passes through the orifice of the relief valve and into chamber A. At such times, Pa > Pb, so the relief valve operates at a pressure lower than its pressure setting. (Primary relief pressure) • When piston reaches the left end in the diagram, the pressure in chamber A rises, so Pa = Pb. For this reason, the relief valve operates at the pressure setting. (Secondary relief pressure) • Because of this, the system can suppress dramatic changes in pressure and can mitigate the shock of starting up and stopping the equipment. (1) (2) (3) (4)

Relief valve Orifice Chamber A Piston

(a) From port A

RY9212004HYM0011US0

(4) Parking Brake 1. When the parking brake is operated When the unload lever is raised, the oil in the brake piston chamber passes through the unload valve and returns to the hydraulic oil tank, thus allowing the force of the spring to press the brake piston downwards, as in the diagram. As a result of this, the friction plate is squeezed between the brake piston and the case, and the friction prevents any rotation. The friction plate and the cylinder block, and the cylinder block and the shaft, are coupled via a spline, so the motor (shaft) will not rotate. 2. When the parking brake is released When the unload lever is lowered, the oil from the pilot pump passes through the unload valve and flows into the brake piston chamber, overpowering the spring and pressing the brake piston upwards, as in the diagram. By doing so, the friction of the friction plate is released and the motor (shaft) rotates. (1) (2) (3) (4)

Brake piston chamber Spring Brake piston Friction plate

(5) Case (6) Cylinder block (7) Shaft RY9212004HYM0012US0

3-M28

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

6. TRAVEL MOTOR [1] SPECIFICATIONS

(1) Counter-balance valve (2) Travel 2-speed/travel automatic reduction

(3) Anticavitation valve (4) Port P1 (G1/2) (5) Port P2 (G1/2)

(6) Port PS (G1/4) (7) Drain port (G1/4)

Item

(8) Supply port (9) Oil inspection port (10) Oil drain port

U35-4

Maker

KUBOTA Seiki

Model (Part No.)

RC788-6160-2

Total displacement

Motor displacement

1st

879.5 cc/rev (53.67 cu.in./rev)

2nd

573.7 cc/rev (35.01 cu.in./rev)

1st

18.082 cc/rev (1.1034 cu.in./rev)

2nd

11.796 cc/rev (0.71984 cu.in./rev)

Reduction Ratio

1 : 48.636

Max Pressure

24.5 MPa (250 kgf/cm2, 3550 psi)

Rated Flow

39.6 L/min. (2420 cu.in./min, 10.5 U.S.GPM)

Theoretical RPM

Theoretical ouptut torque

1st

45 rpm

2nd

69 rpm

1st

3431 N·m (350 kgf·m, 2531 lbf·ft)

2nd

2239 N·m (228 kgf·m, 1651 lbf·ft)

Parking brake control torque

1636 N·m (166.8 kgf·m, 1207 lbf·ft)

Parking brake release pressure

0.90 MPa (9.2 kgf/cm2, 100 psi)

Automatic gear shifting pressure when PS=3.92 MPa, 40 kgf/cm2

Hi → Lo

19.5 MPa (199 kgf/cm2, 2830 psi)

Lo → Hi

19.4 MPa (198 kgf/cm2, 2810 psi) RY9212182HYM0009US0

3-M29

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] COMPONENTS

(To be continued)

3-M30

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued) No.

Qty

No.

(1)

Plug (G3/8)

Name of part

(44)

Name of part

(2)

O-ring

(45)

Internal circlip

(3)

Cover

(46)

Friction plate

(4)

O-ring

(47)

O-ring

Spring washer

Qty 1

(5)

Spring pin

(48)

Brake piston

(6)

Gear case

(49)

Spring (NB)

(7)

Plug (R1/8)

(50)

O-ring

(8)

Ball

132

(51)

Plug (G1/4)

Thrust plate t = 1.6

(52)

O-ring

Thrust plate t = 2.3

(53)

Parallel pin

Thrust plate t = 3.0

(54)

Parallel pin

Drive gear

(55)

Valve plate

(9)

(10) (11)

Planetary gear A

(56)

Ball bearing

(12)

Needle bearing

(57)

Plug

(13)

Collar

(58)

O-ring

(14)

Holder

(59)

Spring

(15)

External circlip

(60)

Spring washer

(16)

Thrust plate B2

(61)

Plug

(17)

External circlip

(62)

O-ring

(18)

Sun gear

(63)

Compression spring

(19)

Planetary gear B

(64)

Poppet

(20)

Needle bearing

(65)

Counter-balance plunger

(21)

Collar

(66)

Parallel pin

(22)

Thrust plate B2

(67)

O-ring

(23)

Ring nut

(68)

Counterbalance body

(24)

Angular bearing

(69)

Plug (R1/8)

(25)

Floating seal

(70)

Orifice (0.4)

(26)

Set screw (M8 Sealock)

(71)

Plug (NPTF1/16, MEC)

(27)

Plug (NPTF1/16, MEC)

(72)

Orifice (0.5)

(28)

Flange holder

(73)

Plug (GPF3/8)

(29)

Spring (piston B)

(74)

O-ring

(30)

Piston (B,D)

(75)

2nd speed spool S

(31)

Cylinder liner gasket

(76)

2nd speed spring S

(32)

Oil seal

(77)

2-speed switching spool

(33)

Ball bearing

(78)

Hex socket bolt

(34)

Shaft

(79)

2nd speed pipe joint

(35)

Steel ball

(80)

Hex socket bolt

(36)

Variable swash-plate

(81)

Anticavitation body

(37)

Piston, ASSY (A)

(82)

Anti-caviation spool

(38)

Retainer plate

(83)

Anticavitation spring

(39)

Retainer holder

(84)

Orifice (0.6)

(40)

(85)

Anticavitation spring P

(41)

Cylinder block

(86)

Poppet

(42)

Spring washer

(87)

O-ring

(43)

Spring (CY)

(88)

O-ring

5 RY9212182HYM0010US0

3-M31

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE (1) Operating Principles • Nine pistons are built into the cylinder block, and the end section of the block is in contact with a valve plate, which has two half-moon shaped ports (port Band port Cfor switching between high and low pressure). • If high-pressure oil is guided to port B, the pressurized oil passes through port B and presses on the swash-plate. • The pistons receive the counterforce from the swash-plate, part of which is converted into rotational force, and the block rotates due to the sum total of the rotational forces exerted by pistons that the hydraulic oil entered. • The cylinder block and the shaft are linked via a spline, so the rotation is transferred to the shaft. (1) (2) (3) (4) (5)

Cylinder Block Piston Valve Plate Swash Plate Shaft

B : Port B C : Port C

RY9212001HYM0002US0

(2) Counter-balance valve When in neutral Role of the counterbalance valve 1. Stops the motor (b) 2. Prevents overrun When control valve (a) is in neutral, no pressure is generated at either port P1 or P2, so ports M1 and M2 are blocked by the plunger, the check valve L and the check valve R, so the motor does not rotate. (1) Plunger (2) Check valve L (3) Check valve R

(a) Control Valves (b) Motor RY9212090HYM0027US0

3-M32

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

If hydraulic oil flows to P1 The pressurized oil that passed through P1 flows through the check valve L and into the motor (b) via the M1 port, thus turning the motor. The oil returning from the motor flows to the counterbalance valve from port M2, but it is blocked by the check valve R, so the pump discharge pressure rises. Pressurized oil passes through orifice L and acts on the left side of plunger, moving the plunger to the right. Oil returning from the port M2 passes through the orifice and, while generating back pressure at the port M2, returns to the tank via the port P2 and the control valve (a). As the pump discharge pressure rises further, the plunger moves further to the right and passes both through the orifice and around the spool, thus reducing the back pressure. In this way, it automatically adjusts the area in the return circuit so that the motor rotates at a speed that matches the pressure on the port P1 side. (1) (2) (3) (4) (5)

Plunger Check valve L Check valve R Orifice L Orifice

(a) Control Valves (b) Motor

RY9212090HYM0028US0

Brake operation When the control valve (a) returns to neutral, it cuts off the supply of pressurized oil from the pump and the pressure at ports P1 and P2 equalize, so spring R works to return the plunger to its neutral position. (moves to the left) When the plunger moves to the left, the oil returning from M2 does so only from the orifice. Also, the motor (b) tries to turn due to inertia, which causes the pressure on the port M2 side to rise. When the plunger moves to the left, the oil in the left pressure chamber escapes to the port P1 side, but due to the orifice effect of the orifice L, the speed with which the plunger moves to the left is limited. By controlling the speed of the plunger, the motor is stopped without generating cavitation while also absorbing the shock pressure from the inertia of the motor. (1) (2) (3) (4) (5)

Plunger Left pressure chamber Spring R Orifice L Orifice

(a) Control Valves (b) Motor

RY9212090HYM0029US0

3-M33

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) Anticaviation Valve When the motor stops → starts and when the motor is rotating

(1) Plunger

(2) Anti-cavitation valve

(3) Spool

(a) Control valve (b) Motor

If pressurized oil flows to port P1, plunger (1) moves to the right and oil flows to the motor via passage M1, passes through passage M2 and is expelled from port P2. Pressurized oil also flows to the left end of spool (3) of the anti-cavitation valve (2) and presses the spool to the right. RY9212182HYM0046US0

3-M34

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

When going from a steady motor speed → deceleration

(1) Plunger

(2) Anti-cavitation valve

(3) Spool (4) Check valve

(a) Control valve (b) Motor

When decelerating, the motor continues to turn due to its inertia. As long as the counterbalance valve is open (the plunger (1) is moved to the right), the motor's return oil is expelled from port P2. At such time, there is not enough oil supplied under pressure from port P1, resulting in cavitation. With this mechanism, the spool (3) of the anti-cavitation valve (2) moves to the right, and the pressure on the M2 passage side rises due to inertia, so the motor's return oil is resupplied to the motor via the anti-cavitation valve (2) → check valve (4) → around the plunger → M1 passage, so cavitation is reduced. (Anti-cavitation function) RY9212182HYM0047US0

3-M35

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

When motor decelerating → stop

(1) Plunger

(2) Anti-cavitation valve

(3) Spool

(a) Control valve (b) Motor

When the pressure on the supply side and the return side equalize, both the plunger (1) and the spool (3) of the anti-cavitation valve (2) return to neutral. RY9212182HYM0048US0

3-M36

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(4) Auto-decelerator Function When under low load

(1) 2-speed switching spool (2) Motor load pressure

(3) 2-speed switching piston

(a) Control Valves

(b) Motor

This function gives priority to power for traveling and when the mini-excavator is traveling in the 2nd speed, if the travel load becomes great, it automatically decelerates to the 1st speed (low-speed). When the travel load is low, it operates in the 2nd speed (high-speed). When the speed switch is pressed, it actuates the solenoid of the unload valve, thus guiding oil from the pilot pump to the PS port. When pressurized oil flows to the PS port, it presses the 2-speed spool to the right as in the diagram (to the left in the circuit diagram). On the other hand, the load pressure (c) of the motor is applied in the motor load pressure chamber (2) and presses the 2-speed spool to the left, as in the diagram (presses to the right in the circuit diagram). When the load is low, the force applied in the motor load pressure chamber is low and the area of the motor load pressure chamber is smaller than the area on the PS port side, so the 2-speed switching spool is pressed to the right, as in the diagram, which keeps the motor in 2nd speed (high speed). Therefore, the high-pressure oil is supplied to the 2-speed switching piston via the 2-speed switching spool, the 2-speed switching piston presses against the swash-plate, and the swash-plate is thereby set to the 2nd speed. Therefore, the excavator travels in 2nd speed when under low load. RY9212182HYM0011US0

3-M37

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

When the load is heavy

(1) 2-speed switching spool

(2) 2-speed switching piston

(a) Control Valves

(b) Motor

The motor load pressure rises, so it overpowers the oil pressure from the PS port and moves the 2-speed switching spool to the left, as in the diagram (to the right in the circuit diagram) and switches to 1st speed (low speed). In this case, the oil path of the 2-speed switching piston connects to the DR port, and high-pressure oil is not supplied to the 2-speed switching piston. A force no longer presses on the swash-plate of the 2-speed switching piston and therefore the swash-plate is set to a 1st speed setting. Consequently, the excavator travels in 1st speed when under high load. When traveling in 1st speed, pressurized oil is not applied to the PS port, so it acts the same as when under a heavy load. RY9212182HYM0012US0

3-M38

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(5) Parking Brake The parking brake is a negative brake composed of a rotating disc (friction material), a brake piston and a spring. When the travel motor is stopped (the travel lever in neutral), the parking brake takes effect. The cylinder block and the disc are linked via a spline and a friction material is applied to both sides of the disc. The disc is spring-loaded and friction is generated between the flange holder and the brake piston, and this limits the force with which the motor can turn, allowing it to function as a parking brake. When pressurized oil is guided into the brake piston chamber, it generates an amount of thrust that matches the area of the brake piston receiving the pressure and overcomes the spring, thus moving the brake piston. The disk rotates freely between the flange holder and the brake piston, eliminating the parking brake function. (1) Spring (2) Brake piston chamber (3) Brake piston

(4) Disc (friction material) (5) Spline (6) Cylinder block RY9212090HYM0032US0

(6) Decelerator • The drive gear meshes with the 1st stage planetary gear while the 2nd stage sun gear meshes with the 2nd stage planetary gear. • The 2nd stage planetary carrier is fixed to the body of the decelerator. • Planetary gears and mesh with ring gear (the housing). • The drive force from the piston motor is transmitted to the drive gear, which is decelerated by each of the gears. • The decelerated drive force is transmitted to the ring gears via the 2nd stage planetary gear of the 2nd stage planetary carrier, which is fixed to the final stage of the decelerator. (The drive force from the 1st stage planetary gear is also transmitted.) • However, the input rotation is opposite the output rotation. (1) (2) (3) (4)

Drive Gear 1st Stage Planetary Gear 1st Stage Planetary Carrier 2nd Stage Sun Gear

(5) 2nd Stage Planetary Gear (6) 2nd Stage Planetary Carrier (7) Ring Gear (Housing) RY9212001HYM0003US0

3-M39

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

7. HYDRAULIC CYLINDER [1] BOOM CYLINDER (1) Specifications U35-4 Maker

Yanagizawa Seiki

Tube outer diameter

96 mm (3.8 in.)

Tube inner diameter

80 mm (3.1 in.)

Rod diameter

45 mm (1.8 in.)

Stroke

545 mm (21.5 in.)

Max compressed length

885 mm (34.8 in.) RY9212182HYM0013US0

(2) Components

(a) G1/2

(b) Cushion Stroke 38 mm RY9212182HYM0014US0

No.

Part Name

Q'ty

(1)

Cylinder tube ASSY

Notes

(13)

No. Spacer

Part Name

Q'ty 1

(2)

Piston rod ASSY

(14)

Cushion seal

(3)

Bushing

(15)

Collar

(4)

Bushing

(16)

O-ring

(5)

Cylinder head

(17)

Backup ring

(6)

Bushing

(18)

Piston

(7)

U-ring

(19)

Seal ring ASSY

(8)

Wiper ring

(20)

Slide ring

(9)

O-ring

(21)

Set screw

(10)

Backup ring

(22)

Steel ball

(11)

O-ring

(23)

Cushion bearing

(12)

Holder

(24)

Grease nipple

Notes

RY9212182HYM0015US0

3-M40

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) Function and Structure Cushion Function A cushion is utilized on the lift end of the boom (side of cylinder that extends) to prevent dirt from spilling. • Cushion function on the lift end of the boom

(a) Flow via a Slit

(b) Flow from Indentation

The discharge pressurized oil is automatically reduced on the lift end of the boom, slowing the operation of the cylinder and cushioning the shock on the lift end of the boom. An indentation and a split in the cushion bearing are provided as a means to reduce the pressure. RY9212001HYM0096US0

3-M41

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] ARM CYLINDER (1) Specifications U35-4 Maker

KUBOTA Seiki

Tube outer diameter

91 mm (3.6 in.)

Tube inner diameter

75 mm (3.0 in.)

Rod diameter

45 mm (1.8 in.)

Stroke

590 mm (23.2 in.)

Max compressed length

905 mm (35.6 in.) RY9212182HYM0016US0

(2) Components

(a) G1/2 No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Cylinder tube ASSY

(8)

Gasket

(2)

Piston rod ASSY

(9)

O-ring

(3)

Bushing

(10)

Piston

(4)

Cylinder head

(11)

Gasket (piston seal)

(5)

Bushing

(12)

Bushing (75)

(6)

U-ring

(13)

Set screw

(7)

Wiper ring

(14)

Ball

Notes

RY9212182HYM0017US0

3-M42

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] BUCKET CYLINDER (1) Specifications U35-4 Maker

KUBOTA Seiki

Tube outer diameter

80 mm (3.1 in.)

Tube inner diameter

65 mm (2.6 in.)

Rod diameter

40 mm (1.6 in.)

Stroke

516 mm (20.3 in.)

Max compressed length

811 mm (31.9 in.) RY9212182HYM0018US0

(2) Components

(a) G3/8(O-ring type) No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Cylinder tube ASSY

(11)

Bushing

(2)

Piston rod ASSY

(12)

Set screw

(3)

Cylinder head

(13)

Ball

(4)

Bushing

(14)

O-ring

(5)

Gasket

(15)

Pipe compressor

(6)

Dust seal

(16)

O-ring

(7)

Gasket

(17)

Plug

Notes

(8)

O-ring

(18)

Bushing

S45C

(9)

Piston

(19)

Bushing

S45C

(10)

Gasket

(20)

Grease nipple

1 RY9212182HYM0022US0

3-M43

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[4] SWING CYLINDER (1) Specifications U35-4 Maker

KUBOTA Seiki

Tube outer diameter

96 mm (3.8 in.)

Tube inner diameter

80 mm (3.1 in.)

Rod diameter

40 mm (1.6 in.)

Stroke

408.5 mm (16.08 in.)

Max compressed length

692.5 mm (27.26 in.) RY9212182HYM0019US0

(2) Components

(a) G1/4 No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Cylinder tube, ASSY

(8)

O-ring

(2)

Piston rod, ASSY

(9)

O-ring

(3)

Bushing

(10)

Piston

(4)

Cylinder head

(11)

Gasket

(5)

Bushing

(12)

Bushing

(6)

Gasket

(13)

Set screw

(7)

Dust seal

(14)

Ball

Notes

RY9212182HYM0023US0

3-M44

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[5] BLADE CYLINDER (1) Specifications U35-4 Maker

KUBOTA Seiki

Tube outer diameter

105 mm (4.13 in.)

Tube inner diameter

90 mm (3.5 in.)

Rod diameter

45 mm (1.8 in.)

Stroke

154 mm (6.06 in.)

Max compressed length

492 mm (19.4 in.) RY9212182HYM0020US0

(2) Components

(a) G3/8 No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Cylinder tube ASSY

(10)

Piston

(2)

Piston rod ASSY

(11)

Gasket

(3)

Bushing

(12)

Bushing

(4)

Cylinder head

(13)

Set screw

(5)

Bushing

(14)

Ball

(6)

Gasket

(15)

O-ring

(7)

Dust seal

(16)

O-ring

(8)

Gasket

(17)

Plug

(9)

O-ring

(18)

Pipe compressor

Notes

RY9212182HYM0024US0

3-M45

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[6] ANGLE CYLINDER (1) Specifications U35-4 Maker

KYB

Tube outer diameter

70 mm (2.8 in.)

Tube inner diameter

55 mm (2.2 in.)

Rod diameter

30 mm (1.2 in.)

Stroke

345 mm (13.6 in.)

Max compressed length

570 mm (22.4 in.) RY9212182HYM0021US0

(2) Components

(a) G1/4(O-ring type) No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Cylinder tube ASSY

(9)

Backup ring

(2)

Piston rod ASSY

(10)

O-ring

(3)

Pin bushing

(11)

Piston

(4)

Cylinder head

(12)

Seal ring ASSY

(5)

Bushing

(13)

Slide ring

(6)

U-ring

(14)

Set screw

(7)

Wiper ring

(15)

Steel ball

(8)

O-ring

Notes

RY9212182HYM0025US0

3-M46

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. PILOT VALVE [1] PILOT VALVE (BOOM, ARM, BUCKET, SWIVEL) (1) Specifications 1. Pilot Valve Left

(1) (2) (3) (4) (5) (6)

Port P Port 1 (swivel left) Port 2 (arm dump) Port 3 (swivel left) Port 4 (arm rake) Port T

(7) Independent operation torque (port 1) (8) Independent operation torque (port 2) (9) Independent operation torque (port 3) (10) Independent operation torque (port 4) (11) Secondary pressure

Maker

KPM (Kawasaki Precision Machinery)

Model

PV48M2160A

Secondary pressure

Noted separately

(a) Secondary pressure (kgf/cm2) (b) Secondary pressure (MPa) (c) Operating torque (N·m) (d) Operating torque (kgf·cm)

(e) Pushrod stroke (mm) (f) Operating angle (deg)

RY9212182HYM0033US0

3-M47

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Pilot Valve Right

(1) (2) (3) (4) (5) (6)

Port P Port 1 (bucket rake) Port 2 (lower boom) Port 3 (dump bucket) Port 4 (lift boom) Port T

(7) Independent operation torque (port 1) (8) Independent operation torque (port 2) (9) Independent operation torque (port 3) (10) Independent operation torque (port 4) (11) Secondary pressure

Maker

KPM (Kawasaki Precision Machinery)

Model

PV48M2161

Secondary pressure

Noted separately

(a) Secondary pressure (kgf/cm2) (b) Secondary pressure (MPa) (c) Operating torque (N·m) (d) Operating torque (kgf·cm)

(e) Pushrod stroke (mm) (f) Operating angle (deg)

RY9212182HYM0034US0

3-M48

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Components Pilot valves left and right No.

Name of part

Q'ty

(1)

Casing

(2)

Plate

(3)

Spool

(4)

Plug

(5)

Pushrod

(6)

Seal

(7)

O-Ring

(8)

Spring seat

Notes

(9)

Washer 2

(10)

Spring

For port 1

(11)

Spring

For port 2

(12)

Spring

For port 3

(13)

Spring

For port 4

(14)

Spring

(15)

Joint

(16)

Round plate

(17)

Adjusting nut

(18)

Bellows

(a) Port 2, 4

(b) Port 1, 3 RY9212001HYM0111US0

3-M49

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) Function and Structure [A] Function The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control valve spool. RY9212001HYM0001US0

[B] Operation 1. When the control lever is in neutral The force of the secondary pressure setting spring (14) does not press on the spool (3). As a result, the spool is held in a neutral position by return spring (11) or (13). At such time, the output port (control valve port) (a) and port T (b) are connected. (3) Spool (a) Output Port (11) Return Spring (b) Port T (13) Return Spring (14) Secondary Pressure Setting Spring RY9212001HYM0112US0

2. When the control lever has been actuated When the control lever is actuated, the pushrod (5) presses down on the spool (3) via the spring seat (8) and the secondary pressure setting spring (14). When doing so, port P (b) and the output port (a) are connected, so the oil from the pilot pump flows through the output port to the control valve. The pressure at the output port rises until it is equivalent to the force of the secondary pressure setting spring, thus balancing the hydraulic pressure on the spool with the tension of the secondary pressure setting spring and maintaining a fixed output port pressure. (3) Spool (a) Output Port (5) Pushrod (b) Port P (8) Spring Seat (14) Secondary Pressure Setting Spring RY9212001HYM0113US0

3-M50

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] PILOT VALVE (TRAVEL) (1) Specifications

(1) Port P (2) Port T (3) Port 1

Maker

(4) Port 2 (5) Port 3 (6) Port 4

(7) Operating torque (8) Secondary pressure

(a) Secondary pressure (MPa) (b) Operating angle (deg) (c) Operating torque (N·m)

Nishina Industrial

Model

–

Secondary pressure

Noted separately RY9212182HYM0035US0

3-M51

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Components

No.

Name of part

Q'ty

Notes

No.

Name of part

Q'ty

(1)

Shim

0.1T

(17)

Bushing

(2)

Shim

0.2T

(18)

Plug

(3)

Seat

(19)

Collar

Notes

(4)

Spring seat

(20)

Flanged plug

(5)

Pushrod

(21)

Hex socket bolt

JISB1176 M4×12×P0.7

(6)

(22)

Hex socket bolt

JISB1176 M10×25×P1.5

(7)

Plate, name

(23)

Hex set screw

JISB1177 M6x6

(8)

Shim

0.2T

(24)

Flat metal washer

JISB1256

(9)

Shim

0.1T

(25)

Rivet screw

#2×4.8

(10)

Spool

(26)

Parallel pin

JISB1354

(11)

Body

(27)

Steel ball

JISB1501

(12)

Cover

(28)

O-Ring

JISB2401 1A P10

(13)

Cam

(29)

O-Ring

JISB2401 1B P11

(14)

Spring

(30)

O-Ring

1B AS568-022

(15)

Spring

(31)

O-Ring

1B AS568-904

(16)

Collar

(32)

Expander

2 RY9212001HYM0115US0

3-M52

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[B] Operation 1. When the control lever is in neutral The oil from the pilot pump that flows into Port P (a) via the unload valve is cut off from port T (b) and port 1 (c) by the spool (10). And port 1 is connected to port T through the inside of the spool, so port 1 is at the tank pressure. (10) Spool

(a) (b) (c) (d)

Port P Port T Port 1 Port 2 RY9212001HYM0116US0

2. When the control lever has been actuated (during governing pressure) When the cam (13) operating angle exceeds 1.9 °, the pushrod (5) presses down on the spool (10) via the spring seat (4) and the secondary pressure setting spring (14). At part A, port P (a) and port 1 (c) are connected, while at part B, port 1 and port T (b) are cut off, so the oil flows from port P to port 1. When the pressure at port 1 gets high enough, it counters the secondary pressure setting spring and presses the spool up, thus cutting off port P and port 1 at part A and allowing port 1 and port T to be connected at part B, and lowering the pressure at port 1. The repetition of this process maintains a constant pressure equal to the secondary pressure setting spring load. If the cam is depressed further, the position of the spool does not change and the pushrod and spring seat move downwards, compressing the secondary pressure setting spring and putting a large load on the spring; this generates pressure equivalent to this load at port 1. (4) Spring Seat (5) Pushrod (10) Spool (13) Cam (14) Spring

(a) (b) (c) (d)

Port P Port T Port 1 Port 2 RY9212001HYM0117US0

3-M53

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

3. When the control lever has been actuated (during short-circuit) When the cam (13) operating angle exceeds 7.8 °, the pushrod (5) and the hex socket bolt (22) come in contact at part C and the spool (10) stops providing control by balancing the pressure. As a result, part A is left open, part B is left closed and the pressures of port P and port 1 equalize. (5) Pushrod (10) Spool (13) Cam (22) Hex Socket Bolt

(a) (b) (c) (d)

Port P Port T Port 1 Port 2 RY9212001HYM0118US0

3-M54

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. UNLOAD VALVE [1] SPECIFICATIONS

(1) PAC port (accumulator) (3) Port B (2-speed travel switch) (5) Port P (to control valve) (2) Port A (pilot operation, swivel (4) Drain port (to hydraulic oil (6) Port C (from pilot pump) parking brake) tank)

(7) Pilot primary relief valve (aPP) (8) Check valve

Maker

Nishina Industrial

Notes

Rated Voltage

12 V

Relief Valve Pressure Setting

3.92 +0.21 MPa 40 +3.0 kgf/cm2 570 +43 psi

at Temp. 50 °C (144 °F), 14.7 L/min (897 cu.in./min, 3.9 USGPM)

Leak volume port P → port T

130 ml/min 7.9 cu.in./min 0.03 USGPM

at 2.5 MPa (25.5 kgf/cm2, 363 psi)

Leak volume port PAC → other ports

90 ml/min 5 cu.in./min 0.02 USGPM

at 3.9 MPa (40.0 kgf/cm2, 569 psi) RY9212182HYM0026US0

3-M55

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] COMPONENTS

No.

Name of part

Q'ty

Notes

No.

Name of part

Q'ty

(1)

Plug

(12)

Solenoid

(2)

Plunger

(13)

Screw adjustment

(3)

Spring

(14)

Flanged plug

(4)

Spring

(15)

Hex socket bolt

(5)

Spool

(16)

Hex socket bolt

(6)

Plunger

(17)

Hex nut

(7)

Spring

(18)

Rivet screw

(8)

Plate, name

(19)

O-Ring

(9)

Cover

(20)

O-Ring

(10)

Plug

(21)

O-Ring

(11)

Body

(22)

O-Ring

Notes

RY9212001HYM0123US0

3-M56

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE (1) Function The unload valve consists of two directional change valves operated by solenoid, a check valve and a relief valve; it perform functions such as unloading control pressure from the pilot pump (returning oil to the hydraulic oil tank) and supplying control pressures to pilot valves for operation and travel, as well as to the swivel motor (for the parking brake) and the travel motor (for switching the two speeds). RY9212001HYM0124US0

(2) Operation With this device, oil from the pilot pump enters port C and is supplied to the control valve from port P, but that is functionally identical to when oil from the pilot pump enters from port P and supplied to the control valve from port C. Following is a description of when oil enters from port P from the pilot pump. RY9212001HYM0125US0

1. When the solenoid is off Oil from port P is cut off from passages to port A and port T by a spool and plunger. Ports A and T are connected. And Port C and Port P are connected, so the pressures at port C and port P are always the same. When the pressure from port P reaches the relief valve pressure setting, the oil from port P returns to the tank via the relief valve (pushes the plunger up). (5) Spool (6) Plunger

A: C: P: T:

Port A Port C Port P Port T RY9212001HYM0126US0

3-M57

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. When the solenoid is on When the solenoid is energized, the solenoid's pushrod presses the spool down, connecting port P to port A and cutting off port A and port T, so the oil from port P flows to port A.

When port P pressure reaches a pressure at or greater than the spring, the plunger moves to the right and pressure oil flows from port P to port PAC.

When the pressure at port P is low, the oil from port PAC is cut off, preventing backflow. (3) Spring (5) Spool (6) Plunger (12) Solenoid

A: C: P: T:

Port A Port C Port P Port T RY9212001HYM0127US0

3-M58

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

10. AUX SOLENOID VALVE [1] SPECIFICATIONS Proportional Control Solenoid Valve (S/P Valve) This valve is an electromagnetic solenoid valve. Normally a solenoid valve is turned off and on via 12V battery voltage, but this valve is controlled via pulsed signals from the computer built into the ECU and the meter panel. (Duty Control) Item

Specifications

Max operating pressure (input pressure)

3.9 MPa 40 kgf/cm2 570 psi

Allowable back pressure (pressure T)

1.0 MPa 10 kgf/cm2 100 psi

Maximum proportional valve operating flow volume (input flow volume)

15.6 L/min, 4.1 GPM

Drain volume when solenoid off

0.4 L/min ≥ (at 20 cST, port P pressure = 4.9 MPa, 50 kgf/cm2, 710 psi)

Waterproof Standard

JIS D 0203 S2 equivalent

Vibration Proof Standard

JIS D 1601–1995

Hydraulic Oil Grade

ISO VG32 to 68 equivalent

Hydraulic Oil Contamination Level

NAS Class 10 or less

Electrical Specifications

Rated Amperage: 1600 mA Coil resistance: 3.2 ± 0.5 Ω (at 20 deg C, 68 deg F)

Secondary pressure control range

0 to 2.7 MPa 0 to 27 kgf/cm2 0 to 390 psi

(1) (2) (3) (4)

P port T port A1 port (Hi) A2 port (Low)

(a) Secondary pressure (MPa) (b) Input amperage (mA)

RY9212095HYM0018US0

3-M59

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] COMPONENTS

No.

Name of part

Qty

Notes

No.

Name of part

Qty

(1)

Casing

(8)

O-ring

(2)

Magnetic proportioning reducing valve

(9)

O-ring

(3)

Hex bolt

(10)

O-ring

(4)

Spool

(11)

Solenoid

(5)

Sleeve

(12)

Seal nut

(6)

Spring

(13)

Adjusting screw

(7)

Retaining ring

(14)

O-ring

Notes

RY9212095HYM0035US0

3-M60

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE 1. When the solenoid is off When the solenoid is off, port P and port B are cut off by the spool. Port B and port T are connected, so no pressure is produced at port B. (1) Spool (2) Solenoid

A: B: P: T:

Port A Port B Port P Port T RY9212095HYM0020US0

2. When the solenoid is on When the solenoid is on, the spool is pressed down, connecting port P and port B. And as port B and port T are cut off, the oil from port P flows to port B. (1) Spool (2) Solenoid

A: B: P: T:

Port A Port B Port P Port T RY9212095HYM0021US0

3-M61

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

11. PROPORTIONAL VALVE FOR ANGLE BLADE CONTROL [1] SPECIFICATIONS

A : Port A

B : Port B

P : Port P

Maker

Nishina Industrial

Rated Voltage

DC 12 V

Leak Volume

220 ml/min or less at Temp. 50 °C (122 °F), 4.9 MPa (50 kgf/cm2, 3130 psi) pressure

T : Port T

RY9212182HYM0027US0

[2] COMPONENTS

No.

Part Name

Q'ty

Notes

No.

Part Name

Q'ty

(1)

Spring

(5)

Flanged plug

(2)

Spool

(6)

Hex set screw

(3)

Body

(7)

O-Ring

(4)

Solenoid

(8)

O-Ring

Notes

RY9212050HYM0024US0

3-M62

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE The pressure from port P is supplied or cut off from port A or port B by the solenoid valve used when operating the angle blade. RY9212050HYM0025US0

1. When the solenoid is off When the solenoid (4) is off, port P and Port B are cut off by the spool (2). Port B and port T are connected, so no pressure is produced at port B. (2) Spool (4) Solenoid

A: B: P: T:

Port A Port B Port P Port T RY9212050HYM0026US0

2. When the solenoid is on When the solenoid (4) is on, the spool (2) is pressed down, connecting port P and port B. And as port B and port T are cut off, the oil from port P flows to port B. (2) Spool (4) Solenoid

A: B: P: T:

Port A Port B Port P Port T RY9212050HYM0027US0

3-M63

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

12. PROPORTIONAL VALVE FOR AC MODE CONTROL [1] SPECIFICATIONS

Port A

P : Port P

T : Port T

Maker

Nishina Industrial

Rated Voltage

DC 12 V

Leak Volume

100 ml/min or less when at Temp. 50 °C (122 °F), 4.9 MPa (50 kgf/cm2, 3130 psi) RY9212182HYM0037US0

[2] COMPONENTS No.

Name of part

Qty

(1)

Spring

(2)

Spool

(3)

Body

(4)

Plate, name

(5)

Solenoid

(6)

Flanged plug

(7)

Hex socket bolt

(8)

Rivet screw

(9)

O-Ring

(10)

O-Ring

Notes

RY9212001HYM0129US0

3-M64

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FUNCTION AND STRUCTURE (1) Function This solenoid valve is used for limiting A/C mode and the solenoid supplies and cuts off pressure to port A from port P. RY9212182HYM0038US0

(2) Operation 1. When the solenoid is off When the solenoid (5) is off, port P and Port A are cut off by the spool (2). Port A nd port T are connected, so no pressure is produced at port A. (2) Spool (5) Solenoid

A: Port A P : Port P T : Port T RY9212001HYM0131US0

2. When the solenoid is on When the solenoid (5) is on, the spool (2) is pressed down, connecting port P and port A. And as port A and port T are cut off, the oil from port P flows to port A. (2) Spool (5) Solenoid

A: Port A P : Port P T : Port T RY9212001HYM0132US0

3-M65

KiSC issued 10, 2022 A

SERVICING CONTENTS 1. PUMP ..........................................................................................................................................3-S1 [1] PUMP REMOVAL AND INSTALLATION ..............................................................................3-S1 [2] PUMP DISASSEMBLY PROCEDURES (STANDARD SPEC)..............................................3-S4 (1) Disassembly Procedures.................................................................................................3-S5 (2) Assembly Procedures......................................................................................................3-S8 [3] SERVICE STANDARDS FOR PUMP PARTS.....................................................................3-S12 2. CONTROL VALVE.....................................................................................................................3-S13 [1] CONTROL VALVE REMOVAL AND INSTALLATION.........................................................3-S13 [2] CONTROL VALVE DISASSEMBLY / ASSEMBLY PROCEDURES ...................................3-S16 3. SWIVEL MOTOR.......................................................................................................................3-S30 [1] SWIVEL MOTOR REMOVAL AND INSTALLATION ...........................................................3-S30 [2] SWIVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES .....................................3-S32 (1) Disassembly Procedures...............................................................................................3-S34 (2) Assembly Procedures....................................................................................................3-S36 4. SWIVEL JOINT..........................................................................................................................3-S41 [1] SWIVEL JOINT REMOVAL AND INSTALLATION ..............................................................3-S41 5. TRAVEL MOTOR ......................................................................................................................3-S45 [1] TRAVEL MOTOR REMOVAL AND INSTALLATION ..........................................................3-S45 [2] TRAVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES .......................................3-S47 (1) Gear Case Disassembly................................................................................................3-S50 (2) Motor Disassembly ........................................................................................................3-S53 (3) Gear Case Assembly.....................................................................................................3-S56 (4) Motor Assembly.............................................................................................................3-S62 [3] SPECIAL TOOLS ................................................................................................................3-S66 6. HYDRAULIC CYLINDER...........................................................................................................3-S69 [1] HYDRAULIC CYLINDER DISASSEMBLY / ASSEMBLY PROCEDURES..........................3-S69 (1) Hydraulic Cylinder Components ....................................................................................3-S69 (2) Disassembly Procedures...............................................................................................3-S70 (3) Assembly Procedures....................................................................................................3-S73 7. PILOT VALVE (CONTROL).......................................................................................................3-S80 [1] USED PARTS OF PILOT VALVE HYDRAULIC HOSE.......................................................3-S80 [2] PILOT VALVE (CONTROL) DISASSEMBLY/ASSEMBLY PROCEDURES........................3-S81 (1) Pilot Valve Components ................................................................................................3-S81 (2) Disassembly ..................................................................................................................3-S81 (3) Assembly .......................................................................................................................3-S85 (4) U-joint Tightening Tool ..................................................................................................3-S88 8. PILOT VALVE (TRAVEL) ..........................................................................................................3-S89 [1] PILOT VALVE (TRAVEL) DISASSEMBLY/ASSEMBLY PROCEDURES ...........................3-S90 (1) Disassembly Procedures...............................................................................................3-S91 (2) Assembly Procedures....................................................................................................3-S94 9. UNLOAD VALVE .......................................................................................................................3-S99 [1] UNLOAD VALVE ASSEMBLY PROCEDURES ..................................................................3-S99 [2] UNLOAD VALVE DISASSEMBLY/ASSEMBLY PROCEDURES ......................................3-S100 (1) Unload Valve Components..........................................................................................3-S100 (2) Disassembly / Assembly Procedures ..........................................................................3-S101 10. TPSS VALVE...........................................................................................................................3-S104 [1] TPSS VALVE.....................................................................................................................3-S104 (1) Specifications ..............................................................................................................3-S104 (2) Components ................................................................................................................3-S105 KiSC issued 10, 2022 A

11. AUX SOLENOID VALVE .........................................................................................................3-S106 [1] AUX SOLENOID VALVE REMOVAL AND INSTALLATION .............................................3-S106 [2] AUX SOLENOID VALVE HOSE ROUTING ......................................................................3-S107 [3] AUX SOLENOID VALVE DISASSEMBLY PROCEDURES ..............................................3-S107 12. ANGLE SOLENOID VALVE.....................................................................................................3-S108 [1] ANGLE SOLENOID VALVE ASSEMBLY PROCEDURES................................................3-S108 13. THIRD LINE VALVE ASSEMBLY ............................................................................................3-S109 [1] THIRD LINE VALVE ASSEMBLY COMPONENTS ...........................................................3-S109 14. ROUTING OF HYDRAULIC HOSES .......................................................................................3-S110 [1] HYDRAULIC HOSE SPECIFICATIONS ............................................................................3-S110 (1) Hydraulic Hose Total Length .......................................................................................3-S110 (2) Types of Connector Fittings (Screw) ...........................................................................3-S110 [2] DELIVERY HOSE ROUTING ............................................................................................3-S111 [3] FRONT HOSE ROUTING..................................................................................................3-S112 [4] ROUTING OF TRAVEL, SWIVEL AND BLADE HOSES (ANGLE BLADE) ......................3-S113 [5] DRAIN HOSE ROUTING ...................................................................................................3-S115 [6] PILOT HOSE ROUTING (P) ..............................................................................................3-S116 [7] PILOT HOSE ROUTING (DELIVERY) ..............................................................................3-S117 [8] PILOT HOSE ROUTING (FRONT) ....................................................................................3-S118 [9] PILOT HOSE ROUTING (TRAVEL, AUX1 ANGLE BLADE) .............................................3-S120 [10]PILOT HOSE ROUTING (DRAIN) .....................................................................................3-S121 15. MEASURING THE PERFORMANCE OF HYDRAULIC DEVICES .........................................3-S122 16. TROUBLESHOOTING.............................................................................................................3-S140

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

1. PUMP [1] PUMP REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212001MBS0004US0

Removing the rear bonnet 1. Remove the bolts and then the rear bonnet. (1) Rear bonnet

(2) Bolt (M10 × 20) RY9212182MBS0026US0

Removing the left bonnet 1. Remove the four mounting bolts of the left bonnet and the fuel tank cap, and then take off the left bonnet. (1) Cap, ASSY (2) Bolt (M8 × 16)

(3) Left bonnet RY9212182MBS0025US0

Removing the side cover 1. Remove the five bolts and the side cover. (1) Bolt (M10 × 25) (2) Bolt (M10 × 25)

(3) Side cover RY9212182MBS0030US0

3-S1

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Attach a vacuum pump to the vacuuming plug and create a negative pressure inside the hydraulic oil tank. (2) Plug

(3) Vacuum pump (air) RY9212182HYS0002US0

Removing the pump 1. Remove all hoses from the pump, and fit plugs to the adapter and disconnected hoses. 2. Loosen the suction hose clamp and remove the suction hose. (5) Suction hose

(6) Hose clamp RY9212182HYS0003US0

3. Attach a nylon sling to the pump and support with a crane. 4. Take off the muffler pipe and remove the two pump mounting bolts. Tightening torque

(3) Nylon sling (4) Muffler pipe

Pump mounting bolts (5)

77.5 to 90.2 N·m 7.9 to 9.2 kgf·m 57.2 to 66.5 lbf·ft

(5) Bolt (M12 × 35) RY9212182HYS0005US0

5. Suspend with a crane, and pull the pump shaft out from the coupling. • Weight of pump : approx. 25 kg. (55 lbs.) RY9212182HYS0008US0

3-S2

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Pump adapter angles

(1) Pipe joint P1 (2) Pipe joint P2

(3) Elbow joint P3 (4) Pipe joint P4

(5) Pipe joint (A/C spec.)

(a) 5 ° (b) 30 °

Pump coupling assembly procedure

RY9212182HYS0117US0

1. Apply the correct amount of grease to the spline section (a). IMPORTANT • Do not apply grease to the rubber section of the coupling. 2. Apply an extremely thin layer of lubricant to the coupling seat surface (b), then tighten to the torque indicated in the following table. Tightening torque

Coupling mounting bolt (2)

85 to 94 N·m 8.6 to 9.6 kgf·m 63 to 69 lbf·ft

IMPORTANT • Do not apply threadlock. (1) Connector (2) Bolt (coupling) (3) Housing (pump)

(a) Spline section (b) Coupling seat surface RY9212182HYS0144US0

3-S3

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] PUMP DISASSEMBLY PROCEDURES (STANDARD SPEC)

No.

Part Name

Qty

No.

Part Name

Qty

No.

Part Name

Qty

(1)

Snap ring

(18)

Ball

(35)

Spring pin

(2)

Seal holder

(19)

Swash-plate

(36)

Body H

(3)

O-ring

(20)

Spring holder

(37)

Seal washer

(4)

Oil seal

(21)

Compression spring

(38)

Set screw

(5)

Shaft

(22)

Spring guide

(39)

Hex nut

(6)

Ball bearing

(23)

Piston, ASSY

(40)

Hole pin

(7)

External circlip

(24)

Shoe holder

(41)

Hex socket plug

(8)

Plug

(25)

Barrel holder

(42)

Spring washer

(9)

O-ring

(26)

Metal washer

(43)

Hex socket bolt

(10)

Body S

(27)

(44)

O-ring

(11)

Metal washer

(28)

Barrel cylinder

(45)

O-ring

(12)

Diaphragm spring

(29)

Retainer

(46)

O-ring

(13)

Stopper pin A

(30)

Spring

(47)

Connector

(14)

O-ring

(31)

Snap ring

(48)

Collar

(15)

Stopper pin B

(32)

Valve plate

(49)

Gear pump

(16)

Plug

(33)

Needle bearing

(50)

Flat metal washer

(17)

Rod

(34)

Gasket

(51)

Bolt

2 RY9212182HYS0010US0

3-S4

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(1) Disassembly Procedures After draining the pump of oil, wash off the pump and put a protector, such as clean paper, cloth, rubber mat, etc., on the work surface and proceed with disassembly and reassembly. Use any tools necessary and exercise caution so no parts are damaged and employ sufficient precautions to prevent any foreign matter from getting inside. RY9212004HYS0163US0

1. Take off the two bolts and remove the gear pump, the collar and the coupling. Tool to use: M13 wrench (49) Gear pump

(51) Bolt (M8 × 25) RY9212004HYS0164US0

2. Remove the O-ring. (44) O-Ring (45) O-Ring

(46) O-Ring RY9212004HYS0165US0

3. Fully loosen the hex nut and remove the set screw. IMPORTANT • Note down the projecting length (L) of the set screw in the previously fixed state. Tool to use: Socket wrench M13 (38) Set screw

(39) Hex nut RY9212004HYS0166US0

3-S5

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Remove the top two of the five hex socket head bolts. Install two provisional fixing bolts (M10 × 65) at positions of about 10 mm (0.39 in.) and fully loosen the three remaining bolts. Next, loosen off the two provisional fixing bolts and separate teh body S. Tool to use: M8 hex socket NOTE • If the body H is difficult to remove, lightly tap the spring insert section with a plastic hammer to aid removal. (10) Body S (36) Body H (43) Hex socket bolt

(A) Provisional fixing bolts

RY9212182HYS0145US0

5. Remove the valve plate, gasket, compression spring and O-ring from the body S. CAUTION • Take care not to cut your hands or fingers on the gasket. (21) Compression spring RY9212004HYS0168US0

6. Remove the cylinder barrel from the body S. (28) Cylinder barrel RY9212004HYS0169US0

7. Remove the spring holder, swash plate and ball from the body S. (18) Ball

(19) Swash-plate RY9212004HYS0170US0

3-S6

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. Remove the stopper pin A, stopper pin B, diaphragm spring, washer and rod G from the body S. (11) Metal washer (12) Diaphragm spring

(13) Stopper pin A (15) Stopper pin B RY9212004HYS0171US0

9. Remove the snap ring on the shaft drive axle from the body S. • Tool to use: snap ring pliers (1) Snap ring

(10) Body S RY9212004HYS0172US0

10. Tap the shaft lightly with a plastic hammer and remove the seal holder (with oil seal & O-ring) and the shaft (with ball bearings), from the body S. • Tool to use: plastic hammer IMPORTANT • Only use a plastic hammer. • Using a plastic hammer enables a light tapping action. RY9212004HYS0173US0

11. Remove the seal holder from the shaft. Remove the O-ring and the oil seal from the seal holder. (2) Seal holder (3) O-ring (4) Oil seal

(5) Shaft (6) Ball bearing RY9212004HYS0174US0

3-S7

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Assembly Procedures 1. Assemble the shaft (with ball bearings) and seal holder (with oil seal and O-ring) on the body S, in this order. • Tool to use: Seal holder insertion jig, plastic hammer IMPORTANT • Apply a small amount of grease to the lip and O-ring of the oil seal, and lightly tap in the seal with a hammer, using the seal holder tap in jig. The seal can be assembled more easily if the body S is placed provisionally on the body H. (2) Seal holder

(10) Body S RY9212004HYS0175US0

2. Assemble the snap ring on the body S. • Tool to use: snap ring pliers IMPORTANT • Install with the curved surface of the snap ring towards the seal holder. (1) Snap ring RY9212004HYS0176US0

3. Install the two diaphragm springs and the washer on the stopper pin A to form the stopper pin A kit. In the same way, install the two diaphram springs and the washer on the stopper pin B to form the stopper pin B kit. IMPORTANT • Make sure that the seal is facing in the right direction. • Install with the rounded side of the washer downwards.

Washer assembly direction (11) Metal washer (12) Diaphragm spring

(13) Stopper pin A (15) Stopper pin B RY9212004HYS0177US0

3-S8

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Assemble the rod on the body S. IMPORTANT • Replace used O-rings with new ones. (17) Rod RY9212004HYS0178US0

5. Assemble the balls on the swash-plate and assemble on the body S. NOTE • If the balls fall out, apply grease before assembling. (18) Ball

(19) Swash-plate RY9212004HYS0179US0

6. After installing the needle in the cylinder barrel, assemble the three pins, the washer and the barrel holder, and carefully assemble the shoe holder fitted with the piston. IMPORTANT • Apply a small amount of hydraulic oil to the piston. (25) Barrel holder (26) Metal washer

(27) Pin (28) Cylinder barrel RY9212004HYS0180US0

7. Assemble the cylinder barrel assembly on the body S. (28) Cylinder barrel RY9212004HYS0181US0

8. Coat the spring holder with grease and attach to the spring, and insert the round part of the spring holder into the hole in the swash-plate. (21) Compression spring RY9212004HYS0182US0

3-S9

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. Install the gasket on the body S mounting surface, using the positioning pins. CAUTION • Take care not to cut your hands or fingers on the gasket. (34) Gasket RY9212004HYS0183US0

10. Use the spring pins on the body H to position the valve plate and mount the plate gently. IMPORTANT • Replace used O-rings with new ones. • The surface of the valve plate with the groove is surface on which the cylinder barrel slides, so make sure the plate is mounted the right way round. (14) O-ring (32) Valve plate

(36) Body H RY9212004HYS0184US0

11. Install two provisional fixing bolts M10 × 65, pitch 1.5, in the two positions on the upper side, and fasten lightly. When the gap between the mating surfaces is 5 to 10 mm (0.20 to 0.39 in.), install M10 × 45 hex socket head bolts in the remaining three points. Remove the provisional fixing bolts, replace with M10 × 45 hex socket head bolts, and fasten.

Tightening torque

Bolt (M10 × 45)

51.0 to 64.7 N·m 5.2 to 6.6 kgf·m 37.7 to 47.7 lbf·ft

• Tool to use: M8 hex socket (36) Body H

(A) Provisional fixing bolts RY9212182HYS0146US0

12. Fix the hex socket head set screw to the projecting length before disassembly.

Tightening torque

Hex nut

14.7 to 19.6 N·m 1.5 to 2.0 kgf·m 10.9 to 14.4 lbf·ft

• Tool to use: Socket wrench M13, Hex socket M4 IMPORTANT • Replace the used seal washer with a new one. An old washer can give rise to oil leaks. RY9212182HYS0147US0

3-S10

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

13. Install O-rings at three points on the mating surfaces between the piston pump kit and the gear pump. Assemble the collar and coupling on the gear pump connector part. IMPORTANT • Apply grease to the O-ring. (47) Connector

(48) Collar RY9212004HYS0187US0

14. Assemble the gear pump using two hex bolts (M8 × 25) and washers.

Tightening torque

Bolt (M8 × 25)

19.6 to 23.5 N·m 2.0 to 2.4 kgf·m 14.5 to 17.3 lbf·ft

• Tool to use: M13 wrench IMPORTANT • After completing assembly, rotate the shaft to check that it turns smoothly. (49) Gear pump RY9212182HYS0148US0

3-S11

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] SERVICE STANDARDS FOR PUMP PARTS Part

Service Standard 1. Ensure there are no scratches, indentations or abnormal wear. (On the sliding parts in particular). 2. Check the gap betwen the piston outer diameter (D) and the cylinder barrel internal diameter (b). • (d) – (D) ≤ 0.05 mm (0.002 in.)

Piston assembly Cylinder barrel Valve plate

3. Check amount of play between piston and shoe • (a) ≤ 0.2 mm (0.01 in.)

Check wear on oil seal installation part (a). • Amount of wear ≤ 0.25 mm (0.0098 in.)

Shaft

Seal (O-ring, oil seal, gasket)

Inspect for gouging, splits and check elasticity. Always replace when reassembling. RY9212182HYS0149US0

3-S12

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. CONTROL VALVE [1] CONTROL VALVE REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212001MBS0004US0

Removing the right swivel cover on the right bonnet. 1. Position the machine as shown in the photo on the left, set the bucket on the ground, and stop the engine. 2. Remove the right bonnet and right swivel cover. (1) Right bonnet

(2) Right swivel cover RY9212182HYS0011US0

Removing the partition cover 1. Remove the partition cover which is located between the driver's seat and the control valve. (1) Partition cover RY9212182HYS0012US0

Removing the control valve 1. Replace the oil filler port of the hydraulic oil tank with a vacuuming plug, connect the vacuum pump and set the interior of the hydraulic oil tank to a negative pressure. Deatch all of the hydraulic hose and link connections, and the electrical wiring of the control valve. IMPORTANT • Plug the adapters and hoses to prevent oil spillages. • Mark the detached hoses so you can tell where to install them. (1) Control valve assembly RY9212182HYS0014US0

2. Attach a shackle to the bracket, connect a nylon sling, and suspend with a crane. Remove the bracket mounting bolts (two each top and bottom), and operate the crane to remove the control valve assembly. Tightening torque

Bracket mounting bolt

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

(When assembling) • Apply thread lock (Loctite 271). (1) Bracket

(2) Nylon sling RY9212182HYS0016US0

3-S13

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

3. Remove the control valve from the bracket.

Tightening torque

Control valve mounting bolt (2)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

(When assembling) • Apply thread lock (Loctite 271). • Weight of control valve : approx. 27 kg. (60 lbs.) (1) Bracket

(2) Bolt (M10 × 16) RY9212182HYS0017US0

(1) (2) (3) (4) (5)

Control valve ASSY Bolt (M10 × 20) Bolt (M10 × 16) AUX1 valve ASSY Bolt (M8 × 20)

(6) Unload valve ASSY (7) Bolt (M10 × 20) (8) Bracket (9) Bolt (M10 × 20) (10) Bracket

(A) AUX1 valve installation hole (C) Control valve installation (B) Control valve installation hole (Standard blade spec.) hole (Angle blade spec.) (D) Control valve installation hole (Normal use) RY9212182HYS0118US0

3-S14

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Control valve adapter angles (standard spec.)

(1) (2) (3) (4) (5) (6)

Swivel Swing Blade Union valve AUX1 Arm

(7) Travel right (8) Supply (9) Travel left (10) Boom (11) Boom lock valve (12) Bucket

(a) (b) (c) (d) (e)

5° 10 ° 15 ° 20 ° 25 °

(f) (g) (h) (i) (j)

30 ° 40 ° 45 ° 60 ° 80 ° RY9212182HYS0119US0

Control valve adapter angles (angle blade spec.)

(1) (2) (3) (4) (5) (6) (7)

Angle Swivel Swing Blade Union valve AUX1 Arm

(8) Travel right (9) Supply (10) Travel left (11) Boom (12) Boom lock valve (13) Bucket

(a) (b) (c) (d) (e)

5° 10 ° 15 ° 20 ° 25 °

(f) (g) (h) (i) (j)

30 ° 40 ° 45 ° 60 ° 80 °

RY9212182HYS0120US0

3-S15

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] CONTROL VALVE DISASSEMBLY / ASSEMBLY PROCEDURES Precautions during Disassembly / Assembly Precautions during Disassembly 1. Generally, hydraulic devices are precision machined, and disassembly should therefore be conducted in a clean environment to prevent entry of debris into the narrow interstices formed in the device structure. 2. Always use clean tools and cleaning oil. 3. After removing from the machine, first wash the outside of the assembly. 4. Before starting work, prepare the necessary parts for the aims and extent of disassembly. Before reassembling, as a rule you should replace all seals and O-rings, etc. Also, since a subassembly is available with the required parts if parts cannot be supplied as single items, refer to the parts catalog beforehand in preparation. Precautions on Assembly 1. Apply clean grease or hydraulic fluid to O-rings and their countersunk parts for mounting. 2. There should be no flaws in O-rings due to forming, and no marks or heat deformation incurred when handling. 3. If permanently deformed, O-rings will not straighten out. (Make sure that no flaws are incurred by an O-ring when passing it through sharp angled sections of a spool.) 4. Do not turn over O-rings on installation. (Fouled O-rings are difficult to re-install and can easily result in oil leakage.) Before assembling, at the mating surface of each section, make sure no cleaning oil, hydraulic fluid, etc., is adhered to the outer surface of the O-ring groove. (If you assemble with oil adhered to a mating surface, this may be mistakenly recognized as oil leakage from that location when the machine is running.) RY9212001HYS0140US0 (1) Angle (2) Swivel (3) Swing (4) Blade (5) Union valve (6) AUX (7) Arm (8) Travel right (9) Supply (10) Travel left (11) Boom (12) Boom lock valve (13) Bucket (14) O-ring (1A, P20) (15) O-ring (1B, P10) (16) O-ring (1B, P9) (17) O-ring (1BW, G4) (18) Rod (L = 458 mm) (19) Nut (M8) RY9212182HYS0150US0

Disassembly of main body of switching section Take a 13 mm socket wrench or a 13 mm spanner and loosen off the 8 (2 sets of 4) M8 hex nuts which fix the main body of the switching section to the valve side surface. When the four roads are removed from the side surface, each switching section main body can be removed. Tightening torque

Nut (19)

16.7 to 17.7 N·m 1.7 to 1.8 kgf·m 12.4 to 13.0 lbf·ft RY9212182HYS0151US0

3-S16

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

1. Angle Section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

No.

Valve ASSY (Overload relief) Pressure Setting

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft Tightening torque

(15)

27.5 MPa 280 kgf/cm2 3990 psi

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

(16)

17.2 MPa 175 kgf/cm2 2490 psi

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

Note s

*1: Apply thread lock. RY9212182HYS0204US0

3-S17

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Swivel Section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

*1: Apply thread lock. RY9212182HYS0206US0

3-S18

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

3. Swing section components Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

No.

Name of part

Qty

(1)

Body

(2)

Spool

(3)

O-ring (1A, P12)

(4)

Dust wiper

(5)

Oil seal retainer

(6)

Spring seat

(7)

Spool end

(8)

Spring

(9)

Cap

(10)

Bolt

(11)

Spring

(12)

Plug

(13)

Poppet

(14)

O-ring (1B, P11)

(15)

Anticavitation Valve

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

(16)

Bolt

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

(17)

Oil seal retainer

(18)

Dust wiper

(19)

O-ring (1A, P12)

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0207US0

3-S19

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Blade section components No.

Name of part

Qty

(1)

Body

(2)

Spool

(3)

O-ring (1A, P12)

(4)

Dust wiper

(5)

Washer

(6)

Spring seat

(7)

Spring

(8)

Notch tank

(9)

Cap

(10)

Ball case

(11)

Oil seal retainer

(12)

Detent spring

(13)

Ball retainer

5 steel ball

(14)

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

(15)

Seal case

(16)

O-ring (1B, S22)

(17)

Stopper

(18)

Cap

(19)

Bolt

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

(20)

Bolt

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

(21)

Poppet

(22)

Spring

(23)

Plug

(24)

O-ring (1B, P11)

(25)

O-ring (1A, P12)

(26)

Dust wiper

(27)

Oil seal retainer

(29)

Anticavitation Valve

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

Valve ASSY (overload relief) pressure setting

Tightening torque

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. No.

(28)

24 MPa 245 kgf/cm2 3500 psi

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft RY9212182HYS0209US0

3-S20

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. Union valve section components No.

Name of part

Qty

(1)

Body

(2)

Spool

Tightening torque

Note s

(3)

Spring seat

(4)

Spring

(5)

O-ring (1B, S22)

(6)

Cap A2

(7)

Bolt

(8)

O-ring (1A, P6)

(9)

Poppet

(10)

Spring

(11)

O-ring (1B, P11)

(12)

Plug

(13)

Piston

(14)

Pilot tie

(15)

Bolt

(16)

O-ring (AS568-904)

(17)

Screw GPM 1/32

1.72 ± 0.25 N·m 0.17 ± 0.02 kgf·m 1.27 ± 0.18 lbf·ft

(18)

Plug (PF1/4)

27.00 ± 2.45 N·m 2.75 ± 0.25 kgf·m 19.90 ± 1.81 lbf·ft

(19)

Plug

18.10 ± 0.49 N·m 1.85 ± 0.05 kgf·m 13.30 ± 0.36 lbf·ft

(20)

Choke plug

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

(21)

Coin filter

(22)

Orifice

(23)

Screw NPT1/16

(24)

Choke plug

No.

(25)

Valve ASSY (overload relief) pressure setting 19.6 MPa 200 kgf/cm2 2920 psi

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0211US0

3-S21

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

6. AUX Section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

No.

(15)

Valve ASSY (Overload relief) Pressure Setting 17.2 MPa 175 kgf/cm2 2490 psi

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0212US0

3-S22

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

7. Arm Section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Cap

(6)

Spool end

(7)

Spring seat

(9)

Compression spring

(10)

Plug

(11)

Poppet

(12)

O-ring (1B, P11)

(13)

Cap

(14)

Bolt

(15)

O-ring (1B, S22)

(16)

Spring

(17)

Poppet

(18)

Plug

(19)

O-ring (1B, S16)

(20)

Plug

No.

(8)

Valve ASSY (Overload relief) Pressure Setting 27.5 MPa 280 kgf/cm2 3990 psi

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0213US0

3-S23

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. Travel left section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

*1: Apply thread lock. RY9212182HYS0214US0

9. Supply section Components No.

Name of part

Q'ty

(1)

Body

(2)

Plug

No.

(3)

Valve ASSY (Overload relief) Pressure Setting 24.5 MPa 250 kgf/cm2 3550 psi

Tightening torque

Note s

Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft RY9212182HYS0215US0

3-S24

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

10. Travel right section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

*1: Apply thread lock. RY9212182HYS0216US0

3-S25

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

11. Boom section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

No.

(15)

Valve ASSY (Overload relief) Pressure Setting 27.5 MPa 280 kgf/cm2 3990 psi

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0217US0

3-S26

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

12. Boom lock section components Tightening torque

No.

Name of part

Qty

(1)

Body

(2)

Lock valve

(3)

Cap seal

(4)

Filter

(5)

Spacer

(6)

Circlip

(7)

Lock valve spring

(8)

Spring seat

(9)

C type collar hole 9

(10)

Needle valve

(11)

Lock valve case

(12)

Piston guide

(13)

O-ring (1B, P8)

(14)

Piston A1

(15)

Piston B

(16)

O-ring (1B, P8)

(17)

Bushing

(18)

Steel ball

(19)

O-ring (1B, P8)

(20)

Ball retainer

(21)

O-ring (AS, 1B17)

(22)

O-ring (1A, P6)

(23)

Parallel pin

(24)

O-ring (1B, P11)

(25)

Poppet

(26)

Spring

(27)

Plug

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

(28)

Plug (SC3A)

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

(29)

O-ring (1B, P14)

34.3 ± 4.9 N·m 3.5 ± 0.5 kgf·m 25.3 ± 3.6 lbf·ft

Note s

63.7 ± 4.9 N·m 6.5 ± 0.5 kgf·m 47.0 ± 3.6 lbf·ft

8.83 ± 0.98 N·m 0.9 ± 0.1 kgf·m 6.51 ± 0.72 lbf·ft

(To be continued)

3-S27

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued) No.

Name of part

Qty

Tightening torque

(30)

Plug

27.00 ± 2.45 N·m 2.75 ± 0.25 kgf·m 20.00 ± 1.81 lbf·ft

(31)

Bolt

10.30 ± 0.49 N·m 1.05 ± 0.05 kgf·m 7.60 ± 0.36 lbf·ft

(32)

O-ring (1B, S16)

(33)

Plug

No.

(34)

Valve ASSY (overload relief) pressure setting 27.5 MPa 280 kgf/cm2 3990 psi

Note s

18.10 ± 0.49 N·m 1.85 ± 0.05 kgf·m 13.30 ± 0.36 lbf·ft Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0220US0

3-S28

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

13. Bucket section Components No.

Name of part

Q'ty

(1)

Body

(2)

Spool

Tightening torque

Note s

4.41 ± 0.49 N·m 0.45 ± 0.05 kgf·m 3.25 ± 0.36 lbf·ft

(3)

Spring seat

(4)

Spring

(5)

Spring seat

(6)

Spool end

(7)

Poppet

(8)

Compression spring

(9)

O-ring (1B, P11)

(10)

Plug

(11)

O-ring (1B, S22)

(12)

Cap

(13)

Cap

(14)

Bolt

6.37 ± 0.49 N·m 0.65 ± 0.05 kgf·m 4.70 ± 0.36 lbf·ft

(16)

Anticavitation valve

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

No.

(15)

Valve ASSY (Overload relief) Pressure Setting 27.5 MPa 280 kgf/cm2 3990 psi

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

Tightening torque

Note s

39.20 ± 1.96 N·m 4.0 ± 0.2 kgf·m 28.90 ± 1.45 lbf·ft

*1: Apply thread lock. RY9212182HYS0219US0

3-S29

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

3. SWIVEL MOTOR [1] SWIVEL MOTOR REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212001MBS0004US0

Removing the step 1. Remove the step and cover. (1) Step

(2) Cover RY9212182HYS0018US0

Removing the Canopy 1. Remove the canopy. (Refer to the chapter "Canopy Assembly/Disassembly".) (1) Canopy RY9212182HYS0019US0

Removing the swivel motor 1. Detach the hydraulic hoses about the swivel motor, from the motor. 2. Remove the six swivel motor mounting bolts. IMPORTANT • Apply thread lock (Loctite 271). Tightening torque

Swivel motor mounting bolt (2)

166.7 to 196.1 N·m 17 to 20 kgf·m 123.0 to 144.6 lbf·ft

3. Connect a nylon sling to the swivel motor and hoist with a crane. • Weight of swivel motor: approx. 35 kg (77 lbs) (1) Swivel Motor (2) Bolt (M14 × 40)

(3) Nylon sling RY9212182HYS0020US0

3-S30

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Swivel motor adapter angles

(1) (2) (3) (4) (5) (6) (7)

Straight Pipe Joint Straight Pipe Joint Pipe Joint Straight Pipe Joint Pipe Joint Pipe Joint Pipe Joint (T, G2)

(A) (B) (C) (D) (E) (F)

Control Valve Swivel Left Control Valve Swivel Right Makeup Drain Left Pilot Valve (P) Port Right Pilot Valve (P) Port

(G) Travel Pilot Valve (P) Port (H) AUX1 (P) Port (I) Control Valve (PP1) (J) AC (P) Port (K) AUX1 (P) Port (L) Control Valve (PP1)

(a) (b) (c) (d) (e)

5° 10 ° 45 ° 90 ° Canopy Spec.

RY9212182HYS0121US0

3-S31

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] SWIVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES

(To be continued)

3-S32

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued) No. (1)

Name of part O-ring

Qty

No.

(35)

Name of part Piston, ASSY (A)

Qty 1

(2)

Hex socket bolt

(36)

(3)

Housing

(37)

Friction plate

(4)

Plug

(38)

Cylinder block

(5)

O-ring

(39)

Spring washer 2

(6)

Compression spring

(40)

Spring (CY)

(7)

Poppet

(41)

Internal circlip

(8)

Plug (G1/2)

(42)

O-ring

(9)

O-ring

(43)

Brake piston

(10)

Shockless piston

(44)

Spring (NB)

(11)

Filter

(45)

O-ring

(12)

O-ring

(46)

Valve plate

(13)

Backup ring

(47)

Ball bearing

(14)

O-ring

(48)

O-ring

(15)

Poppet seat ring

(49)

Parallel pin

(16)

Poppet

(50)

Parallel pin

(17)

Poppet guide

(51)

O-ring

(18)

Spring seat ring

(52)

Parallel pin

(19)

Compression spring

(53)

Plug (R1/4)

(20)

Spring guide

(54)

Cover

(21)

O-ring

(55)

Hex socket bolt

(22)

Backup ring

(56)

Pinion shaft

(23)

Backup ring

(57)

Ball bearing

(24)

O-ring

(58)

Gear case

(25)

O-ring

(59)

Oil seal

(26)

Housing

(60)

Ball bearing

(27)

Set screw

(61)

External circlip

(28)

Nut

(62)

Holder

(29)

Ball bearing

(63)

Collar

(30)

External circlip

(64)

Needle bearing

(31)

Shaft

(65)

Planetary gear

(32)

Thrust plate

(66)

Thrust plate

(33)

Retainer plate

(67)

Bolt

(34)

Retainer holder

1 RY9212004HYS0220US0

3-S33

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(1) Disassembly Procedures 1. Remove the cover. • Tool to use: M10 hex wrench (54) Cover RY9212004HYS0221US0

2. Remove the springs (NB) and the O-rings. (44) Spring (NB) (48) O-ring

(51) O-ring RY9212004HYS0222US0

3. Remove the brake piston. • Tool to use: air gun CAUTION • Send air through the brake release oil hole to remove the piston. • Take care as the brake piston may fly out. RY9212004HYS0223US0

4. Remove the cylinder block and sub-assembly. IMPORTANT • Turn the assembly platform sideways. RY9212004HYS0224US0

5. Remove the shockless piston and plug. (8) Plug

(10) Shockless piston RY9212004HYS0225US0

3-S34

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

6. Remove the shaft and ball bearing. (29) Ball bearing

(31) Shaft RY9212004HYS0226US0

7. Remove the housing. • Tool to use: M10 hex wrench (3) Housing RY9212004HYS0227US0

8. Remove the thrust plate. • Tool to use: Socket wrench M10 (66) Thrust plate RY9212004HYS0228US0

9. Remove the planetary gear, needle bearing, collar and the holder. (62) Holder (63) Collar

(64) Needle bearing (65) Planetary gear RY9212004HYS0229US0

10. Remove the external circlip. • Tool to use: snap ring pliers CAUTION • Turn the assembly platform sideways, so that the pinion shaft does not fall out. (61) External circlip RY9212004HYS0230US0

3-S35

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

11. Remove the pinion shaft and ball bearing. • Tool to use: plastic hammer IMPORTANT • Take care so the pinion shaft does not fly out. • At the end, take the pinion shaft out by hand. (56) Pinion shaft

(57) Ball bearing RY9212004HYS0231US0

12. Remove the oil seal. • Tool to use: Slotted screwdriver (59) Oil seal RY9212004HYS0232US0

(2) Assembly Procedures 1. Install the oil seal. • Tool to use: Oil seal installation tool IMPORTANT • Apply grease to the lip and circumference part of the oil seal. • Make sure the oil seal is facing the right way.

(59) Oil seal

(A) Tap in tool (a) 61 (b) 89.8 RY9212182HYS0191US0

2. Mount the gear case on the pinion shaft. IMPORTANT • Do not scratch the oil seal. (58) Gear case RY9212004HYS0234US0

3-S36

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

3. Assemble the external circlip. • Tool to use: snap ring pliers IMPORTANT • Install with the rounded side downwards. (61) External circlip RY9212004HYS0235US0

4. Put the gear case on the assembly platform and install the holder. (62) Holder RY9212004HYS0236US0

5. Install the collar, needle bearing and planetary gear on the holder. IMPORTANT • Install the planetary gear with the protruding side up. (63) Collar (64) Needle bearing

(65) Planetary gear RY9212004HYS0237US0

6. Mount the thrust plate. • Tools to use: Socket wrench M10, Locktite 271 Tightening torque

9.8 to 11.3 N·m 1.00 to 1.15 kgf·m 7.30 to 8.33 lbf·ft

Bolt (67)

IMPORTANT • Apply Loctite to the bolts. (66) Thrust plate

(67) Bolt RY9212182HYS0152US0

7. Install the housing. • Tool to use: M10 hex wrench Tightening torque

(2) Hex socket bolt

Hex socket bolt (2)

102.9 to 117.6 N·m 10.5 to 12.0 kgf·m 75.9 to 86.7 lbf·ft

(3) Housing RY9212182HYS0153US0

3-S37

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. Install the shaft and ball bearing. IMPORTANT • Apply grease to the circumference of the ball bearing. (29) Ball bearing

(31) Shaft RY9212004HYS0240US0

9. Install the poppets, springs and plugs. • Tool to use: M8 hex wrench Tightening torque

49.0 to 58.8 N·m 5.0 to 6.0 kgf·m 36.0 to 43.4 lbf·ft

Plug (4)

IMPORTANT • Apply hydraulic oil to the poppet. (4) Plug (6) Spring

(7) Poppet RY9212182HYS0154US0

10. Install the valve ASSY. • Tool to use: Socket wrench M26 Tightening torque

58.8 to 68.6 N·m 6.0 to 7.0 kgf·m 43.4 to 50.6 lbf·ft

Valve ASSY

RY9212182HYS0155US0

11. Install the shockless piston and plug.

Tightening torque

Plug (8)

58.8 to 68.6 N·m 6.0 to 7.0 kgf·m 43.4 to 50.6 lbf·ft

IMPORTANT • Apply hydraulic oil to the shockless piston. • The piston itself should slide smoothly. (8) Plug

(10) Shockless piston RY9212182HYS0156US0

12. Mount the thrust plate. IMPORTANT • Turn the assembly platform sideways. • Install with the chamfered side down. (32) Thrust plate RY9212004HYS0244US0

3-S38

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

13. Install the cylinder block and sub-assembly. IMPORTANT • Apply hydraulic oil to the cylinder block and piston and install. RY9212004HYS0245US0

14. After installing the cylinder block, make sure it is recessed below the level of the edge of the housing. IMPORTANT • Return the assembly platform to its original position. RY9212004HYS0246US0

15. Install the O-ring on the brake piston. IMPORTANT • Apply grease to the O-ring. • Align with position of anti-rotation hole. (42) O-ring (43) Brake piston

(45) O-ring RY9212004HYS0247US0

16. Install the brake piston. • Tool to use: plastic hammer IMPORTANT • Keep parallel with the housing during assembly. (43) Brake piston RY9212004HYS0248US0

Brake piston anti-rotation hole. (A) Brake piston anti-rotation hole. (B) Shaft centre

3-S39

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

17. Install the cover on the valve plate. IMPORTANT • Apply grease to the back of the valve plate. • Make sure that the valve plate is facing the right way. (46) Valve plate

(54) Cover RY9212004HYS0250US0

18. Install the O-rings and springs (NB). IMPORTANT • Apply grease to the O-ring. (44) Spring (NB) (48) O-ring

(51) O-ring RY9212004HYS0251US0

19. Install the cover. • Tool to use: M10 hex wrench Tightening torque

Hex socket bolt (55)

102.9 to 117.6 N·m 10.5 to 12.0 kgf·m 75.9 to 86.7 lbf·ft

(54) Cover RY9212182HYS0157US0

3-S40

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. SWIVEL JOINT [1] SWIVEL JOINT REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212001MBS0004US0

Removing the Canopy 1. Remove the canopy. (Refer to the chapter "Canopy Assembly/Disassembly".) (1) Canopy RY9212182HYS0019US0

Stabilizing the Mini-excavator 1. Position the mini-excavator on hard, level ground, operating the equipment and blade to lift the body. DANGER • Put blocks under the crawler to prevent the mini-excavator from lowering. (1) Block RY9212166HYS0118US0

Removing the Swivel Motor 1. Remove the swivel motor from the machine. Refer to the chapter "Swivel Motor Assembly/Disassembly". (1) Swivel Motor RY9212182HYS0031US0

Removing the hydraulic hoses 1. Remove all the hydraulic hoses on the swivel joint side (inside the travel frame) and plug or cap the adapters and hoses to prevent foreign matter from getting into them. Remove the stopper mounting bolt and the stopper. IMPORTANT • Apply a threadlock (Loctite 271). Tightening torque

77.5 to 90.2 N·m 7.9 to 39.2 kgf·m 57.2 to 66.5 lbf·ft

Stopper (2)

(1) Stopper Mounting Bolt

(2) Stopper RY9212182HYS0223US0

3-S41

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Removing the hydraulic hoses 1. Remove the bottom cover of the track frame. 2. Remove all the hydraulic hoses on the body side (inside the track frame). Plug or cap the adapters and hoses to prevent foreign matter from getting into them. RY9212182HYS0222US0

Removing the swivel joint 1. To stop the swivel joint from falling, attach a nylon sling to the body and suspend. 2. Remove the four swivel joint fixing bolts. IMPORTANT • Apply thread lock (Loctite 271). Tightening torque

Swivel joint

77.5 to 90.2 N·m 7.9 to 39.2 kgf·m 57.2 to 66.5 lbf·ft

3. Turn the swivel joint, remove from the track frame and lower slowly. • Weight of swivel joint : approx. 14 kg. (31 lbs.) (1) Bolt (M12 X 40) RY9212182HYS0221US0

3-S42

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Swivel Joint Adapter Angle (Angle Blade Specification)

(A) (B) (C) (D)

2-Speed Pilot Blade (Down) Blade (Up) Travel Left (Forward)

(E) Travel Right (Forward) (F) Travel Left (Backward) (G) Travel Right (Backward)

(H) Drain (I) Angle (Left) (J) Angle (Right)

G1/4

24.5 to 29.4 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft

G3/8

49.0 to 53.9 N·m 5.0 to 5.5 kgf·m 36.0 to 39.8 lbf·ft

G1/2

58.8 to 63.7 N·m 6.0 to 6.5 kgf·m 43.4 to 47.0 lbf·ft

3/4 UNF

44.1 to 53.9 N·m 4.5 to 5.5 kgf·m 32.5 to 39.8 lbf·ft

Tightening torque

(a) 15 ° (b) 60 °

RY9212182HYS0039US0

3-S43

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Swivel joint assembly diagram

(A) Outer side

(B) Lip

(a) 10º (factory spec.)

(b) 60 °

1. Gasket (U) assembly direction Apply grease to the inner and outer surfaces of the gasket (U), and install with the seal lip on the outer side. 2. Coupling the body and shaft When coupling the shaft to the body, apply grease to the inner and outer circumferential surfaces of the gasket. No.

Part Name

Qty

No.

(6)

Collar

Gasket (U)

(7)

External circlip

Gasket

(8)

O-ring

(4)

Shaft

(9)

Cover

(5)

Collar

(10)

Internal circlip

(1)

Body

(2) (3)

Part Name

Qty

RY9212182HYS0040US0

3-S44

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. TRAVEL MOTOR [1] TRAVEL MOTOR REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the mini-excavator. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212001MBS0004US0

Removing the travel motor 1. Remove the crawler track. Refer to the chapter Crawler Track for the removal and installation of the crawler track. DANGER • Jack up the mini-excavator with the front-end and the blade and place timbers under the frame. RY9212182HYS0041US0

2. Remove the three cover mounting bolts and remove the cover. Attach the breather hose of the hydraulic fluid tank to the vacuum pump, and apply vacuum pressure to the hydraulic fluid tank. Disconnect the hydraulic hoses. RY9212182HYS0042US0

3. Temporarily suspend the travel motor with a nylon sling and remove the nine bolts. IMPORTANT • Apply thread lock compound (Loctite 271). Tightening torque

Bolt (1)

103.0 to 117.7N·m 10.5 to 12.0 kgf·m 76.0 to 86.8 lbf·ft

(1) Bolt (M20 × 30) RY9212182HYS0043US0

4. Use a crane to hoist and remove the travel motor. Remove the sprocket mounting bolts in nine locations, and remove the sprocket. IMPORTANT • Apply thread lock compound (Loctite 271). Tightening torque

Bolt (3)

103.0 to 117.7N·m 10.5 to 12.0 kgf·m 76.0 to 86.8 lbf·ft

• Travel motor weight: Approx. 36 kg (79 lbs) (1) Nylon Sling (2) Sprocket

(3) Bolt (M20 × 30) RY9212182HYS0044US0

3-S45

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Travel Hose Routing (1) (2) (3) (4) (5)

Swivel joint side A L/R travel 2-speed (2S)

Travel Motor L Travel Motor R Swivel Joint Blade Cylinder Angle Cylinder

Travel motor / cylinder side L/R travel 2-speed port

B Blade down (Brown)

Cylinder (Bottom)

C Blade up (Pink)

Cylinder (Rod)

D Travel left forward (Blue)

Left travel motor (P1)

E Travel right forward (Green)

Right travel motor (P2)

F Travel left backward (Red)

Left travel motor (P2)

G Travel right backward (Yellow)

Right travel motor (P1)

H Drain

Travel motor drain port (Upper side

I Angle left

Angle cylinder (Bottom)

J Angle right

Angle cylinder (Rod) RY9212182HYS0047US0

3-S46

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] TRAVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES

(To be continued)

3-S47

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued)

(To be continued)

3-S48

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued) No.

Qty

No.

(1)

Plug (G3/8)

Name of part

(44)

Name of part

(2)

O-ring

(45)

Internal circlip

(3)

Cover

(46)

Friction plate

(4)

O-ring

(47)

O-ring

Spring washer

Qty 1

(5)

Spring pin

(48)

Brake piston

(6)

Gear case

(49)

Spring (NB)

(7)

Plug (R1/8)

(50)

O-ring

(8)

Ball

132

(51)

Plug (G1/4)

Thrust plate t = 1.6

(52)

O-ring

Thrust plate t = 2.3

(53)

Parallel pin

Thrust plate t = 3.0

(54)

Parallel pin

Drive gear

(55)

Valve plate

(9)

(10) (11)

Planetary gear A

(56)

Ball bearing

(12)

Needle bearing

(57)

Plug

(13)

Collar

(58)

O-ring

(14)

Holder

(59)

Spring

(15)

External circlip

(60)

Spring washer

(16)

Thrust plate B2

(61)

Plug

(17)

External circlip

(62)

O-ring

(18)

Sun gear

(63)

Compression spring

(19)

Planetary gear B

(64)

Poppet

(20)

Needle bearing

(65)

Counterbalance plunger

(21)

Collar

(66)

Parallel pin

(22)

Thrust plate B2

(67)

O-ring

(23)

Ring nut

(68)

Counter-balance body

(24)

Angular bearing

(69)

Plug (R1/8)

(25)

Floating seal

(70)

Orifice (0.4)

(26)

Set screw (M8 Sealock)

(71)

Plug (NPTF1/16, MEC)

(27)

Plug (NPTF1/16, MEC)

(72)

Orifice (0.5)

(28)

Flange holder

(73)

Plug (GPF3/8)

(29)

Spring (piston B)

(74)

O-ring

(30)

Piston (B,D)

(75)

2nd speed spool S

(31)

Cylinder liner gasket

(76)

2nd speed spring S

(32)

Oil seal

(77)

2-speed switching spool

(33)

Ball bearing

(78)

Hex socket bolt

(34)

Shaft

(79)

2nd speed pipe joint

(35)

Steel ball

(80)

Hex socket bolt

(36)

Variable swash-plate

(81)

Anticavitation body

(37)

Piston, ASSY (A)

(82)

Anti-caviation spool

(38)

Retainer plate

(83)

Anticavitation spring

(39)

Retainer holder

(84)

Orifice (0.6)

(40)

(85)

Anticavitation spring P

(41)

Cylinder block

(86)

Poppet

(42)

Spring washer

(87)

O-ring

(43)

Spring (CY)

(88)

O-ring

5 RY9212182HYS0065US0

3-S49

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(1) Gear Case Disassembly Gear Case Disassembly 1. Insert the spring pin. • Tools to use: Tap in punch 4 mm (0.2 in.) and hammer (5) Spring pin RY9212182HYS0159US0

2. Attach the cover removal tool and knock it upwards to remove the cover. IMPORTANT • After removing the cover, detach the spring pin from the cover. • Tool to use: Cover removal tool (3) Cover RY9212004HYS0043US0

If a cover removal tool is not available • Detach the two plugs and attach an eyebolt. • Put the rod through the eyebolt holes. • Knock upwards on both sides of the bar and remove the cover. • Tools to use: Eyebolt, round bar (3) Cover RY9212004HYS0044US0

3. Remove the drive gear. (10) Drive gear RY9212004HYS0045US0

4. Remove the holder and sub-assembly. Components of the holder & sub-assembly (11) Planetary gear A (12) Needle bearing

(13) Collar (14) Holder RY9212004HYS0046US0

3-S50

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. Remove the sun gear. (17) External circlip

(18) Sun gear RY9212004HYS0047US0

6. Drain off any gear oil. NOTE • If there is no gear oil, skip this step. RY9212004HYS0048US0

7. Remove the thrust plate B2. • Tool to use: snap ring pliers (16) Thrust plate B2 RY9212004HYS0049US0

8. Remove the planetary gear B, needle bearing, collar and the throust plate B2 . (22) Thrust plate B2 RY9212004HYS0050US0

9. Remove the set screws (M8 Sealock) (two places). • Tool to use: M4 hex wrench (23) Ring nut

(26) Set screw (M8 Sealock) RY9212004HYS0051US0

3-S51

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

10. Remove the ring nut. • Tool to use: Ring nut fastening jig (e) Ring nut fastening jig RY9212004HYS0052US0

11. Remove the gear case from the flange holder. (6) Gear case

(28) Flange holder RY9212004HYS0053US0

12. Remove the floating seal from the gear case side. • Tool to use: Slotted screwdriver (25) Floating seal RY9212004HYS0054US0

13. Remove the floating seal from the flange holder side. • Tool to use: Slotted screwdriver (25) Floating seal

(28) Flange holder RY9212004HYS0055US0

14. Remove the balls. (132 balls) IMPORTANT • Do not lose any of the balls. • If you leave just one of the balls in place, the bearing cannot be removed, so keep close track of the balls. (8) Ball RY9212004HYS0056US0

3-S52

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

15. Use a press to remove the angular bearing. RY9212004HYS0057US0

(2) Motor Disassembly Motor Disassembly 1. Remove the anticavitation unit. Remove the plug, anticavitation spring and anticavitation spool in order. • Tool to use: M8 hex socket (73) Plug (GPF3/8) (82) Anti-caviation spool

(83) Anticavitation spring RY9212182HYS0124US0

2. Remove the plug, anticavitation spring P and poppet. • Tool to use: M8 hex socket (85) Anticavitation spring P

(86) Poppet RY9212182HYS0125US0

3. Remove the anticavitation body. IMPORTANT • Replace O-rings with new ones during reassembly. • Tool to use: M6 hex socket (87) O-ring

(88) O-ring RY9212182HYS0126US0

3-S53

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Remove the 2-speed switch. Remove, in order, the plug, the 2nd speed joint, the 2nd speed spool, the 2nd speed spring S, and the 2-speed switching spool. • Tool to use: Socket wrench 22 mm (0.87 in.) Socket wrench 8 mm (0.3 in.)

2-speed Switch Components (73) Plug (GPF3/8) (74) O-ring (75) 2nd speed spool S

(76) 2nd speed spring S (77) 2-speed switching spool (79) 2nd speed pipe joint RY9212182HYS0049US0

5. Remove the counterbalance valve. Remove the plug. IMPORTANT • There is little room for the socket wrench, so be careful not to let it slip. • Tool to use: Socket wrench 36 mm (1.4 in.) RY9212182HYS0050US0

6. Remove the pressure spring, the spring washer, and the counterbalance plunger. (60) Spring washer

(65) Counterbalance plunger RY9212182HYS0051US0

Valve components (57) Plug (59) Compression spring (60) Spring washer (65) Counterbalance plunger (73) Plug (GPF3/8)

(75) 2nd speed spool S (76) 2nd speed spring S (77) 2-speed switching spool (79) 2nd speed pipe joint RY9212182HYS0127US0

3-S54

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

7. Remove the bolts and lift up the body with the plastic hammer. Insert a flathead screwdriver into the gap and strike the body with the hammer from the opposite direction and remove. IMPORTANT • Be very careful because the screwdriver may scratch the baseplate if inserted with great force. • Tools to use: Plastic hammer, slotted screwdriver RY9212182HYS0052US0

8. Remove the 14 springs (NB). (49) Spring (NB) RY9212090HYS0075US0

9. While pressing down on the brake piston with a rag, blow air through the brake release oil passage hole and remove the brake piston. CAUTION • Be careful because if you blast air into the passage, the brake piston may come flying out. • The brake release oil passage is a small hole between the bolts - please check carefully. RY9212090HYS0076US0

10. Rotate the assembly platform through 90 degrees and remove the friction plate, cylinder block and sub-assembly. (38) Retainer plate (39) Retainer holder (40) Pin

(37) Piston ASSY (41) Cylinder block (46) Friction plate RY9212182HYS0187US0

11. Turn the assembly platform back to its original position and remove the piston and (2nd speed) assembly. (29) Spring (piston B)

(30) Piston (B,D) RY9212090HYS0077US0

3-S55

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

12. Remove the shaft and ball bearing. (32) Oil seal (33) Ball bearing

(34) Shaft RY9212090HYS0078US0

13. Turn the assembly platform and remove the oil seal. IMPORTANT • If you did not take out the ball bearings when removing the shaft, take them out now together with the shaft. (28) Flange holder

(32) Oil seal RY9212004HYS0068US0

(3) Gear Case Assembly Gear Case Assembly 1. Set the angular bearing in the gear case and install it with a press. RY9212004HYS0069US0

2. After installing, check to make sure the groove (a) around the circumference of the bearing comes right to the center. (a) Circumference groove RY9212004HYS0070US0

3. Put the 132 balls in. (8) Ball RY9212004HYS0071US0

3-S56

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Install the plug. • Tool to use: Hex wrench 4 mm (0.2 in.) Tightening torque

Plug

9.8 to 14.7 N·m 1.0 to 1.5 kgf·m 7.23 to 10.80 lbf·ft

(7) Plug (R1/8) RY9212182HYS0160US0

5. Set the floating seal installation tool (a) on the gear case. (6) Gear case

(a) Floating seal installation tool RY9212004HYS0073US0

6. Grease the O-ring and set the floating seal on the gear case. (25) Floating seal RY9212182HYS0188US0

7. Install the seal in the gear case with the floating seal installation tool (b). (b) Floating seal installation tool (pusher) RY9212004HYS0075US0

8. Apply a little gear oil on the sliding surface of the floating seal. (4 places, every 90º) (25) Floating seal RY9212004HYS0076US0

3-S57

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. Assemble the plug with sealing tape wrapped around it, on the flange holder. • Tool to use: Hex wrench 4 mm (0.2 in.) Tightening torque

Plug (27)

8.8 to 10.7 N·m 0.9 to 1.1 kgf·m 6.5 to 7.9 lbf·ft

NOTE • If new parts are used, sealing tape is not needed. (27) Plug (NPTF1/16, MEC) RY9212182HYS0161US0

10. Set the flange holder on the assembly platform. Set the floating seal installation tool (c) on the flange holder. (c) Floating seal installation tool guide (flange holder) RY9212004HYS0078US0

11. Grease the O-ring and set the floating seal on the flange holder. (25) Floating seal RY9212182HYS0189US0

12. Install the floating seal in the flange holder with the floating seal installation tool. (b) Floating seal installation tool (pusher) RY9212004HYS0080US0

13. Apply a little gear oil on the sliding surface of the floating seal. (4 places, every 90º) (25) Floating seal RY9212182HYS0190US0

3-S58

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

14. Install the ring nut. • Tool to use: Ring nut fastening jig Tightening torque

156.8 N·m 16 kgf·m 115.6 lbf·ft

Nut

(e) Ring nut fastening jig RY9212182HYS0162US0

15. Strike the perimter of the gear case with a hammer (4 places, 90° apart) Rotate the gear case by hand to seat the angular bearing. • Tool to use: plastic hammer (6) Gear case RY9212004HYS0083US0

16. Assemble the ring nut set srews (2 places). • Tool to use: Hex wrench 4 mm (0.2 in.) Tightening torque

Set screw (26)

(23) Ring nut

12.3 to 14.2 N·m 1.25 to 1.45 kgf·m 9.1 to 10.4 lbf·ft (26) Set screw (M8 Sealock) RY9212182HYS0163US0

17. Install the collar, needle bearing and planetary gear B on the thrust plate B2. (19) Planetary gear B RY9212004HYS0085US0

18. Install the sun gear. (17) External circlip

(18) Sun gear RY9212004HYS0086US0

3-S59

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

19. Install the holder and assemble the collar, needle bearing and planetary gear A on it. IMPORTANT • Make sure the projecting surface is facing upwards.

(11) Planetary gear A (12) Needle bearing

(13) Collar (14) Holder RY9212004HYS0087US0

20. Measure the distance between the edge of the holder and the gear case. This is measurement A (A). Measure the distance between the gear case tooth surface and the gear case. This is measurement B (B). • Tool to use: depth gauge • Subtract measurement B (B) from measurement A (A) to calculate measurement C. Select the appropriate plate to suit the value of measurement C. Measurement C

Plate thickness

0.65 to 1.10 mm (0.020 to 0.043 in.)

1.6 mm (0.063 in.)

1.10 to 1.80 mm (0.043 to 0.071 in.)

2.3 mm (0.091 in.)

1.80 to 2.35 mm (0.071 to 0.093 in.)

3.0 mm (0.12 in.) RY9212182HYS0164US0

21. Install the selected thrust plate. (9) Thrust plate RY9212004HYS0089US0

3-S60

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

22. Assemble the cover fitted with the O-ring. IMPORTANT • Apply grease to the O-ring. • Align the gear case hole with the cover hole when assembling the cover. (3) Cover

(4) O-ring RY9212004HYS0090US0

23. Insert the spring pin. (4 places) • Tool to use: hammer IMPORTANT • The split in the spring pin must face sideways. (5) Spring pin

(a) Spring pin split positioning RY9212004HYS0091US0

24. Turn the assembly platform through 90°and put in gear oil. Fill with gear oil until the oil flows out of the inspection port and then insert the plug. • Tool to use: Hex wrench 8 mm (0.3 in.) Tightening torque

Amount of gear oil

49.0 to 58.8 N·m 5.0 to 6.0 kgf·m 36.2 to 43.3 lbf·ft

Plug

Factory Spec

600 cc RY9212182HYS0165US0

3-S61

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(4) Motor Assembly Motor Assembly 1. Tap the oil seal into the oil seal installation tool. IMPORTANT • Make sure that the oil seal is facing in the right direction. • Apply grease to the lip and circumference of the seal . • Tool to use: Oil seal installation tool (32) Oil seal

(a) Diameter 42 mm (1.7 in.) (b) Diameter 34.8 mm (1.37 in.) (g) Oil seal installation tool RY9212182HYS0166US0

2. Install the piston and assembly (2nd speed). IMPORTANT • The spring (piston B) comes out easily, so apply some grease to it. • Press the piston B down and make sure it moves smoothly. (29) Spring (piston B) (30) Piston (B,D)

(A) Correct (B) Incorrect RY9212090HYS0081US0

3. Install the shaft and swash-plate in order. IMPORTANT • Make sure the piston assembly moves smoothly. (34) Shaft

(36) Swash-plate RY9212090HYS0082US0

3-S62

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Install the three pins in the cylinder block. IMPORTANT • Grease the pins before installing them. (40) Pin

(41) Cylinder block RY9212004HYS0096US0

5. Install the retainer holder. (39) Retainer holder

(41) Cylinder block RY9212004HYS0097US0

6. Install the cylinder block, sub-assembly and friction plate. IMPORTANT • Turn the assembly platform sideways. (46) Friction plate RY9212004HYS0098US0

7. Check and make sure that the cylinder block's sliding surface sinks below the edge of the holder. IMPORTANT • Turn the assembly platform upright. (A) Holder (flange) mating surface (B) Cylinder block sliding surface

(a) 2.5 to 4.6 mm (0.099 to 0.180 in.) RY9212182HYS0167US0

3-S63

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. Install the brake piston. IMPORTANT • Apply grease to the O-ring. (47) O-ring (50) O-ring

(a) Position of brake piston anti-rotation hole. (b) 35° (c) 55° RY9212182HYS0053US0

9. Install the ball bearing, valve plate and O-rings on the counterbalance body. IMPORTANT • Make sure the valve plate is facing the right way. • Apply grease to prevent detachment of the valve plate. • Apply grease to the O-ring. (55) Plate (56) Ball bearing

(67) O-ring RY9212182HYS0054US0

10. Install the counterbalance body. • Tool to use: Hex wrench 8.0 mm (0.3 in.) Tightening torque

Hex socket bolt (78)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

IMPORTANT • Make sure the base plate does not fall off. • Tighten the hex socket bolts in a criss-cross pattern. (68) Counterbalance body

(78) Hex socket bolt RY9212182HYS0055US0

11. Install the compression spring and the plug. • Tool to use: Socket wrench 36 mm (1.4 in.) Tightening torque

(57) Plug

Plug (57)

235 to 245 N·m 24 to 25 kgf·m 174 to 180 lbf·ft (59) Compression spring RY9212182HYS0056US0

3-S64

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

12. Assemble the 2-speed switching spool, the compression spring, and the 2nd speed spool S. IMPORTANT • The spools should slide smoothly by themselves. • Make sure that the spools are facing in the right direction. • Apply hydraulic oil to the spools. • Make sure that the all components are correctly located and facing in the right direction. (75) 2-speed switching spool (76) 2nd speed spring S

(77) 2nd speed spool S RY9212182HYS0057US0

13. Install the plug and adapter. • Tool to use: Socket wrench 8.0 mm (0.3 in.) Socket wrench 22 mm (0.87 in.) Tightening torque

49.0 to 58.8 N·m 5 to 6 kgf·m 36.2 to 43.3 lbf·ft

Plug (74)

(73) Plug (GPF3/8) (74) O-ring (75) 2-speed switching spool

(76) 2nd speed spring S (77) 2nd speed spool S (79) 2nd speed pipe joint RY9212182HYS0058US0

14. Install the body (anti-cavitation). IMPORTANT • There are many O-rings, so be careful not to forget to install any of them. • Tool to use: M6 hex socket

Tightening torque

Hex socket bolt (80)

(80) Hex Socket Bolt

23.5 to 27.5 N·m 2.4 to 2.8 kgf·m 17.4 to 20.2 lbf·ft

(81) Body (Anti-Cavitation) RY9212182HYS0059US0

15. Install the spool (anti-cavitation) and spring (anti-cavitation) . IMPORTANT • Apply hydraulic oil to the entire spool. • The spool itself slides smoothly. (82) Spool (Anti-Cavitation)

(83) Spring (Anti-Cavitation) RY9212182HYS0060US0

16. Install the two plugs. • Tool to use: M8 hex socket

Tightening torque

Plug (73)

9.8 to 14.7 N·m 1.0 to 1.5 kgf·m 7.2 to 10.8 lbf·ft

(73) Plug RY9212182HYS0061US0

3-S65

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

17. Assemble the poppet, anticaviation spring P and plug (GPF 3/8). • Tool to use: M8 hex socket Tightening torque

9.8 to 14.7 N·m 1.0 to 1.5 kgf·m 7.2 to 10.8 lbf·ft

Plug (73)

(73) Plug (GPF3/8) (85) Anticavitation spring P

(86) Poppet RY9212182HYS0128US0

[3] SPECIAL TOOLS

No.

Part name

(a)

Floating seal installation tool [Guide (housing)]

(b)

Floating seal installation tool (pusher)

(c)

Floating seal installation tool [Guide (for flange holder)]

(d)

Cover removal tool

(e)

Ring nut socket

(f)

Oil seal installation tool RY9212182HYS0168US0

3-S66

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(a) Floating seal installation tool [Guide (housing)] A

17 mm (0.67 in.)

12 mm (0.47 in.)

5 mm (0.2 in.)

15 °

198 mm (7.80 in.)

179.6 mm (7.063 in.)

170.5 mm (6.713 in.)

1 mm (0.04 in.) bevel

Ra=6.3a RY9212182HYS0169US0

(b) Floating seal installation tool (pusher) A

22 mm (0.87 in.)

17 mm (0.67 in.)

5 mm (0.2 in.)

170.3 mm (6.705 in.)

168.5 mm (6.634 in.)

F G

7.0 mm (0.28 in.) 156 mm (6.14 in.)

208 mm (8.19 in.)

1 mm (0.04 in.) bevel

Ra=6.3a RY9212182HYS0170US0

20 mm (0.79 in.)

3 mm (0.1 in.)

17 mm (0.67 in.)

15 °

198 mm (7.80 in.)

179.4 mm (7.063 in.)

170.5 mm (6.713 in.)

1 mm (0.04 in.) bevel

Ra=6.3a RY9212182HYS0171US0

(d) Cover removal tool A B C D E

80 mm (3.1 in.) 13 mm (0.51 in.) 60 mm (2.4 in.) R3/8 12.5 mm (0.492 in.)

M12 × P1.25

25 mm (0.98 in.)

315 mm (12.4 in.)

2 mm (0.08 in.) bevel

5 mm (0.2 in.) bevel

(1) Tempered RY9212182HYS0172US0

3-S67

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(e) Ring nut socket A

12.7 mm (0.50 in.)

152 mm (5.98 in.)

146 mm (5.75 in.)

8 to 16 mm (0.32 to 0.62 in.)

90 mm (3.5 in.)

14 mm (0.55 in.)

56 mm (2.2 in.)

9 mm (0.4 in.)

(1) Weld RY9212182HYS0173US0

(f) Oil seal installation tool A

110 mm (4.33 in.)

12 mm (0.47 in.)

11 mm (0.43 in.)

2 mm (0.08 in.)

42.0 mm (1.7 in.)

34.8 mm (1.37 in.)

19.8 mm (0.78 in.)

30 °

16.0 mm (0.63 in.)

30 mm (1.2 in.) RY9212182HYS0174US0

3-S68

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

6. HYDRAULIC CYLINDER [1] HYDRAULIC CYLINDER DISASSEMBLY / ASSEMBLY PROCEDURES (1) Hydraulic Cylinder Components Boom Cylinder

No.

Part Name

Q'ty

No.

Part Name

Q'ty

(1)

Cylinder tube ASSY

(13)

Spacer

(2)

Piston rod ASSY

(14)

Cushion seal

(3)

Bushing

(15)

Collar

(4)

Bushing

(16)

O-ring

(5)

Cylinder head

(17)

Backup ring

(6)

Bushing

(18)

Piston

(7)

U-ring

(19)

Seal ring ASSY

(8)

Wiper ring

(20)

Slide ring

(9)

O-ring

(21)

Set screw

(10)

Backup ring

(22)

Steel ball

(11)

O-ring

(23)

Cushion bearing

(12)

Holder

(24)

Grease nipple

1 RY9212182HYS0236US0

3-S69

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Disassembly Procedures Cylinder Disassembly 1. Drain the oil from inside the cylinder, and fasten the cylinder bottom in a vice across the bolt width. RY9212001HYS0427US0

2. Place an anti-rotation device in one position of the cylinder head. (5) Cylinder head RY9212182HYS0266US0

3. Use a wrench (hook) or wrench (key) to loosen the cylinder head. While loosening the cylinder head screw, remove the cylinder head. (5) Cylinder head RY9212182HYS0267US0

4. Pull out the piston rod assembly together with the cylinder head, and place on a block. IMPORTANT • Check whether or not the pipe cap has been removed. • Place an oil receptacle under the port on the cylinder head. • Draw the piston rod assembly out, keeping it horizontal, to avoid dropping it and causing damage to parts immediately after it is withdrawn. (2) Piston rod ASSY

(5) Cylinder head RY9212182HYS0268US0

5. Fasten the piston rod assembly (2) in a vice across the bolt width and use a cushioning material. IMPORTANT • Place the rod on a block of wood. (2) Piston Rod ASSY RY9212001HYS0431US0

3-S70

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

6. Remove the set screw , and remove the steel ball. IMPORTANT • The set screw is caulked in two locations. Use a hand drill or similar device to remove the caulking, then loosen the set screw . • After removing, use a hand tap (M8 × 1.25) to carry off the piston side. • If the set screw is damaged on removal, replace it with a new one. (21) Set Screw (22) Steel Ball

(a) Drill RY9212182HYS0269US0

7. Use a wrench (socket wrench) on the hexagonal nut section of the piston, and loosen it. If a large amount of torque is required, prepare a dynamic wrench with hydraulic jack - hydraulic cylinder. (18) Piston RY9212182HYS0270US0

8. Remove the piston, cushion bearing and cylinder head in this order. (3) Cylinder head (12) Holder

(18) Piston (23) Cushion bearing RY9212182HYS0271US0

3-S71

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. Remove the slide ring by hand, split the seal ring by tapping it with a flat tip screwdriver (a), and remove. Remove the O-ring with a spatula. IMPORTANT • Do not use seals once removed. (19) Seal Ring, O-Ring (20) Slide Ring

(a) Slotted Screwdriver RY9212182HYS0272US0

10. Remove the O-ring and backup ring on the cylinder head. IMPORTANT • If removal is difficult, use a screwdriver, taking care not to damage the cylinder head. • Do not re-use seals that have been removed. (5) Cylinder head (9) O-ring

(10) Backup ring (11) O-ring RY9212182HYS0273US0

11. Lift the U-ring with a screwdriver, and remove it from the cylinder head. IMPORTANT • Do not re-use seals that have been removed. (5) Cylinder head

(7) U-ring RY9212182HYS0274US0

12. Remove the wiper ring. The wiper ring is press-fitted. Strike the rubber part with a tool, such as a screwdriver, to tap it out. IMPORTANT • Do not re-use seals that have been removed. (8) Wiper ring RY9212182HYS0275US0

3-S72

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

13. Using the jigs (A) (H), push out the bushing with a press. IMPORTANT • Do not use seals once removed. (5) Cylinder head (6) Bushing

(A) Tool (H) Tool RY9212182HYS0276US0

(3) Assembly Procedures Precautions on Assembly Replacing Seals All seals must be replaced when disassembling the cylinder. Replacing O-rings Thoroughly clean the mounting groove before fitting the backup ring and O-ring. Take care over the backup ring location. Apply grease or hydraulic fluid to the backup ring and O-ring, for smoothness of assembly. If not sufficiently lubricated, O-rings may become twisted during assembly, resulting in oil leakage. RY9212001HYS0444US0

Cylinder Head Assembly 1. Use press-fitting tool (A) to press-fit the bushing (4). IMPORTANT • Apply hydraulic fluid beforehand to the cylinder head inner surface. Also check that there is no unevenness due to scratching, etc., of the bushing after press fitting. (5) Cylinder head (6) Bushing

(A) Tool RY9212182HYS0277US0

U-ring Assembly 1. Fit the U-ring assembly jig (B) on the cylinder head. (5) Cylinder head

(B) Tool RY9212182HYS0278US0

3-S73

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Coat the U-ring with hydraulic oil, install the U-ring on the cylinder head, and push the U-ring into the installation groove, using the U-ring assembly jig (C). IMPORTANT • Be sure to install the U-ring in the right direction. • The U-ring should be softened by previously immersing it in hot water (at about 90°C) for 5 to 10 minutes. (5) Cylinder head (6) Bushing (7) U-ring

RY9212182HYS0279US0

Wiper ring assembly 1. Apply hydraulic oil to the wiper ring. Place the tool (D) on the metal ring part of the wiper ring, and use a press to insert it. (5) Cylinder head (8) Wiper ring

(D) Tool RY9212182HYS0280US0

Seal assembly 1. Assemble the O-ring and backup ring coated with hydraulic oil on the cylinder head. (6) Bushing (7) U-ring (8) Wiper ring

(9) O-ring (10) Backup ring RY9212182HYS0281US0

Piston assembly 1. Install the O-ring for the seal ring assembly. Apply hydarulic oil to the O-ring. (18) Piston

(19) O-ring RY9212182HYS0282US0

3-S74

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Quickly install the seal ring for the sealing assembly using the tools(E) (F). (18) Piston (19) Seal ring, O-ring

(E) Tool (F) Tool RY9212182HYS0283US0

3. After installing the seal ring assembly, quickly pass through the correcting tool (G) for correction. (G) Tool RY9212001HYS0452US0

4. To facilitate installation of the two slide rings , first roll them tight (see photo left) before installing. (18) Piston

(20) Slide ring RY9212182HYS0284US0

Piston rod assembly 1. Fasten the piston rod in a vice, apply hydraulic fluid to the seal section of the cylinder head, and install the piston rod. IMPORTANT • Take care so that the lip of the wiper ring and U-ring does not catch on the stepped section. (2) Piston rod

(5) Cylinder head RY9212182HYS0285US0

3-S75

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Fit the holder and cushion bearing coated with hydraulic oil, to the piston rod. (In the case of the boom cylinder) IMPORTANT • Make sure that the cushion bearing is assembled in the right direction. (2) Piston rod (12) Holder

(23) Cushion bearing RY9212182HYS0286US0

3. Fit the piston to the piston rod. (2) Piston Rod

(18) Piston RY9212182HYS0287US0

4. Tighten the piston. IMPORTANT • Tighten the piston to the specified torque. (18) Piston RY9212182HYS0288US0

5. Insert the steel ball in the piston. (18) Piston

(22) Steel Ball RY9212182HYS0289US0

6. Tighten the set screw. (21) Set Screw RY9212182HYS0290US0

3-S76

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

7. Use a punch to caulk in two locations on the circumference of the piston. (18) Piston (21) Set Screw (22) Steel Ball

a : Punch b : Caulking RY9212182HYS0291US0

8. Hold the cylinder tube horizontally in a vice, and insert the piston rod which has been coated with hydraulic oil. (1) Cylinder tube

(2) Piston rod RY9212001HYS0465US0

9. Use a wrench (hook) or wrench (key) to tighten the cylinder head. (5) Cylinder head RY9212182HYS0292US0

10. Firmly bend the lock washer into the cylinder head groove. RY9212001HYS0467US0

3-S77

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM Item Tube outer diameter / inner diameter / rod diameter

Notes 96 mm - 80 mm - 45 mm (3.8 in. - 3.1 in. - 1.8 in.)

Stroke

545 mm (21.5 in.)

Max compressed length Boom

885 mm (34.8 in.)

Piston torque

1140 N·m (116.2 kgf·m, 840.8 lbf·ft)

Head torque

490 N·m (50 kgf·m, 361 lbf·ft)

Piston screw size

55 mm (2.2 in.)

Manufacturer's name

Yanagizawa Seiki

Tube outer diameter / inner diameter / rod diameter

Arm

91 mm - 75 mm - 45 mm (3.6 in. - 3.0 in. - 1.8 in.)

Stroke

590 mm (23.2 in.)

Max compressed length

905 mm (35.6 in.)

Piston torque

800 to 850 N·m (81.6 to 86.6 kgf·m, 590 to 627 lbf·ft)

Head torque

750 to 800 N·m (76.5 to 81.6 kgf·m, 553 to 590 lbf·ft)

Piston screw size

M36 × P3.0

Manufacturer's name

KUBOTA Seiki

Tube outer diameter / inner diameter / rod diameter

Bucket

M36 × P3.0

Piston spanner face-to-face width

80 mm - 65 mm - 40 mm (3.1 in. - 2.6 in. - 1.6 in.)

Stroke

516 mm (20.3 in.)

Max compressed length

811 mm (31.9 in.)

Piston torque

620 to 660 N·m (63.2 to 67.3 kgf·m, 457 to 487 lbf·ft)

Head torque

390 to 430 N·m (39.8 to 43.8 kgf·m, 288 to 317 lbf·ft)

Piston screw size

M30 × P2.0

Manufacturer's name

KUBOTA Seiki

Tube outer diameter / inner diameter / rod diameter

96 mm - 80 mm - 40 mm (3.8 in. - 3.1 in. - 1.6 in.)

Stroke

408.5 mm (16.08 in.)

Max compressed length Swing

692.5 mm (27.26 in.)

Piston torque

620 to 660 N·m (63.2 to 67.3 kgf·m, 457 to 487 lbf·ft)

Head torque

800 to 850 N·m (81.6 to 86.6 kgf·m, 590 to 627 lbf·ft)

Piston screw size

M30 × P2.0

Manufacturer's name

KUBOTA Seiki

Tube outer diameter / inner diameter / rod diameter

105 mm - 90 mm - 45 mm (4.13 in. - 3.5 in. - 1.8 in.)

Stroke

154 mm (6.06 in.)

Max compressed length Blade

492 mm (19.4 in.)

Piston torque

800 to 850 N·m (81.6 to 86.6 kgf·m, 590 to 627 lbf·ft)

Head torque

900 to 950 N·m (91.8 to 96.9 kgf·m, 664 to 701 lbf·ft)

Piston screw size

M36 × P3.0

Manufacturer's name

KUBOTA Seiki

Tube outer diameter / inner diameter / rod diameter

70 mm - 55 mm - 30 mm (2.8 in. - 2.2 in. - 1.2 in.)

Stroke

345 mm (13.6 in.)

Max compressed length Angle

570 mm (22.4 in.)

Piston torque

326 N·m (33.2 kgf·m, 240 lbf·ft)

Head torque

275 N·m (28 kgf·m, 203 lbf·ft)

Piston screw size

M24 × P2.0

Piston spanner face-to-face width

41 mm (1.6 in.)

Manufacturer's name

KYB

3-S78

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

RY9212182HYS0063US0

Cylinder Inspection 1. Warping of the piston rod 1. Put the piston rod by itself on the V blocks. 2. Set a dial gauge on the center of the rod. 3. Rotate the piston rod and read the measurements on the dial gauge. Warpage equals 1/2 the difference in the readings. 4. Replace any rod that exceeds its usage limit. • Factory spec for warpage : 0.05 mm (0.002 in.) ≥ • Usage limit for warpage : 0.5 mm (0.02 in.) 2. Wear in the rod and bushings 1. Measure the diameter of the outside of the piston rod and that of the inside of the bushing in the cylinder head and calculate the gap.

Factory specification

Allowable limits

Rod size

Gap

25 to 40 mm 0.99 to 1.5 in.

0.25 mm ≥ 0.01 in. ≥

45 to 75mm 1.8 to 3.0 in.

0.30 mm ≥ 0.01 in. ≥

25 to 40 mm 0.99 to 1.5 in.

0.4 mm 0.02 in.

45 to 75mm 1.8 to 3.0 in.

0.5 mm 0.02 in.

3. Wear in the tube and piston ring 1. Measure the inside diameter of the cylinder tube. 2. Measure the outside diameter of the piston ring and calculate the clearance.

Factory specification

Allowable limits

Rod size

Gap

60 mm ≥ 2.4 in. ≥

0.05 to 0.30 mm 0.002 to 0.010 in.

65 to 115 mm 2.6 to 4.53 in.

0.05 to 0.35 mm 0.002 to 0.010 in.

120 mm ≤ 4.72 in. ≤

0.05 to 0.40 mm 0.002 to 0.020 in.

60 mm ≥ 2.4 in. ≥

0.60 mm 0.02 in.

65 to 115 mm 2.6 to 4.53 in.

0.70 mm 0.03 in.

120 mm ≤ 4.72 in. ≤

0.80 mm 0.03 in. RY9212182HYS0175US0

3-S79

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

7. PILOT VALVE (CONTROL) [1] USED PARTS OF PILOT VALVE HYDRAULIC HOSE Used parts of pilot valve hydraulic hose Left P/V Used part

Hose tape color

Swivel left

Gray

Arm dump

Black

Swivel right

Light blue

Arm crowd

Blue

P port

66666666

T port

55555555

Right P/V Used part

Hose tape color

Bucket crowd

White

Boom down

Yellow

Bucket dump

Red

Boom up

Green

P port

44444444

T port

33333333

(a) (b) (c) (d) (e) (f)

P port Port 3 Port 2 T port Port 1 Port 4 RY9212032HYS0055US0

3-S80

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] PILOT VALVE (CONTROL) DISASSEMBLY/ASSEMBLY PROCEDURES (1) Pilot Valve Components No.

Part Name

Q'ty

(1)

Casing

(2)

Plate

(3)

Spool

(4)

Plug

(5)

Pushrod

(6)

Pushrod

(7)

Seal

(8)

O-Ring

(9)

Spring seat

(10)

Spring seat

(11)

Washer 2

(12)

Spring (Ports 1 and 3)

(13)

Spring (Port 2)

(14)

Spring (Port 4)

(15)

Spring

(16)

Spring

(17)

Joint

(18)

Round plate

(19)

Adjusting nut

(20)

Lock nut

(21)

Lever

(22)

Handle

(23)

Spring Pins

(24)

Boot

1 RY9212032HYS0056US0

(2) Disassembly Disassembly Procedures CAUTION • All of the parts are precisely made, so be very careful in handling them and taking care not to drop or hit parts against each other. • If you hit a part too hard while working on it, it may result in burrs or other damage, thus preventing installation as well as oil leaks and/or compromised performance, so be careful when handling parts. • If parts are left disassembled or left partway disassembled, humidity or foreign matter may cause rust, so if interrupting the work is unavoidable, take precautions to protect the parts from rust and dust. RY9212001HYS0476US0

1. Clamp the pilot valve in a vise. IMPORTANT • When clamping it in a vise, use a sheet of copper to prevent scratching the pilot valve. (1) Casing (18) Nut (Disc)

(19) Nut (Adjustment) RY9212182HYS0192US0

3-S81

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

2. Use two wrenches on the nuts (adjustment and disc) to remove them. • Tools to use : 22 mm and 32 mm (0.87 in. and 1.3 in.) wrenches (19) Nut (Adjustment) RY9212182HYS0176US0

3. Mark the relationship of holes to the casing. RY9212001HYS0479US0

4. After mounting tool (B) on the U-joint, use tool (A) to turn the U-joint counterclockwise and loosen it.

CAUTION • When removing the U-joint, take care that it does not pop off. (17) U-Joint

(A) Tool (B) Tools (2) RY9212182HYS0193US0

3-S82

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. Remove the plate. (2) Plate RY9212001HYS0481US0

6. Slip a slotted screwdriver in the groove in the plug to remove the plug. CAUTION • Take care so the plug does not go flying. • Take care not to damage it by exerting force unevenly. • If a burr is formed, use a whetstone to remove it. (4) Plug RY9212182HYS0194US0

7. Remove the reducing valve ASSY (a) and the return spring. IMPORTANT • Tag the springs to positively ID which port they go to. (12) Spring (13) Spring (14) Spring

(a) Reducing Valve ASSY

RY9212182HYS0195US0

3-S83

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. To disassemble the reducing valve, press the spring seat in and while compressing the secondary pressure spring, shift the spring seat to the side and remove it from the spool via the larger hole. IMPORTANT • Be careful not to scratch the surface of the spool. • Do not depress the spring seat 6.0 mm (0.2 in.) ≤. • Do not disassemble the reducing valve unless there is a problem with it. Components of the Reducing Valve (3) Spool (9) Spring Seat (10) Spring Seat

(11) Metal Washer 2 (13) Spring RY9212182HYS0177US0

9. Remove the plug from the pushrod. (4) Plug (5) Pushrod

(6) Pushrod (8) O-Ring RY9212182HYS0196US0

10. Remove the O-ring and seal from the plug. IMPORTANT • Use a mini slotted screwdriver. • Be careful not to scratch the inside surface of the plug.

Components of the Plug (4) Plug (6) Pushrod

(7) Seal (8) O-Ring RY9212182HYS0197US0

3-S84

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(3) Assembly Assembly Procedures CAUTION • Prepare your workbench in the same way as for disassembly. • Follow the same general precautions as in the disassembly. • When assembling the parts, remove all bits of metal or foreign matter from all the parts and make sure there aren't any burrs or dings on the parts. • Replace used O-rings with new ones. • Take care not to damage the O-rings when installing them. RY9212001HYS0001US0

1. Make sure there aren't any burrs or scratches inside the casing. RY9212001HYS0487US0

2. Install the return spring in the casing. IMPORTANT • Install it in the same position as before disassembly. (12) Spring (13) Spring

(14) Spring RY9212182HYS0198US0

3. Install the metal washer, spring and spring sea in order to the spool. IMPORTANT • Do not depress the spring seat 6.0 mm (0.2 in.) or more. • Be careful not to scratch the spool. (3) Spool (9) Spring Seat (10) Spring Seat

(11) Metal Washer 2 (13) Spring RY9212182HYS0178US0

4. Install the reducing valve ASSY. After installing it, make sure the spool moves smoothly. IMPORTANT • Install it in the same position as before disassembly. RY9212001HYS0490US0

3-S85

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. Install the O-ring on the plug. (4) Plug

(8) O-Ring RY9212182HYS0199US0

6. Install the seal on the plug. IMPORTANT • Be careful that the seal faces the right direction. • Apply hydraulic oil on the circumference and lip of the seal. (4) Plug (5) Pushrod (6) Pushrod

(7) Seal (8) O-Ring RY9212182HYS0200US0

7. Install the plug on the pushrod. IMPORTANT • Apply hydraulic oil to the pushrod. (4) Plug (5) Pushrod

(6) Pushrod (8) O-Ring RY9212182HYS0201US0

8. Install the plug ASSY into the case. If the return spring is too stiff, use the plate to install the ASSY. IMPORTANT • Be careful not to scratch the hole of the casing by prying on the spool. • Take care so the plug ASSY does not go flying. RY9212001HYS0494US0

3-S86

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. Install the plate. (2) Plate RY9212001HYS0495US0

10. Install the U-joint.

Tightening torque

U-joint

44 to 50 N·m 4.5 to 5.1 kgf·m 32.5 to 36.8 lbf·ft

(A) Tool RY9212182HYS0179US0

11. Install the nut (disc) on the universal joint. Tighten it until it touches all four pushrods equally. CAUTION • If you tighten it too far, the mechanism will not function properly when the lever is in neutral, so be careful to adjust the nut to the correct position. (18) Nut (Disc) RY9212182HYS0202US0

12. Tighten the nut (adjustment). Put the wrench on the bolt width of the disc and tighten the nut. • Tools to use : 22 mm (0.87 in.) wrench (or socket), 32 mm (1.3 in.) wrench Tightening torque

Nut (adjustment)

63.7 to 73.5 N·m 6.5 to 7.5 kgf·m 47.0 to 54.2 lbf·ft RY9212182HYS0180US0

13. Apply grease to the rotating parts of the universal joint and to the ends of the pushrods. RY9212001HYS0499US0

3-S87

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(4) U-joint Tightening Tool A

29 mm (1.1 in.)

B C

26.5 mm (1.04 in.) 23.5 mm (0.925 in.) (nut width)

19 mm (0.75 in.)

13 mm (0.51 in.)

69 mm (2.7 in.)

54 mm (2.1 in.)

50 mm (2.0 in.)

46 mm (1.8 in.)

25 mm (0.98 in.)

17 mm (0.67 in.)

23 mm (0.91 in.)

27 mm (1.1 in.)

31 mm (1.2 in.)

Hole H 6 mm (0.2 in.)

Axle n 6 mm (0.2 in.)

16 mm (0.63 in.)

15.5 mm (0.61 in.)

0.5 × 15 mm (0.02 × 0.59 in.)

12.5 mm (0.492 in.)

9.5 mm (0.37 in.)

11.6 mm (0.457 in.)

6.5 mm (0.26 in.)

0.5 mm (0.02 in.) bevel

R 13 mm (0.51 in.)

R 5.8 mm (0.23 in.)

R 4.5 mm (0.18 in.)

(1) Bushing

(a) U-Joint Tightening Tool, Detailed Schematic (b) Bushing, Detailed Schematic (c) Assembled U-Joint RY9212182HYS0181US0

3-S88

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

8. PILOT VALVE (TRAVEL) Pilot Valve (Travel) Exploded View (1) Valve assembly (PV, travel) (2) Plug (G1/4) (3) Pedal assembly (travel left) (4) Pedal (travel 2) (5) Pedal assembly (travel right) (6) Headed pin (7) Flat metal washer (8) Snap pin (9) Bolt (M10 × 25) (10) Bolt (M10 × 25) (11) Lever (travel, right) (12) Lever (travel, left) (13) Bolt (M8 × 20) (14) Snap pin 8 (15) Flat metal washer (16) Headed pin (17) Damper (HST)

Bolt (10)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Bolt (13)

17.7 to 20.6 N·m 1.8 to 2.1 kgf·m 13.0 to 15.2 lbf·ft

Tightening torque

RY9212182HYS0293US0

(1) (2) (3) (4)

Valve Assembly (PV, Travel) Pipe Joint Filter Assembly Straight Pipe Joint RY9212182HYS0064US0

3-S89

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[1] PILOT VALVE (TRAVEL) DISASSEMBLY/ASSEMBLY PROCEDURES

No.

Name of part

No.

Name of part

No.

Name of part

(1)

Shim (t = 0.1 mm, 0.04 in.)

(12)

Cover

(23)

Hex set screw

(2)

Shim (t = 0.2 mm, 0.08 in.)

(13)

Cam

(24)

Flat metal washer

(3)

Seat

(14)

Spring

(25)

Rivet screw

(4)

Sleeve

(15)

Spring

(26)

Parallel pin

(5)

Pusher

(16)

Collar

(27)

Ball

(6)

(17)

Bushing

(28)

O-Ring

(7)

Nameplate

(18)

Plug

(29)

O-Ring

(8)

Shim (t = 0.2 mm, 0.08 in.)

(19)

Collar

(30)

O-Ring

(9)

Shim (t = 0.1 mm, 0.04 in.)

(20)

Flanged plug

(31)

O-Ring

(10)

Spool

(21)

Hex socket bolt

(32)

Expander

(11)

Body

(22)

Hex socket bolt

(33)

Pusher ASSY RY9212001HYS0503US0

3-S90

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(1) Disassembly Procedures 1. Remove the boot. (17) Bushing RY9212001HYS0504US0

2. Remove the two hex socket set screws. CAUTION • Note that there are two hex set screws per hole. • Tool to use : M3 hex socket (23) Hex Set Screw RY9212001HYS0505US0

3. Remove the pin. • Tool to use : Hammer and pin punch (6) Pin

(12) Cover RY9212001HYS0506US0

4. Remove the cam. (13) Cam RY9212001HYS0507US0

5. Remove the hex socket bolt. • Tool to use : M8 hex socket (22) Hex Socket Bolt RY9212001HYS0508US0

3-S91

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

6. Remove the cover. (12) Cover RY9212001HYS0509US0

7. Remove the pusher ASSY. IMPORTANT • There is a shim on the edge of the pusher ASSY. • If it comes off, return it to the top of the sleeve. (12) Cover

(33) Pusher ASSY RY9212001HYS0510US0

8. Remove the O-rings. • Tool to use : Slotted screwdriver (28) O-Ring RY9212182HYS0203US0

9. Mark the positioning of the body hole and the spool ASSY. RY9212001HYS0512US0

10. Spool ASSY from the body (a) Remove the spring. (11) Body (15) Spring

(a) Spool ASSY RY9212001HYS0513US0

3-S92

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

11. Remove the O-ring from the body. (11) Body

(30) O-Ring RY9212001HYS0514US0

12. Remove the shim. (1) Shim RY9212001HYS0515US0

13. Clamp the spool in a vice and remove the hex socket bolt. IMPORTANT • Use a copper plate in the vice to prevent it from scratching the spool. • Be careful not to overtighten the vice as this will deform the spool. • Tool to use : M3 hex socket (21) Hex Socket Bolt RY9212001HYS0516US0

Components of the Spool ASSY (1) Shim (4) Sleeve (8) Shim (10) Spool

(14) Spring (16) Collar (21) Hex Socket Bolt (24) Flat Metal Washer RY9212001HYS0517US0

14. Remove the flanged plug. • Tool to use : M6 hex socket (11) Body

(20) Flanged Plug RY9212001HYS0518US0

3-S93

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

15. Remove the seat. • Tool to use : M5 hex socket (3) Seat RY9212001HYS0519US0

16. Remove the ball. • Tool to use : Magnet (27) Ball RY9212001HYS0520US0

(2) Assembly Procedures 1. Insert the ball in the body. (11) Body

(27) Ball RY9212001HYS0521US0

2. Apply Loctite to the threads of the seat. • Tool to use : Loctite 262 (3) Seat RY9212001HYS0522US0

3. Install the seat.

Tightening torque

Seat (3)

14.7 N·m 1.5 kgf·m 10.8 lbf·ft

• Tool to use : M5 hex socket RY9212182HYS0182US0

3-S94

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

4. Install the flanged plug.

Tightening torque

Flanged plug (20)

24.5 N·m 2.5 kgf·m 18.1 lbf·ft

• Tool to use : M6 hex socket (20) Flanged Plug RY9212182HYS0183US0

5. Clamp the spool in a vice and install the flat metal washer. IMPORTANT • Be careful to follow the order of installation. • Use a copper plate in the vice to prevent it from scratching the spool. • Be careful not to overtighten the vice as this will deform the spool. (10) Spool

(24) Flat Metal Washer RY9212001HYS0525US0

6. Install the shim. IMPORTANT • Be careful to follow the order of installation. (8) Shim RY9212001HYS0526US0

7. Install the spring. IMPORTANT • Be careful to follow the order of installation. (14) Spring RY9212001HYS0527US0

8. Install the sleeve. IMPORTANT • Be careful to follow the order of installation. (4) Sleeve RY9212001HYS0528US0

3-S95

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. Install the collar. IMPORTANT • Be careful to follow the order of installation. (16) Collar RY9212001HYS0529US0

10. Apply Loctite to the threads of hex socket bolt. • Thread locking compound (Loctite 242) (21) Hex Socket Bolt RY9212001HYS0530US0

11. Install the hex socket bolt.

Tightening torque

Hex socket bolt (21)

4.9 N·m 0.5 kgf·m 3.6 lbf·ft

• Tool to use : M3 hex socket (21) Hex Socket Bolt RY9212182HYS0184US0

12. Install the shim. IMPORTANT • Install the same number of shims as were disassembled. (1) Shim

(4) Sleeve RY9212001HYS0532US0

13. Install the O-ring. (11) Body

(30) O-Ring RY9212001HYS0533US0

3-S96

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

14. Install the spring. (15) Spring RY9212001HYS0534US0

15. Install the spool ASSY (a). IMPORTANT • Install in the same holes in the body as during disassembly. (11) Body (15) Spring

(a) Spool ASSY RY9212001HYS0535US0

16. Install the O-ring in the cover. (28) O-Ring RY9212001HYS0536US0

17. Install the pusher ASSY. (12) Cover

(33) Pusher ASSY RY9212001HYS0537US0

18. Install the cover.

Tightening torque

Cover (12)

22.6 N·m 2.3 kgf·m 16.7 lbf·ft

• Tool to use : M8 hex socket (12) Cover

(22) Hex Socket Bolt RY9212182HYS0185US0

3-S97

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

19. Apply grease to the pusher ASSY balls. (33) Pusher ASSY RY9212001HYS0539US0

20. Apply grease to the sliding part of the pin and install it. (6) Pin (12) Cover

(13) Cam RY9212001HYS0540US0

21. Install the hex socket set screws. IMPORTANT • Note that each one has two hex socket set screws.

Tightening torque

Hex set screw (23)

9.8 N·m 1.0 kgf·m 7.2 lbf·ft

• Tool to use : M3 hex socket (23) Hex Set Screw RY9212182HYS0186US0

22. Install the boot. (17) Bushing RY9212001HYS0542US0

NOTE • Use shims (1), (2), (8) or (9) as needed. It is not a problem if there are no shims at all or a lot of shims. • Shims are used as needed, so be sure to install them where there were used before. RY9212001HYS0543US0

3-S98

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

9. UNLOAD VALVE [1] UNLOAD VALVE ASSEMBLY PROCEDURES

Unload valve installation bolt (9)

39.2 to 45.1 N·m 4.0 to 4.6 kgf·m 28.9 to 33.3 lbf·ft

Accumulator (3)

48.1 to 55.9 N·m 4.9 to 5.7 kgf·m 35.5 to 41.2 lbf·ft

Tightening torque

(1) (2) (3) (4) (5) (6)

Unload valve ASSY Bracket Accumulator Elbow joint Pipe joint (L, G1/4-G1/4) Pipe joint (L, G3/8-G3/8)

(7) Plug (G1/4) (8) Pipe joint ASSY (T, F2-F3) (9) Bolt (M10 × 20) (a) 30 ° (b) 45 ° RY9212182HYS0085US0

3-S99

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] UNLOAD VALVE DISASSEMBLY/ASSEMBLY PROCEDURES (1) Unload Valve Components

No.

Name of part

Q'ty

Notes

No.

Name of part

Q'ty

(1)

Plug

(12)

Solenoid

(2)

Plunger

(13)

Screw adjustment

(3)

Spring

(14)

Flanged plug

(4)

Spring

(15)

Hex socket bolt

(5)

Spool

(16)

Hex socket bolt

(6)

Plunger

(17)

Hex nut

(7)

Spring

(18)

Rivet screw

(8)

Nameplate

(19)

O-Ring

(9)

Cover

(20)

O-Ring

(10)

Plug

(21)

O-Ring

(11)

Body

(22)

O-Ring

Notes

RY9212001HYS0584US0

3-S100

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Disassembly / Assembly Procedures Precautions during Disassembly / Assembly The clearances of the body and spool are calculated to fit. Be sure to check their positions during disassembly and re-install them in the same positions during assembly. The same with the solenoid, reinstall it in the same position and orientation. RY9212001HYS0585US0

Solenoid Valve Disassembly 1. Remove the two hex socket nuts per solenoid and remove the solenoid. IMPORTANT • Take care that the pushrods do not fall out of the solenoids. Tightening torque

Hex socket bolt (15)

3.92 N·m 0.4 kgf·m 2.89 lbf·ft

• Tool to use : M4 hex socket (12) Solenoid (15) Hex socket bolt

(23) Pushrod RY9212182HYS0110US0

2. Remove the O-rings. IMPORTANT • During assembly, install the O-rings to the solenoids and then install them to the body. • Apply grease to the O-rings. (19) O-Ring RY9212001HYS0587US0

3. Remove the flanged plug.

Tightening torque

Flanged plug (14)

26.5 N·m 2.7 kgf·m 19.5 lbf·ft

• Tool to use : M6 hex socket (14) Flanged plug RY9212182HYS0111US0

4. Remove the springs and spools. IMPORTANT • During assembly, apply hydraulic oil to the spool. (4) Spring

(5) Spool RY9212001HYS0589US0

3-S101

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

5. Remove the hex nut and the adjustment screw.

Tightening torque

15.7 N·m 1.6 kgf·m 11.6 lbf·ft

Hex nut (17)

• Tool to use : M17 wrench (13) Screw adjustment

(17) Lock nut RY9212182HYS0112US0

6. Remove the cover.

Tightening torque

Hex socket bolt (16)

3.92 N·m 0.4 kgf·m 2.89 lbf·ft

• Tool to use : M4 hex socket (9) Cover

(16) Hex socket bolt RY9212182HYS0113US0

7. Remove the plug. (10) Plug RY9212001HYS0592US0

8. Remove the O-ring. (21) O-Ring RY9212001HYS0593US0

9. Remove the spring. (7) Spring RY9212001HYS0594US0

3-S102

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

10. Remove the plunger. IMPORTANT • During assembly, apply hydraulic oil to the plunger. • Tool to use : Magnet (6) Plunger RY9212001HYS0595US0

Check Valve Disassembly 11. Remove the plug.

Tightening torque

Plug (1)

21.0 N·m 2.1 kgf·m 15 lbf·ft

• Tool to use : M6 hex socket (1) Plug RY9212182HYS0114US0

12. Remove the spring. (3) Spring RY9212001HYS0597US0

13. Remove the plunger. IMPORTANT • During assembly, apply hydraulic oil to the plunger. (2) Plunger RY9212001HYS0598US0

14. Remove the flanged plug.

Tightening torque

Flanged plug (14)

26.5 N·m 2.7 kgf·m 19.5 lbf·ft

• Tool to use : M6 hex socket (14) Flanged plug RY9212182HYS0115US0

Perform the procedures in reverse to assemble the parts. RY9212001HYS0017US0

3-S103

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

10. TPSS VALVE [1] TPSS VALVE (1) Specifications

(1) Port 1 (PV Side) (2) Port 2 (PV Side) (3) Port 3 (PV Side)

(4) Port 4 (PV Side) (5) Port A (C/V Side)

(6) Port B (C/V Side) (7) Port C (C/V Side)

(8) Port D (C/V Side) (9) Bolt (M10 x 20) RY9212182HYS0086US0

(1) (2) (3) (4) (5) (6)

Lever Hex Socket Bolt Snap Pin Rod (TPSS) Split Pin Lever (TPSS)

(7) Bracket (8) Bolt (M10 × 25) (A) ISO (B) JD RY9212182HYS0131US0

3-S104

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(2) Components

No. (1)

Name of part

Q'ty

Notes

Housing

(2)

Shaft

(3)

Washer

(4)

Spring Pins

JIS B 2808 D4*16 L-A

(5)

Snap ring

JIS B 2804 for shaft 28

(6)

Oil Seal

VR 38A BM1220A0

(7)

O-ring

JIS B 2401 1A P26

(8)

O-ring

JIS B 2401 1A P32

(9)

Hex socket bolt (M6x16)

(10)

Lever

NI Plating

RY9212050HYS0073US0

3-S105

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

11. AUX SOLENOID VALVE [1] AUX SOLENOID VALVE REMOVAL AND INSTALLATION

(1) (2) (3) (4) (5) (6) (7)

Proportional valve ASSY Bracket Pipe joint (L, G1/4-G1/4) Filter, ASSY Straight pipe joint Straight pipe joint Pipe joint (T, G2)

(a) 45 ° A : AUX1 only B : Angle spec.

RY9212182HYS0132US0

3-S106

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] AUX SOLENOID VALVE HOSE ROUTING

(1) To Control Valve (2) To Swivel Motor (3) To Control Valve

(4) To Angle Solenoid Valve (5) To Angle Solenoid Valve (6) To Oil Tank

(A) AUX1 Angle Spec. (B) AUX1 Spec.

(a) 20 ° (b) 45 ° RY9212182HYS0133US0

[3] AUX SOLENOID VALVE DISASSEMBLY PROCEDURES Tightening torque

7 ± 1 N·m 0.7 ± 0.1 kgf·m 5.2 ± 0.7 ft·lbs

Hex bolt (1)

NOTE • The adjustment nut on top of the solenoid is set in advance when shipped from the factory. • Service port flow. Do not adjust the feel with this nut. (Adjust according to the digital panel procedures.) (1) Hex bolt (M5 × 0.8) (2) Proportional control solenoid

(3) O-Ring (4) Case RY9212095HYS0071US0

3-S107

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

12. ANGLE SOLENOID VALVE [1] ANGLE SOLENOID VALVE ASSEMBLY PROCEDURES

(1) (2) (3) (4)

Angle Solenoid Valve Bracket Bolt (M10 × 20) Straight Pipe Joint

(5) Filter Assy. (6) Pipe Joint (a) 30 ° RY9212182HYS0134US0

3-S108

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

13. THIRD LINE VALVE ASSEMBLY [1] THIRD LINE VALVE ASSEMBLY COMPONENTS

(1) (2) (3) (4) (5) (6) (7) (8)

Body Spool Spring Pins O-ring (04811-10180) O-ring (04810-00160) O-ring (04810-00200) O-ring (04811-10200) O-ring (04612-50180)

(9) Lever (10) Washer (11) Spring Pins (a) A-C port oil passage lever position (b) A-B port oil passage lever position RY9212182HYS0116US0

3-S109

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

14. ROUTING OF HYDRAULIC HOSES [1] HYDRAULIC HOSE SPECIFICATIONS (1) Hydraulic Hose Total Length (a) Total Length RY9212004HYS0147US0

(2) Types of Connector Fittings (Screw) (a) Straight Type Parallel Female Thread for Pipe (Male 30 ° Seat) (b) 45 ° Type Parallel Female Thread 45 ° for Pipe (Male 30 ° Seat) (c) 90 ° Type Parallel Female Thread 90 ° for Pipe (Male 30 ° Seat) (d) Quick Coupler Type RY9212182HYS0087US0

3-S110

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[2] DELIVERY HOSE ROUTING

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6321-2

24.5 MPa 250 kgf/cm2 3550 psi

1/2

1970 mm 77.56 in.

White

G1/2 Straight

–

Pump - C/V P1

(2)

RC788-6322-2

24.5 MPa 250 kgf/cm2 3550 psi

1/2

1940 mm 76.38 in.

Green

G1/2 Straight

–

Pump - C/V P2

(3)

RC788-6323-1

20.5 MPa 209 kgf/cm2 2970 psi

1/2

2160 mm 85.04 in.

Pink

G1/2 Straight

–

Pump - C/V P3

(20)

RC788-6451-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

810 mm 31.9 in.

Gray

G3/8 Straight

–

C/V - Swivel motor Swivel left

(21)

RC788-6452-1

20.5 MPa 209 kgf/cm2 2970 psi

1/2

790 mm 31.1 in.

Aqua

G3/8 Straight

–

C/V - Swivel motor Swivel right

(37)

RC788-6324-1

7.0 MPa 70 kgf/cm2 1000 psi

3/8

500 mm 19.7 in.

Yellow

G3/8 Straight

–

Pump P4 - Line filter

(38)

RC788-6325-1

7.0 MPa 70 kgf/cm2 1000 psi

3/8

1290 mm 50.79 in.

–

G3/8 · 90°

G3/8 Straight

Corrugated

Line filter - Unload valve

No.

Part number

(1)

Guard

Point used

RY9212182HYS0135US0

3-S111

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[3] FRONT HOSE ROUTING

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6411-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1635 mm 64.37 in.

Green

G3/8 Straight

(5)

RC788-6412-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1805 mm 71.06 in.

Yellow

(6)

RC788-6413-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1890 mm 74.41 in.

(7)

RC788-6414-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

(8)

RC788-6415-1

24.5 MPa 250 kgf/cm2 3550 psi

(9)

RC788-6416-1

(26)

No.

Part number

Guard

Point used

(4)

G3/8 Straight

Plastic tube

C/V - Boom CYL Lift boom

G3/8 Straight

Plastic tube

C/V - Boom CYL Lower boom

Black

G3/8 Straight

Plastic tube

C/V - Boom back Arm CYL dump

1895 mm 74.61 in.

Blue

G3/8 Straight

Plastic tube

C/V - Boom back Arm CYL rake

3/8

1930 mm 75.98 in.

Red

G3/8 Straight

Plastic tube

C/V - Boom back Bucket CYL dump

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1885 mm 74.21 in.

White

G3/8 Straight

Plastic tube

C/V - Boom back Bucket CYL rake

RC788-6491-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

2095 mm 82.48 in.

Pink

G1/2 Straight

Plastic tube

C/V - Pipe SP discharge side

(27)

RC788-6492-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

1910 mm 75.2 in.

Green

G1/2 Straight

Plastic tube

Third line valve - Pipe SP return side

(28)

RC788-6493-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

570 mm 22.4 in.

Green

G1/2 Straight

G1/2 · 90°

–

Third-line valve - C/V AUX1 return RY9212182HYS0136US0

3-S112

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[4] ROUTING OF TRAVEL, SWIVEL AND BLADE HOSES (ANGLE BLADE)

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6441-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

700 mm 27.6 in.

Blue

G1/2 Straight

(17)

RC788-6442-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

690 mm 27.2 in.

Red

(18)

RC788-6443-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

680 mm 26.8 in.

(19)

RC788-6444-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

(20)

RC788-6451-1

20.5 MPa 209 kgf/cm2 2970 psi

(21)

RC788-6452-1

(24)

No.

Part number

Guard

Point used

(16)

G1/2 · 90°

–

C/V - R/J Travel Left forward

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Left backward

Green

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Right forward

690 mm 27.2 in.

Yellow

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Right backward

3/8

810 mm 31.9 in.

Gray

G3/8 Straight

–

C/V - Swivel motor Swivel left

20.5 MPa 209 kgf/cm2 2970 psi

1/2

790 mm 31.1 in.

Aqua

G3/8 Straight

–

C/V - Swivel motor Swivel right

RC788-6471-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

850 mm 33.5 in.

Pink

G3/8 Straight

G3/8 · 90°

Protective tube

C/V - R/J Blade up

(25)

RC788-6472-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

910 mm 35.8 in.

Green

G3/8 Straight

G3/8 · 90°

Protective tube

C/V - R/J Blade down

(35)

RC788-6473-1

20.5 MPa 209 kgf/cm2 2970 psi

1/4

1030 mm 40.6 in.

Greenish yellow

G1/4 Straight

G1/4 · 90°

–

3-S113

C/V - R/J Angle left

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM Hose No.

Part number

(36)

RC788-6385-1

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

20.5 MPa 209 kgf/cm2 2970 psi

1/4

930 mm 36.6 in.

Orange

G1/4 Straight

G1/4 · 90°

Guard

Point used

–

C/V - R/J Angle right RY9212182HYS0137US0

3-S114

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[5] DRAIN HOSE ROUTING

Hose No.

Part number

(1)

Point used

Max. operating pressure

I.D.

O.D.

Total length

RC788-6453-1

3.5 MPa 36 kgf/cm2 510 psi

15.9 mm 0.626 in.

23.5 mm 0.925 in.

650 mm 25.6 in.

C/V T1 - Swivel motor make-up

(2)

RC611-6457-2

–

26 mm 1.0 in.

30 mm 1.2 in.

460 mm 18.1 in.

C/V T1 - Swivel motor make-up [Protective tube]

(3)

RC788-6454-1

1.5 MPa 15 kgf/cm2 220 psi

13 mm 0.51 in.

19.8 mm 0.78 in.

360 mm 14.2 in.

Swivel motor drain - Hydraulic oil tank (bottom front pipe)

(4)

RC788-6459-1

–

22 mm 0.87 in.

26 mm 1.0 in.

240 mm 9.45 in.

Swivel motor drain - Hydraulic oil tank (bottom front pipe) [Protective tube]

(5)

RC411-6455-1

1.5 MPa 15 kgf/cm2 220 psi

13.0 mm 0.51 in.

19.8 mm 0.78 in.

480 mm 18.9 in.

S/J Drain - Hydraulic oil tank (bottom rear pipe)

(6)

RC788-6448-1

–

22 mm 0.87 in.

26 mm 1.0 in.

210 mm 8.27 in.

S/J Drain - Hydraulic oil tank (bottom rear pipe) [Protective tube]

(7)

RC788-6351-1

0.78 MPa 8 kgf/cm2 110 psi

25 mm 0.98 in.

37 mm 1.5 in.

Molded hose

(8)

RC788-6362-1

3.5 MPa 36 kgf/cm2 510 psi

15.9 mm 0.626 in.

23.5 mm 0.925 in.

145 mm 5.71 in.

Hydraulic oil tank - Return pipe

(9)

RC788-6362-1

3.5 MPa 36 kgf/cm2 510 psi

15.9 mm 0.626 in.

23.5 mm 0.925 in.

145 mm 5.71 in.

Return pipe - Oil cooler (before)

(10)

RC788-6361-1

3.5 MPa 36 kgf/cm2 510 psi

15.9 mm 0.626 in.

23.5 mm 0.925 in.

1620 mm 63.78 in.

Third-line valve - Oil cooler (after)

(11)

RB238-6363-2

–

26 mm 1.0 in.

30 mm 1.2 in.

1000 mm 39.37 in.

Third-line valve - Oil cooler (after) [Protective tube]

Hydraulic oil tank - C/V T1

RY9212182HYS0138US0

3-S115

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[6] PILOT HOSE ROUTING (P)

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6326-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

680 mm 26.8 in.

C/V PP1 Nothing

G1/4 · 90°

(21)

RC788-6327-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1620 mm 68.78 in.

Nothing C/V-PP2

(22)

RC788-6328-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

740 mm 29.1 in.

(23)

RC788-6329-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

(34)

RC788-6324-1

7.0 MPa 70 kgf/cm2 1000 psi

(35)

RC788-6325-1

(36)

(38)

No.

Part number

Guard

Point used

(20)

G1/4 Straight

–

C/V (Pp1) - Swivel M (SM-P5) (P)

G1/4 Straight

Corrugated tube

Unload valve (P) C/V (Pp2)

Nothing C/V-PP1

G1/4 Straight

–

Unload valve - C/V [Pp1]

1400 mm 55.12 in.

Nothing 2S

G1/4 · 90°

G1/4 Straight

–

Unload valve - R/J (2-speed)

3/8

500 mm 19.7 in.

Yellow 1 - Nothing

G3/8 Straight

–

Pump (4) - Pilot filter

7.0 MPa 70 kgf/cm2 1000 psi

3/8

1290 mm 51.79 in.

–

G3/8 · 90°

G3/8 Straight

–

Pilot filter - Unload valve (P)

RC788-6385-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

570 mm 22.4 in.

AC-P SM-P4

G1/4 · 90°

G1/4 Straight

–

A/C Solenoid valve Swivel M (SM-P4) (P)

RC788-6387-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1660 mm 65.35 in.

White

G1/4 Straight

G1/4 · 90°

–

A/C Solenoid valve Pump (Pc) RY9212182HYS0139US0

3-S116

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[7] PILOT HOSE ROUTING (DELIVERY)

(A) Angle spec. Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6331-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1600 mm 62.99 in.

66666666 - White SM-P2

G1/4 · 90°

(25)

RC788-6332-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1050 mm 41.34 in.

44444444 - White SM-P3

(26)

RC788-6335-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

380 mm 15 in.

(27)

RC788-6336-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

(39)

RC788-7581-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

No.

Part number

(24)

Guard

Point used

Quick

–

Steering P/V (left) Swivel M (SM-P2) (P)

G1/4 · 90°

Quick

–

Steering P/V (right) - Swivel M (SM-P3) (P)

TR-P Nothing

G1/4 · 90°

Quick

–

Travel P/V - Swivel M (SM-P1) (P)

1100 mm 43.31 in.

AX1-P SM-P6

G1/4 · 90°

G1/4 Straight

–

AUX1 Proportional valve - Swivel M (SM-P6) (P)

950 mm 37.4 in.

Nothing ANG-P

G1/4 · 90°

G1/4 Straight

–

Angle valve - AUX1 proportional valve (P) RY9212182HYS0140US0

3-S117

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[8] PILOT HOSE ROUTING (FRONT)

(To be continued)

3-S118

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued) Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

No.

Part number

Guard

Point used

(1)

RC788-6251-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

2130 mm 83.86 in.

Green 1 - Green 1

G1/4 · 90°

Quick

–

TPSS (A) - C/V [Lift boom]

(2)

RC788-6252-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

840 mm 33.1 in.

Yellow 1 - Yellow 1

G1/4 · 90°

Quick

–

TPSS (C) - C/V [Lower boom]

(3)

RC788-6259-2

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1370 mm 53.94 in.

Yellow 1 - Yellow 1

G1/4 · 90°

Quick

–

C/V (Lower boom) C/V (release lock) (Lock valve release)

(4)

RC788-6253-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

910 mm 35.8 in.

Black 1 Black 1

G1/4 · 90°

Quick

–

TPSS (D) - C/V [Dump arm]

(5)

RC788-6254-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1950 mm 76.77 in.

Blue 1 Blue 1

G1/4 · 90°

Quick

–

TPSS (B) - C/V [Rake arm]

(6)

RC788-6255-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

2360 mm 92.91 in.

Red 1 Red 1

G1/4 · 90°

Quick

–

Control P/V - C/V (Dump bucket)

(7)

RC788-6256-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1060 mm 41.73 in.

White 1 White 1

G1/4 · 90°

Quick

–

Control P/V - C/V (Rake bucket)

(8)

RC788-6257-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1940 mm 76.38 in.

Gray 1 Gray 1

G1/4 · 90°

Quick

–

Control P/V - C/V (swivel left)

(9)

RC788-6258-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

2560 mm 100.8 in.

Aqua 1 Aqua 1

G1/4 · 90°

Quick

–

Control P/V - C/V (swivel right)

(14)

RC788-6275-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

460 mm 18.1 in.

Green 1 - Nothing

G1/4 · 90°

Quick

–

Control P/V to TPSS (Raise boom)

(15)

RC788-6276-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

650 mm 25.6 in.

Yellow 1 - Nothing

G1/4 · 90°

Quick

–

Control P/V to TPSS (Lower boom)

(16)

RC788-6283-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1220 mm 48.03 in.

Black 1 Black 1

G1/4 · 90°

Quick

–

Control P/V to TPSS (Dump arm)

(17)

RC788-6284-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1260 mm 49.61 in.

Blue 1 Blue 1

G1/4 · 90°

Quick

–

Control P/V to TPSS (Rake arm) RY9212182HYS0141US0

3-S119

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[9] PILOT HOSE ROUTING (TRAVEL, AUX1 ANGLE BLADE)

(A) Angle spec. Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6265-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

2500 mm 98.43 in.

Blue 2 Blue 2

G1/4 · 90°

G1/4 Straight

–

Travel P/V to C/V (Left Fwd)

(11)

RC788-6266-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1360 mm 53.54 in.

Red 2 Red 2

G1/4 · 90°

G1/4 Straight

–

Travel P/V to C/V (Left Bwd)

(12)

RC788-6267-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

2570 mm 101.2 in.

Green 2 - Green 2

G1/4 · 90°

G1/4 Straight

–

Travel P/V to C/V (Right Fwd)

(13)

RC788-6268-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1300 mm 51.18 in.

Yellow 2 - Yellow 2

G1/4 · 90°

G1/4 Straight

–

Travel P/V to C/V (Right Bwd)

(18)

RC788-6271-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

470 mm 18.5 in.

Nothing Pink 2

G1/4 · 90°

G1/4 Straight

–

AUX1 Proportional valve - C/V (AUX1 Hi)

(19)

RC788-6272-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

460 mm 18.1 in.

Nothing Brown 2

G1/4 · 90°

G1/4 Straight

–

AUX1 Proportional valve - C/V (AUX1 Low)

(41)

RC788-7583-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

980 mm 38.6 in.

Pink 2 Nothing

G1/4 · 90°

G1/4 Straight

–

Angle valve - C/V (angle right)

(42)

RC788-7584-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1620 mm 68.78 in.

Yellowis h Green 2Nothing

G1/4 · 90°

G1/4 Straight

–

Angle valve - C/V (angle left)

No.

Part number

(10)

Guard

Point used

RY9212182HYS0142US0

3-S120

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

[10] PILOT HOSE ROUTING (DRAIN)

(A) Angle spec. Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC788-6341-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1470 mm 57.87 in.

55555555 - Nothing

Quick

(29)

RC788-6342-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1000 mm 39.37 in.

33333333 to Nothing

(30)

RC788-6345-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

900 mm 35.4 in.

(31)

RC788-6346-2

7.0 MPa 70 kgf/cm2 1000 psi

1/4

(32)

RC788-6356-1

7.0 MPa 70 kgf/cm2 1000 psi

(33)

RC788-6359-1

(37)

(40)

No.

Part number

Guard

Point used

(28)

G1/4 Straight

–

Control P/V (left) Oil tank (centre) (T)

G1/4 · 90°

Quick

–

Control P/V (right) Oil tank (bottom) (T)

TR-T Nothing

G1/4 · 90°

Quick

–

Travel P/V (right) Oil tank (top) (T)

320 mm 12.6 in.

AX1-T Nothing

G1/4 · 90°

G1/4 Straight

–

AUX1 Proportional valve - Oil tank (T)

1/4

300 mm 11.8 in.

BM-T Nothing

G1/4 · 90°

G1/4 Straight

–

C/V (Lock release drain) - Oil tank (T)

7.0 MPa 70 kgf/cm2 1000 psi

3/8

540 mm 21.3 in.

–

G3/8 · 90°

G3/8 Straight

–

Unload valve (T) Oil tank rear surface (T)

RC788-6386-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1140 mm 44.88 in.

AC-T Nothing

G1/4 · 90°

G1/4 Straight

–

A/C Solenoid valve - Oil tank (T)

RC788-7582-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1010 mm 39.76 in.

Nothing ANG-T

G1/4 · 90°

G1/4 Straight

–

Angle valve - AUX1 proportional valve (T) RY9212182HYS0143US0

3-S121

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

15. MEASURING THE PERFORMANCE OF HYDRAULIC DEVICES Main pump flow measurement Measurement preparation 1. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Connect a vacuum pump. 3. Attach a pressure gauge to the pump pressure detection port. 4. Connect a test hose between the pipe joint of the pump being measured and the IN side of the flow meter. 5. Join the detached hose and the test hose, and connect to the OUT side of the flow meter. 6. Remove the vacuum pump. 7. Start and idle the engine, and check that there is no oil leakage. Measurement 1. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Open the loading valve of the flow meter all the way and start the engine. Set the engine speed to maximum, gradually close the loading valve of the oil pressure tester, and measure the flow and engine speed at each pressure level. 3. Perform the measurement 3 times; take the average and use this as the measurement value. (Pump performance inspection procedure) The pump performance inspection involves placing a specified pressure load on the pump discharge side and performing measurement at a specified engine speed to check the volumetric efficiency.

1. The volumetric efficiency of the pump is proportional to the rotational speed and inversely proportional to the load pressure, so the engine speed is set to maximum this test. 2. Volumetric efficiency is the ratio between the discharge amount per revolution (cc/rev) at a specified load and the theoretical discharge amount (calculated value). The specified load is the main relief set pressure. 3. The measurement value of the discharge flow at the specified load must be corrected to one pump revolution because the rotational speed of the pump is reduced from its normal speed.

(1) (2) (3) (4) (5)

Pump pressure detection port P1 hose P2 hose P3 hose Adapter

(6) (7) (8) (9)

Test hose Flow meter Pump Control Valves RY9212182HYS0088US0

3-S122

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Measuring the main pump flow (when measuring the combined flow of P1 and P2) (1) (2) (3) (4) (5) (6) (7) (8)

Pump Control Valve Flow Meter Delivery Hose Test hose Joint Test Hose Pressure Gauge

Measurement preparation 1. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Follow the chapter Releasing Pressure in the Hydraulic System to release pressure in the hydraulic line. 3. Use the vacuum pump and attach a pressure gauge to the pressure test port. 4. Disconnect the P1 and P2 delivery hoses on the pump side and plug the disconnected hoses. 5. Connect a test hose to the P1 and P2 discharge ports and connect the flow meter on the IN side. (Use an adapter to combine the flows.) 6. Attach a branch adapter to the OUT side of the flow meter and connect the P1 and P2 delivery hoses that were plugged in step 1. 7. Remove the vacuum pump and bleed air from the pump, making sure there are no oil leaks in any of the lines. Measurement 1. Open the loading valve of the flow meter all the way and start the engine. 2. Bring the hydraulic oil temperature to 50 ± 5 °C (122 ± 9 °F). 3. Set the engine to maximum RPM. 4. Gradually close the flow meter's loading valve until it reaches the main relief pressure, then measure the oil flow and engine RPM at each pressure. 5. Take three measurements of the oil flow, determine the average and take that as the measured value. 6. Convert the measured value to what it would be with the engine at its rated RPM. RY9212182HYS0297US0

3-S123

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

AUX flow [Measurement Procedure] 1. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Follow the chapter Releasing Pressure in the Hydraulic System to release pressure in the hydraulic line. 3. Connect a vacuum pump. 4. Connect the AUX discharge (high-pressure side) and the IN side of the flow meter with a test hose. 5. Connect the OUT side of the flow meter and the AUX discharge (low-pressure side) with a test hose. 6. Remove the vacuum pump. 7. Open the loading valve of the flow meter all the way and start the engine. 8. Set engine speed to max. rpm and then carry out AUX operation. 9. Gradually close the flow meter loading valve and measure the oil flow at each pressure. 10. Perform the measurement 3 times; take the average and use this as the measurement value. [Measurement Conditions] • Engine speed : Max. rpm • Oil temperature : 50 ± 5 °C (122 ± 9 °F) IMPORTANT • Ensure that the oil flow direction and the input direction into the flow meter are correct. (1) Test Hose (2) Flow Meter

(A) AUX High-Pressure Side (B) AUX Low-Pressure Side RY9212182HYS0298US0

3-S124

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Pilot pressure Pilot 1 Primary Pressure Measuring Procedure 1. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Follow the chapter Releasing Residual Pressure in the Hydraulic System to release pressure from the hydraulic line. 3. Remove the plug (4) from the adapter's inspection port on the discharge side of the pump to be measured, and attach a pressure gage. 4. Start and idle the engine, and check that there is no oil leakage when the machine's lock lever is released. 5. Raise the engine speed to maximum rpm, and measure the pilot pressure under zero load. Perform the measurement 3 times; take the average and use this as the measurement value. Conduct the test at oil temperature 50 ± 5 °C (122 ± 9 °F). Pilot 1 Primary Pressure Adjustment Method 1. Loosen the relief valve lock nut (1) on the unload valve (3). Use a hexagonal wrench to turn the adjuster screw (2), and tighten the lock nut. 2. After adjusting, check the set pressure. Tightening torque

(1) (2) (3) (4)

Lock nut (1)

Lock nut Adjuster screw Unload valve Pump 4 pressure check port plug

15.7 N·m 1.6 kgf·m 11.6 lbf·ft (a) Pressure increase (b) Pressure decrease

RY9212182HYS0089US0

3-S125

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Pilot Secondary Pressure Measuring Procedure 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine. 2. In accordance with "Releasing Residual Hydraulic System Pressure" in this manual, release pressure from the hydraulic line. 3. Fit a T-joint to the pilot port on the control valve side to be measured, and attach a pressure gage. 4. Start and idle the engine, and after checking that there is no oil leakage. 5. Operate the measuring lever after raise engine speed to maximum rpm, and take the pilot pressure reading at full throttle. 6. Perform the measurement 3 times, take the average and use this as the measurement value. Conduct at oil temperature 50 ± 5 °C (122 ± 9 °F). RY9212182HYS0090US0 (1) Angle rod (2) Angle bottom (3) Swivel right (4) Swivel left (5) Swing rod (6) Swing bottom (7) Blade bottom (8) Blade rod (9) AUX return (10) AUX discharge (11) Arm bottom (12) Arm rod (13) Travel forward (14) Travel backward (15) Travel forward (16) Travel backward (17) Boom rod (18) Boom bottom (19) Bucket rod (20) Bucket bottom (21) P1 Port (22) P2 Port (23) P3 Port (24) T1 Port (25) T2 Port (26) Drain port (a) P1 Relief valve (b) P2 Relief valve (c) P3 Relief valve RY9212182HYS0091US0

3-S126

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Main relief valve pressure Main relief valve measuring procedure 1. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Remove the plug from the adapter's inspection port on the discharge side of the pump to be measured, and attach a pressure gage. 3. Start and idle the engine, and check that there is no oil leakage. 4. Slowly operate the control lever of the front operation to be measured, operate until the cylinder reaches the end of its stroke, then relieve. 5. Measure three times at maximum engine speed, and take the average value as the measurement. 6. Conduct the test at oil temperature 50 ± 5 °C (122 ± 9 °F). Main Relief Valve Adjustment Procedure 1. Loosen the relief valve lock nut. Use a hexagonal wrench to turn the adjuster screw, and tighten the lock nut. 2. Operate the lever at maximum engine speed, and check the pressure setting. Tightening torque

(1) (2) (3) (4) (5)

19.6 N·m 2.0 kgf·m 14.5 lbf·ft

Lock nut (4)

Pump 1 pressure check port plug Pump 2 pressure check port plug Pump 3 pressure check port plug Nut Adjustment screw

(a) Pressure increase (b) Pressure decrease

RY9212182HYS0092US0

(1) Angle rod (2) Angle bottom (3) Swivel right (4) Swivel left (5) Swing rod (6) Swing bottom (7) Blade bottom (8) Blade rod (9) AUX return (10) AUX discharge (11) Arm bottom (12) Arm rod (13) Travel forward (14) Travel backward (15) Travel forward (16) Travel backward (17) Boom rod (18) Boom bottom (19) Bucket rod (20) Bucket bottom (21) P1 Port (22) P2 Port (23) P3 Port (24) T1 Port (25) T2 Port (26) Drain port (a) P1 Relief valve (b) P2 Relief valve (c) P3 Relief valve RY9212182HYS0091US0

3-S127

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Measuring the Overload Relief Valve Pressure IMPORTANT • If it is necessary to check the overload relief pressure on this machine, measure the main relief pressure of each circuit (boom, arm, bucket, blade, AUX and angle) and if the main relief pressures are within factory specifications, the overload relief valve is judged to be normal. • If there is a problem, we recommend replacing the overload relief valve as an assembly. • If a measurement has to be made for some reason, the procedures is as follows. (1) Pressure Measuring Kit (2) Straight Pipe Joint (G3/8-G1/4) (3) Straight Pipe Joint (G1/2-G3/8) RY9212166HYS0153US0

[Measurement preparations] 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic lines. 3. Use the vacuum pump and disconnect the high pressure hose from the port where the overload relief valve to be measured is mounted and plug the hose. 4. Attach the pressure measuring kit to the disconnected port. 5. Remove the vacuum pump. [Measurement] 1. Increase pressure until the overload relief valve opens. 2. Measure the pressure three times, determine the average and take that as the measured value. CAUTION • When disconnecting the pressure measuring kit, take appropriate care in removing it as the line is pressurized. RY9212148HYS0329US0

Overload Relief Valve Layout Diagram (1) Angle rod (2) Angle bottom (3) Blade bottom (4) AUX return (5) AUX discharge (6) Arm bottom (7) Arm rod (8) Boom rod (9) Boom bottom (10) Bucket bottom (a) P1 Relief valve (b) P2 Relief valve (c) P3 Relief valve

RY9212182HYS0093US0

3-S128

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Pressure measurement kit for overload relief valve No.

Name of part

Number

(1)

Support

(2)

Pipe joint (M12-G2)

(3)

Bolt (M10 x 35)

(4)

Nut (M12)

(5)

Test hose

CAUTION • Use a test hose that can withstand pressure up to the measurement pressure. A : Nozzle Tester RY9212166HYS0103US0

(1) Support A

100 mm (3.94 in.)

50 mm (2.0 in.)

t = 2.3 mm (0.09 in.)

70 mm (2.8 in.)

15 mm (0.59 in.)

600 mm (23.6 in.)

2–11 mm (2–0.43 in.)

Material std.: STKR400 RY9212148HYS0337US0

(2) Pipe joint (M12-G1/4) A

47 mm (1.8 in.)

12 mm (0.47 in.)

15 mm (0.59 in.)

20 mm (0.79 in.)

10 mm (0.39 in.) ≤

12 mm (0.47 in.) ≤

8 mm (0.3 in.)

3 mm (0.1 in.)

18 mm (0.71 in.)

9.5 ± 0.2 mm (0.37 ± 0.01 in.)

19 +0, –0.35 mm (0.75 +0, –0.01 in.)

21.9 mm (0.86 in.)

M12 × 1.5

G1/4

0.52 rad (30 °) RY9212148HYS0309US0

3-S129

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Swivel relief valve pressure 1. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Remove the plug from the adapter's inspection port on the discharge side of the pump to be measured, and attach a pressure gauge. 3. Start and idle the engine, and check that there is no oil leakage. 4. Place the bucket against something robust, lock the machine so that it does not move, slowly operate the swivel lever from left to right and from right to left, and take the relief pressure reading at maximum engine speed. Perform the measurement 3 times; take the average and use this as the measurement value. Conduct the test at oil temperature 50 ± 5 °C (122 ± 9 °F). NOTE • When measuring at the relief valve pressure inspection port side of the swivel motor, the pressure is about 10% higher than the relief valve pressure setting. For more accurate measurement, attach the pressure gauge to the discharge port side of the swivel motor. (1) Pump 3 pressure check port plug

(2) Swivel right relief valve (3) Swivel left relief valve RY9212182HYS0094US0

Swivel motor drain volume 1. Before measuring, repeat swivel left and right operations to sufficiently warm up the swivel motor. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 3. Follow the chapter Releasing Residual Pressure in the Hydraulic System to release pressure from the hydraulic line. 4. Connect a vacuum pump. 5. Disconnect the swivel motor drain hose from the swivel motor, and insert a plug in the disconnected hose. 6. Connect the test hose (e.g., low-pressure polyvinyl hose) to the drain port on the swivel motor. 7. Remove the vacuum pump. 8. Operate the swivel lever at full stroke for one minute with the engine at maximum rpm, and while maintaining a uniform swivel rate, collect the hydraulic fluid from the drain hose in a receptacle and measure. 9. Take the measurement from right to left and left to right two to three times, and determine the average value. CAUTION • Before commencing measurement, make sure there are no persons or obstacles within the swivel range. (a) 1.0 m

(b) Drain port RY9212182HYS0095US0

3-S130

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Travel mode drain volume 1. Before measurement, turn on the travel motor and warm up sufficiently. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place the machine on flat hard ground, lower the bucket and the blade, and stop the engine. 3. Follow the chapter Releasing Residual Pressure in the Hydraulic System to release pressure from the hydraulic line. 4. Connect a vacuum pump. 5. Disconnect the travel motor drain hose from the travel motor, and insert a plug in the disconnected hose. 6. Connect the test hose (eg., low-pressure use polyvinyl hose) to the drain port on the travel motor side. 7. After disconnecting the vacuum pump, start the engine, jack up the machine and raise the crawler above ground level. CAUTION • Place safety blocks and supports under the jacked up machine to prevent it from dropping. 8. Rotate the crawler on the measurement side for one minute with the engine at maximum rpm, collect hydraulic fluid from the test hose in a receptacle and measure. Take the measurement from right to left and left to right two to three times, and determine the average value. CAUTION • For safety's sake, keep hands and feet out from under the crawler. RY9212004HYS0129US0

Swivel Block Performance 1. Before measuring, repeat swivel left and right operations to sufficiently warm up the swivel motor. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place soil or a weight of the specified weight (JIS heap × specific gravity 1.8) in the bucket. 3. The ground slope for measuring should be 20° and the machine should be set on the slope with the front equipment perpendicular to the sloping surface. 4. The front of the machine should have the arm cylinder fully compressed and the bucket cylinder fully extended, with the boom held on a straight line between the boom base pin and bucket pin. 5. Place markers on the circumference of the swivel bearing and track frame. 6. Start the engine, release the safety lock lever at idling rpm (lever down), and measure the slippage over one minute. 7. Take the measurement from right to left and left to right two to three times, and determine the average value. CAUTION • Before commencing measurement, make sure there are no persons or obstacles within the swivel range. RY9212182HYS0096US0

3-S131

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Travel block performance 1. Before measurement, turn on the travel motor and warm up sufficiently. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. For this measurement, set the machine on hard ground or concrete with a slope angle of 20°. 3. Stop the machine on the slope, and set the front equipment to travel attitude. 4. Place the travel lever in neutral and stop the engine. 5. Make marks on the track frame and crawler, and measure the slippage over ten minutes. RY9212182HYS0097US0

Hydraulic cylinder drift 1. Before measuring, repeat front equipment operations to fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Place soil or a weight of the specified weight (JIS heap × specific gravity 1.8) in the bucket, and set the machine on level ground. 3. The front equipment should have the arm cylinder fully compressed, the bucket cylinder fully extended, and the bucket bottom approximately 1.0 m above ground level. Note that the arm cylinder should return about 50 mm from the stroke end, and be outside the cushion range. 4. Stop the engine, and place marks on the boom, arm and bucket cylinder rods. 5. After ten minutes has elapsed, measure the boom cylinder compression, arm cylinder extension and bucket cylinder compression. (a) 1.0 m RY9212182HYS0098US0

Hydraulic Cylinder Operating Time Boom cylinder measurement 1. Before measuring, repeat front equipment operations to fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. The attitude for measurement should be with maximum compressed length of the arm cylinder and bucket cylinder. 3. Raise the engine speed to maximum rpm, operate the boom control lever to full stroke, and measure the time required from the bucket ground contact position (maximum down position) to maximum up position (position above ground). (Do not include cushion operating time) RY9212182HYS0099US0

3-S132

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Arm cylinder measurement 1. Before measuring, repeat front equipment operations to fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. With the engine at maximum rpm, operate the arm control lever to full stroke, and measure the time required for arm in and out. RY9212182HYS0100US0

Bucket cylinder measurement 1. Before measuring, repeat front equipment operations to fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. With the engine at maximum rpm, operate the bucket control lever to full stroke, and measure the time required for bucket rake and dump. RY9212182HYS0101US0

Swing cylinder measurement 1. Before measuring, repeat front equipment operations to fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. The front attitude should be with the arm cylinder fully compressed, bucket cylinder fully extended, and bucket bottom approximately 1 m above ground level. 3. At maximum engine rpm, perform a full throttle stroke swing from left to right and right to left, and measure the time required to achieve this. RY9212182HYS0102US0

Blade cylinder measurement 1. Before measuring, repeat front equipment operations to fully warm up each cylinder. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. The vehicle attitude for measurement should be jacked up by the front, assuring full stroke of cylinder, top to bottom. 3. With the engine at maximum rpm, operate the blade control lever to full stroke, and measure the time required for blade up and down operation. RY9212182HYS0103US0

Measurement of required swivel time 1. Before measuring, repeat left-right swivel operations to thoroughly warm up the swivel motor. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. The attitude for measurement should be with maximum extension of the boom cylinder, arm cylinder and bucket cylinder. 3. At maximum engine rpm, operate the swivel control lever at full stroke, and measure the time taken for three turns of the swivel unit. CAUTION • Before commencing measurement, make sure there are no persons or obstacles within the swivel range. RY9212182HYS0104US0

3-S133

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Travel speed 1. Before measuring, adjust the left and right crawlers to even tension, and operate the travel motor to thoroughly warm it up. Hydraulic oil temperature of 50 ± 5 °C (122 ±9 °F). 2. Measure travel performance in the travel attitude. 3. At maximum engine rpm, perform a 5 m run-up and 10 m forward run, and measure the time required. (a) Run-up (5 m)

(b) Measuring area (10 m) RY9212182HYS0105US0

Amount of travel drift 1. Before measuring, adjust the left and right crawlers to even tension, and operate the travel motor to thoroughly warm it up. Hydraulic oil temperature of 50 ± 5 °C (122 ± 9 °F). 2. Determine a 10 m travel course on firm, flat ground, and set the measuring attitude to travel attitude. 3. At maximum engine rpm, travel for 10 m, and measure the amount of drift (a). 4. Perform the measurement three times, backwards and forwards; determine the average value, and take this as the measured value. (a) Travel drift

(b) 10 m RY9212004HYS0139US0

3-S134

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Piston Pump Horsepower Control Graph (Measured on New Vehicle)

(1) P3 = 0.49 MPa (5.0 kgf/cm2, 71 psi)

(2) P3 = 19.6 MPa (200 kgf/cm2, 2840 psi)

(a) Discharge flow: q1 = q2 (cc/rev)

(b) Discharge pressure: P1 + P2 (MPa)

Pump Input RPM: 2200 rpm Gear pump pressure P3 = 0.49 MPa

Gear pump pressure P3 = 19.6 MPa

Pressure (MPa)

Delivery flow (cc/rev)

Pressure (MPa)

Delivery flow (cc/rev)

PA1 = 4.0

QA1 = 17.2

PB1 = 4.0

QB1 = 17.15

PA2 = 15.0

QA2 = 16.8

PB2 = 5.0

QB2 = 17.0

PA3 = 30.0

QA3 = 10.9

PB3 = 20.0

QB3 = 9.0

PA4 = 49.0

QA4 = 5.3

PB4 = 40.0

QB4 = 2.95

PB5 = 49.0

QB4 = 2.75

CAUTION • Measured values may vary depending on the machine. • This data is of values converted to the rated RPM. • The usage limit is 80% of the discharge volume. RY9212182HYS0299US0

3-S135

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

AUX discharge flow rate data (Measured on New Vehicle)

(a) Flow Rate (L/min)

(b) Pressure (MPa)

Pressure

MPa (kgf/cm2) [psi]

3.0 (30) [400]

5.0 (51) [730]

10 (100) [1400]

15 (150) [2200]

17.2 (175) [2490]

Flow Rate

L/min (U.S. gal.)

62 (16)

56 (15)

44 (12)

37 (9.8)

CAUTION • Measured values may vary depending on the machine. • This measurement data is of the values set for the maximum discharge flow rate. (limit = maximum) RY9212182HYS0300US0

3-S136

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Relief Pressure Table (Measured on New Vehicle) Item

U35-4

P1 Main relief pressure (aP1)

Notes

24.5 ± 0.5 MPa 250 ± 5 kgf/cm2 3550 ± 73 psi

P2 Main relief pressure (aP2)

P3 Main relief pressure (aP3)

19.6 ± 0.5 MPa 200 ± 5 kgf/cm2 2840 ± 73 psi

Pilot relief pressure (aPP)

4.1 ± 0.5 MPa 42 ± 5 kgf/cm2 590 ± 73 psi AC switch ON

3.9 MPa 40 kgf/cm2 570 psi

AC switch OFF

0 MPa 0 kgf/cm2 0 psi

AC mode solenoid valve pressure

Bottom (b1B)

27.5 ± 1.0 MPa 280 ± 10 kgf/cm2 3990 ± 145 psi

Boom Rod (b1R) Bottom (b2B)

27.5 ± 1.0 MPa 280 ± 10 kgf/cm2 3990 ± 145 psi

Arm Rod (b2R)

Bucket

Bottom (b3B)

27.5 ± 1.0 MPa 280 ± 10 kgf/cm2 3990 ± 145 psi

Blade

Bottom (b4B)

24.0 ± 1.0 MPa 240 ± 10 kgf/cm2 3500 ± 145 psi

Left (b6L)

17.2 ± 1.0 MPa 175 ± 10 kgf/cm2 2490 ± 145 psi

AUX1 Right (b6R)

Bottom (b8B)

17.2 ± 1.0 MPa 175 ± 10 kgf/cm2 2490 ± 145 psi

Rod (b8R)

27.5 ± 1.0 MPa 280 ± 10 kgf/cm2 3990 ± 145 psi

Angle

Left (cSL)

20.6 ± 1.0 MPa 210 ± 10 kgf/cm2 2990 ± 145 psi

Swivel Right (cSR)

RY9212182HYS0294US0

3-S137

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Motor Drain Volume (Measured on New Vehicle) Item

U35-4

When turning

60 ml/min 4.0 cu.in./min

When locked

820 ml/min 50cu.in./min

When turning (1st speed)

62 ml/min 4.0 cu.in./min

When turning (2nd speed)

110 ml/min 6.7 cu.in./min

When locked (1st speed)

520 ml/min 32 cu.in./min

When locked (2nd speed)

620 ml/min 38 cu.in./min

Swivel Motor

Travel motor

Notes

RY9212182HYS0301US0

3-S138

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Performance reference list (Quality standard values) Item

Boom (CAB)

Arm

Bucket Hydraulic cylinder operation time Swing

Blade

Angle (Angle spec.)

U35-4 Ground to max. lift

2.4 ± 0.3 sec

Max. lift to ground

2.8 ± 0.3 sec

Crowd

3.0 ± 0.3 sec

Dump

2.5 ± 0.3 sec

Crowd

2.6 ± 0.3 sec

Dump

1.6 ± 0.3 sec

Left

5.9 ± 0.5 sec

Right

4.4 ± 0.5 sec

Max down to Max up

2.1 ± 0.3 sec

Max up to Max down

2.8 ± 0.3 sec

Left

± 0.3 sec

Right

± 0.3 sec

Std. when new

≤ 20.0 mm ≤ 0.79 in.

Usage limit

≤ 100.0 mm ≤ 3.94 in.

Std. when new

≤ 20.0 mm ≤ 0.79 in.

Usage limit

≤ 100.0 mm ≤ 3.94 in.

Std. when new

≤ 10.0 mm ≤ 0.39 in.

Usage limit

≤ 50.0 mm ≤ 1.97 in.

Std. when new

≤ 20.0 mm ≤ 0.79 in.

Usage limit

≤ 70.0 mm ≤ 2.76 in.

When stopped

≤ 5.0 mm ≤ 0.20 in.

When Idling

≤ 30.0 mm ≤ 1.18 in.

Boom

Arm Hydraulic cylinder drift Bucket

Blade

Swivel Block Performance

Swivel speed

Notes

3 revs

19.1 to 23.3 sec / 3 revs 0 mm 0 in.

Travel block performance Rubber Travel speed Steel

1st

10.9 to 13.3 sec / 10 m (394 in.)

2nd

7.1 to 8.6 sec / 10 m (394 in.)

1st

11.3 to 13.8 sec / 10 m (394 in.)

2nd

7.1 to 8.6 sec / 10 m (394 in.) ≤ 600.0 mm ≤ 23.6 in.

Amount of travel drift

RY9212182HYS0296US0

3-S139

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

16. TROUBLESHOOTING Troubleshooting Front Systems All front operations slow or not moving Cause

Inspection point

Reference page

Remedy

Defect of the engine itself

Engine speed measurement

Adjust each engine part

–

Insufficient hydraulic fluid volume or oil degradation

Check hydraulic tank oil level and oil quality

Replenish the hydraulic fluid supply or change the oil

G-13

Suction line (suction filter) blockage

Inspect the suction line (suction filter)

Wash the suction line Replace the suction line

1-S18

Pilot filter blockage

Pilot filter blockage inspection

Replace pilot filter

Pilot relief valve faulty operation or poor pilot pump performance

Measure pilot primary pressure

Adjust, wash or replace pilot relief valve Replace pilot pump

3-S125

Poor main relief valve operation or seating

Main relief valve pressure measurement

Adjust, wash or replace main relief valve

3-S127

Defective pump installation coupling

Pump installation coupling inspection

Replace pump connector

3-S3

Pump drive shaft damaged

Pump drive shaft inspection

Replace shaft

3-S4

Pump internal parts wear or damage

Pump inspection

Repair or replace pump

3-S4

–

Either pilot valve right or left front does not move or is slow Cause

Inspection point

Reference page

Remedy

Pilot valve line filter blockage

Pilot valve line filter blockage inspection

Clean pilot valve line filter

–

Defective pilot valve

Pilot secondary pressure measurement of applicable cylinder

Pilot valve disassembly, cleaning or replacement

3-S126

Low power of entire hydraulic system Cause

Inspection point

Remedy

Reference page

Pilot relief valve faulty operation or poor pilot pump performance

Measure pilot primary pressure

Adjust, wash or replace pilot relief valve Replace pilot pump

3-S125

Poor main relief valve operation or seating

Main relief valve pressure measurement

Adjust, wash or replace main relief valve

3-S3

(To be continued)

3-S140

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

(Continued) A certain cylinder only does not move or is slow Cause

Inspection point

Reference page

Remedy

Applicable pilot valve defect

Pilot secondary pressure measurement of applicable cylinder

Pilot valve disassembly, cleaning or replacement

3-S126

Defective specified pressure of overload relief valve

Inspection of overload relief valve of applicable cylinder

Wash overload relief valve seat surface or replace

3-S128

Sticking of control valve spool

Inspection of control valve spool of applicable cylinder

Control valve spool disassembly and washing

3-S16

Defective seal of cylinder internal parts

Inspection of applicable cylinder

Cylinder disassembly and seal replacement

3-S69

Low power of certain implement Cause

Inspection point

Remedy

Reference page

Pilot relief valve faulty operation or poor pilot pump performance

Measure pilot primary pressure

Adjust, wash or replace pilot relief valve Replace pilot pump

3-S125

Defective specified pressure of overload relief valve

Inspection of overload relief valve of applicable cylinder

Wash overload relief valve seat surface or replace

3-S128

Major front leak (drift) volume Cause

Inspection point

Reference page

Remedy

Defective specified pressure of overload relief valve

Inspection of overload relief valve of applicable cylinder

Wash overload relief valve seat surface or replace

3-S128

Sticking of control valve spool

Inspection of control valve spool of applicable cylinder

Control valve spool disassembly and washing

3-S16

Defective seal of cylinder internal parts

Inspection of applicable cylinder

Cylinder disassembly and seal replacement

3-S69

RY9212182HYS0107US0

3-S141

KiSC issued 10, 2022 A

HYDRAULIC SYSTEM

U35-4, WSM

Travel System Troubleshooting No travel on one side. Slow. Meandering. Cause

Inspection point

Reference page

Remedy

Crawler tension trouble or earth blockage around crawler

Crawler tension and blockage inspection

Knocking earth off crawler and crawler tension adjustment

–

Defective travel pilot valve operation

Travel pilot valve secondary pressure measurement

Travel pilot valve disassembly, cleaning or replacement

3-S90

Sticking of control valve spool

Control valve spool inspection

Control valve spool disassembly and washing

3-S16

Sticking of control valve spool

Travel motor counterbalance spool inspection

Travel motor counterbalance valve disassembly, cleaning or replacement

3-S47

Defective travel motor

Travel motor drain volume measurement

Travel motor disassembly, replacement

3-S131

Internal leak of swivel joint

Remove the travel outlet hose of the swivel joint, plug it and measure the relief pressure

Swivel joint seal replacement

3-S44

RY9212182HYS0108US0

Swivel System Troubleshooting Swivel speed low or no swivel Cause

Inspection point

Reference page

Remedy

Defective pilot valve

Travel pilot valve secondary pressure measurement

Pilot valve disassembly, cleaning or replacement

3-S90

Sticking of swivel section spool

Control valve swivel section spool inspection

Clean spool

3-S16

Defective swivel relief specified pressure

Swivel relief pressure measurement

Swivel relief valve washing or replacement

3-S130

Internal defect of swivel motor

Swivel motor drain volume measurement

Swivel motor disassembly, replacement

3-S130

Snagging or sticking of friction plate for swivel motor parking brake

Inspection of friction plate for swivel motor parking brake

Replace friction plate

3-S32

Swivel drifts Cause

Inspection point

Reference page

Remedy

Sticking of pilot valve spool

Check that the pilot valve spool has returned to neutral

Pilot valve disassembly, cleaning or replacement

3-S81

Sticking of swivel section spool

Control valve swivel section spool inspection

Control valve spool disassembly and washing

3-S16

Defective swivel relief specified pressure

Swivel relief pressure measurement

Swivel relief valve washing or replacement

3-S130

Sticking of swivel motor make-up poppet or defective seat surface

Swivel motor make-up poppet inspection

Make-up poppet disassembly and washing

3-S32

Internal defect of swivel motor

Swivel motor drain volume measurement

Swivel motor disassembly, replacement

3-S130

RY9212182HYS0109US0

3-S142

KiSC issued 10, 2022 A

4 ELECTRICAL SYSTEM

KiSC issued 10, 2022 A

SERVICING CONTENTS 1. READING THE ELECTRICAL CIRCUIT DIAGRAMS .................................................................4-S1 [1] LAYOUT OF ELECTRICAL CIRCUIT DIAGRAMS ...............................................................4-S1 (1) Main Layout .....................................................................................................................4-S1 [2] LAYOUT OF CONNECTOR DIAGRAMS ..............................................................................4-S5 (1) Main Layout .....................................................................................................................4-S5 [3] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS .........................................4-S7 2. ELECTRONIC DEVICE LAYOUT................................................................................................4-S8 3. WIRING CIRCUIT......................................................................................................................4-S12 [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING .................................4-S12 [2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS .......................................4-S12 [3] UNPLUGGING ELECTRICAL CONNECTORS AND WIRING LAYOUT ............................4-S13 4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION)..................................................4-S15 5. CHECKS....................................................................................................................................4-S16 [1] POWER AND GROUND .....................................................................................................4-S16 [2] STARTING AND STOPPING DEVICES .............................................................................4-S19 6. METER PANEL OPERATING PROCEDURE ...........................................................................4-S23 [1] METER OPERATING UNIT ................................................................................................4-S23 (1) Names and Functions of Each Meter and Switch..........................................................4-S23 [2] OPERATING METHOD REFERENCE LIST ......................................................................4-S23 [3] DETAILS OF THE OPERATIONAL PROCEDURES ..........................................................4-S24 (1) Refer to the Hour Meter, Clock, Engine rpm, Water Temperature, and Fuel ................4-S24 (2) View Operating Information ...........................................................................................4-S24 (3) Checking Periodic Inspection Items ..............................................................................4-S27 (4) How to set the Clock......................................................................................................4-S28 (5) Switching-over of the items of “AM/PM · 24 hours” .......................................................4-S28 (6) Anti-Theft Settings .........................................................................................................4-S29 (7) Auxiliary Port Operation.................................................................................................4-S30 [4] SERVICE DEALER SETTINGS ..........................................................................................4-S38 (1) Diagnosis.......................................................................................................................4-S39 (2) Setting ...........................................................................................................................4-S48 [5] LIST OF WARNING ALARM DISPLAYS.............................................................................4-S65 (1) Warning Display List......................................................................................................4-S65 (2) Warning Display List......................................................................................................4-S67 7. TROUBLESHOOTING (METER PANEL EDITION) ..................................................................4-S69 [1] MACHINE RELATED SYSTEM...........................................................................................4-S69 (1) Engine Oil Pressure Errors............................................................................................4-S69 (2) Charging System Errors ................................................................................................4-S73 (3) Fuel Sensor Errors ........................................................................................................4-S76 (4) Water Temperature Sensor Errors ................................................................................4-S80 [2] FRONT-END SYSTEMS .....................................................................................................4-S84 (1) Lever Lock System Errors .............................................................................................4-S84 (2) Travel 2-Speed System Error ........................................................................................4-S89 [3] AUTO IDLING (AI) SYSTEM ...............................................................................................4-S94 (1) Governor Sensor Errors ................................................................................................4-S94 (2) Accelerator Sensor Errors .............................................................................................4-S98 (3) AI Motor Errors ............................................................................................................4-S102 (4) Testing the AI Pressure Switch ...................................................................................4-S107 (5) Testing the AI Switch...................................................................................................4-S111 [4] POWER SUPPLY SYSTEM ..............................................................................................4-S115 KiSC issued 10, 2022 A

(1) Over Voltage................................................................................................................4-S115 (2) 5V Short System Error.................................................................................................4-S116 [5] COMMUNICATION SYSTEM ............................................................................................4-S117 (1) CAN Communication Errors ........................................................................................4-S117 [6] AUX SYSTEM....................................................................................................................4-S120 (1) AUX1/Thumb System Errors ......................................................................................4-S120 [7] ANGLE BLADE SYSTEM ..................................................................................................4-S125 (1) Angle Blade System Error ...........................................................................................4-S125 [8] TRAVEL ALARM (OPTION) ..............................................................................................4-S130 8. DEALER SETTING MODE FLOWCHART ..............................................................................4-S132

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

1. READING THE ELECTRICAL CIRCUIT DIAGRAMS [1] LAYOUT OF ELECTRICAL CIRCUIT DIAGRAMS (1) Main Layout (a)

Battery

(b)

Fuses

(c)

Basic structural components

(d)

Sensors, etc. (input system)

(e)

Machine ECU

(f)

Solenoids, etc. (output system)

(g)

Auxiliary equipment

(h)

A/C

(i)

Basic direction of electrical flow

CAUTION • Please note that some items do not conform to this layout. RY9212182ELS0174US0

Electrical wiring chart symbols for harnesses and wires

Item

(Example) Contents of illustration

(a)

Name of part

SENSOR, FUEL

(b)

Specification code

All use (common)

Reference

Table shown on circuit diagram

(c)

Wire size

0.50 mm

(d)

Wire color

Black

Wire color page

(e)

Unit symbol

Potentimeter with sliding contact

Unit symbol page

(f)

Pin name

EARTH

(g)

Pin No.

(h)

Connector name

SENSOR, FUEL

Connector diagram RY9212166ELS0074US0

4-S1

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Colors of Wiring Color of wiring

Color code

Black

Green

Blue

Pink

Red

White

Yellow

Brown

Gray

Light Green

Orange

Sky Blue

(Ex.) 1.25-Y/R means : 1.25 : Wire size (mm2) Y : Base color (yellow) R : Stripe color (red) • Do not pull on or step on wires. Also, do not cut wires on burred edges or the like. • Do not twist or pinch wiring when installing it. (a) Wire Size (mm2) (b) Insulation Base Color

4-S2

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Unit symbol

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Variable Non-Linear Variable Fixed Setting Step Variable Non Ionizing Radiation (NIR) Body GND Thermistor Resistor Variable Resistor

(10) Potentiometer with Sliding Contact (11) Heating Element (12) Condenser (13) Electrolytic Capacitor (14) Magnetic Core Inductance (15) PNP Transistor (16) NPN Transistor (17) Semiconductor Diode

(18) Light-Emitting Diode (LED) (19) Two-Way Breakdown Diode (20) Coil (21) a-Contact (22) Auto-Resetting b-Contact (23) Auto-Resetting a-Contact (24) Relay Coil (25) Fuse (26) Lamp

(27) Buzzer (28) Horn (29) Speaker (30) AC Voltage Source (31) Switch (32) OFF (No Auto-Reset) (33) ON (34) START (Auto-Reset) RY9212166ELS0075US0

4-S3

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Bus bar markings

(A) Diagram Using Bus

(B) Diagram Showing All Circuits, Not Using Bus

1. Diagrams of circuits with a lot of junction branches, such as power supply circuits, are very complicated if depicted literally, so a bus should be used where necessary. 2. A circuit is connected to either side of the bus. 3. Wire attributes are used respectively for the circuits connected to either side of the bus. (The circuits forming a pair on either side of the bus must be connected.) RY9212166ELS0076US0

Battery teminal and composite terminal markings If terminals are fastened together, such as battery terminals • Fasten terminals (2) and (3) together with one bolt. RY9212166ELS0077US0

4-S4

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[2] LAYOUT OF CONNECTOR DIAGRAMS (1) Main Layout Connector arrangement sequence In alphabetical order downwards from top left, and then to column next right.

RY9212166ELS0078US0

Depiction of Connectors

In principle, the connector locking part is shown on the top side. Female connector terminal numbers start from 1 in the top right corner, looking at the connecting face. Male connector terminal numbers start from 1 in the top left corner. (A) (B) (C) (D)

10 terminals or fewer 11 terminals or more

Female Connector Terminal Male Connector Terminal Not Waterproofed Waterproofed

Above-stated pin numbers in all cases. Numbers assigned according to numbering specifications. Manufacturer's instructions given.

Use manufacturer's stated pin numbers.

Manufacturer's instructions not given.

Numbers assigned according to above-stated numbering specifications.

RY9212166ELS0079US0

4-S5

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Group

C (Connector)

Separator

"_"

Waterproofed / Not waterproofed

Male / Female

O : Open (not waterproofed) W: Waterproofed

F : Female M : Male

LA : Round automotive terminal

F : Female

LE : Claw-shaped automotive terminal

F : Female

BA : Automotive battery lead terminal

F : Female

CB : Female bullet terminal

F : Female

CA : Male bullet terminal

M : Male

PA : Flat male embedded bullet terminal (w/out cover)

M : Male

No. of Terminals

Separator

Housing

8-pin

Separator

Comment

Separator

" ("

Alphanumeric characters

")"

"_" Hole dia. M○○

Blank column

"_" 01

Tab width 250 (6.3 mm) 187 (4.75 mm) 110 (2.8 mm)

M : Male

F : Female

Manufacturer's sleeve part no. (enter terminal part no. in series column)

PA : Flat female bullet terminal (w/out cover)

F : Female

Tab width 250 (6.3 mm) 187 (4.75 mm) 110 (2.8 mm)

M : Bolt embedded terminal

M : Male

Bolt size : M○○

O : Flat female bullet terminal (w/ cover)

Identifying suffix

1234-5678-20 Connector manufacturer's part no.

Manufacturer's sleeve part no. (enter terminal part no. in series column)

O : Flat male embedded bullet terminal (w/ cover)

Separator

1-9→ A-Z

"_"

Starter, alternator power terminals, etc.

Example) C_WF08_1234-5678-20_1 (8-terminal waterproofed female connector)  If there is no manufacturer's connector part number, for instance, when there is a direct connector on the unit side, then follow the method indicated below. • Use the manufacturer's connector part number on the harness side. • For the symbol indicating male/female, use the "M" or "F" on the unit-side connector. • Put "DUMMY" in the comment column. Example) C_WM02_7283-7027-40_1 (DUMMY) (A unit-side two-terminal waterproofed male connector "Kubota Part No.: 1J574-59681 Sensor, Intake temperature") RY9212166ELS0080US0

4-S6

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[3] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS 1. When disconnecting connectors, grasp the body of the connector and pull it out; do not pull on the wiring harness. If the connector is the locking type, release the lock and then pull to disconnect. 2. When removing a connector's plastic cover (for water protection) to inspect it, be careful not to let any water get in the connector. If water does get in, dry it thoroughly before reassembling the connector and putting its plastic cover securely in place. 3. Straighten any bent connector terminals and make sure none are sticking out or missing. Also make sure there is no corrosion on the connector's terminals before connecting it. 4. When connecting a locking connector, be sure to press it in until you hear it click and then pull gently on the harness close to the connector and make sure the harness does not come out. RY9212001ELS0224US0

4-S7

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

2. ELECTRONIC DEVICE LAYOUT

(To be continued)

4-S8

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(Continued) No. (1)

Name of part

No.

Name of part

Alternator

(19)

Fuse box

(2)

Water temperature sensor

(20)

Main ECU

(3)

Engine oil switch

(21)

Power socket

(4)

Glow plug

(22)

Function expander coupler (4P)

(5)

Starter

(23)

CAN communication coupler (2P)

(6)

Engine stop solenoid

(24)

Fuel sensor

(7)

Engine rotation sensor

(25)

Meter panel

(8)

Fuel pump

(26)

Horn switch

(9)

AI motor

(27)

AUX1 joystick lever

(10)

Governor sensor

(28)

Travel 2-speed switch

(11)

Battery

(29)

Angle blade control switch

(12)

Slow-blow fuses

(30)

Key switch

(13)

Ground

(31)

Anti-theft antenna

(14)

Unload valve

(32)

Accelerator pedal

(15)

AUX solenoid valve

(33)

Worklight switch

(16)

Angle solenoid valve

(34)

Engine stop button

(17)

AI pressure switch

(35)

Lock lever switch

(18)

Horn RY9212182ELS0145US0

4-S9

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM (1) (2) (3) (4) (5) (6) (7) (8) (9)

Alternator Water temperature sensor Engine oil switch Glow plug Starter Engine stop solenoid Engine rotation sensor Fuel pump AI motor

(10) Governor sensor (11) Battery (12) Slow-blow fuses (13) Ground (14) Unload valve (15) AUX solenoid valve (16) Angle solenoid valve (17) AI pressure switch RY9212182ELS0146US0

4-S10

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM (18) Horn (19) Fuse box (20) Main ECU (21) Power socket (22) Function expander coupler (4P) (23) CAN communication coupler (2P) (24) Fuel sensor (25) Meter panel (26) Horn switch (27) AUX1 joystick lever

(28) Travel 2-speed switch (29) Angle blade control switch (30) Key switch (31) Anti-theft antenna (32) Accelerator pedal (33) Worklight switch (34) Engine stop button (35) Lock lever switch

RY9212182ELS0147US0

4-S11

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

3. WIRING CIRCUIT [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING 1. Do not touch the wiring or the area around it. Do not touch where uncovered. 2. Do not clamp to fuel hoses. 3. Connect connectors and terminals securely so they do not come unplugged when pulled on gently. 4. Be sure to clamp the harness at the clamp position. 5. Clamps for securing harnesses (1) Anchor Type (Insert Firmly Until it Catches.) (2) Screw Type (Insert to the End of the Screw.) (3) and (4) Insert Type : Insert Until it Locks.

(A) Harness (B) Clamp the Harness so It Stays in Position and Does Not Move. Insert the End of the Cable Tie Into the Hole on the Other Side to Clamp the Harness. RY9212001ELS0025US0

[2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS 1. When disconnecting connectors, grasp the body of the connector and pull it out; do not pull on the wiring harness. If the connector is the locking type, release the lock and then pull to disconnect. 2. When removing a connector's plastic cover (for water protection) to inspect it, be careful not to let any water get in the connector. If water does get in, dry it thoroughly before reassembling the connector and putting its plastic cover securely in place. 3. Straighten any bent connector terminals and make sure none are sticking out or missing. Also make sure there is no corrosion on the connector's terminals before connecting it. 4. When connecting a locking connector, be sure to press it in until you hear it click and then pull gently on the harness close to the connector and make sure the harness does not come out. RY9212001ELS0224US0

4-S12

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[3] UNPLUGGING ELECTRICAL CONNECTORS AND WIRING LAYOUT 1. Push lock and disconnect type Place Used • Virtually all connectors (a) Push RY9212004ELS0113US0

2. Pull up lock and disconnect type Place Used • 2-speed switch connector • Anti-theft antenna connector (a) Pull up RY9212004ELS0114US0

ECU (main) connector assembly/disassembly (When removing) • Press the lock button, release the lever and pull out the connector. (When assembling) • Press the connector all the way in, close the lever and make sure it is securely locked. (a) Lever (b) Lock button

4-S13

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

2. Names of the Terminal Signals of the Main ECU Connector (Harness Side)

Connector Terminal

Signal Name

Connector Terminal

Connector

Signal Name

Terminal

Signal Name

–

GND (AI motor)

Accelerator angle sensor

GND

Boom bottom side pressure sensor

Lever lock switch

+12V Power (AI motor)

AUX2/AUX1 control knob sensor (L)

Starter switch

Motor (+, FWD rotation)

TXD (anti-theft antenna)

Start signal input

Motor (-, BWD rotation)

Buzzer

AUX1/Thumb holding switch (R)

–

GND (sensor)

Compressor clutch signal input

Boom angle sensor

AI self-holding relay

Motor angle sensor

Right AUX1 solenoid

Boom rod side pressure sensor

Angle-R (SW)

AUX1/Thumb control knob sensor(R)

Angle-L (SW)

+12V Power output

LED (anti-theft)

Travel pressure switch

–

Bucket lock solenoid relay

AI mode-switching switch

AC SW (Sol Power Supply)

Multipurpose SW (console)

AC SW (Sol Power Supply)

TXD (check connector) Multipurpose switch (lever)

RXD (anti-theft antenna)

–

– +5V Power output (sensor) – –

AUX1 solenoid (–)

AC SW (Sol Power Supply)

AUX2 solenoid (–)

Left AUX1 solenoid

–

AUX2 solenoid (–)

AUX2/AUX1 holding switch (L)

–

Angle (L) (SOL)

AI pressure switch

Engine rotation input

+B power (supplied directly)

–

Left AUX2 solenoid

–

Angle (R) (SOL)

Travel 2-speed solenoid

RXD (check connector)

Glow relay

Right AUX2 solenoid

CAN (H-0)

Rotating light relay

Anti-theft horn relay

CAN (L-0)

LED (multi-purpose)

–

CAN (H-1)

LED (AI mode)

CAN (L-1)

26 27

– Arm angle sensor

Travel 2-speed switch –

–

Lever lock solenoid

Multipurpose Sol RY9212050ELS0020US0

4-S14

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4. TROUBLESHOOTING (START-UP EQUIPMENT VERSION) Engine does not start Checkpoint

Cause

Solution

Check whether "Wrong Key" is displayed when it is in the start position. Determine whether it is the registered key or not in the tester mode.

The engine was not started with the registered key.

Start the engine with the registered key.

Is the unload lever up or not? Is the message "Lift the lever" displayed?

The lever lock switch (limit) is pressed in.

Lift the unload lever and then start the engine.

Check slow-blow and other fuses.

Slow-blow and/or other fuses are blown.

After determining the cause of slow-blow and/or other fuses blowing, replace them.

Check whether GND wire(s) are securely connected to the body.

Ground defective

Tighten GND wire bolt(s).

Check battery voltage and specific gravity.

Battery fault

Recharge or replace the battery.

Check continuity between key switch terminals.

Key switch faulty

Replace the key switch.

Measure the voltage at terminal B of the starter.

Break in continuity of the harness or starter relay.

Repair the harness. Replace the harness, starter relay and/or fuses.

Measure the voltage at terminal S of the starter.

Break in continuity in the harness, starter relay and/or fuses.

Repair the harness. Replace the harness, starter relay and/or fuses.

Disconnect the lever lock switch (limit) connector and measure the voltage at the connector terminals on the harness side.

Break in continuity in the harness or lever lock switch (limit) fuses.

Repair the harness. Replace the harness and/or fuses. Replace the lever lock switch (limit).

Cause

Solution

The engine fails to start sometimes. Checkpoint Is the key on a metal keyring or have a metal fob?

The fob and/or keyring are interfering with communication between the key and the antenna.

Engine starts even with unregistered keys Checkpoint Check whether the anti-theft system is "OFF" or not initialized.

Cause

As the anti-theft function is not working, even unregistered keys can start the engine.

Get rid of the fob and/or ring.

Solution Make the anti-theft settings and register the key. RY9212166ELS0004US0

4-S15

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

5. CHECKS [1] POWER AND GROUND Slow-blow fuses IMPORTANT • When replacing a slow-blow fuse, always use the same capacity fuse and replace it after determining why it blew. (1) Slow-blow fuses RY9212182ELS0002US0

Inspecting slow-blow fuses • Measurement parameter : check continuity across its terminals RY9212001ELS0028US0

Fuses IMPORTANT • When replacing a fuse, always use the same capacity fuse and replace it after determining why it blew. (1) Fuse box RY9212182ELS0003US0

Fuse capacity and their circuits (1) A/C Controller (+B) (2) Blower Motor (3) ECU (AC) (4) Relay (5) Alternator (6) Lever Lock (7) Fuel Pump (8) Wiper / Washer (9) Radio (AC) (10) Power Socket (11) Compressor

(12) Engine Stop (13) Meter (+B) (14) ECU (+B) (15) Horn SW (16) Horn (17) Work Light (18) Beacon (19) Room Light (20) ECU (Power) (21) Starter Signal RY9212182ELS0004US0

Inspecting fuses • Measurement parameter : check continuity across its terminals RY9212001ELS0031US0

4-S16

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Precautions when a Fuse Blows When a fuse blows, there are 2 potential causes. The first is when an overload of current exceeds the rated amperage of the fuse, blowing it; the other is when it blows due to a repetitive, intermittent current. These two cases can be readily recognized visually, so when a fuses blows, take note of the following points. 1. When a fuse blows due to an overload of current exceeding its rated capacity. An overload current produces a blown fuse such as shown at left (A). You should not immediately replace a fuse that blows in this way with a new one. The fuse will just blow again when subjected to the overload current, so first inspect the circuit for a short or a problem with a device, then after fixing the problem, install a fuse of the same capacity. The purpose of the original fuse is to provide a margin of safety, so never replace a fuse with one of a higher capacity. If you replace a fuse with one of a higher capacity, it presents the danger of a current overload damaging the electrical device(s) and/or the wiring in the circuit before blowing the fuse. 2. When a fuse blows due to a repetitive, intermittent current. A repetitive, intermittent current produces a blown fuse such as shown at left (B). In general, this kind of blown fuse occurs after a relatively long period of time, so it does not happen very often. With this kind of blown fuse, it is OK to replace it with a fuse of the same capacity. (A) Fuse Blown by Current Overload (B) Fuse Blown by Thermal Fatigue RY9212001ELS0032US0

4-S17

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Ground Check whether GND wire(s) are securely connected to the body. RY9212182ELS0005US0

Battery Check the voltage between the terminals 1. Connect a circuit tester between the (+) and (-) terminals of the battery and measure the voltage across the terminals. 2. If the measurement is below factory specs, check the specific gravity of the electrolyte. Voltage between terminals

Factory specification

At least DC 12V

Check the condition of terminal connections 1. Put an electrical load on the battery. (E.g.: Turn the key switch to RUN and turn a worklight on. 2. Connect the (+) side if the circuit tester to the (+) terminal of the battery and the (-) side of the circuit tester to the (+) battery cable. Measure the voltage. 3. Connect the (-) side if the circuit tester to the (-) terminal of the battery and the (+) side of the circuit tester to the (-) battery cable. Measure that voltage. 4. If the measurements are greater than factory specs, check the condition of the contacts at the terminals. Voltage between terminals (1) (-) Terminal

Factory specification

At least DC 0.1 V

(2) (+) Terminal RY9212001ELS0034US0

4-S18

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[2] STARTING AND STOPPING DEVICES Key switch Checks 1. Remove the key switch's 3P connector. 2. Turn the key switch to the RUN position and then check the continuity between the red / white wire terminal of the connector on the key switch side and the red wire terminal on the connector. 3. Turn the key switch to the START position and then check the continuity between the black/white wire terminal of the connector on the key switch side and the red wire terminal on the connector. Key switch circuit table

(1) Red / white (2) Black / white

(3) Red RY9212182ELS0006US0

Starter 1. Power supply to terminal B IMPORTANT • The battery voltage always exists at terminal B of the starter, so do not short it during inspection. 1. Connect the (+) side of the circuit tester to terminal B of the starter and the (–) side to the body and measure the voltage. 2. If the measurement meets the factory spec, the harness between the battery and terminal B is OK. 3. If the measurement is outside of factory specs, check the condition of the battery cable (+) contact and that of the GND (–) cable and the body. Measured voltage

Factory Specification

11 to 14 V (battery voltage)

2. Power supply to starter's pull-in and holding coils 1. Remove the connector from the starter's S terminal. 2. Connect the (+) of the circuit tester to the connector on the harness side and the (–) to the body. 3. Put the machinery operation lock lever in the lock position and measure the voltage with the key switch held in the START position. If the measurement meets factory specs, the circuit from the battery to the S terminal is OK (harness, key switch, auto-release relay). Measured voltage (1) Terminal B

Factory Specification

11 to 14 V (battery voltage)

(2) Terminal S RY9212182ELS0007US0

4-S19

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Relay capacity and their circuits (1) (2) (3) (4) (5)

Glow (40A) Blower (20A) Engine Stop (20A) Compressor (20A) Glow (20A)

(6) Horn (20A) (7) Beacon (20A) (8) Worklight (20A) (9) ECU Main Motor (20A) (10) Starter (20A) RY9212182ELS0008US0

Starter relay Harness-side voltage 1. Turn the key switch OFF and remove the starter relay. 2. Turn the key switch to RUN and measure the voltage between connector terminal 3 on the fuse box side and the body. 3. If the measurement meets factory specs, it is OK. Measured voltage

Factory Spec

11 to 14 V (battery voltage) RY9212182ELS0009US0

Starter relay test 1. Turn the key switch OFF and remove the starter relay. 2. Impress the battery voltage between relay terminals 3 and 5 and check for continuity between relay terminals 1 and 2. 3. If the measurement meets factory specs, it is OK. Between terminals

Factory specification

(a) Relay Terminal 5 (b) Relay Terminal 3

Continuity

Glow relay Harness-side voltage 1. Turn the key switch OFF and remove the glow relay. 2. Turn the key switch to OFF and measure the voltage between connector terminal 3 on the fuse box side and the body. 3. If the measurement meets factory specs, it is OK. Measured voltage

Factory Spec

11 to 14V (battery voltage)

4. Turn the key switch to RUN and measure the voltage between connector terminal 1 on the fuse box side and the body. 5. If the measurement meets factory specs, it is OK. Measured voltage

Factory Spec

11 to 14 V (battery voltage) RY9212182ELS0010US0

Glow relay test 1. Turn the key switch OFF and remove the glow relay. 2. Measure the resistance between terminals 1 and 4. 3. Check for continuity between terminals 2 and 3. Measured items

(+)

Factory specification

(–)

Coil

Terminal 1

Terminal 4

72 to 88 Ω

Contact

Terminal 2

Terminal 3

No continuity

(a) Terminal 1 (b) Terminal 3

4-S20

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Engine stop solenoid connector voltage 1. Remove the engine stop solenoid's 2P connector. 2. Turn the key switch to RUN and measure the voltage between connector terminal 1 on the wire harness side and the body. Turn the key switch to START and measure the voltage between connector terminal (2) on the wire harness side and the body. 3. If the measurement meets factory specs, it is OK. Measured voltage

Factory specification

11 to 14 V (battery voltage) RY9212182ELS0011US0

Engine stop solenoid relay Harness-side voltage 1. Turn the key switch OFF and remove the engine stop solenoid relay. 2. Turn the key switch to OFF and measure the voltage between connector terminal 1 on the fuse box side and the body. 3. If the measurement meets factory specs, it is OK. Measured voltage

Factory Spec

11 to 14 V (battery voltage)

4. Turn the key switch to RUN and measure the voltage between connector terminal 3 on the fuse box side and the body. 5. If the measurement meets factory specs, it is OK. Measured voltage

Factory Spec

11 to 14 V (battery voltage)

Engine stop solenoid relay test 1. Turn the key switch OFF and remove the engine stop solenoid relay. 2. Impress the battery voltage between relay terminals 3 and 5 and check for continuity between relay terminals 1 and 2. 3. If the measurement meets factory specs, it is OK. Between terminals

Factory Spec

(a) Relay terminal 5 (b) Relay terminal 3

Continuity

Engine stop solenoid 1. Remove the engine stop solenoid. Measure the resistance between connector terminal 1 (holding coil) and connector 2 (pull-in coil). 2. Push the plunger in and check for no continuity. 3. If the resistance is 0 Ω, it is shorted, so replace it. Alternatively, if the resistance is infinite, the coil is open, so replace it. Factory specification

Measured items

(+)

(–)

Holding coil

Terminal 2

Body (Frame)

14 to 18 Ω 0.1 to 0.5 Ω (state: free)

Pull-in coil

Terminal 1

(1) Engine stop solenoid

Body (Frame)

No continuity (state: plunger pressed)

(A) Pull-in coil (B) Holding coil (a) Press in RY9212182ELS0013US0

4-S21

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Switch (limit) connector voltage 1. Remove the 2P connector of the lever lock switch (limit). 2. Turn the key switch to RUN and measure the voltage between the connector terminal (blue/white) on the wire harness side and the body. 3. If the measurement meets factory specs, it is OK. Measured voltage

Factory specification

11 to 14V (battery voltage) RY9212182ELS0014US0

Switch (limit) 1. Remove the 2P connector of the limit switch. 2. Move the equipment lock lever up and down and check for continuity between the connector terminals when the limit switch is pressed and when it is free. Key switch circuit table

(1) Limit switch (2) Connector

(3) Terminals (black wire) RY9212182ELS0015US0

4-S22

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

6. METER PANEL OPERATING PROCEDURE [1] METER OPERATING UNIT (1) Names and Functions of Each Meter and Switch Normal display (1) User Settings Switch (Switch 1) (7) Water Temperature Gauge (2) Crane (Switch 2) (8) Hour Meter / Engine Tachometer (3) AUX Port Operation Switch (9) Fuel Gauge (Switch 3) (10) Warning Lights (Red, Yellow) (4) Information Switch (Switch 4) (11) Oil Lamp (5) Display Changing Switch (Switch 5) (12) Charging Lamp (6) Clock Display (13) 2-Speed Lamp RY9212182ELS0016US0

Displayed when menu selected (1) Return Halt Settings and Return to (4) Forward Moves Selected Item Original Screen. Forward. (2) Down Move Selection Down One (5) Set/Select Sets the Selected Item. Item. Moves Menu Selection Selects the Item in the Menu Position Down. Selection Position. (3) Up Move Selection Up One Item. Moves Menu Selection Position Up. RY9212182ELS0017US0

[2] OPERATING METHOD REFERENCE LIST Mode

Operation items

Reference Page

Operational procedures

(1)

Refer to the Hour Meter, Clock, Engine rpm, Water Temperature, and Fuel

Turn the key from OFF to ON. (Pressing SW5 will change the display.)

4-S24

(2)

Refer to the Operational Information

Turn the key from OFF to ON and press SW1. Select "Log Record".

4-S24

(3)

Periodic inspection

Turn the key from OFF to ON and press SW1. Select "Periodic Check".

4-S25

(4)

How to set the Clock

Turn the key from OFF to ON and press SW1. Select "Clock Set".

4-S28

(5)

Switching-over of the items of "AM/PM · 24 hours"

Turn the key from OFF to ON and press SW1. Select "Various Settings" and select "Calender / Clock Set".

4-S28

Anti-theft settings

(6)

(Re-registers when the black key has been lost)

Insert the red key in the key OFF and press SW1 or SW5.

4-S29

AUX port

(7)

AUX port operation

Turn the key from ON to OFF. Press SW3.

4-S30

Normal

User Settings

RY9212182ELS0018US0

4-S23

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[3] DETAILS OF THE OPERATIONAL PROCEDURES (1) Refer to the Hour Meter, Clock, Engine rpm, Water Temperature, and Fuel When the engine is started, the electronic meter display can be changed to three different display modes, by pressing the display changing switch. (1) (2) (3) (a) (b) (c) (d)

Starter key at [RUN] position. (A)STOP, (B)RUN, (C)START Press switch 5. Press switch 5 to return to screen (2).

Opening Screen While Glow Plugs On Hour Meter Tachometer (Numerical) RY9212182ELS0038US0

(2) View Operating Information The "Log Record" option can be used to check the last 3 months' operation of the machine. (1)

Starter key at [RUN] position. (A)STOP, (B)RUN, (C)START Press switch 1 (user settings).

(2)

(3)

(4)

(5)

Select "Log Record" and press switch 5. Press switch 2 to see a work log (of the days the machine was operated) for the last month, and up to the month before last (90 days previous). Operating time for month (bar graph display)

RY9212182ELS0039US0

4-S24

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

If a periodic check notification has been displayed Check items are shown on the LCD screen at the corresponding hour meter time. (1)

"Periodic Check Soon" is displayed 10 hours before the periodic check time. Press switch 4 to verify the items to be checked. The displayed items are to be serviced.

(2)

NOTE • When the periodic check time has passed, the notification "Periodic Check Passed" is shown. • After completing servicing, the check information display is automatically cancelled when the key switch is turned on and off 10 or more times. RY9212166ELS0012US0

If the check items cannot all be displayed on one screen (1) (2)

Press the information switch (switch 4). Pressing the cursor switches (switch 2 or 3) scrolls the check items up or down. RY9212182ELS0041US0

4-S25

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Periodic Check Items List (The following check items are displayed on the LCD screen at the corresponding hour meter time.) [For US, CA] No.

Check points

1 Engine oil (CF-4)

100

250

500

600

750

1000

Consequently



every 500 hrs



every 1000 hrs

Outer element



every 1000 hrs

Inner element



every 1000 hrs



every 500 hrs



every 500 hrs



every 500 hrs



every 1000 hrs

replace



every 1000 hrs

–



every 2000 hrs



every 500 hrs



change

2 Hydraulic oil 3 Air filter element

Hour meter indicator

Intervals

replace

4 Fuel filter 5 Engine oil filter 6 Drive unit oil

change

7 Hydraulic return filter element

 

replace

8 Hydraulic suction filter element 9 Pilot filter 10 Idler, Track roller, Grease 11 Breather filter

every 500 hrs



replace



 First operation RY9212182ELS0042US0

Periodic Check Items List (The following check items are displayed on the LCD screen at the corresponding hour meter time.) [For AU] No.

Hour meter indicator

Check points

50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000

1 Engine oil (CF-4)





every 250 hrs



change 

every 1000 hrs

Outer element



every 1000 hrs

Inner element



every 1000 hrs



every 500 hrs

2 Hydraulic oil Air cleaner 3 element

replace 4 Fuel filter



5 Engine oil filter 6 Drive unit oil

 change

7 Hydraulic return filter element 8

Hydraulic suction filter element









10 Idler, Track roller, Grease

every 250 hrs



replace

every 500 hrs every 500 hrs



9 Pilot filter

11 Breather filter

Intervals



every 1000 hrs



every 1000 hrs every 2000 hrs

– replace



every 500 hrs

 First operation RY9212182ELS0180US0

4-S26

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(3) Checking Periodic Inspection Items (1)

Starter key at [RUN] position. (A)STOP, (B)RUN, (C)START

Press switch 1 (user settings). (2)

(3)

(4)

(5)

Press switch 2 to select "Periodic Check" and then press switch 5.

[Periodic check item screen 1] 1st line : Item 2nd line : Next check time minus hour meter.  indicates negative value. 3rd line : Next check time Press switch 2 to move to the next item. [Periodic check item screen 2] Press switch 2 to move to the next item. (Show all 12 items) Press switch 3 to move to the last item. RY9212166ELS0084US0

4-S27

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(4) How to set the Clock (1) (2)

Starter key at [RUN] position. (A)STOP, (B)RUN, (C)START Press switch 1 (user settings).

(3)

Press switch 2 to select "Clock Set".

(4)

With "Clock Set" selected, press switch 5.

(5) (6)

Set the clock and then press switch 5. Setup complete

[Clock setting guide] • Pressing switch 4 ( ) changes the setting item from Yr→ Mo→ Day→ Hr→ Min→ Yr. • Pressing switch 2 ( ) reduces the number. • Pressing switch 3 ( ) increases the number. • Pressing switch 1 while on the clock setting screen takes the screen back without changing the time. NOTE • The display shown left appears when the clock stops, due to disconnection of the battery, etc. Press the Set switch (switch 5) to set the clock again. RY9212182ELS0043US0

(5) Switching-over of the items of “AM/PM · 24 hours” (1) (2)

Starter key at [RUN] position. (A)STOP, (B)RUN, (C)START Press switch 1 (user settings).

(3)

Press switch 2 to select "Various Settings" and then press switch 5.

(4)

Select "Calendar / Time display settings" and then press switch 5.

(5)

Choose the display order: yyyy/mm/dd, dd/mm/yyyy, mm/dd/yyyy, and AM/PM or 24-hr display.

(6)

When the setting has been changed, press switch 5 to complete.

(a) Day/Month/Year Display (b) Clock Display (c) Cursor Movement Switches (Switches 2 and 3) (d) Item Movement Switch (Switch 4)

Scroll the selected item up and down with the cursor movement switches (switches 2 and 3), to change the Year/Month/Day order on side (A). (This change is reflected in the Year/Month/Day order on the time adjustment screen.) Move the cursor to side (B) with the item movement switch (switch 4), and select either "AM/PM" or "24 hour". Press the Set switch (switch 5) to make the changes and exit the procedure. Press "Completed" with the direction cursor switch (switch 1) to exit without making changes. RY9212182ELS0044US0

4-S28

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(6) Anti-Theft Settings Registering the Black Key in the Machine

(1)

Insert the red key into the key switch. (Leave key in without turning. If accidently moved to [RUN] position, return to [STOP]. (a) Red key Press the display changing switch once.

(2)

The meter panel shows [Pull out Key]. (3)

(4)

Remove the red key from the key switch. (a) Red key

The meter panel shows [Insert Key]. (5)

(6)

Insert the black key into the key switch. (Leave key in without turning. If accidently moved to [RUN] position, return to [STOP], and repeat operation. (b) Black key After completing all of the registration steps, press the user setting switch.

(7)

RY9212182ELS0045US0

4-S29

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(7) Auxiliary Port Operation With a front-mounted digital meter, an optimal flow volume can be set for the AUX port, depending on the attachment. The flow can be set in 20 steps, left and right. Up to five patterns can be registered. When the attachment is changed, the oil volume can be reset at a touch, by calling up the registered icon. RY9212182ELS0046US0

[A] Selecting the Action Modes The AUX port has been factory-set to four action modes. You can select one of them. Up to six action modes can be preset. Each time the AUX port enable switch (switch 3) is pressed, the action modes change over one after another. And the icon and action mode number on the screen change accordingly. RY9212032ELS0062US0

AUX 1 mode only [Mode 0] AUX disable (normal screen) AUX 1 port : No activation

[Mode 1] AUX 1 port : Max. flow volume

[Mode 2] AUX 1 port : Limited flow volume

[Mode 3] AUX 1 port : One way flow (Send oil to the port 2 only) (1) No Lighting (2) Blinking

(3) Icon (4) Action Mode No. RY9212166ELS0014US0

4-S30

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Check operating mode settings When one operating mode is selected and switch 4 is pressed while the " mark" is displayed as the bottom right icon, then the flow rate setting is displayed.

(1) Icon (2) Information mark (3) Information switch (switch 4)

(4) Port 1 (5) Port 2 RY9212182ELS0049US0

[B] Service Port Handling Procedure 1. Turn the starter key to the "START" position. After starting the engine, leave the engine to warm up for about 10 minutes without applying a load. (1) Starter Switch

(A) STOP (B) RUN (C) START RY9212182ELS0050US0

2. Lower the machine operation lock lever. (Release lock) (1) Machine Operation Lock Lever

(A) Release (B) Lock RY9212182ELS0051US0

3. Press the AUX port operation switch (switch 3). NOTE • If the machine operation lock lever is not in the "Unlock" position, then the following message appears. Move the machine operation lock lever to the "Unlock" position, and press the AUX port operation switch (switch 3).

(1) AUX Port Operation Switch (Switch 3) RY9212182ELS0052US0

4-S31

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4. Operation of AUX port switch on machine operation lever [Right-side AUX port switch] • Move the switch to the right: Oil flows to port 1 (a) • Move the switch to the left: Oil flows to port 2 (b) IMPORTANT • Proportional control makes it possible to vary the operating speed of the attachment. E.g. When the AUX port switch is moved to the middle, the attachment moves at about half speed. (1) Machine operation lever right

(a) Port 1 (b) Port 2 RY9212182ELS0053US0

Hold one-way flow When the one-way flow hold switch on the right-side machine operation lever is pressed, the oil continues to flow to the AUX port 2 (b) . When this switch is pressed again or the AUX port switch is moved, the oil flow is interrupted. NOTE • If the one-way flow hold switch of the left-side machine operation lever is pressed, it will not function. In this case, a message such as the following is shown on the screen.

(1) Machine operation lever right (2) One-way flow hold switch right

(b) Port 2 RY9212182ELS0054US0

4-S32

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Setting the Maximum Flow Volume The AUX port maximum flow is set to three operating modes, 1, 2, 3, upon shipment. The maximum flows 4 and 5 can be set by the operating mode. RY9212182ELS0055US0

Setting procedure 1. Turn the starter key to the "START" position. Lower the machine operation lock lever. (Release lock) Press the user setting switch (switch 1) and the followng display appears on the screen. (1) User Settings Switch (Switch 1) RY9212182ELS0056US0

2. Press the cursor movement switches (switch 2 or 3) to select "AUX Flow Ctr Set" and press the Set switch (switch 5). (1) Cursor Movement Switches (Switches 2 and 3)

(2) Set Switch (Switch 5) RY9212182ELS0057US0

3. The mode number changes each time switch 5 is pressed. Choose the mode number you want to set. (1) Icon (2) Mode number

(3) Switch 5 RY9212182ELS0058US0

4. Use the following procedure to set the icon. The setting cursor (arrow) moves each time you press switch 4, so move the cursor over the icon. (1) Setting cursor (2) Icon

(3) Switch 4 RY9212182ELS0059US0

5. The icon changes each time switch 2 or 3 is pressed. Choose the icon you want to set. (1) Switch 2 (2) Switch 3

(3) Icon RY9212182ELS0060US0

4-S33

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Types of AUX icons NOTE • There is no relationship between the icons and the flow control settings. Select icons to suit the images of attachments to be connected. • In an action mode with the disable icon preset, such action mode is skipped even if selected. • Take an example of the following settings : AUX (standard) icon for action mode 1, Breaker icon for action mode 2, Disable icon for actions modes 3, 4 and 5. Each time the AUX port enable switch (switch 3) is pressed, the display changes from action mode 1, action mode 2 to normal mode in this order. (a) (b) (c) (d) (e)

AUX (Standard) Brush Cutter Rotary Grapple Grapple Auger

(f) (g) (h) (i) (j)

Clamshell Breaker Tilt Bucket Blank (Disable) Thumb RY9212166ELS0203US0

[ Setting example ] (a) Blank (Disable) Icon RY9212032ELS0080US0

6. Setting the max flow of each AUX port Press switch 4 to move the setting cursor (arrow) to the port 2 position of the right-side AUX port. (1) Settings cursor (arrow)

(2) Switch 4 RY9212182ELS0063US0

4-S34

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM (1) AUX1

(a) Port 1 (b) Port 2 RY9212182ELS0064US0

7. Press switch 2 or 3 to set the max flow. When the bar is set to the maximum level, the flow rate becomes a maximum. If the bar is set to the minimum level (so the bar is not displayed), the oil flow stops. When the switch 4 is pressed again, the system moves to the next port, and settings can be made for all of the other ports. NOTE • There are attachments that will not operate, even if the bar level is slightly above the minimum position. Moreover, even if the ports 1 and 2 (or 3 and 4) are set to the same level, the same speed may not be obtained, but this will not impede the operation of the machine. Readjust the bar to the optimum level, depending on the attachment used. • When the same attachment is installed on another machine, the same setting may not produce the same operating speed, due to variations between the machines. Choose an optimal setting for each machine. (1) Switch 2 (Increase flow) (2) Switch 3 (Decrease flow)

(A) Max Flow (B) No Flow RY9212182ELS0065US0

8. Return to Procedure 3 and set the next operating mode. Once the settings for all operating modes are complete, press switch 1 to return to the normal screen. Max flow of AUX Port Thumb port 1 Max flow (theoretical value) Max pressure

AUX1 port

39.6 L/min

60.5 L/min 2

17.2 MPa (175 kgf/cm , 2500 psi)

IMPORTANT • If the AUX port is unused for a long time, dirt may collect under the AUX port pipe. Remove the plug from the AUX port pipe, and drain approx. 100 cc of oil from either side before connecting an attachment. (1) Switch 1 RY9212182ELS0066US0

4-S35

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

AUX port max. flow setting procedure

RY9212182ELS0067US0

4-S36

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Releasing Residual Pressure in the Hydraulic Circuit Releasing Residual Pressure in the Front Machine 1. Place the machine and the blade on the ground. 2. Turn the starter key to the "STOP" position to switch off the engine. 3. When the engine has stopped, turn the start key back to "RUN". 4. Put the machine operation lock lever in the [Unlock] position. 5. Move the machine operation lever to release the residual pressure in the hydraulic circuit. (1) Machine Lock Lever

(A) Release (B) Lock RY9212182ELS0149US0

Releasing Residual Pressure in the AUX port 1. Place the machine and the blade on the ground. 2. Turn the starter key to the "STOP" position to switch off the engine. 3. When the engine has stopped, turn the start key back to "RUN". 4. Put the machine operation lock lever in the [Unlock] position. (1) Machine Lock Lever

(A) Release (B) Lock RY9212182ELS0150US0

5. Set the AUX port operating switch to "ON". (1) AUX Port Operating Switch RY9212182ELS0151US0

6. Check that none of the AUX port flows are at minimum. If residual pressure is expelled with the AUX port flow set to minimum, then the residual pressure may not be expelled completely and the hose connector may not detach. (1) AUX Port Flow Display

(A) AUX Port Flow Volume (B) Max. (C) Min. RY9212182ELS0152US0

7. Move the AUX port switch connected to the machine operating lever, left and right, to release the residual pressure in the AUX port. (B) AUX Port Flow at Maximum

4-S37

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[4] SERVICE DEALER SETTINGS Mode

(1) Diagnosis

Operation items [A] Tester

While setting "SW5", for the main key from OFF to ON. Tester mode appears on the screen.

[B] Check the Failure Record that Occurred in the Past

Press "SW5", turn the main key from OFF to ON, and select "Retrieve Fail Record".

[C] Cancel of Failure Record

While pressing "SW5", turn the main key from OFF to ON, and select "Delete Fail Record".

[A] AI (Motor, cable, governor sensor adjusted)

While pressing "SW5", turn the main key from OFF to ON, and select "AI set".

AUX1

AUX2 / Thumb

(2) Setting

Operational procedures

[B] Knob exchanged

While pressing "SW5", turn the main key from OFF to ON, and select "AUX1 setting".

[C] with attachment

(With attachment) Setting of the start point, start the engine or lift up the lock lever.

[D] pressure rise of header

(Without attachment) Setting of the start point.

[E] Feeling adjustment

While pressing "SW5", turn the main key from OFF to ON, and select "Feeling adjustment".

[F] Knob exchanged 

While pressing "SW5", turn the main key from OFF to ON, and select "AUX2 / Thumb setting".

[G] with attachment 

(With attachment) Setting of the start point, start the engine or lift up the lock lever.

[H] pressure rise of header 

(Without attachment) Setting of the start point.

[I] Feeling adjustment 

While pressing "SW5", turn the main key from OFF to ON, and select "Feeling adjustment".

[J] Overload warning 

While pressing "SW5", turn the main key from OFF to ON, and select "Overload warning".

[K] Model (ECU and digital panel replaced)

While pressing "SW5", turn the main key from OFF to ON, and select "Model Set". 1. AI motor drive 2. Periodical check guidance cancellation method.

[L] Others

3. Need/non-need of periodic check guidance display. 4. Periodical check offset time. 5. Request for clock adjusting guidance display.

[M] Operate AUX2 by AUX1 knob (Or operate AUX1 by AUX2 knob) 

While pressing "SW5", turn the main key from OFF to ON, and select "Exchang (AUX1, AUX2/thumb)".

[N] Changed condition of Multipurpose switch 

While pressing "SW5", turn the main key from OFF to ON, and select "Multipurpose".

[O] At the time of Replacing the Meters and ECU's

In the case of confirming whether or not.

[P] Resetting of the Clock after Removing the Battery

In the case of resetting of the clock.

[Q] Anti-Theft Device

[R] Overheat Caution

Setting valves of the water temperatures.

: Not used in North American spec. RY9212182ELS0175US0

4-S38

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(1) Diagnosis [A] Tester Using the tester mode to check information about the sensor statuses and switches. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Diagnosis" and press switch 5. (3) Select "Tester" and press switch 5. (4) To [Screen 1] (a) RY9212182ELS0068US0

[Screen 1] Item

Description/std. value

Engine RPM

When engine stopped: 0 Engine RPM: 1050 rpm

Battery voltage

Battery voltage ±0.5V

Oil

Before engine start: ON After engine start: OFF

Charge

Before engine start: ON After engine start: OFF

Starter

Ket to START position : ON Other position : OFF RY9212182ELS0019US0

4-S39

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[Screen 2] Item Voltage (Water temperature)

Description/std. value

Water temperature

Voltage and temperature are displayed. 0 °C (32 °F)→ 4.38 V, 100 °C (212 °F) → 0.91 V (Details are shown in the following table.)

Voltage (Fuel)

E : Higher, F : Lower

Resistance (Fuel)

Full-up (F) : 5 Ω or less Empty (E) : 101.0 Ω or higher

(A) Water Temperature vs Voltage

(a) Water Temperature (°C) (b) Voltage (V) RY9212182ELS0020US0

Fuel dot number Design Value

U35-4

Full

5 Ω or less

1/2 Full

37.45 Ω

3 dots left *

101.0 Ω

Empty

101.0 Ω or higher

* Fuel caution RY9212182ELS0069US0

[Screen 3] Item

Description/std. value

2-speed SW

Press switch: ON

2-speed solenoid

Solenoid : ON/OFF

Lever lock SW

Press switch: ON

Lever lock solenoid

Solenoid : ON/OFF RY9212182ELS0021US0

[Screen 4] Item Accelerator POT

Governor POT Motor amperage

Description/std. value Current value: (0.25 to 4.75V) Set value : Idle (Low), Max (High) Current value: (0.25 to 4.75V) Set value : Idle (Low), Max (High) AI motor operating: 0.0 to 15.0A AI motor stopped: 0.0 to 2.0.0A RY9212182ELS0022US0

4-S40

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[Screen 5] Item

Description/std. value

AI pressure SW

Operation idle : ON Operating: OFF

AI operating SW

Press switch: ON

Compressor

Operating: ON

Water temperature

Displays voltage and temperature 0°C -> 4.38V, 100°C -> 0.91V

Idle up

Idle up set value RY9212182ELS0023US0

[Screen 6] Item

Description/std. value Current value: (0.25 to 4.75V)

AUX1

Set value : Left (Low), Right (High) Set value: neutral (centre)

Amperage

Operating: 0.5 to 2.0A Stopped: 0 to 0.2A

AUX hold SW

Press switch: ON RY9212182ELS0070US0

[Screen 7] Item

Description/std. value Current value: (0.25 to 4.75V)

AUX2/Thumb knob

Set value : Left (Low), Right (High) Set value: neutral (centre)

Amperage

Operating: 0.5 to 2.0A Stopped: 0 to 0.2A

AUX hold SW

Press switch: ON RY9212182ELS0071US0

[Screen 8] Item

Description/std. value

AUX1 R Set AUX1 L Set AUX2 Thumb R Set

AUX start point set value

AUX2 Thumb L Set RY9212182ELS0072US0

[Screen 9] Item

Description/std. value

Arm POT

Current value: (0.25 to 4.75V)

Arm limit set value

Arm limit set value (see table below)

Arm limit setting solenoid

Output : ON, Stopped : OFF

Design Value Arm crowd

1.04 ±0.28 V

Arm dump

4.23 ±0.28 V RY9212182ELS0024US0

4-S41

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[Screen 10] Item

Description/std. value

Anti-theft antenna

Antenna normal  Antenna malfunction: X

Present/Absent, ON/OFF

Key present , Anti-theft mode  Key absent X, anti-theft off X

Red key, Black key

Matching red key , Matching black key  Non-matching red key X, Non-matching black key X

Yellow or green key

Matching yellow key , Matching green key  Non-matching yellow key X, Non-matching green key X

(Tag) yellow or green

Matching yellow key , Matching green key  Non-matching yellow key X, Non-matching green key X RY9212182ELS0025US0

[Screen 11] Item Angle right SW Angle left SW Angle right solenoid Angle left solenoid

Description/std. value Press switch: ON

Output : ON, Stopped : OFF RY9212182ELS0026US0

[Screen 12] Item Tilt right SW

Description/std. value Press switch: ON

Tilt left SW Tilt right solenoid Tilt left solenoid

Output : ON, Stopped : OFF RY9212182ELS0073US0

[Screen 13] Item

Description/std. value

Actual load Rated load Radius

Current value

Height Travel pressure sensor

Current value (MPa) RY9212182ELS0027US0

4-S42

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[Screen 14] Item

Description/std. value Current value: (0.25 to 4.75V)

Arm POT

Set value: Arm crowd (low) Arm dump end (high) Current value: (0.25 to 4.75V)

Boom POT

Set value: boom up end (high)

Bottom pressure, rod pressure

Current value: (0.50 to 4.50V)

Design Value Arm crowd

1.04 ±0.28 V

Arm dump

4.23 ±0.28 V

Boom up

4.22 ±0.28 V RY9212182ELS0028US0

[Screen 15] Item Boom bottom pressure Warning pressure Boom rod pressure

Description/std. value Current value (V) Current value (MPa) Current value (MPa) Current value (V) Current value (MPa) RY9212182ELS0074US0

[Screen 16] Item Multipurpose switch 1 SW Multipurpose switch 2 SW Multipurpose switch solenoid

Description/std. value Press switch: ON Output : ON, Stopped : OFF RY9212182ELS0075US0

[Screen 17] Item

Description/std. value

Compressor

ON when operating

Boom up pressure SW

Output : ON, Stopped : OFF

EP SW

Press switch: ON

Pump solenoid

Current amperage [A] RY9212182ELS0076US0

[Screen 18] Item Travel pressure sensor DPF SW

Description/std. value Current value (V) Current value (MPa) Press switch: ON

Worklight SW

Press switch: ON

Engine stop SW

Press switch: ON RY9212182ELS0077US0

4-S43

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[Screen 19] Japan RX Spec. only Sensor / Switch mounted Item

Description/std. value

Boom POT Arm POT

Current value: (0.25 to 4.75V)

Offset POT Set Boom Arm

Set value: boom up (high), arm crowd (low)

Set OFF

Set value: offset right (high) Design Value

Arm crowd

1.41 ±0.28 V

Boom up

4.38 ±0.28 V

Offset right

3.37 ±0.28 V RY9212182ELS0029US0

[Screen 20] Japan RX Spec. only Sensor / Switch mounted Item

Description/std. value

Boom solenoid Arm dump/crowd

Stopped: 0.0 to 0.6A Operating: 0.4 to 1.2 A

Offset solenoid Set ArD ArC

Start point setting: arm dump, arm crowd

Set Bo Of

Start point setting: boom up, offset right RY9212182ELS0030US0

[Screen 21] Japan RX Spec. only Sensor / Switch mounted Item Emergency SW

Description/std. value Press switch: ON ON

Boom up pressure SW

Boom up operation : ON

Boom height limit

Normal : ON; At height limit: OFF RY9212182ELS0031US0

[Screen 22] Item

Description/std. value

Meter

If correct,  (If no meter, )

ECU (main)

If correct,  (If no ECU (main), )

ECU (AS)

If RX→, U→X, KX→X (If no ECU(AS), )

ECU (CRS)

Common rail → No common rail →X RY9212182ELS0032US0

[Screen 23] Item

Description/std. value

Meter

(Empty)

Ver

Program version

Rev

Program creation date (Y/M/D)

Serial No.

Serial no. (different number each machine) RY9212182ELS0033US0

4-S44

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[Screen 24] Item

Description/std. value

ECU (main)

(Empty)

Ver

Program version

Rev

Program creation date (Y/M/D)

Serial No.

Serial no. (different number each machine) RY9212182ELS0034US0

[Screen 25] Item

Description/std. value

ECU (AS)

(Empty)

Ver

Program version

Rev

Program creation date (Y/M/D)

Serial No.

Serial no. (different number each machine) RY9212182ELS0035US0

Return to original display RY9212182ELS0036US0

CAUTION • Indication does not disappear even if you turn off the key in the tester mode. When it is completed, press SW1, and get out of tester mode. (When you turn off the key and leave if as tester mode, indication disappears three minutes later.) RY9212182ELS0037US0

4-S45

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Reading the Failure History (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Diagnosis" and press switch 5. (3)

(4)

Select "Retrieve fail record" and press switch 5. Display screen if there is no fail record

(5) Fail record display screen. (6)

(a) Shows ECU where a Failure has been Detected. (Main) (Meter) Related Part (b) Number of Occurrences (1 to 255) (c) First Occurrence Date (Day/Month/Year) and Hour Meter Reading, and Last Occurrence Date (Day/Month/Year) and Hour Meter Reading. RY9212182ELS0078US0

[C] Erasing Failure History (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Diagnosis" and press switch 5. (3)

(4)

Select "Delete fail record" and press switch 5. Deletion of the fail record completed.

(5) RY9212182ELS0079US0

4-S46

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

List of Failure Codes

ECU (Meter)

ECU (Main)

Failure codes

Cause of generation and the measures

Engine Oil Err

Detect the decrease in the engine oil pressure. The oil switch is in trouble or defect in harness, repair or replace it.

Charging Sys Err

Detect the power generation decrease. The alternator is in trouble or the fan belt came off or defect in harness, repair or replace it.

Overheat

The machine is overheated and must cool off by idling.Refill the radiator with coolant by its boiled-over amount. Unclog the radiator and other components before use again.Check also the hydraulic system for oil leak and other troubles.

Fuel Sensor

The fuel sensor is in trouble or defect in harness, repair or replace it.

Water Temperature Sensor

The water temperature sensor is in trouble or defect in harness, repair or replace it.

CAN Sys (Main)

Defect in harness or defect in ECU (main), repair or replace it.

Setting Data Err

Set the model again. It is defective in the meter when still not repaired.

Lever Lock Sol

The lever lock Sol is in trouble or defect in harness, repair or replace it.

2-Speed Sol

The travel 2-speed Sol is in trouble or defect in harness, repair or replace it.

Multipurpose Sol

The multipurpose Sol is in trouble or defect in harness, repair or replace it.

AUX1 Knob

The AUX1 port knob is in trouble or defect in harness, repair or replace it.

AUX1 R Sol

The AUX1 Sol (right) is in trouble or defect in harness, repair or replace it.

AUX1 L Sol

The AUX1 Sol (left) is in trouble or defect in harness, repair or replace it.

External 5V

The sensor's 5V power supply is short-circuited, repair or replace it.

Overvoltage

A jimper cable is connected to a 24V battery or improper device to get the engine started or the alternator is in trouble, repair or replace it.

Angle R Sol

The Angle Blade Sol (right) is in trouble or defect in harness, repair or replace it.

Angle L Sol

The Angle Blade Sol (left) is in trouble or defect in harness, repair or replace it.

Governor Sensor

The governor sensor is in trouble or defect in harness, repair or replace it.

Accel Sensor

The accelerator sensor is in trouble or defect in harness, repair or replace it.

AI Motor

The AI motor is in trouble or defect in harness, repair or replace it.

Antenna

The antenna for anti-theft is in trouble or defect in harness, repair or replace it. RY9212182ELS0176US0

4-S47

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(2) Setting [A] AI Setting Setup procedure required when adjusting the AI motor, AI motor cable or governor sensor (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2)

(3)

Press switch 2 to select "Setting" and then press switch 5. Select "AI Set" and press switch 5.

(4)

(5)

This screen is displayed if set to "Not AI spec." by the model settings.

(a)

From here, follow instructions on panel to complete settings. Raise the lever lock.

(6) Start the engine. (7)

(8)

Set the idle rpm and press switch 5. (Press switches 2 and 3 to change the rpm in 50 rev increments.) • Pressing switch 2 ( ) reduces the number. • Pressing switch 3 ( ) increases the number. U35-4 → 1050 rpm (factory spec.) 1300 rpm (max. value)

(9)

Set the accelerator to [MAX] and press Switch 5.

(10)

Set the accelerator to idling and press Switch 5.

(b)

Setup completed in about 1 minute and 20 seconds.

RY9212182ELS0080US0

4-S48

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] AUX1 Setting (Knob exchanged) Setup for knob (AUX1) when exchanging AUX1 knob (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

Select "AUX1 Set" and press switch 5.

(5)

Select "Knob Set (AUX1)" and press switch 5.

(6)

Turn the AUX1 knob to the right end and press switch 5.

(7)

Turn the AUX1 knob to the left end and press switch 5.

(8)

Turn the AUX1 knob to neutral and press switch 5. [Setup complete]

(9)

(a)

If AUX1 set to "Not AUX Spec." by model settings. RY9212182ELS0081US0

4-S49

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] AUX1 Setting (with attachment) If the AUX1 proportionating valve or spool is changed: Setup mode with light-load attachment fitted, such as thumb. If not available, can also be used with bucket. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4) (5)

Select "AUX1 Set" and press switch 5. Select "(w/ Attach) Set" and press switch 5. When messages are displayed, follow the relevant instructions.

(6)

(7)

(a): Raise lever lock (b): Start engine (c): Lower lever lock Set the accelerator to [MAX], move the attachment to the indicated position, and press Switch 5.

(8)

When the attachment has moved left, press switch 5.

(9)

When the attachment has moved right, press switch 5. [Setup complete]

(10)

(d)

If AUX1 set to "Not AUX Spec." by model settings. RY9212182ELS0082US0

4-S50

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] AUX1 Setting (pressure rise of header) If the AUX1 proportionating valve or spool has been changed, a pressure rise is set for the pressure header. This is a fine adjustment made when an attachment is not available. 1. Place a lid on both AUX port outlets and connect a pressure gauge. 2. Adjust each side and when both pressures have risen suddenly, press SW5 to set. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

(5)

Select "AUX1 Set" and press switch 5. Select "(w/out Attach) Set" and press switch 5. When messages are displayed, follow the relevant instructions.

(6)

(7)

(a): Raise lever lock (b): Start engine (c): Lower lever lock Set the accelerator to [MAX], move the attachment to the indicated position, and press Switch 5.

(8)

When the SP port (left) pressure rises suddenly, press switch 5.

(9)

When the SP port (right) pressure rises suddenly, press switch 5. [Setup complete]

(10)

(d)

If AUX1 set to "Not AUX Spec." by model settings. RY9212182ELS0083US0

4-S51

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[E] AUX1 Setting (Feeling adjustment) Setup for changing feeling of AUX1 Mode for unexpected situations where the adjustment for operating with or without an attachment has not been successful and manual correction is required. The existing set values can be changed directly by operating the buttons. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4) (5)

Select "AUX1 Set" and press switch 5. Select "Feeling Adj." and press switch 5. When messages are displayed, follow the relevant instructions.

(6)

(7)

(a): Raise lever lock (b): Start engine (c): Lower lever lock Change the numerical values, while continually checking the feeling, and press switch 5. [Setup complete]

(8)

(d)

If AUX1 set to "Not AUX Spec." by model settings. RY9212182ELS0084US0

4-S52

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[F] AUX2 / Thumb Setting (Knob exchanged) Knob (AUX2/Thumb) setup when AUX2/Thumb knob is changed (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

Select "AUX2/Thumb Set" and press switch 5.

(5)

Select "Knob Set (AUX2/Thumb)" and press switch 5.

(6)

Turn the AUX2 knob to the right end and press switch 5.

(7)

Turn the AUX2 knob to the left end and press switch 5.

(8)

Turn the AUX2 knob to neutral and press switch 5. [Setup complete]

(9)

(a)

If AUX2/Thumb set to "Not AUX Spec." by model settings.

RY9212182ELS0085US0

4-S53

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[G] AUX2 Setting (with attachment) If the AUX2/Thumb proportionating valve or spool is changed: Setup mode with light-load attachment fitted, such as thumb. If not available, can also be used with bucket. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

(5)

Select "AUX2/Thumb Set" and press switch 5. Select "(w/ Attach) Set" and press switch 5. When messages are displayed, follow the relevant instructions.

(6)

(7)

(a): Raise lever lock (b): Start engine (c): Lower lever lock Set the accelerator to [MAX], move the attachment to the indicated position, and press Switch 5.

(8)

When the attachment has moved left, press switch 5.

(9)

When the attachment has moved right, press switch 5. [Setup complete]

(10)

(d)

If AUX2/Thumb set to "Not AUX Spec." by model settings. RY9212182ELS0086US0

4-S54

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[H] AUX2 / Thumb Setting (pressure rise of header) If the AUX2/Thumb proportionating valve or spool has been changed, a pressure rise is set for the pressure header. This is a fine adjustment made when an attachment is not available. 1. Place a lid on both AUX port outlets and connect a pressure gauge. 2. Adjust each side and when both pressures have risen suddenly, press SW5 to set. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

Select "AUX2/Thumb Set" and press switch 5.

(5)

Select "(w/out Attach) Set" and press switch 5. When messages are displayed, follow the relevant instructions.

(6)

(7)

(a): Raise lever lock (b): Start engine (c): Lower lever lock Set the accelerator to [MAX], move the attachment to the indicated position, and press Switch 5.

(8)

When the SP port (left) pressure rises suddenly, press switch 5.

(9)

When the SP port (right) pressure rises suddenly, press switch 5. [Setup complete]

(10)

(d)

If AUX2/Thumb set to "Not AUX Spec." by model settings. RY9212182ELS0087US0

4-S55

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[I] AUX2 / Thumb Setting (Feeling adjustment) Setup for changing feeling of AUX2/Thumb Mode for unexpected situations where the adjustment for operating with or without an attachment has not been successful and manual correction is required. The existing set values can be changed directly by operating the buttons. (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

(5)

Select "AUX2/Thumb Set" and press switch 5. Select "Feeling Adj." and press switch 5. When messages are displayed, follow the relevant instructions.

(6)

(7)

(a): Raise lever lock (b): Start engine (c): Lower lever lock Change the numerical values, while continually checking the feeling, and press switch 5. [Setup complete]

(8)

(d)

If AUX2/Thumb set to "Not AUX Spec." by model settings. RY9212182ELS0088US0

4-S56

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[J] Overload Warning Setting Setup for "Over load warning pressure (EU spec.)" (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

(5)

Select "Over Load Warning" and press switch 5. Enter the warning pressure number and press switch 5.

Press switch 5. (6) [Setup complete] (7)

(a)

If Over load warning set to not available by model settings. RY9212182ELS0089US0

4-S57

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[K] Model Setting Setup procedure required when changing the ECU or meter (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

Press switch 2 to select "Model Set" and then press switch 5.

(5)

Press switch 2 to select "Model" and then press switch 5. Select "Country name" and press switch 5.

(6) Select "AI YES or NO" and press switch 5. (7)

(8)

Select "Over load warning YES or NO" and press switch 5.

(9)

Select AUX1 spec. "Hand (Yes)" and press switch 5.

(10)

Select AUX2/Thumb spec. "Hand (Yes)" and press switch 5.

(11)

Select the Arm control spec. "YES or NO" and press switch 5.

(12)

Select "YES" if there is an angle blade and "NO" if there is no angle blade, and then press switch 5.

(13)

Select "YES" if there is a tilt blade and "NO" if there is no tilt blade, and then press switch 5.

(14)

(15)

(16)

(17)

(18)

Select "Multipurpose Operating YES or NO" and press switch 5. Select "Arm Type" and press switch 5. Select "Compartment Type" and press switch 5. Select "Force mode" and press switch 5. Select "Common Rail System YES or NO" and press switch 5. [Setup complete]

(19) RY9212182ELS0090US0

4-S58

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Setup example for U35-4 Screen No.

Content displayed

Notes

(5)

Select Model

U35-4

(6)

Select destination

America Canada

(7)

Select AI Yes/No

Standard equipment, so select YES

(8)

Select Over Load Warning Yes/No

Set to NO

(9)

Select AUX-1 Yes/No

Set to YES

(10)

Select AUX-2/Thumb Yes/No

Set to NO

(11)

Select Arm Control Yes/No

Set to NO

(12)

Select Angle Yes/No

Set to YES for Angle spec.

(13)

Select Tilt Yes/No

Set to YES for Tilt spec.

(14)

Select Multipurpose Switching Yes/No

Set to NO when shipped

(15)

Select arm spec.

Set to 1

(16)

Select compartment spec.

Set to canopy or cab

(17)

Select horsepower control mode

Set 2 for A/C spec and 0 otherwise.

(18)

Select common rail system Yes/No

Set to NO RY9212182ELS0177US0

[L] Others 1. AI motor drive Setup procedure when moving AI motor lever position (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2)

(3)

Press switch 2 to select "Setting" and then press switch 5.

(4)

Press switch 2 to select "Others" and then press switch 5.

(5) (6)

Select "AI Motor Drive" and press switch 5. Switch 2 moves the AI motor to idling and switch 3 moves the AI motor to [MAX]. RY9212182ELS0091US0

4-S59

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

2. Clearing Periodic Check Guidance Setup procedure for changing method of clearing periodic check guidance (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2)

(3)

Press switch 2 to select "Setting" and then press switch 5.

(4)

Press switch 2 to select "Others" and then press switch 5.

(5)

Press switch 2 to select "Clear Periodic Check Guidance" and then press switch 5.

(6)

Select "Auto" or "Manual" and press switch 5. (Set to Auto on shipment) [Setup complete]

(7)

Method of clearing periodic check guidance

[Auto]

• Turn key on and off ten times. • At the question "Periodic Check completed?" on the periodic check screen, press "Yes".

[Manual]

• At the question "Periodic Check completed?" on the periodic check screen, press "Yes". • (Screen is not cleared by switching key on and off.) RY9212182ELS0092US0

3. Switching periodic check guidance display on/off Setup procedure for switching display of periodic check guidance on/off (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2)

(3)

Press switch 2 to select "Setting" and then press switch 5.

(4)

Press switch 2 to select "Others" and then press switch 5.

(5)

Press switch 2 to select "Periodic Check Guidance Display" and then press switch 5.

(6)

Select "On / Off " and press switch 5. [Setup complete]

(7) RY9212182ELS0093US0

4-S60

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4. Periodic check offset time Procedure for entering operating time in new meter after replacement (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2)

(3)

Press switch 2 to select "Setting" and then press switch 5.

(4)

Press switch 2 to select "Others" and then press switch 5.

(5)

(6)

Press switch 2 to select "Adjust Periodic Check Offset Time" and then press switch 5. Set the hour meter to the reading before replacement and press switch 5. [Setup complete]

(7) RY9212182ELS0094US0

5. Clock adjustment guidance display Setup procedure for switching off clock setup warning (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2)

(3)

Press switch 2 to select "Setting" and then press switch 5.

(4)

Press switch 2 to select "Others" and then press switch 5.

(5)

Select "Clock Set Warning" and press switch 5.

(6)

Select "On / Off " for the clock adjustment guidance and press switch 5. [Setup complete]

(7) RY9212182ELS0095US0

4-S61

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[M] Operate AUX2 / Thumb by AUX1 knob (Or operate AUX1 by AUX2 / Thumb knob) (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3) Select "Others" and press switch 5. (4)

(5)

Select "Exchange (AUX1 AUX2/Thumb)" and press switch 5.

(6)

Select "Normal" or "Reverse" and press switch 5. [Setup complete]

(7) RY9212182ELS0096US0

[N] Set up changed condition of Multipurpose switch (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3) Select "Other" and press switch 5. (4)

(5)

(6)

Select "Multipurpose mode" and press switch 5.

Change the mode number and then press switch 5. • Available mode numbers: 00 to 10 Mode number when shipped: 00 (Multipurpose switch function disabled and AUX2 hold function disabled) [Setup complete]

(7)

NOTE • See "Multipurpose switch function" for details of the multipurpose switch settings. RY9212182ELS0097US0

4-S62

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[O] At the time of Replacing the Meters and ECU’s The message below is shown when the meter and ECU are changed. 1. To check for temporary change for the meter and ECU of another machine (1)

Switch 1, press "No".

(2)

Normal screen displayed. RY9212182ELS0098US0

2. If meter and ECU changed for new parts Switch 5, press "Yes". (1)

(2)

Press switch 5 "Yes" if the meter has been changed. Press switch 1 "No" if the ECU has been changed. [Initializes saved settings.] Pressing switch 4 allows you to check the items that need to be set up.

(3)

(4)

Check the required items, and then turn the key to [STOP] and make the necessary settings.

RY9212182ELS0099US0

4-S63

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[P] Resetting of the Clock after Removing the Battery If clock is not to be reset (1)

(2)

Disconnect the battery, then reconnect the battery and turn the key to [RUN], (A)STOP, (B)RUN, (C)START When "Set Clock" is displayed, press Switch 1 "No". Normal screen

(3) RY9212182ELS0100US0

If clock is to be reset (1)

(2)

Disconnect the battery, then reconnect the battery and turn the key to [RUN], (A)STOP, (B)RUN, (C)START When "Set Clock" is displayed, press Switch 5. Set the clock and then press switch 5.

(3) [Setup complete] (4)

[Clock setting guide] • Pressing switch 4 ( ) changes the setting item from Yr→ Mo→ Day→ Hr→ Min→ Yr. • Pressing switch 2 ( ) reduces the number. • Pressing switch 2 ( ) increases the number. • Pressing switch 1 while on the clock setting screen takes the screen back without changing the time. Clock precision: 2 seconds/day The clock set warning can be switched off if so desired by the user. (Set to display when shipped) RY9212182ELS0101US0

4-S64

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[5] LIST OF WARNING ALARM DISPLAYS (1) Warning Display List When needed, pressing switch 4 Display

displays a detailed description. Problem or failure (Circumstances)

Behaviour of machine (provisional action)

Meter Engine oil pressure error

Fall in oil pressure in engine lubrication system

Risk of engine seizure : stop engine immediately

–

Meter Over heat

Cooling water temperature above set temperature

Halt work until the message disappears. Keep engine idling.

–

Meter Charging System Error

Failure or charging error in charging system

The machine will operate until the battery dies.

Meter Fuel Sensor Error

Failure in fuel sensor system

The fuel level indicator is not displayed on the meter. Other functions of the machine can be used.

Failure in communications system

The engine may start and the machine may move. However, the machine cannot carry out any work.

Failure in 2-speed switching system

Machine continues at low speed rather than switching to high speed. Other functions can be used.

AUX1 Port system failure

The engine restarts and the machine moves. But AUX1 is not usable. If other equipment is functioning, then work can be continued.

Lamp

Pressing SW4

Red

–

Red

–

CANSys (main)

Message in fail record

Meter CAN Sys (Main)

Red CANSys (CRS)

Red

Meter CAN Sys (CRS)

2-speed SOL

Main 2-speed solenoid

AUX1 knob

Main AUX1 knob

AUX1 right SOL

Main AUX1 right solenoid

AUX1 left SOL

Main AUX1 left solenoid

Over voltage

Main Over voltage

Angle right solenoid

Main Angle right solenoid

Red

Angle left solenoid

Main Angle left solenoid

Accelerator sensor

Main Aceelerator sensor

4-S65

• Jump start cable connected to 24V battery or unsuitable device • Failure in alternator

If connected to 24V battery, stop immediately

Failure in angle system

The engine restarts and the machine moves. But the angle is not usable. If other equipment is functioning, then work can be continued.

Failure in accelerator dial

Engine doesn't return automatically to idling, but other functions can be used.

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

Display

Lamp

Pressing SW4

Message in fail record

Problem or failure (Circumstances)

Behaviour of machine (provisional action)

Red

Antenna

Main Antenna

Failure in anti-theft system

Engine cannot be started

Red

Lever lock solenoid

Main Lever lock solenoid

Failure in lever lock system

Engine will start, but machine cannot be operated

Sensor or 5V power shorted

Major system failure. The engine may start and the machine may move. However, the machine cannot carry out any work.

Red

External 5V

Main external 5V

RY9212182ELS0178US0

4-S66

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(2) Warning Display List Display

Lamp

Cause

Yellow

Fuel low Displayed at 6 minute intervals.

Yellow

Water temperature rising. Displayed at 6 minute intervals.

Yellow

Tried to start engine with an unregistered key

Yellow

Tried to start engine with red key

Yellow

Periodic check within 10 hours

Yellow

Periodic check time has passed

Yellow

Periodic check set for this month

Yellow

The clock may be set to the wrong time.

–

When meter or ECU replaced without doing setup

–

During setup after changing the meter or the ECU, this screen comes up to confirm the meter has been changed.

4-S67

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM Display

Lamp

Cause

–

When neither the meter nor the ECU have been replaced, but some settings need to be made.

–

Tried to start the engine with the lever lock still down.

–

Switch 3 (AUX) pressed with the lever lock still up.

–

Key turned to OFF but not taken out (Anti-theft spec. only)

–

Switch 3 (AUX) pressed on a machine without AUX1/AUX2/Thumb spec.

–

AI switch pressed on a machine without AI spec.

–

Multipurpose switch pressed without being registered.

–

Screen for clearing the trip fuel amount

–

Communicating with the key

RY9212182ELS0179US0

4-S68

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

7. TROUBLESHOOTING (METER PANEL EDITION) [1] MACHINE RELATED SYSTEM (1) Engine Oil Pressure Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Check whether the oil lamp (b) is lit in red or off. (1) Engine Oil Press Err Stop Engine

(a) Warning Lamp (b) Oil Lamp RY9212032ELS0008US0

[Test Conditions] 1. Key switch : ON (a) If the oil lamp is lit : caused by a short (b) If the oil lamp is off : caused by break in wiring Criteria Regular : no break Irregular : has a break Irregular : shorted RY9212166ELS0089US0

2. Reading the failure history 1. Select the failure history read mode. 2. Read the failure history and check the date (y/m/d) and hour meter of the last occurrence. Ex.) The last failure record was February 6, 2009 at 37 hours. (a) Failure (b) Number of Failure

4-S69

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

3. Tester mode 1. Select the tester mode. 2. Check the operation of the oil switch according to the table below. Regular

Oil Lamp

When cut off

Oil Lamp

When shorted

Oil Lamp

Key Off

Off

Key On

Lit

Off

Lit

Key Start

Off

Lit

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Engine Speed Battery V Oil SW Charging Starter RY9212032ELS0002US0

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The oil switch connector is disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the oil switch again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212166ELS0090US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The oil switch wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the oil switch again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212182ELS0102US0

4-S70

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the oil switch connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

Oil switch connector

<1>

Connector Name (- terminal side) Body GND

Pin No. –

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0092US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect meter connector. 3. Test the continuity based on the table below. Measurement (a)

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

<9>

Oil switch connector

<1>

Meter connector

Regular : Continuity Irregular : No continuity RY9212166ELS0093US0

[D] Testing the Equipment Itself 1. Measuring engine pressure [Measurement Conditions] 1. Remove the oil switch, attach a pressure gauge and measure the pressure. When Idling

Engine Oil Pressure At Rated RPM

Tightening torque

Usable Limit

49 KPa 0.5 kgf/cm2 7.0 psi

Factory specification

294 to 441 KPa 3.0 to 4.5 kgf/cm2 42.7 to 64.0 psi

Usable Limit

250 KPa 2.5 kgf/cm2 36 psi

Oil switch tapering screw R1/8

15 to 19 N-m 1.5 to 2.0 kgf·m 11 to 14 lbf·ft

Criteria Regular : Within factory specification Irregular : Outside factory specification

2. Settings after replacing device

RY9212182ELS0103US0

1. No settings required. RY9212001ELS0013US0

4-S71

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

3. Erasing failure history 1. After completing repairs, select Erase Failure History and erase the records. 2. After erasing the records, read the failure history again and make sure there are no failures. Criteria Regular : Failure history erased Irregular : failure history not erased (1) No Fail Record RY9212032ELS0003US0

4-S72

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(2) Charging System Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Check whether the charging lamp (b) is lit in red or off. (1) Charging Sys Err

(a) Warning Lamp (b) Charging Lamp RY9212032ELS0009US0

[Test Conditions] 1. Key switch : ON (a) If the charging lamp is lit : caused by a short (b) If the charging lamp is off : caused by break in wiring Criteria Regular : no break Irregular : has a break Irregular : shorted RY9212166ELS0095US0

3. Tester mode 1. Select the tester mode. 2. Check the operation of the charging lamp according to the table below. Regular Key Off

Charging Lamp

When cut off

Charging Lamp

When shorted

Charging Lamp

Off

Key On

Lit

Off

Lit

Key Start

Off

Lit

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Engine Speed Battery V Oil SW Charging Starter RY9212166ELS0163US0

4-S73

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses Check whether the alternator fuse (10A) is blown. RY9212001ELS0064US0

2. Checking relays 1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The alternator connector is disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the charging switch again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212166ELS0097US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The alternator connector wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the charging switch again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212182ELS0105US0

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect alternator connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

Alternator connector

<1>

Body GND

–

(b)

Alternator connector

<2>

Body GND

–

Connector Name (- terminal side)

Pin No.

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0099US0

4-S74

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect meter connector. 3. Remove the 10A fuse. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

(a)

Meter connector

(b)

10A fuse

Pin No.

Connector Name (- terminal side)

<10>

Alternator connector

<2>

Meter connector

<1>

–

Pin No.

Regular : Continuity Irregular : No continuity RY9212166ELS0100US0

[D] Testing the Equipment Itself 1. Inspecting the alternator 1. Check for a cut, loose or slipping fan belt. 2. Measure the voltage between terminal B of the alternator and body GND. If the measured voltage is about 12V, it is normal. If the measured voltage is low, it may indicate insufficient battery capacity or looseness in connections somewhere before the alternator. 3. Next, start the engine and measure the voltage generated when the alternator is operating. Take the measurement between terminal B on the alternator side and the body GND. If the measured voltage is about 14V, it is normal. If the measured voltage does not vary from the battery voltage (about 12V), then the alternator itself or the regulator is faulty. Criteria Regular : Within factory specification Irregular : Outside factory specification (A) Displacement 7 to 9 mm (0.3 to 0.4 in.) RY9212182ELS0106US0

2. Settings after replacing device 1. No settings required. RY9212001ELS0013US0

4-S75

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(3) Fuel Sensor Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel Check whether or not the warning lamp (a) on the panel is blinking red or not. (1) Fuel Sensor Err

(a) Warning Lamp RY9212032ELS0010US0

[Test Conditions] 1. Key switch : ON (a) If the fuel level is at the top : caused by a short (b) If the fuel level is blank : caused by a break Criteria Regular : no break Irregular : has a break Irregular : shorted RY9212166ELS0102US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Check the display for the voltage and resistance of the fuel based on the following table. Fuel voltage

Resistance

2.3 V

92Ω

When cut off

5.00 V

260Ω

When shorted

0.00 V

0Ω

Regular (reference value)

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Water Temp. Fuel Refueling SW RY9212166ELS0103US0

4-S76

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. Fuel sensor connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the voltage and resistance for the fuel again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212166ELS0104US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The fuel sensor wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the voltage and resistance for the fuel again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212166ELS0105US0

4-S77

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the fuel sensor connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Fuel sensor connector

<1>

Fuel sensor connector

<2>

(b)

Fuel sensor connector

<1>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0106US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect meter connector. 3. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Fuel sensor connector

<1>

Meter connector

<1>

(b)

Meter connector

<14>

Fuel sensor connector

<2>

Regular : Continuity Irregular : No continuity RY9212166ELS0107US0

4-S78

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Inspecting the fuel sensor [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the connector from the fuel sensor and take measurements. 3. Refer to the following table for the resistance at different float positions. Factory specification Float position

F (a)

1/2 (b)

E (c)

Resistance value (Ω)

3 ±1

32.5

110 ±2.5

Criteria Regular : Within factory specification Irregular : Outside factory specification (a) Full (b) Half

2. Settings after replacing device

RY9212166ELS0108US0

1. No settings required. RY9212001ELS0013US0

4-S79

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(4) Water Temperature Sensor Errors [A] Checking via the Meter Panel Display 1. LCD Panel Display Check whether or not the warning lamp (a) on the panel is blinking red or not. (1) Water Temp. Sensor Err

(a) Warning Lamp RY9212032ELS0012US0

[Test Conditions] 1. Key switch : ON (a) If the water temperature level is at the top : caused by a short (b) If the water temperature level is at the bottom : caused by a break Criteria Regular : no break Irregular : has a break Irregular : shorted RY9212182ELS0167US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Check the display for the voltage and temperature of the water based on the following table. Water temperature voltage

Water temperature

Regular

1.0 V

86 °C, 187 °F

When cut off

5.00 V

–50 °C, –58 °F

When shorted

0.00 V

150 °C, 302 °F

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Water Temp. Fuel Refueling SW RY9212032ELS0013US0

4-S80

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. Water temperature sensor connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the voltage and temperature of the water temperature again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212182ELS0168US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The water temperature sensor wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the voltage and temperature for the water temperature again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212182ELS0143US0

4-S81

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the water temperature sensor connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

(a)

Water temperature connector

<1>

Water temperature connector

<2>

(b)

Water temperature connector 2

<1>

Body GND

–

Pin No.

Connector Name (- terminal side)

Pin No.

Regular : 5V Irregular : Large discrepancy from 5V RY9212182ELS0169US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect meter connector. 3. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

(a)

Water temperature connector

<1>

Meter connector

<2>

(b)

Water temperature connector

<3>

Meter connector

<2>

Pin No.

Connector Name (- terminal side)

Pin No.

Regular : Continuity Irregular : No continuity RY9212182ELS0170US0

4-S82

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Inspecting the water temperature sensor [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the connector from the water temperature sensor and take measurements. 3. Refer to the following table for the resistance at different temperatures. 4. Refer to the graph at left on the relationship between water temperature and resistance. Water Temperature (°C)

Resistance

– 20

15.04 kΩ

2.45 kΩ

1.66 kΩ

1.15 kΩ

811 Ω

584 Ω

428 Ω

318 Ω

240 Ω

100

183.6 Ω

110

141.7 Ω

Criteria Regular : Within factory specification Irregular : Outside factory specification (A) Water Temperature and Resistance

(a) Water Temperature (°C) (b) Resistance (Ω)

2. Settings after replacing device

RY9212182ELS0171US0

1. No settings required. RY9212001ELS0013US0

4-S83

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[2] FRONT-END SYSTEMS (1) Lever Lock System Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) Lever lock SOL (1) Lever Lock Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0014US0

3. Tester mode 1. 2. 3. 4.

Select the tester mode. Start the engine. Put the machinery operation lever lock in the [Unlock] position. Operate the lever lock switch and lever lock solenoid and check the switch according to the following table. Regular

Warning lamp

When cut off

Warning lamp

When shorte d

Warning lamp

Lever lock switch ON

Off

Lever lock switch OFF

Off

Lever lock solenoid ON

Off

Lever lock solenoid OFF

Off

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) 2 Speed SW 2 Speed SOL Lever Lock SW Lever Lock SOL Air Cleaner

RY9212166ELS0201US0

4-S84

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the 5A lever lock fuse is blown. RY9212001ELS0088US0

2. Checking relays 1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The lever lock switch connector is disconnected. 3. The lever lock solenoid connector is disconnected. 4. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the lever lock switch and lever lock solenoid in the tester mode. Criteria Regular : no break Irregular : has a break (a) Lever Lock Solenoid Connector

(b) Lever Lock Switch Connector RY9212182ELS0108US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The lever lock switch connector wire and/or lever lock solenoid connector are pinched against or touching the body. If the insulation is damaged, repair it properly and check the lever lock switch and the lever lock solenoid again in the tester mode. Criteria Regular : no short Irregular : shorted (a) Lever Lock Switch Connector C RY9212182ELS0109US0

4-S85

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check (lever lock switch) [Measurement Conditions] 1. Disconnect the lever lock switch connector. 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position. 4. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Lever lock switch connector

<2>

Lever lock switch connector

<1>

(b)

Lever lock switch connector

<2>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0112US0

2. Continuity check (lever lock switch) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect lever lock switch connector and lever lock solenoid connector. 3. Put the machinery operation lever lock in the [Unlock] position. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Lever lock fuse

–

Lever lock switch connector

<2>

(b)

Lever lock switch connector

<2>

Lever lock solenoid connector

<1>

Regular : Continuity Irregular : No continuity RY9212166ELS0113US0

4-S86

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

3. Voltage check (lever lock solenoid) [Measurement Conditions] 1. Disconnect lever lock solenoid connector. 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position. 4. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Lever lock solenoid connector

<1>

Lever lock solenoid connector

<2>

(b)

Lever lock solenoid connector

<1>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0114US0

4. Continuity check (lever lock solenoid) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the ECU connector. 3. Disconnect lever lock solenoid connector. 4. Put the machinery operation lever lock in the [Unlock] position. 5. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

Lever lock solenoid connector

<1>

ECU connector

<67>

(b)

Lever lock solenoid connector

<2>

ECU connector

<62>

Connector Name (- terminal side)

Pin No.

Regular : Continuity Irregular : No continuity RY9212166ELS0115US0

4-S87

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Inspecting the lever lock switch [Test Conditions] 1. Key switch : OFF 2. Disconnect the lever lock switch connector from the machine, press the switch and measure it separately. Criteria Regular : no break Irregular : has a break (a) Lever Lock Switch (b) Lever Lock Switch Connector

2. Testing the lever lock solenoid [Test Conditions] 1. Key switch : OFF 2. Disconnect lever lock solenoid connector from the machine and test the solenoid separately. Lever lock solenoid

Factory specification

12 Ω ±10 %

Criteria Regular : no break Irregular : has a break (a) Lever Lock Solenoid Terminals

3. Settings after replacing device

RY9212166ELS0117US0

1. No settings required. RY9212001ELS0020US0

4. Erasing failure history 1. After completing repairs, select Erase Failure History and erase the records. 2. After erasing the records, read the failure history again and make sure there are no failures. Criteria Regular : Failure history erased Irregular : failure history not erased (1) No Fail Record RY9212032ELS0004US0

4-S88

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(2) Travel 2-Speed System Error [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) 2-speed solenoid (1) Travel2 Speed Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0016US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch. 4. Operate the 2-speed switch and check the 2-speed switch and 2-speed solenoid based on the following table. Regular

2speed lamp

When cut off

2speed lamp

When shorte d

2speed lamp

2-speed switch ON

Lit

Off

2-speed switch OFF

Off

2-speed solenoid ON

Lit

Off

2-speed solenoid OFF

Off

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) 2 Speed SW 2 Speed SOL Lever Lock SW Lever Lock SOL Air Cleaner

(a) 2-Speed Switch

RY9212166ELS0202US0

4-S89

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. RY9212001ELS0008US0

2. Checking relays 1. Checking relays is not necessary.

RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The 2-speed solenoid connector disconnected. 3. The 2-speed switch connector disconnected. 4. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the 2-speed solenoid and the 2-speed switch in the tester mode. Criteria Regular : no break Irregular : has a break (a) 2-Speed Solenoid Connector

(b) 2-Speed Switch Connector RY9212182ELS0112US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wiring of the 2-speed solenoid connector and/or the 2-speed switch connector are pinched against or touching the body. If the insulation is damaged, repair it properly and check the 2-speed solenoid and the 2-speed switch again in the tester mode. Criteria Regular : no short Irregular : shorted (a) 2-Speed Solenoid Connector

(b) 2-Speed Switch Connector RY9212182ELS0113US0

4-S90

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check (2-speed solenoid) [Measurement Conditions] 1. Disconnect the travel 2-speed solenoid connector. 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch. 4. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

2-speed solenoid connector

<1>

2-speed solenoid connector

<2>

(b)

2-speed solenoid connector

<1>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0118US0

2. Continuity check (2-speed solenoid) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the travel 2-speed solenoid connector. 3. Disconnect the ECU connector. 4. Put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch. 5. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side) 2-speed solenoid connector

(a)

Pin No.

<1>

Connector Name (- terminal side) ECU connector

Pin No.

<81>

Regular : Continuity Irregular : No continuity RY9212166ELS0119US0

3. Voltage check (2-speed switch) [Measurement Conditions] 1. Disconnect the angle grip SW connector. 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch. 4. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Angle grip SW connector

<1>

Angle grip SW connector

<2>

(b)

Angle grip SW connector

<1>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0166US0

4-S91

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4. Continuity check (2-speed switch) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the ECU connector. 3. Put the machinery operation lever lock in the [Unlock] position and press the 2-speed switch. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Angle grip SW connector

<2>

ECU connector

<57>

(b)

Angle grip SW connector

<1>

ECU connector

<41>

Regular : Continuity Irregular : No continuity RY9212166ELS0167US0

4-S92

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Testing the 2-speed switch [Test Conditions] 1. Key switch : OFF 2. Disconnect the angle grip SW connector from the machine, press the switch and measure it separately. Criteria Regular : no break Irregular : has a break (a) 2-Speed Switch RY9212166ELS0168US0

2. Testing the 2-speed solenoid [Test Conditions] 1. Key switch : OFF 2. Disconnect 2-speed solenoid connector from the machine and test the solenoid separately. 2-speed solenoid

Factory specification

12 Ω ±10 %

Criteria Regular : Within factory specification Irregular : Outside factory specification (a) 2-Speed Solenoid Terminals RY9212166ELS0120US0

3. Settings after replacing device 1. Select the AI setting. Criteria Regular : setting complete Irregular : setting failed (1) AI Set AUX Set AUX2/Thumb Set RY9212032ELS0018US0

4-S93

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[3] AUTO IDLING (AI) SYSTEM (1) Governor Sensor Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) Accelerator sensor (1) AI Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0007US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Turn the accelerator dial to the right (hi-speed) and to the left (lo-speed) and check the governor pot voltage based on the following table. Design Value

Governor POT

Regular

When cut off

Idling

1.68 ± 0.2 V

0.05 V

MAX

3.39 ± 0.28 V

0.05 V

When shorted Voltage fails to stabilize

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Accel POT Governor POT Motor Current

(b) Slow (c) Fast RY9212032ELS0019US0

4-S94

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The governor connector is disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely, turn the accelerator dial to the right (hi-speed) and the left (lo-speed) and check the voltage of the governor POT again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212182ELS0117US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wiring of the governor sensor connector is pinched against or touching the body. If the insulation is damaged, repair it properly, turn the accelerator dial to the right (hi-speed) and the left (lo-speed) and check the voltage of the governor POT again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212182ELS0118US0

4-S95

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the governor sensor connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Governor sensor connector

<3>

Governor sensor connector

<1>

(b)

Governor sensor connector

<3>

Body GND

–

Regular : 5V Irregular : Large discrepancy from 5V RY9212182ELS0154US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the governor sensor connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Governor sensor connector

<2>

ECU connector

<27>

(b)

Governor sensor connector

<1>

ECU connector

<10>

(c)

Governor sensor connector

<3>

ECU connector

<11>

Regular : Continuity Irregular : No continuity RY9212182ELS0155US0

4-S96

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Testing the potentiometer [Measurement Conditions] 1. Key switch : OFF 2. Remove the potentiometer out the AI motor ASSY and measure the resistance value. Measurements (a) <1> <3>

Measurement (b)

Factory specification

2 kΩ ± 20 %

<1> – <2> <2> – <3>

As shown in the diagram at left, rotate the shaft of the potentiometer and confirm that the needle of the circuit tester moves smoothly. Criteria Regular : Within factory specification Irregular : Outside factory specification RY9212182ELS0156US0

2. Settings after replacing device 1. Select the AI setting. Criteria Regular : setting complete Irregular : setting failed (1) AI Set AUX Set AUX2/Thumb Set RY9212032ELS0005US0

4-S97

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(2) Accelerator Sensor Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) Accelerator sensor (1) AI Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0007US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Turn the accelerator dial to the right (hi-speed) and to the left (lo-speed) and check the accelerator POT voltage based on the following table. Design Value

Accelerator POT

Regular

When cut off

Idling

1.68 ± 0.2 V

0.05 V

MAX

3.39 ± 0.28 V

0.05 V

When shorted Voltage fails to stabilize

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Accel POT Governor POT Motor Current

(b) Slow (c) Fast RY9212032ELS0020US0

4-S98

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. AI console connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely, turn the accelerator dial to the right (hi-speed) and the left (lo-speed) and check the voltage of the accelerator sensor again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212166ELS0121US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wiring of the AI console connector is pinched against or touching the body. If the insulation is damaged, repair it properly, turn the accelerator dial to the right (hi-speed) and the left (lo-speed) and check the voltage of the accelerator sensor again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212166ELS0122US0

4-S99

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the AI console connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

AI console connector

<8>

AI console connector

<4>

(b)

AI console connector

<8>

Body GND

–

Regular : 5 V Irregular : Large discrepancy from 5 V RY9212166ELS0123US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the AI console connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

AI console connector

<7>

ECU connector

<7>

(b)

AI console connector

<8>

ECU connector

<11>

(c)

AI console connector

<4>

ECU connector

<10>

Regular : Continuity Irregular : No continuity RY9212166ELS0124US0

4-S100

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Testing the accelerator sensor [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the accelerator sensor from the machine and test it separately. Factory specification

Min.

Max.

Accelerator sensor 4 to 8

1 kΩ ± 10 %

Accelerator sensor 3 to 4

720 Ω

380 Ω

Accelerator sensor 3 to 8

380 Ω

720 Ω

Criteria Regular : Within factory specification Irregular : Outside factory specification (a) Accelerator Dial Terminal Numbers RY9212166ELS0125US0

2. Settings after replacing device 1. Select the AI setting. Criteria Regular : setting complete Irregular : setting failed (1) AI Set AUX Set AUX2/Thumb Set RY9212032ELS0005US0

4-S101

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(3) AI Motor Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) Accelerator sensor (1) AI Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0007US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Turn the accelerator dial to the right (hi-speed) and to the left (lo-speed) and check the AI motor amperage based on the following table. Motor Amperage

AI Motor Operating

0.0 to 15.0 A

AI Motor Stopped

0.0 to 2.0 A

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Accel POT Governor POT Motor Current

(b) Slow (c) Fast RY9212032ELS0021US0

4-S102

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the AI motor fuse (15A) is blown. RY9212001ELS0171US0

2. Checking relays 1. Replace either the left or the right ECU main power relay. After replacing it, check for normal operation. Criteria Regular : no break Irregular : has a break (a) ECU Main Power Relay RY9212182ELS0119US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. AI motor connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the AI motor's amperage again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212182ELS0120US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wiring of the AI motor connector is pinched against or touching the body. If the insulation is damaged, repair it properly and check the amperage of the AI motor again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212182ELS0121US0

4-S103

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check-1 [Measurement Conditions] 1. Disconnect the AI motor connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

AI motor connector

<1>

Body GND

–

(b)

AI motor connector

<2>

Body GND

–

Connector Name (- terminal side)

Pin No.

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212182ELS0157US0

2. Voltage check-2 [Measurement Conditions] 1. Remove the ECU power fuse (30A). 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(b)

ECU power fuse (30A), fuse box side

<1>

Connector Name (- terminal side) Body GND

Pin No.

–

Regular : 12 V Irregular : Large discrepancy from 12 V (a) ECU Power Fuse (30A) RY9212182ELS0158US0

3. Voltage check-3 [Measurement Conditions] 1. Remove the ECU main power relay. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

(a)

ECU main power relay fuse box side

Pin No.

<5>

Connector Name (- terminal side) Body GND

Pin No.

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212182ELS0159US0

4-S104

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4. Continuity check-1 [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the AI motor connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

AI motor connector

<1>

ECU connector

<5>

(b)

AI motor connector

<2>

ECU connector

<4>

Connector Name (- terminal side)

Pin No.

Regular : Continuity Irregular : No continuity RY9212182ELS0160US0

5. Continuity check-2 [Measurement Conditions] 1. Key switch : OFF 2. Remove the ECU power fuse (30A). 3. Remove the ECU main power relay. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

ECU power fuse (30A)

<1>

Key switch connector

<3>

(b)

ECU power fuse (30A)

<2>

ECU main power relay fuse box side

<1>

(c)

ECU main power relay fuse box side

<3>

ECU power fuse (30A)

<2>

Regular : Continuity Irregular : No continuity RY9212182ELS0161US0

6. Continuity check-3 [Measurement Conditions] 1. Key switch : OFF 2. Remove the ECU power fuse (30A). 3. Remove the ECU main power relay. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

ECU main power relay fuse box side

<2>

ECU connector

<12>

(b)

ECU main power relay fuse box side

<5>

ECU connector

<3>

Connector Name (- terminal side)

Pin No.

Regular : Continuity Irregular : No continuity RY9212182ELS0162US0

4-S105

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Inspecting the accelerator wire [Test Conditions] 1. Key switch : OFF 2. Pull the accelerator wire on the engine side (b) and check whether the accelerator wire on the AI motor side (a) is stuck. (a) AI Motor Side

(b) Engine Side RY9212001ELS0181US0

2. Testing the AI motor [Test Conditions] 1. Remove the AI motor from the machine. 2. Check to see if the AI motor will rotate when driven by an external 12V source. (No left and right. Motor reverses if polarity is reversed.) 3. The connector terminals are close together, so be careful not to short them when applying electricity. If you are concerned with the danger of shorting them, replace with a new AI motor. RY9212001ELS0182US0

3. Settings after replacing device 1. Select the AI setting. Criteria Regular : setting complete Irregular : setting failed (1) AI Set AUX Set AUX2/Thumb Set RY9212032ELS0022US0

4-S106

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(4) Testing the AI Pressure Switch [A] Checking via the Meter Panel Display 1. Content of Meter Panel Display 1. When the auto-idle switch (a) on the panel is pressed, check whether the auto-idle lamp (b) lights or is off. Criteria Regular : lamp lights Irregular : lamp off (a) Auto-Idle Switch

(b) Auto-Idle Lamp RY9212182ELS0172US0

2. Reading the failure history 1. Checking the failure history is not required. RY9212001ELS0048US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Check the operation of the auto-idle switch according to the table below. Regular

When cut off

When shorted

Operating Not operating Criteria Regular : no break Irregular : has a break Irregular : shorted (1) AI Press SW AI operation SW Compressor Water Temp. Motor Current RY9212032ELS0023US0

4-S107

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The auto-idle pressure switch connector is disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the auto-idle switch again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212166ELS0127US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wire of the auto-idle pressure switch connector is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the auto-idle switch again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212182ELS0122US0

4-S108

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the auto-idle pressure switch connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Auto-idle pressure switch connector

<1>

Auto-idle pressure switch connector

<2>

(b)

Auto-idle pressure switch connector

<1>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0129US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the auto-idle pressure switch connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Auto-idle pressure switch connector

<1>

ECU connector

<76>

(b)

Auto-idle pressure switch connector

<2>

ECU connector

<50>

Regular : Continuity Irregular : No continuity RY9212166ELS0130US0

4-S109

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Measuring the auto-idle pressure [Measurement Conditions] 1. Remove the auto-idle pressure switch from the control valve and attach a pressure gauge and test the pressure. Operating pressure

AI pressure switch

25 ± 3 kgf/cm2 2.5 ± 0.3 MPa 360 ± 45 psi

OFF

Accelerate from idling rpm to max rpm.

20 ± 3 kgf/cm2 2.0 ± 0.3 MPa 280 ± 45 psi

Decelerate from max rpm to idling rpm.

Engine RPM

The AI switch is normally closed (normally ON) Criteria Regular : Within factory specification Irregular : Outside factory specification (a) Pressure

(b) State of Pressure Switch RY9212166ELS0131US0

2. Settings after replacing device 1. Select the AI setting. Criteria Regular : setting complete Irregular : setting failed (1) AI Set AUX Set AUX2/Thumb Set RY9212032ELS0005US0

4-S110

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(5) Testing the AI Switch [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. When the auto-idle switch (a) on the panel is pressed, check whether the auto-idle lamp (b) lights or is off. Criteria Regular : lamp lights Irregular : lamp off (a) Auto-Idle Switch

(b) Auto-Idle Lamp RY9212166ELS0132US0

2. Reading the failure history 1. Checking the failure history is not required. RY9212001ELS0048US0

3. Tester mode 1. Select the tester mode. 2. Check the operation of the auto-idle switch according to the table below. Regular

When cut off

When shorted

With AI SW pressed With AI SW released Criteria Regular : no break Irregular : has a break Irregular : shorted (1) AI Press SW AI operation SW Compressor Water Temp. Motor Current RY9212166ELS0169US0

4-S111

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. 2. Checking relays

RY9212001ELS0008US0

1. Checking relays is not necessary. RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. Auto-idle console connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the operation of the auto-idle switch again in the tester mode. Criteria Regular : no break Irregular : has a break RY9212182ELS0124US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wiring of the auto-idle console connector is pinched against or touching the body. If the insulation is damaged, repair it properly and check the operation of the auto-idle switch again in the tester mode. Criteria Regular : no short Irregular : shorted RY9212166ELS0134US0

4-S112

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect auto-idle console connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Auto-idle console connector

<2>

Auto-idle console connector

<6>

(b)

Auto-idle console connector

<2>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0135US0

2. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect auto-idle console connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

Auto-idle console connector

<6>

ECU connector

<75>

(b)

Auto-idle console connector

<2>

ECU connector

<76>

Regular : Continuity Irregular : No continuity RY9212166ELS0136US0

4-S113

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[D] Testing the Equipment Itself 1. Testing the accelerator dial [Measurement Conditions] 1. Key switch : OFF 2. Remove the accelerator dial from the machine and replace with a new accelerator dial. 3. Select the tester mode and check the voltage of the accelerator dial. Criteria Regular : Within factory specification Irregular : Outside factory specification RY9212166ELS0137US0

2. Settings after replacing device 1. Select the AI setting. Criteria Regular : setting complete Irregular : setting failed (1) AI Set AUX Set AUX2/Thumb Set RY9212032ELS0005US0

4-S114

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[4] POWER SUPPLY SYSTEM (1) Over Voltage [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) Over voltage (1) Over Voltage Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0027US0

Check whether the machine has been jump started with a 24 V battery. (a) 12 V

(b) 24 V RY9212182ELS0125US0

An alternator recharging error is also possible. Refer to the pages on the recharging system errors. RY9212182ELS0126US0

4-S115

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

(2) 5V Short System Error [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) External 5 V (1) External 5V Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0028US0

Testing the 3.5V line

[Test Conditions] 1. Check whether each line is pinched against or touching the body If the insulation is damaged, repair it properly and check the meter display again. (A) AI console connector (B) Governor sensor connector (C) JS control (right) RY9212182ELS0127US0

4-S116

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[5] COMMUNICATION SYSTEM (1) CAN Communication Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. EX.) CAN system (main) • When a CAN communication error is displayed, the oil lamp (c) and charging lamp (d) light up and the engine will not start. (1) CAN Sys Err

(a) (b) (c) (d)

Warning Lamp Info Button Oil Lamp Charging Lamp RY9212032ELS0030US0

3. Tester mode 1. Select the tester mode. 2. Confirm the ECU is . Regular

Irregular

ECU (main)



ECU (AS)

ECU (CRS)

(1) Meter / ECU Display Screen RY9212182ELS0173US0

4-S117

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Check whether the 5 A ECU main (+B) fuse is blown. RY9212001ELS0219US0

2. Checking relays 1. Checking relays is not necessary. 3. Causes when a break in wiring

RY9212001ELS0009US0

1. Checking for breaks in wiring is not necessary. RY9212001ELS0220US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The CAN connector wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the ECU (main) again in the tester mode. Criteria Regular : no break When shorted : has a break (A) CAN Communication (2 Wires) RY9212182ELS0128US0

4-S118

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the ECU connector. 3. Disconnect the CAN connector. 4. Check for continuity in the combinations in the table below. Measurement

Connector Name (+ terminal side)

Pin No. <1>

Connector Name (- terminal side) ECU connector

Pin No.

(a)

CAN connector

<60>

(b)

CAN connector

<2>

ECU connector

<79>

(c)

ECU main 5A fuse

<2>

ECU connector

<59>

Regular : Continuity Irregular : No continuity (A) Details on C Measurements

(d) ECU (+B) 5A Fuse RY9212182ELS0165US0

[D] Testing the Equipment Itself 1. Erasing failure history 1. After completing repairs, select Erase Failure History and erase the records. 2. After erasing the records, read the failure history again and make sure there are no failures. Criteria Regular : Failure history erased Irregular : failure history not erased (1) No Fail Record RY9212032ELS0032US0

4-S119

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[6] AUX SYSTEM (1) AUX1/Thumb System Errors [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) AUX1 Sys Err (1) AUX1 Sys Err (2) AUX2 Sys Err

(a) Warning Lamp (b) Info Button RY9212032ELS0048US0

3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Measure the voltage of AUX switch based on the table below. Set value (ex.)

Indicated value AUX1 knob switch

0.25 to 4.75 V

Left (small)

Right (large)

Center (medium)

At stop

0.95 V

4.41 V

2.36 V

Output current

0.5 to 2.0 A Regular

AUX one way hold SW ON

↓

AUX one way hold SW OFF

↓

0 to 0.2 A

When cut off

When shorted

Criteria Regular : no break Irregular : has a break Irregular : shorted (1) AUX1 Knob Current AUX Hold SW

(2) Control Lever (Right) (3) AUX One Way Hold SW RY9212182ELS0129US0

4-S120

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. RY9212001ELS0008US0

2. Checking relays 1. Checking relays is not necessary.

RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. AUX1 SOL connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the AUX1 SOL again in the tester mode. Criteria Regular : no break Irregular : has a break (a) AUX1 (L) SOL

(b) AUX1 (R) SOL RY9212182ELS0130US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The AUX switch connector wire and/or AUX1 SOL wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the AUX switch and AUX SOL again in the tester mode. Criteria Regular : no short When shorted : shorted (a) AUX1 (L) SOL

(b) AUX1 (R) SOL RY9212182ELS0131US0

4-S121

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check (AUX one way hold Switch) [Measurement Conditions] 1. Disconnect the AUX1 switch connector. 2. Key switch : ON 3. AUX one way hold Switch : ON 4. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

AUX1 switch connector

<5>

AUX1 switch connector

<6>

(b)

AUX1 switch connector

<5>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212182ELS0132US0

2. Voltage check (AUX1 Switch) [Measurement Conditions] 1. Disconnect the AUX1 switch connector. 2. Key switch : ON 3. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

AUX1 switch connector

<1>

AUX1 switch connector

<2>

(b)

AUX1 switch connector

<1>

Body GND

–

Regular : 5 V Irregular : Large discrepancy from 5 V RY9212182ELS0133US0

3. Continuity check (AUX one way hold Switch) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the AUX1 switch connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

AUX1 switch connector

<5>

ECU connector

<41>

(b)

AUX1 switch connector

<6>

ECU connector

<69>

Regular : Continuity Irregular : No continuity RY9212182ELS0134US0

4-S122

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4. Continuity check (AUX1 Switch) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the AUX1 switch connector. 3. Disconnect the ECU connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

Pin No.

(a)

AUX1 switch connector

R Lever <3>

ECU connector

R Lever <28>

(b)

AUX1 switch connector

<1>

ECU connector

<11>

(c)

AUX1 switch connector

<2>

ECU connector

<10>

Regular : Continuity Irregular : No continuity RY9212182ELS0135US0

5. Continuity check (AUX1 (L) SOL) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the ECU connector. 3. Disconnect the AUX1 SOL connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

AUX1 SOL Connector

<1>

ECU Connector

<23>

(b)

AUX1 SOL Connector

<2>

ECU Connector

<19>

Connector Name (– terminal side)

Pin No.

Regular : Continuity Irregular : No continuity RY9212182ELS0136US0

4-S123

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

6. Continuity check (AUX1 (R) SOL) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the ECU connector. 3. Disconnect the SOL connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (– terminal side)

Pin No.

(a)

SOL Connector

<1>

ECU Connector

<24>

(b)

SOL Connector

<2>

ECU Connector

<19>

Regular : Continuity Irregular : No continuity RY9212182ELS0137US0

[D] Testing the Equipment Itself 1. Testing the AUX1 solenoid [Test Conditions] 1. Key switch : OFF 2. Disconnect AUX1 solenoid connector from the machine and test the solenoid separately. AUX1 solenoid

Factory specification

3.2 ± 0.5 Ω (at 20 °C, 68 °F)

Criteria Regular : no break Irregular : has a break (a) AUX1 Solenoid Terminals

2. Settings after replacing device

RY9212182ELS0138US0

1. No settings required. RY9212001ELS0013US0

4-S124

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[7] ANGLE BLADE SYSTEM (1) Angle Blade System Error [A] Checking via the Meter Panel Display 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red or not. 2. Press the info button (b) and check the additional content. Ex.) Angle Sys Err (1) Angle Blade Sys Err

(a) Warning Lamp (b) Info Button RY9212166ELS0152US0

3. Tester mode 1. 2. 3. 4.

Select the tester mode. Start the engine. Put the machinery operation lever lock in the [Unlock] position. Operate the angle blade switch and check the switch according to the following table. Regular

When cut off

When shorted

Angle Blade switch ON Angle Blade switch OFF Angle Blade solenoid ON Angle Blade solenoid OFF Criteria Regular : no break Irregular : has a break Irregular : shorted (1) Angle R SW Angle L SW Angle R SOL Angle L SOL

4-S125

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Checking fuses is not necessary. RY9212001ELS0008US0

2. Checking relays 1. Checking relays is not necessary.

RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The angle grip switch connector is disconnected. 3. The angle blade solenoid connector is disconnected. 4. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the angle blade switch and angle blade solenoid in the tester mode. Criteria Regular : no break Irregular : has a break (a) Angle R Solenoid Connector (b) Angle L Solenoid Connector

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The angle blade switch connector wire and/or angle blade solenoid connector wire are pinched against or touching the body. If the insulation is damaged, repair it properly and check the angle blade switch and the angle blade solenoid again in the tester mode. Criteria Regular : no short Irregular : shorted (a) Angle R Solenoid Connector (b) Angle L Solenoid Connector

4-S126

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[C] Testing with a Circuit Tester 1. Voltage check (angle blade switch) [Measurement Conditions] 1. Disconnect the angle blade switch connector 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position. 4. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

(a)

Angle blade switch connector

(b)

Angle blade switch connector

Pin No. <1>

Connector Name (- terminal side)

Pin No. <3>

<1>

Angle blade switch connector

<4>

<1>

Body GND

–

Regular : 12 V Irregular : Large discrepancy from 12 V RY9212166ELS0155US0

2. Voltage check (angle blade L solenoid) [Measurement Conditions] 1. Disconnect angle blade L solenoid connector. 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position. 4. Angle blade left switch : ON 5. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

Angle blade L solenoid connector

<1>

Body GND

–

(b)

Angle blade L solenoid connector

<1>

Angle blade L, R solenoid connector

<2>

Connector Name (- terminal side)

Pin No.

Regular : 12 V Irregular : Large discrepancy from 12 V (1) Angle Blade Control Switch

(A) Turn the Right (B) Turn the Left RY9212166ELS0156US0

4-S127

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

3. Voltage check (angle blade R solenoid) [Measurement Conditions] 1. Disconnect angle blade R solenoid connector. 2. Key switch : ON 3. Put the machinery operation lever lock in the [Unlock] position. 4. Angle blade right switch : ON 5. Measure the voltage based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

(a)

Angle blade R solenoid connector

<1>

Body GND

–

(b)

Angle blade R solenoid connector

<1>

Angle blade L, R solenoid connector

<2>

Connector Name (- terminal side)

Pin No.

Regular : 12 V Irregular : Large discrepancy from 12 V (1) Angle Blade Control Switch

(A) Turn the Right (B) Turn the Left RY9212166ELS0157US0

4. Continuity check (angle blade switch) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect angle blade switch connector and angle blade solenoid connector. 3. Put the machinery operation lever lock in the [Unlock] position. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

(a)

Angle blade switch connector

<3>

ECU connector

<68>

(b)

Angle blade switch connector

<4>

ECU connector

<71>

Pin No.

Connector Name (- terminal side)

Pin No.

Regular : Continuity Irregular : No continuity RY9212166ELS0158US0

4-S128

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

5. Continuity check (angle blade L, R solenoid) [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the ECU connector. 3. Disconnect angle blade L, R solenoid connector. 4. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

(a)

Angle blade L, R solenoid connector

(b)

Angle blade L, R solenoid connector

Pin No. L<1> R<1> L<2> R<2>

Connector Name (- terminal side)

Pin No. L<20>

ECU connector

R<18> –

Body GND

–

Regular : Continuity Irregular : No continuity RY9212166ELS0159US0

[D] Testing the Equipment Itself 1. Testing the angle blade solenoid [Test Conditions] 1. Key switch : OFF 2. Disconnect angle blade solenoid connector from the machine and test the solenoid separately. Lever lock solenoid

Factory specification

12 Ω ± 10 %

Criteria Regular : no break Irregular : has a break (a) Angle Blade Solenoid Terminals

2. Settings after replacing device

RY9212166ELS0160US0

1. No settings required. RY9212001ELS0013US0

4-S129

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

[8] TRAVEL ALARM (OPTION) 1. Checking fuses 1. Checking fuses is not necessary. RY9212001ELS0008US0

2. Checking relays 1. Checking relays is not necessary.

RY9212001ELS0009US0

3. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The travel alarm pressure switch connector is disconnected. 3. The travel alarm connector is disconnected. 4. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off. (pull with a max of 3 kgf (30 N, 7 lbf) of force) If it comes off, plug the connector back in securely and check the alarm sound. Criteria Regular : no break Irregular : has a break (a) (b) (c) (d)

Travel Pilot Valve Pressure Switch Travel Alarm (Forward) Horn

(e) Travel Alarm (Rear) (f) Swivel Frame A : Pull on the Harness RY9212050ELS0012US0

4. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The wire is pinched against or touching the body. If the insulation is damaged, repair it properly and check the alarm sound. Criteria Regular : no short Irregular : shorted RY9212050ELS0013US0

4-S130

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

5. Continuity check [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the pressure switch connector. 3. Disconnector lever lock switch connector. 4. Disconnect the travel alarm connector (rear) or (front). 5. Test the continuity based on the table below. Measurement

Connector Name (+ terminal side)

Pin No.

Connector Name (- terminal side)

(a)

Pressure switch connector

<1>

Lever lock switch connector

(b)

Pressure switch connector

<2>

Travel alarm connector

Pin No.

<1> <1> <1>

Regular : Continuity Irregular : No continuity RY9212182ELS0166US0

6. Pressure switch No. 1

Contents Rated voltage

Specifications 10 to 15.5 V

Pressure

0.44 ± 0.05 MPa → OFF 0.74 ± 0.05 MPa → ON

Switching

Normally open

Tightening torque

Switch (pressure, 7.5K)

9.8 to 14.7 N·m 1.0 to 1.5 kgf·m 7.23 to 10.8 lbf·ft

(1) R1/8 Nut RY9212050ELS0018US0

7. Settings after replacing device 1. No settings required. RY9212050ELS0055US0

4-S131

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

8. DEALER SETTING MODE FLOWCHART

4-S132

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4-S133

KiSC issued 10, 2022 A

ELECTRICAL SYSTEM

U35-4, WSM

4-S134

KiSC issued 10, 2022 A

5 CABIN

KiSC issued 10, 2022 A

MECHANISM CONTENTS 1. AIR CONDITIONING SYSTEM .................................................................................................. 5-M1 [1] STRUCTURE ....................................................................................................................... 5-M1 [2] HOW THE MECHANISMS OF THE SYSTEM WORK ......................................................... 5-M2 [3] COMPRESSOR.................................................................................................................... 5-M3 [4] AIR CONDITIONING UNIT................................................................................................... 5-M6 [5] CONDENSER..................................................................................................................... 5-M11 [6] RECEIVER ......................................................................................................................... 5-M12 [7] PRESSURE SWITCH......................................................................................................... 5-M13 [8] SYSTEM CONTROLS ........................................................................................................ 5-M14 [9] ADJUSTING THE AIR FLOW AND DIRECTION ............................................................... 5-M15 [10]ELECTRICAL SYSTEM...................................................................................................... 5-M16 (1) Electrical Circuits .......................................................................................................... 5-M16 (2) Relays........................................................................................................................... 5-M17 (3) Blower Switch ............................................................................................................... 5-M18 2. WIPER ...................................................................................................................................... 5-M19 [1] WIPER SWITCH................................................................................................................. 5-M19 [2] WIPER ................................................................................................................................ 5-M19 [3] WIPER MOTOR ................................................................................................................. 5-M20

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

1. AIR CONDITIONING SYSTEM [1] STRUCTURE

(1) Control Panel (2) Outside Air Inlet (3) Outside Air Duct

(4) Cabin Air Inlet (5) In/Outside Air Duct (6) Air Duct ASSY

(7) Air Conditioning Unit (8) Compressor (9) Condenser

(10) Receiver (11) Heater Core

The cabin is equipped with a high-capacity, low-profile air conditioner that can circulate cabin air or bring in fresh air from outside. Cabin air is sucked into the cabin air inlet (4), which is located behind the seat; it then passes through the in/outside air duct (5) to the air conditioning unit (7) (cabin air circulation). Fresh air is taken in via the outside air inlet (2) and passes through the in/outside air duct (5) and enters the air conditioning unit (7) (fresh air intake). The inside or outside air that is sucked into the air conditioning unit (7) is cooled and dehumidified by the cooler of the air conditioning unit (7). When the system is used for heating, the air is heated by the heater core (11) and then expelled from the air duct ASSY (6). The vents installed inside the cabin can be opened and closed as well as adjusted to blow in different directions. Cooling Capacity

3.2 kW ±10 %

Heating Capacity

4.1 kW ±10 %

Type of Refrigerant (charge capacity)

Factory specification

R134a 0.65 to 0.75 kg (1.43 to 1.65 lbs)

Pressure Sensor (Low)

0.196 MPa (2.0 kgf/cm2, 28.4 psi)

Pressure Sensor (High)

3.14 MPa ( 32.0 kgf/cm2, 455 psi) RY9212182CAM0001US0

5-M1

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[2] HOW THE MECHANISMS OF THE SYSTEM WORK

(1) Capillary Tube (Heat Sensitive (7) Condenser Capillary Tube) (8) Receiver (2) Expansion Valve (9) Dryer (3) Evaporator (10) Pressure Switch (4) Blower Motor (11) Heater Core (5) Compressor (12) Hot Water Valve (6) Engine Cooling Fan

A : Cooled Air B : Low Pressure and Temperature Vapor C, D : Air Passes Through In / Outside Air Filter

E : High Pressure/Temperature Gas F : Hot Air G : Liquid

This air conditioning system works as follows. 1. Refrigerant passes through the evaporator (3), is vaporized and then is compressed by the compressor (5) to approximately 1.47 MPa (15 kgf/cm2, 210 psi) and raised to a temperature of approximately 70 °C (158 °F) the refrigerant is then sent in this state to the condenser (7). 2. The vaporized refrigerant passes through the condenser (7), where it is cooled down to approximately 50 °C (122 °F) and the refrigerant changes back from a vapor to a liquid; it is then sent on to the receiver (8). Then the heat from inside the cabin that is captured by the condenser (7) is released outside the cabin. 3. The liquid refrigerant collects in the receiver (8) and any moisture is removed from the refrigerant by the dryer (9). 4. The liquid refrigerant then passes on to the expansion valve (2), where it is sprayed through the small holes in the valve into the evaporator (3), which produces a mist of the refrigerant; its pressure and temperature drop and the refrigerant evaporates. 5. The refrigerant simultaneously captures heat from the surface of the evaporator's (3) pipes and evaporates vigorously at 0 °C (32 °F). 6. As this happens, warm air from inside the cabin is drawn into the evaporator (3) by the blower motor (4) and the refrigerant captures the heat and evaporates. In this way the air in the cabin is cooled. [NOTE] • Because the warm air inside the cabin is cooled quickly, the moisture in the air condenses. In other words, the air in the cabin can be dehumidified. 7. The refrigerant vaporized in the evaporator (3) is returned to the compressor (5) and compressed, changing it back into a liquid. In doing so, the refrigerant is put under high pressure and temperature. 8. The air that passed through the evaporator (3) can be adjusted to the desired temperature by then passing it through the heater core (11). Engine coolant is heated by the engine and the amount of the coolant that flows into the heater core (11) is controlled by the hot water valve (12), and this adjusts the temperature of the air that flows through the heater core (11). RY9212001CAM0002US0

5-M2

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[3] COMPRESSOR The vane type of compressor installed in this system is composed of a cylinder (1) that is elliptical in cross-section, along with five vanes (3) attached to the rotor (2). This vane compressor has two each of intake and discharge ports. The five vanes (3) are attached to the rotor (2) and as it rotates, the tips of the vanes come in contact with the walls of the cylinder (1) and an airtight compression space is maintained both by the centrifugal force exerted by the rotor (2) along with the back pressure on the vanes (3), which is in proportion to the rpms of the rotor (2). As a result, the volume changes in each of the five segments of the cylinder, which are divided by the five vanes (3) in the cylinder (1). Each time that the rotor (2) rotates, each of the five segments of the cylinder goes through two cycles of intake, compression and discharge. (1) Cylinder (2) Rotor

(3) Vane RY9212001CAM0003US0

How it Works As the rotor (3) turns, the volume of space in a segment, as divided by the cylinder (1) and vanes (4), increases, sucking refrigerant gas from the intake port (2) into the cylinder space. As the rotor (3) turns further, the volume of the space created between the cylinder (1) and vanes (4) decreases, compressing the refrigerant gas. As the rotor (3) continues to turn, the refrigerant gas is compressed further, putting it under a great deal of pressure, pressing on the discharge valve and opening it. The refrigerant gas is then expelled via the discharge port (5). (1) (2) (3) (4) (5)

Cylinder Intake Port Rotor Vane Discharge Port

(A) Compression Cycle (B) Discharge Cycle (C) Intake Cycle

RY9212001CAM0004US0

Compressor Oil The compressor oil is dissolved in the refrigerant and circulates throughout the entire cooling system acting as the lubricating oil for the compressor. However, because the previously used R12 compressor oil does not dissolve in R134a, it does not circulate through the cooling cycle. So it drastically reduces the working life of the compressor. As a result, it is imperative that the right compressor oil is always used. The mineral oil that is used in an R12 cooling system cannot be used in an R134a cooling system. A synthetic PAG oil has to be used in an R134a cooling system. This oil mixes extremely well with refrigerant gas and provides the entire system with the optimum lubrication. Volume of Oil 110 to 120 cc 0.116 to 0.127 U.S.qts 0.098 to 0.106 lmp.qts

Product Name ND–OIL8 <PAG* oil>

*PAG : Polyalkylene glycol (synthetic oil) RY9212001CAM0005US0

5-M3

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Magnetic Clutch A magnetic clutch is a device that governs the mechanical linkage between the engine and the compressor. When the engine is rotating and the AC switch is on, air at cabin temperature comes out and when the temperature reaches the temperature set with the temperature control switch, or when the cabin gets hot, the clutch works to stop or to drive the compressor, respectively. The hub of the magnetic clutch is attached to the compressor shaft and when it is not driving the compressor, it is separate from the rotor and just the pulley turns. When the AC switch is turned on, current flows into the stator coil, making the stator into a magnet, which then holds onto the hub and the pulley turns along with the compressor. (1) (2) (3) (4)

Pressure Plate Ball Bearing Snap Ring Pulley

(5) Rotor w/ Pulley (6) Stator (7) Snap Ring RY9212001CAM0006US0

B. Safety Valve The valve opens when the refrigerant pressure reaches the specified pressure, thus relieving the pressure. When the pressure becomes abnormally high, it overcomes the force of the spring, allowing refrigerant to leak out of the relief port; when the pressure drops the reverse happens--the spring overcomes the pressure and the safety valve closes. When an error occurs, this also keeps the discharge of refrigerant to a minimum. (1) Safety Valve

a : 113 L/min. (27.2 U.S.gals./min., (A) Refrigerant Leak Route 24.86 lmp.gals./min.) (B) Functional Characteristics b : 2.75 MPa (C) Amount of Refrigerant (28.1 kgf/cm2, 399.7 psi) Leaked c : 3.43 MPa (D) Pressure (35.0 kgf/cm2, 497.8 psi) d : 4.12 MPa (42.0 kgf/cm2, 598.0 psi) RY9212001CAM0007US0

5-M4

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Temperature Sensor A temperature sensor is installed on the head of the vane type of compressor. This sensor detects the temperature of the refrigerant and when the refrigerant becomes unusually hot, it cuts off the magnetic clutch, stopping the compressor. The temperature sensor is composed of a bimetallic strip and contacts. A bimetallic strip is a sandwich of two metals with different rates of expansion and it bends when heated due to these different rates of expansion. This characteristic is exploited when there is an excessive temperature via the rod, which breaks the contact and switches the magnetic clutch off. OFF

153 to 163 °C 307 to 325 °F

120 ± 5 °C 248 ± 41 °F

Temperature Sensor

11.8 ± 1.47 N·m 1.2 ± 0.15 kg·fm 8.7 ± 1.08 lbf·ft

Operating Ranges

Tightening torque

(1) Temperature Sensor (2) Compressor

A : Contact B : Bimetallic Strip C : Rod

(a) To battery + Terminal RY9212001CAM0008US0

5-M5

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[4] AIR CONDITIONING UNIT

(A) Diagram of Linkages and Electrical Parts

The diagram above was created for general explanations of the air conditioning unit, so it may differ from the air conditioning unit installed in the machine covered by this workshop manual. Similarly, this does not guarantee the parts used inside the air conditioning unit are the same. The air conditioning unit is composed of an evaporator, an expansion valve, a heater core, a blower, etc. No.

Name of part

No.

Name of part

No.

Name of part

(1)

Upper case

(10)

Bolt

(19)

O-Ring

(2)

Side cover

(11)

Fin thermistor

(20)

Servo motor

(3)

Lower case

(12)

Clamp

(21)

Linkage lever

(4)

Linkage cover

(13)

AC Amp

(22)

Blower resistor

(5)

Intake cover

(14)

Heater core

(23)

Self-tapping screw

(6)

Evaporator

(15)

Pipe

(24)

Self-tapping screw

(7)

O-Ring

(16)

Hot water valve

(25)

Cap

(8)

O-Ring

(17)

Pipe clip

(26)

Blower motor

(9)

Expansion valve

(18)

Screw

(27)

Wire harness RY9212148CAM0001US0

5-M6

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Evaporator The evaporator takes the refrigerant, which has been made liquid by the condenser and cooled and put under low-pressure by the expansion valve, and by evaporating it, the heat and humidity of the air passing through the evaporator is removed, thus producing cool, dehumidified air. (a) Fins (b) Tubes

(A) Inlet (B) Outlet RY9212001CAM0010US0

Heater Core The heater core dissipates the heat of the heated engine coolant. So, the air that is blown through it by the blower motor passes through the fins of the heater core and the air takes on the heat of the coolant. (1) Heater Core

(A) Inlet (B) Outlet RY9212001CAM0011US0

Blower The blower is built into the right side of the AC unit. The blower forces cool, warm or fresh outside air through the vents into the cabin. The rpm of the blower motor can be adjusted to three levels with the blower resistor. The blower fan is the type that uses centrifugal force and it sucks in air parallel to its axis of rotation and blows it out perpendicular to the centrifugal force, or in other words, perpendicular to the axis of rotation. Specifications (at 20 °C) Model

DC Ferrite

Rated Voltage

12 V

No load RPM

4300 ± 400 rpm

No load amperage

1 to 3 A

Direction of rotation (viewed from drive side)

Left

Rated load torque

461 N·m, 47.0 kgf·m, 340 lbf·ft

RPM

2800 ± 280 rpm

Amperage

18.3 ± 1.8A

(1) Blower

(A) Circuit Diagram (a) (+) Terminal (b) (-) Terminal RY9212001CAM0012US0

5-M7

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Blower resistor Acts as the blower switch and controls the rpm of the blower motor by switching the degree of resistance. The fan speed can be switched to three levels, 1, 2 and 3, with 3 being the fastest. (1) (2) (3) (4)

MI HI LO Blank

(A) Blower Resistor (B) Wiring Diagram

RY9212166CAM0004US0

5-M8

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Expansion Valve [Functions] The expansion valve works in the following two ways. 1. By spraying the liquid refrigerant, which is hot and under high pressure, it makes it expand rapidly, producing a low-temp, low-pressure refrigerant vapor. 2. It adjusts the amount of refrigerant according to the vaporized state of the refrigerant in the evaporator. In order to take full advantage of the capabilities of the evaporator, a state must always be maintained in which the liquid refrigerant takes on the ambient heat, then it is completely vaporized at the outlet of the evaporator. In order to do so, the expansion valve automatically adjusts the volume of refrigerant in response to changes in the cabin temperature (cooling load) and changes in the compressor RPM. [Structure (box type)] • The expansion valve is composed of a diaphragm, heat-sensing rod, and a needle valve (ball) and the refrigerant gas is enclosed upstream of the diaphragm. The downstream side of the diaphragm is pressurized by the evaporator outlet pressure. [How it Works] • The heat-sensitive rod senses the temperature of the refrigerant passing to the evaporator and the temperature at that point is communicated to the refrigerant gas on the upstream side of the diaphragm via the heat-sensitive rod. As such, the pressure of the gas varies with the temperature, thus moving the heat-sensitive rod directly connected to the diaphragm and adjusting the opening of the needle valve. Evaporator outlet temperature

Operation

When low (when cooling load is low)

The pressure of the gas in the diaphragm chamber drops, reducing the volume and moving the heat-sensitive rod to the right, which constricts the needle valve and reduces the flow of refrigerant to the evaporator.

When high (when cooling load is high)

The pressure of the gas in the diaphragm chamber rises, increasing the volume and moving the heat-sensitive rod to the left, which opens the needle valve and supplies more refrigerant to the evaporator.

(1) Evaporator

A : Diaphragm B : Heat-Sensitive Rod C : Spring

D : Body E : Needle Valve

(a) From Receiver (Hi-Pressure) (b) To Compressor (Lo-Pressure) (c) To Evaporator (d) From Evaporator RY9212001CAM0014US0

5-M9

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Fin Thermistor (for frost control) [Function] Senses the temperature of the fins of the evaporator and when they are too cold, it stops the compressor and prevents frost from forming before it happens. [How it Works] The sensor of the fin thermistor senses the evaporator's fin temperature and if the resistance inside the sensor exceeds the thermo-amp resistance setting, its internal circuit shuts off the power to the compressor clutch. Specifications Rated Voltage

DC12 V

Measurement Conditions

DC13 ±0.2 V at 25 ± 5 °C (77 ± 9 °F)

Temperature Detection

OFF R1

4383 ±131 Ω (2 °C, 36 °F)

ON R2

(4095 Ω) (3.35 °C, 38 °F)

Hysteresis

215 ±5.0 Ω (1 °C, 34 °F)

Usage Conditions Temperature Range

–30 to 80 °C (–22 to 176 °F)

Voltage Range

DC10 to 16 V

Operating Voltage Range

DC8 to 16 V (at 25 °C, 77 °F)

Temperature Detection

10 °C / 50 °F

15 °C / 59 °F

20 °C / 68 °F

25 °C / 77 °F

30 °C / 86 °F

Resistance Value

2.96 kΩ

2.34 kΩ

1.87 kΩ

1.50 kΩ

1.22 kΩ

(1) Fin Thermistor (2) Thermo-Amp

(a) Evaporator Fin Temperature Detector RY9212001CAM0015US0

Hot Water Valve The hot water valve is the valve that adjusts the volume of engine coolant that flows into the heater core, and this adjustment changes the temperature of the heater core and thus controls the temperature of air flowing through it. (a) Open (MAX Hot) (b) Closed (MAX Cool)

5-M10

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Servo Motor (for adjusting temperature) The servo motor is composed of a motor, a potentiometer, movable contacts, etc., and operates according to signals from the AC's CPU. The servo motor uses a DC ferrite motor and rotates forward and reverse. Its potentiometer also uses variable resistance and changes the resistance value according to the operating angle. The servo motor and the hot water valve are linked via a linkage lever and turning the temperature control dial on the control panel opens/closes the hot water valve and adjusts the temperature of air vented inside the cabin. Specifications (at 20 °C, 68 °F) Model

DC Ferrite

Rated Voltage

12 V

Rated load torque

0.3 N·m, 0.03 kgf·m, 0.2 lbf·ft

RPM

3.5 to 5.5 rpm

Amperage

0.02 to 0.10 A

Potentiometer Linearity

±3%

Impressed Voltage Terminals

6 (POS.2) 7 (POS.1)

(1) Servo Motor (2) Linkage Lever (3) Hot Water Valve

(A) Potentiometer Output Schematic (a) Voltage (V) (b) Operating Angle 60 ° (c) MAXCOOL (d) MAXHOT (e) CW RY9212001CAM0017US0

[5] CONDENSER The hot, compressed refrigerant is under high pressure and in a gaseous state; the condenser cools it and returns it to a liquid state. In the interval between entering and passing through the condenser, the refrigerant is cooled and becomes liquid refrigerant again. At this point, it is necessary to be sure the refrigerant is liquid at the outlet of the condenser. If the refrigerant is not condensed enough in the condenser some refrigerant would be in a gaseous state and that would reduce the AC's cooling efficiency. (1) (2) (3) (4) (5)

Tubes Fins Vapor Vapor/Liquid Mix Liquid

(a) (b) (c) (d)

Gaseous Refrigerant Liquid Refrigerant Inlet (70 °C, 158 °F) Outlet (50 °C, 122 °F) RY9212001CAM0018US0

5-M11

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[6] RECEIVER The receiver is composed of a receiver tank, dryer, strainer and a receiver tube. [Receiver Tank] In the AC system, the rpm of the compressor changes in response to changes in the engine rpm, so the appropriate amount of refrigerant in the cooling circuit also changes. The receiver tank is the part that reacts to those changes; when a lot of refrigerant is not required in the cooling circuit, excess refrigerant is stored temporarily in the tank and when more coolant is needed, it is supplied to the circuit via the receiver tube. It also acts to store the balance of refrigerant charges and for extra refrigerant to counteract the leak of small amounts of refrigerant, such as via permeation of rubber hoses. [Dryer] If any moisture exists in the cooling circuit, it damages the system by deteriorating the valves of the compressor, its oil, by corroding metal parts in the circuit, and/or freezes in the expansion valve and blocks the circuit. The AC system uses synthetic zeolite as a dryer that is compatible with the circuit, and it absorbs any moisture that gets mixed into the circuit during installation or charging of refrigerant. If the expansion valve freezes up frequently due to moisture (icing), it means the dryer has lost its ability to absorb it, so the receiver has to be replaced. [Strainer] If dirt gets into the cooling circuit, it blocks the expansion valve, damages the compressor and otherwise hampers its cooling function. The strainer works to prevent any dirt flowing in the refrigerant from going any further. The strainer cannot be cleaned, so when it becomes severely clogged up, (in which case the high pressure gets high, low pressure gets low), the receiver has to be changed. [Sight Glass] The sight glass is mounted at the receiver joint on top of the receiver and it is the only place in the circuit where the amount of refrigerant can be visually inspected. (1) (2) (3) (4)

Dryer Receiver Tube Strainer Receiver Tank

(A) Refrigerant Inlet (B) Refrigerant Outlet

RY9212001CAM0019US0

5-M12

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[7] PRESSURE SWITCH This dual type of switch detects unusually high and low pressures in the cooling cycle. If the pressure gets abnormally high or, due to a leak, abnormally low, it may damage the equipment or deteriorate the lubricating ability of the compressor oil, leading to scorching and breakdown. To prevent these kind of problems from occurring, the switch cuts the power to the compressor clutch and stops the compressor. Refrigerant pressure

Operation

(A)

No increase in pressure state (when abnormally low)

The refrigerant pressure becomes less than the force of the spring, so the spring presses the plate up and the upper contact opens (OFF).

(B)

Contact ON (normal operation)

The refrigerant pressure is greater than the force of the spring, so the pressure plate is pressed down, which presses the upper contact down, closing the contact (ON).

(C)

Contact OFF (abnormally high pressure)

The refrigerant pressure becomes greater than the force of the plate spring and the plate spring pushes down on the pin, which press on the lower contact, opening it (OFF).

(1) (2) (3) (4) (5) (6) (7)

Diaphragm Plate Spring Pin Plate Contact Spring Terminal

a : 0.19 MPa (2.0 kgf/cm2, 28.4 psi) b : 3.14 MPa (32 kgf/cm2, 455 psi) D : OFF E : ON P : Pressure PS : Pressure Switch RY9212001CAM0020US0

5-M13

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[8] SYSTEM CONTROLS Control Panel  AC Switch (AC specification) Press this switch [ON] to use the AC. When the AC is [ON], the indicator lamp lights up. Press the switch again to turn it [OFF].  Temperature Control Dial Turning the dial to the left to cool, to the right for heat.  Fan Switch The fan can be switched to 3 different speeds. The strongest speed is [3]. [Operating the AC]  Heating 1. Adjust the fan switch and the temperature control dial to the desired temperature. NOTE • When not using the heater in the summer, turn the temperature control dial all the way to the left (cool air side) so hot air does not raise the cabin temperature. Dry Heat Press the AC switch to operate the AC. Turn the fan switch to operate the fan. Turn the temperature control dial to the right (warm air) and adjust the air temperature. NOTE • Keep the door closed while operating the AC.

 1. 2. 3.

Cooling Press the AC switch to operate the AC. Turn the fan switch to operate the fan. Turn the temperature control dial to the left (cool air) and adjust the air temperature. NOTE • The moisture from dehumidifying the cabin collects in the AC unit and is expelled outside the machine. • The idle boost function operates when the compressor is operating.

 1. 2. 3.

 Defrost To eliminate fog or frost from the front window, 1. open the front vents and point them toward the front window. 2. Turn the fan switch to [3] and the temperature control dial to the right (warm air). (1) Temperature Control Dial (2) Indicator Lamp

(3) AC Switch (4) Fan Switch RY9212001CAM0021US0

5-M14

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[9] ADJUSTING THE AIR FLOW AND DIRECTION Air Flow The air flows inside the cab as in the diagram. The ideal condition can be achieved by adjusting the 6 vents. (A) Front Window (B) Chest (C) Feet

(D) Side (E) Rear RY9212001CAM0022US0

Adjusting Air Direction  Front vent Air vents can be adjusted in whatever direction you desire. To use a vent as a defroster (stop the front window from fogging up), point the vent toward the front window. (1) Front Vent (A) Front Window (2) Cabin Air Inlet (Cab Air Filter) (B) Chest (C) Feet RY9212001CAM0023US0

5-M15

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[10] ELECTRICAL SYSTEM (1) Electrical Circuits

(1) Battery (2) Slow-Blow Fuse (80A) (3) Slow-Blow Fuse (50A) (4) Fuse (5A) (5) Fuse (10A) (6) Fuse (30A) (7) Start Switch (8) Power Relay (9) Work Light Switch (10) Blower Motor Relay (11) Blower Motor (12) Blower Resistor

(13) Blower Switch (Shorting Type) (A) (14) Compressor Clutch Relay (B) (15) Pressure Switch (C) (16) Compressor Magnetic Clutch (D) (17) Fin Thermistor (Frost Sensor) (18) Indicator Lamp (a) (19) AC Switch (b) (20) Volume (Temperature Setting) (c) (21) Servo Motor (d) (e) (f) (g)

Fixed Voltage Circuit Servo Motor Drive Circuit CPU Electronic Thermo Amp Potentiometer Signal ILL– Potentiometer Power Blower Motor Potentiometer GND Electronic Thermo GND

(h) (Free) (i) Servo Motor Output1 (COOL Output) (j) (Free) (k) Servo Motor Output2 (HOT Output) (l) (Free) (m) (Free) (n) Headlight Switch (o) IG (p) +B power

The processes up to the compressor's magnetic clutch engaging are indicated below. 1. Start switch → power relay ON → blower motor relay ON → blower switch ON (LO, MI or HI) →blower motor ON 2. AC switch ON (indicator lamp lights up) → pressure switch ON → fin thermistor ON → compressor clutch relay ON → compressor magnetic clutch ON (compressor operates) RY9212166CAM0001US0

5-M16

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(2) Relays Current flows in the components of the AC system to the blower motor and compressor's magnetic clutch. If all of the current were supplied via the main switch, the current would be too much for the switch, so the contacts of the main switch would be in danger of burning out. Similarly, if this current flowed directly from the battery and the operator forget to turn the blower motor off, the battery would discharge. The system is equipped with relays in order to prevent these kind of problems. When the current flows through the coils of these relays, their contacts close, allowing electricity to be supplied from the battery. By adopting these relays, only a tiny amount of current is needed to operate the relays, so very little current flows through the main switch. As a result, the concern over its contacts burning out is eliminated and when the main switch is open, the relays' contacts open at the same time. When this occurs, the flow of electricity in the AC circuit ceases and the possibility of the battery discharging is also eliminated. (a) (b) (c) (d)

Relay Terminal 1 Relay Terminal 2 Relay Terminal 5 Relay Terminal 3

(A) Connection Diagram

RY9212166CAM0002US0

5-M17

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(3) Blower Switch When the blower switch is in the LO, MI, or HI position

(1) (2) (3) (4) (5) (6) (7) (8)

Battery Slow-Blow Fuse (80A) Slow-Blow Fuse (50A) Fuse (5A) Fuse (10A) Fuse (30A) Start Switch Power Relay

(9) Headlight Switch (16) Compressor Magnetic Clutch (A) (10) Blower Motor Relay (17) Fin Thermistor (Frost Sensor) (B) (11) Blower Motor (18) Indicator Lamp (C) (12) Blower Resistor (19) AC Switch (D) (13) Blower Switch (Shorting Type) (20) Volume (Temperature Setting) (14) Compressor Clutch Relay (21) Servo Motor (15) Pressure Switch

Fixed Voltage Circuit Servo Motor Drive Circuit CPU Electronic Thermo Amp

When the starter switch and the blower switch are turned on, electricity flows from the battery to the coil of the blower motor relay, turning the blower motor relay on. With the blower motor relay on, the electricity flows to the blower motor as indicated below.  Lo Position • Battery → slow-blow fuse (80A) → slow-blow fuse (50A) → fuse (30A) → blower motor relay → blower motor → blower resistor → ground  Mi Position • Battery → slow-blow fuse (80A) → slow-blow fuse (50A) → fuse (30A) → blower motor relay → blower motor → blower resistor → blower switch (E→A) → ground  Hi Position • Battery → slow-blow fuse (80A) → slow-blow fuse (50A) → fuse (30A) → blower motor relay → blower motor → blower resistor → blower switch (F→A) → ground RY9212166CAM0003US0

5-M18

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

2. WIPER [1] WIPER SWITCH This switch has four positions, namely (a), (b), (c) and (d) as indicated in the figure. When the starter key is in its [RUN] position and the switch is pressed to its (b) position, the wiper motor operates; pressing it in further to its (a) position operates the window washer. When the operator releases the switch, it automatically returns from position (a) to position (b). The window washer also operates if it is pressed in to position (d) on the [OFF] side. When it is released, it automatically returns in the same way to position (c). (1) (2) (3) (4) (5) (6)

Switch Spring Contact Switch Body Movable Contact Insulator

(a) Wash 1 Position (Both Wiper Motor and Window Washer Operate) (b) On position (Only the Wiper Motor Operates) (c) Off Position (d) Wash 2 Position (Only the Window Washer Operates) RY9212148CAM0005US0

[2] WIPER The wiper is composed of a motor, wiper arm, wiper blade, etc. The motor is fixed speed and automatically returns to a set position. (1) (2) (3) (4)

Washer Nut Wiper Arm Nut

(5) (6) (7) (8)

Wiper Blade Wiper Motor Wiper Motor Cover Flange Nut RY9212001CAM0028US0

5-M19

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[3] WIPER MOTOR A cylindrical ferrite magnet and an armature are assembled inside the housing of the wiper motor. A worm gear and a helical gear are attached to the end of the armature and act as reduction gears and the rod and a segmented arm provide reciprocating motion, which is communicated to the wiper arm via the arms axis. The motor is a 2-brush specification model and its rpm cannot be altered. (1) (2) (3) (4) (5) (6) (7)

Segmented Arm Arm's Axis Rod Worm Gear Armature Axle Brush Armature

(8) Ferrite Magnet (9) Helical Gear (10) Breaker (11) Motor (12) Switch (A) Wiring Diagram (Motor Stop Position) RY9212001CAM0029US0

5-M20

KiSC issued 10, 2022 A

SERVICING CONTENTS 1. 2. 3. 4.

TROUBLESHOOTING.................................................................................................................5-S1 MAINTENANCE AND SERVICE RELATED SPECIFICATIONS.................................................5-S4 TORQUE .....................................................................................................................................5-S5 PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM .......................................5-S6 [1] USE OF SERVICE TOOLS ...................................................................................................5-S6 (1) Manifold Gauge Set.........................................................................................................5-S6 (2) Refrigerant Charging Hoses ............................................................................................5-S9 (3) Vacuum Pump Adapter .................................................................................................5-S10 (4) Electric Gas Leak Tester ...............................................................................................5-S10 (5) Canister Tap Valve ........................................................................................................5-S10 (6) T-Joint............................................................................................................................5-S11 (7) R134a Refrigerant Collection/Recycling Device............................................................5-S11 5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM .............................................5-S12 [1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE...................................................5-S12 [2] COLLECTION, VACUUMING AND CHARGING.................................................................5-S16 (1) Collecting Refrigerant ....................................................................................................5-S16 (2) Vacuuming Out the System...........................................................................................5-S16 (3) Charging from the High-Pressure Side..........................................................................5-S18 (4) Charging from the Low-Pressure Side ..........................................................................5-S18 (5) Inspections and Troubleshooting...................................................................................5-S19 6. INSPECTION AND DISASSEMBLY..........................................................................................5-S21 [1] CHECKS AND ADJUSTMENTS .........................................................................................5-S21 (1) Compressor ...................................................................................................................5-S21 (2) Relays............................................................................................................................5-S21 (3) Blower Motor .................................................................................................................5-S23 (4) Blower Resistor .............................................................................................................5-S24 (5) Blower Switch ................................................................................................................5-S25 (6) Servo Motor (for Temp Control).....................................................................................5-S26 (7) Pressure Switch.............................................................................................................5-S27 [2] DISASSEMBLY AND ASSEMBLY ......................................................................................5-S28 (1) Connecting / Disconnecting AC Hoses..........................................................................5-S29 (2) Mounting and Removing the Compressor .....................................................................5-S31 (3) Connecting / Disconnecting Hoses................................................................................5-S34 (4) Removing and Mounting the Receiver ..........................................................................5-S36 (5) Removing and Mounting AC Ducts ...............................................................................5-S37 (6) Removal and Installation of AC Cabin Outside Sir ........................................................5-S39 7. CABIN REMOVAL AND MOUNTING ........................................................................................5-S41 [1] REMOVING THE CABIN .....................................................................................................5-S41 8. WINDOW WASHER ..................................................................................................................5-S43 [1] WIPER SWITCH..................................................................................................................5-S43 [2] COMPONENT SCHEMATIC ...............................................................................................5-S44 [3] WIPER MOTOR ..................................................................................................................5-S45 [4] WASHER MOTOR ..............................................................................................................5-S45 9. LIGHTING DEVICES (CAB WORK LIGHT, INTERIOR LIGHT)................................................5-S46 10. REMOVAL AND INSTALLATION OF GLASS ...........................................................................5-S49 [1] PREPARATION ...................................................................................................................5-S49 [2] REMOVING GLASS ............................................................................................................5-S49 [3] INSTALLING GLASS...........................................................................................................5-S50 [4] GLASS TRIM TYPE ............................................................................................................5-S51 KiSC issued 10, 2022 A

[5] HOW TO REPLACE THE GLASS OF THE RIGHT-SIDE WINDOW ..................................5-S51 11. FRONT WINDOW......................................................................................................................5-S54 [1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP) .............................5-S54 [2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP) ...................................5-S55

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

1. TROUBLESHOOTING Compressor Problem and/or Situation

Noise (compressor on)

Noise (compressor off)

Possible Cause Wearing of or damage to the compressor's bearings

Replace

Compressor valve damaged

Replace

Belt slipping

Adjust or replace

Compressor bracket mounting bolt(s) loose

Tighten

Lines vibrating

Tighten and/or add clamp(s)

Blower damaged

Repair or replace

Magnetic clutch, idler pulley and/or crank pulley bearings damaged or wearing

Replace

Air Conditioning System Problem and/or Situation

Cooling not working (air not blowing)

Cooling not working (compressor not turning)

Cooling not working (other)

Cooling not working effectively (not enough air blowing) Not cooling effectively (lots of foam visible in sight glass) Too much refrigerant (no foam in sight glass) Not cooling effectively (compressor not rotating properly)

Solution

Possible Cause

Solution

Blown fuse

Replace

Main AC relay defective

Replace

AC's blower motor damaged

Replace

AC's blower switch broken

Replace

Wiring harness unplugged or poor contact

Fix

Blown fuse

Replace

Magnetic clutch broken

Repair or replace

AC switch broken

Replace

Pressure switch broken

Replace

Belt slipping

Adjust or replace

Not enough refrigerant

Check with a manifold gauge

Expansion valve broken

Replace

Compressor broken

Replace

Filter clogged

Clean or replace

Frost on the evaporator

Clean or replace the temperature switch

AC's blower motor damaged

Replace

AC blower resistor broken

Replace

Not enough refrigerant

Check with a manifold gauge

Refrigerant gas leaking from the cooling circuit

Repair and/or recharge refrigerant

Air got in

Check with a manifold gauge

Refrigerant overcharged

Check with a manifold gauge

Belt slipping

Adjust or replace

Magnetic clutch broken

Repair or replace

Compressor broken

Replace

5-S1

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Problem and/or Situation Not cooling effectively (other)

Not heating effectively

Not enough air flow (blower motor not turning)

Not enough air flow (air flow does not change to speed 3)

Not enough air flow (other)

Not cooling effectively (compressor clutch not working)

Not cooling effectively (high-pressure level too high)

Not cooling effectively (high-pressure level too low) Not cooling effectively (low-pressure level too high)

Possible Cause

Solution

Thermistor broken

Replace

Hot water valve damaged

Replace

Condenser clogged with dirt or debris

Clean

Expansion valve broken

Replace

Hot water valve damaged

Replace

Servo motor broken

Check and repair

Blower fan switch broken

Check and repair

AC main relay broken

Replace

Brushes have poor contact

Replace

Blown fuse

Replace

Miswiring or poor connections

Check and repair

Blower resistor damaged

Replace

Relay damaged

Replace

Blower fan switch broken

Replace

Blower not tight enough

Check and repair

Blower deformed

Replace

Blower hitting its casing

Check and repair

Something blocking the inlet

Check and repair

Frost on the evaporator

Clean or replace

Filter clogged

Clean or replace

Vent ducts clogged or detached

Check and repair

Battery voltage too low

Charge the battery

Rotor is hitting the stator

Replace

Miswiring or loose connectors

Check and repair

Relay damaged

Replace

Coil shorted

Replace

Ground defective

Check and repair

Coil burned out

Replace

Refrigerant overcharged

Check with a manifold gauge

Condenser clogged with dirt or debris

Clean

Air got in

Check with a manifold gauge

Not enough refrigerant

Check with a manifold gauge

Compressor discharge valve damaged

Replace

Compressor gasket damaged

Replace

Error in the low-pressure line (cracked or clogged)

Replace

Refrigerant overcharged

Check with a manifold gauge

Expansion valve too far open

Replace

5-S2

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Problem and/or Situation

Possible Cause

Solution

Not enough refrigerant

Check with a manifold gauge

Frost on the evaporator

Clean or replace

Error in the low-pressure line (cracked or clogged)

Replace

Expansion valve clogged

Replace

Not cooling effectively (both low and high pressure levels too high)

Refrigerant overcharged

Check with a manifold gauge

Not cooling effectively (both low and high pressure levels too low)

Not enough refrigerant

Check with a manifold gauge

Cannot control temperature (servo motor and/or temperature control dial defective)

Servo motor broken

Replace

Temperature control dial broken

Replace

Controller of the wire harness is off

Repair or replace

Cannot control the temperature (hot water valve does not open normally)

Servo motor broken

Replace

Hot water valve damaged

Replace

Cannot control the temperature (poor heater hose layout)

Heater hose is pinched

Fix

Heater hose is bent or broken

Repair or replace

Drain hose bent or broken

Check and repair

Drain hose clogged

Clean

Not cooling effectively (low-pressure level too low)

Water leak (water leak inside the cab) Wiper Problem and/or Situation

Wiper doesn't work

Wiper moves too slowly

Wiper fails to stop in the correct position

Possible Cause

Solution

Fuse blown (a part inside the wiper motor or some other moving part is shorted or burned out)

Pinpoint the cause of the damage and replace

Wiper motor faulty (damaged armature, worn motor brushes, motor shaft locked)

Replace

Wiper switch faulty

Replace

Faulty operation of linkage mechanism due to foreign matter

Fix

Wiper arm locked or rusted together

Grease up or replace

Wiper motor faulty (damaged armature, poor contact due to worn motor brushes, faulty operation of motor shaft)

Replace

Battery voltage low

Recharge or replace

Wiper arm shaft rusty, foreign matter stuck in it

Grease up or replace

Poor contact in wiper switch

Replace

Wiper motor faulty (Dirty or poor contact of the contacts at the auto-stop position due to foreign matter)

Replace RY9212001CAS0001US0

5-S3

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

2. MAINTENANCE AND SERVICE RELATED SPECIFICATIONS Factory specification

Allowable Limit Value

0.30 to 0.65 mm 0.0118 to 0.0255 in.

–

3.0 to 4.0 Ω

–

Pressure (low-pressure side)

0.15 to 0.20 MPa 1.5 to 2.0 kgf/cm2 21 to 28 psi

–

Pressure (high-pressure side)

1.27 to 1.66 MPa 13 to 17 kgf/cm2 185 to 242 psi

–

Pressure setting (low-pressure side)

Lower than the values below About 0.196 MPa 2.0 kgf/cm2 28.4 psi

–

Pressure setting (high-pressure side)

Higher than the values below About 3.14 MPa 32 kgf/cm2 455 psi

–

AC drive belt

Tension

Deflects 12 to 15 mm (0.47 to 0.59 in.) when 68.6 N (7 kgf, 15.4 lbf) of forced is applied

–

Refrigerant

Type (recharge volume)

R134a 0.75 to 0.85 kg 1.65 to 1.87 lbs

–

Compressor Oil

Type (usage volume)

ND-OIL8 <PAG*oil> 100 to 120 cc 0.106 to 0.127 U.S.qts 0.088 to 0.106 Imp.qts

–

Item AC Compressor Magnetic Clutch

Air Gap

Magnetic Clutch Stator Coil

Electrical Resistance

Cooling Cycle (cooling cycle when operating normally)

Pressure switch (dual type) (when pressure switch is off)

*PAG : Polyalkylene glycol (synthetic oil) RY9212182CAS0022US0

5-S4

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

3. TORQUE The following table indicates the specified tightening torques for nuts. Items

N·m

kgf·m

lbf·ft

M16 nut

107.9 to 127.5

11.0 to 13.0

79.6 to 94.0

Assembly

M6 bolt

3.9 to 6.9

0.4 to 0.7

2.9 to 5.1

Cushion

M8 bolt

17.7 to 20.6

1.8 to 2.1

13.0 to 15.2

M8 bolt

16.7 to 19.6

1.7 to 2.0

12.3 to 14.5

M6 nut

7.8 to 9.3

0.8 to 1.0

5.8 to 6.9

M8 bolt

16.7 to 19.6

1.7 to 2.0

12.3 to 14.5

M8 bolt

3.9 to 6.9

0.4 to 0.7

2.9 to 5.1

Compressor

M6 bolt

7.8 to 11.8

0.8 to 1.2

5.8 to 8.7

Condenser

M6 bolt

A/C unit

M6 bolt

3.9 to 6.9

0.4 to 0.7

2.9 to 5.1

Receiver

M6 bolt M6 screw

3.9 to 6.9

0.4 to 0.7

2.9 to 5.1

M8 screw

9.8 to 15.7

1.0 to 1.6

7.2 to 11.6

M6 screw

10.8 to 16.2

1.10 to 1.65

8.0 to 11.9

Cabin mounting Condensor mounting Compressor mounting Compressor bracket mounting Receiver mounting Cooler hose assembly

AC mounting Magnetic clutch mounting

RY9212182CAS0023US0

5-S5

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

4. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM [1] USE OF SERVICE TOOLS (1) Manifold Gauge Set Always follow the warnings and regulations below when inspecting or repairing the air conditioning system. It is also extremely important that no one other than specially trained service personnel handles refrigerants. CAUTION • If the liquid refrigerant comes in contact with skin, it results in frostbite, so always be careful when handling refrigerants. Always wear goggles when working on this system in order to protect your eyes. • Refrigerant service containers are made very sturdy for safety. However, they can explode if handled improperly. Always follow the instructions printed on their labels. In particular, never heat a refrigerant container above 40 °C (104 °F). Also, never drop one from any height. • Do not steam clean this system. In particular, this system is under extremely high pressure, so do not steam clean the condenser as it may cause the system to explode. • If an error is made in handling the service valve or in connecting a hose between the compressor's service valve and a manifold gauge, it may cause the refrigerant service container or the charging hose to explode. When connecting hoses or handling service valves, always check the pressure on the high-pressure side or on the low-pressure side. • When recharging refrigerant with the compressor operating, do not open the high-pressure valve of the manifold gauge. • Be careful of gas toxicity. The refrigerant gas in its natural state is harmless and is not toxic. However, when it comes in contact with very hot parts, it can break down chemically, producing hazardous materials. • Do not heat service canisters unless absolutely necessary. When necessary to heat a canister, use water at or below 40 °C (104 °F). Never use boiling water to heat a canister. IMPORTANT • Using R12 refrigerant in an R134a AC system may cause problems to result, such as leaks of refrigerant at O-rings and fogging of the sight glass. Consequently, the shapes of line joints, service valves and service tools are different in order to prevent mistakes in connecting or recharging the wrong system. • Always keep the work area clean, dry and free of any dirt or dust. Always wipe off any water from line fittings with a clean cloth before opening the fitting. • Only use R134a refrigerant service tools. • When discharging refrigerant, use an R134a refrigerant collection/recycling machine. • Prior to connecting a charging hose to the tap valve of a refrigerant canister, check each seal and make sure it is not clogged up. • When disconnecting charging hoses from compressor and receiver valves, do so as quickly as possible to minimize the leakage of gas. • Be careful to only charge with the specified amount of refrigerant; never overcharge the system. This is important because overcharging the refrigerant can cause poor cooling performance among other things. • Hand tighten when connecting the charging hose to the canister's tap valve. Do not use pliers to tighten the charging hose. • Store refrigerant containers in a cool, dark place and never leave them in direct sunlight or in a hot place. • R134a compressor oil readily absorbs moisture, so always seal any parts after disconnecting them. • Do not use any of the old style R12 refrigerant or previous kinds of refrigerant compressor oil. (To be continued)

5-S6

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(Continued) CAUTION • Take care with the following points on storing and handling service canisters. • Store in a cool, dry place. • Never drop or strike a canister. • Do not use service canisters that are deformed, have unusable screws or are otherwise damaged. • Never heat a service canister unless necessary. If one must be heated for some reason, use water at or below 40 °C (In such cases, never warm the canister while heating the water.) Do not immerse the valve of the service canister in water. Do not turn the service canister upside down. Turning it upside down allows liquid refrigerant into the compressor, which damages the valve. • Do not shake hard. (If the mounting of the valve is not secure, it may come off.) • Use ND-OIL8 (made by DENSO (Co. Ltd.)) compressor oil. (ND-OIL6 is designated for use with R12, so do not mistakenly use ND-OIL6.) CAUTION • Precautions on Inspecting and Charging AC Gas • Perform all work in a well-ventilated location. • Be careful when handling high-pressure valves. When recharging refrigerant with the engine running, do not open the high-pressure valve (HI) of the manifold gauge. Overcharging refrigerant may cause problems such as poor cooling and overheating. IMPORTANT • Observance of laws and regulations Refrigerant is the subject of global environmental protection issue. Therefore, when handling the refrigerant cycle, we are subjected to abide the laws and regulations. RY9212050CAS0001US0

The manifold gauge set has a valve handle for opening and closing valves. The valve handle marked LO is for use on the low-pressure valve (5) and the valve handle marked HI is for use on the high-pressure valve (3). The following circuits can be achieved by variously opening and closing the high and low pressure valves. (1) Low-Pressure Gauge (2) High-Pressure Gauge (3) High-Pressure Valve

(4) Valve Core (5) Low-Pressure Valve RY9212001CAS0005US0

When low and high pressure valves are closed The following 2 circuits are formed. Port (C) → Low-pressure gauge (1) Port (A) → High-pressure gauge (2) CAUTION • Be sure to open the valve core (d). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0006US0

5-S7

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

With the low-pressure valve open and the high-pressure valve closed The following circuits are formed. Port (C) → Low-pressure gauge (1) Port (C) → Port (B) Port (C) → Port (D) Port (A) → High-pressure gauge (2) CAUTION • Be sure to open the valve core (D). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0007US0

With the low-pressure valve closed and the high-pressure valve open The following circuits are formed. Port (C) → Low-pressure gauge (1) Port (A) → Port (B) Port (A) → Port (D) (Be sure to open the valve core.) Port (A) → High-pressure gauge (2) CAUTION • Be sure to open the valve core (D). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0008US0

With low and high pressure valves open The following circuits are formed. Port (A) → High-pressure gauge (2) Port (A) → Low-pressure gauge (1) Port (A) → Port (B) Port (A) → Port (C) Port (A) → Port (D) (Be sure to open the valve core.) CAUTION • Be sure to open the valve core (D). (1) Low-Pressure Gauge

(2) High-Pressure Gauge RY9212001CAS0009US0

5-S8

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(2) Refrigerant Charging Hoses The three kinds of refrigerant charging hoses are distinguishable by color. Each of the refrigerant charging hoses is to be used as follows. • In line with the AC manufacturer's recommendation, the blue hose (6) is to be used on the low-pressure side (intake side), the green hose (5) on the cooling side (center connection port) and the red hose (3) on the high-pressure side (discharge side). (When connecting) • Press the quick-disconnect adapter (4) into the recharge valve and press part A in until you hear it catch. CAUTION • While pressing in to make a connection, be careful not to bend any lines. • When connecting a quick-disconnect adapter, if you move the sleeve (7) before the quick-link connector is connected to the charge valve, move the sleeve back to its original position and then try making the connection again. • If there is any refrigerant left in the refrigerant charging hose, it can be difficult to connect the quick-link connector. In this case, make the connection after relieving the pressure remaining in the refrigerant charging hose. (Pressing on the pusher (8) eliminates any remaining pressure.) (When disconnecting) • With part A of the quick-disconnect adaptor held in place, slide part B up. CAUTION • After removing the quick-disconnect adaptor, be sure to put a cap on the service valve of the adaptor. (1) (2) (3) (4) (5) (6)

Low-Pressure Valve High-Pressure Valve Red Hose Quick-Disconnect Adapter Green Hose Blue Hose

(7) Sleeve (8) Pusher (9) Sleeve a : Makes a Catching Sound RY9212001CAS0010US0

5-S9

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(3) Vacuum Pump Adapter Purpose of the Vacuum Pump Adapter 1. After the AC cooling system is vacuumed, when the vacuum pump is stopped, there is a vacuum inside the hoses of the manifold gauge, so the oil of the vacuum pump flows back into the refrigerant charging hose. If the refrigerant system is charged in this state, the vacuum pump oil remaining in the refrigerant charging hose will go into the AC refrigerant system along with the refrigerant. A vacuum pump adaptor equipped with a solenoid valve is used to prevent this backflow of oil from the vacuum pump. The role of the solenoid valve is to close when electricity is flowing to the solenoid valve, cutting it off from outside air and maintaining the vacuum; when the electricity is cut off, the valve opens, bringing in outside air and relieving the vacuum. 2. If this adapter is connected to the currently used R12 vacuum pump, it enables the vacuum pump to be used for both R134a and R12. (1) (2) (3) (4)

Vacuum Pump Adapter Vacuum Pump For R134a Solenoid Valve

(5) Air (6) For R12 (7) Plug Cap RY9212001CAS0011US0

(4) Electric Gas Leak Tester The old style R12 gas leak tester are not sensitive enough for R134a and cannot be used. Consequently a new and very sensitive electrical gas leak tester has been designed that can be used with both R134a and R12. [NOTE] Halogenated Torch Gas Leak Testers • Because this tester detects gas leaks based on the reaction of chlorine in the refrigerant, it cannot detect R134a because it does not contain chlorine. (1) Electrical Gas Leak Tester RY9212001CAS0012US0

(5) Canister Tap Valve The canister tap valve used in recharging the refrigerant of the AC system has to be used as follows. 1. Before attaching the canister tap valve to the refrigerant container, rotate the handle (1) counterclockwise until the needle of the valve is completely retracted. 2. Rotate the plate nut (disk) (3) counterclockwise to its highest position and then screw the canister tap valve into the sealed tap. 3. Rotate the plate nut clockwise as far as you can and fasten the center charging hose to the canister tap valve. 4. Tighten the plate nut securely by hand. 5. Rotate the handle (1) clockwise to open a hole in the sealed tap. 6. To charge the system with refrigerant, turn the handle (1) counterclockwise. To stop charging, turn the handle clockwise. (1) Butterfly handle (2) Connector

(3) Disc (4) Needle RY9212001CAS0013US0

5-S10

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(6) T-Joint A T-joint (2) is used when using two refrigerant canisters (4) at the same time to make gas recharging more efficient. 1. Attach a refrigerant canister service valve on each side of the T-joint (2) and connect a refrigerant charging hose (1) to the T-joint. (1) Refrigerant Charging Hose (Green) (3) Canister Tap Valve (2) T-Joint (4) Refrigerant Canister RY9212001CAS0014US0

(7) R134a Refrigerant Collection/Recycling Device When it is necessary to discharge the refrigerant in order to work on the backhoe, a collection / recycling device must be used. (Never release refrigerant into the atmosphere.) IMPORTANT • Use a dedicated R134a refrigerant collection/recycling device. • To prevent any damage to the compressor, use neither R12 system refrigerant nor cooling system oil in R134a equipment. RY9212001CAS0015US0

5-S11

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM [1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE IMPORTANT • Be aware that the gauge pressure values noted in the following test are measured under identical conditions and they may vary somewhat from your gauge pressure values, depending on the prevailing conditions. Conditions • Ambient temperature : 30 to 35 °C (86 to 95 °F) • Engine RPM : Approx. 1,500 • Temperature control lever : Max cooling position • Blower switch : HI Position RY9212001CAS0016US0

Manifold connections and test preparations 1. Close the manifold gauge's high and low pressure valves tightly. 2. Connect the red refrigerant charging hose to the high-pressure charge valve and the blue or yellow refrigerant charging hose to the low-pressure charge valve. CAUTION • Use the refrigerant pressure in the refrigerant cycle to completely flush out the air in the refrigerant charging hose from the end of the manifold gauge's connection. 3. Start up the engine and set it at approximately 1500 rpms. 4. Turn the AC switch on and set the temperature control dial to the max cooling position. 5. Set the blower switch to its HI position. (1) Refrigerant Charging Hose (Blue or Yellow) (2) Refrigerant Charging Hose (Red) (3) High-Pressure Valve (4) Low-Pressure Valve

(5) Manifold Gauge (6) Low-Pressure Side Charge Valve (7) High-Pressure Side Charge Valve

RY9212182CAS0001US0

When operating normally If the refrigerant cycle is operating normally, readings will be around the factory specifications in the table below.

Gas Pressure

(1) Low Pressure Side

Factory specification

Low pressure side

0.15 to 0.20 MPa 1.5 to 2.0 kgf/cm2 21 to 28 psi

High pressure side

1.27 to 1.66 MPa 13 to 17 kgf/cm2 185 to 242 psi

(2) High Pressure Side RY9212001CAS0018US0

5-S12

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Without enough refrigerant 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too low. Low-pressure side (1) : 0.05 to 0.10 MPa (0.5 to 1.0 kgf/cm2, 7.1 to 14.2 psi) High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2, 99.6 to 142.2 psi) • Foam visible in the sight glass. • Air output by the AC appears to be cooled. 2. Possible Cause • Gas leaking from the circuit of the refrigerant cycle. 3. Solution Methods • Use an electric gas leak tester to check for leaks and repair any found. • Recharge the system with an appropriate amount of refrigerant. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0019US0

Excess refrigerant or insufficient condenser cooling 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm2, 28.4 to 49.8 psi) High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2, 284.5 to 355.6 psi) 2. Possible Causes • Cycle charged with too much refrigerant. • Poor condenser cooling. 3. Solution Methods • Clean the condenser. • Adjust the tension of the AC drive belt to the appropriate tension. • If the 2nd item above is normal, check the amount of refrigerant. CAUTION • To discharge excess refrigerant, loosen the manifold's gauge's low-pressure valve and slow discharge it. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0020US0

5-S13

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Air mixed into the cycle 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm2, 28.4 to 49.8 psi) High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2, 284.5 to 355.6 psi) • The line on the low-pressure side (1) feels cold to the touch. 2. Possible Causes • Air is mixed in the refrigerant cycle 3. Solution Methods • Replace the receiver. • Check the amount of compressor oil and whether it is contaminated. • Vacuum it out and charge the cycle again with fresh refrigerant. CAUTION • If you fail to vacuum out a refrigerant cycle like that mentioned above and simply charge the cycle with refrigerant, the problem may recur. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0021US0

Moisture mixed into the cycle 1. Symptoms that appear in the refrigerant cycle • At first the AC works normally, but after some time, the pressure on the low-pressure side (1) becomes a vacuum and the high-pressure side (2) is at a low pressure. Low-pressure side (1) : Vacuum; High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2, 99.6 to 142.2 psi) 2. Possible Causes • Moisture in the refrigerant cycle freezes up in the expansion valve orifice, creating a temporary blockage. As time elapses, the ice thaws and it returns to normal. 3. Solution Methods • Replace the receiver. • Eliminate the moisture in the refrigerant cycle by repeatedly vacuuming it out. • Recharge the system with an appropriate amount of refrigerant. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0022US0

5-S14

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Refrigerant fails to circulate 1. Symptoms that appear in the refrigerant cycle • Low-pressure side (1) becomes a vacuum and the high-pressure side (2) is at low pressure. Low-pressure side (1) : Vacuum; High-pressure side (2) : 0.49 to 0.59 MPa (5 to 6 kgf/cm2, 71.2 to 85.3 psi) 2. Possible Causes • The line above the expansion valve orifice is frozen up and the refrigerant cannot flow due to moisture and/or dirt stuck in the refrigerant cycle. 3. Solution Methods Wait for some time to elapse and determine whether it is dirt or moisture blocking the line by whether AC operation recovers or not. • If the problem is moisture, the problem resolves itself, as indicated in the previous section. • If the cause is dirt, remove the expansion valve and blow out any dirt with compressed air. • If the dirt cannot be eliminated, replace the expansion valve and the receiver. Vacuum out the line and charge the cycle with an appropriate amount of fresh refrigerant. • If the problem is caused by a gas leak in the heat-sensitive tube, replace the expansion valve. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0023US0

Expansion valve too far open 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.29 to 0.39 MPa (3 to 4 kgf/cm2, 42.7 to 56.9 psi) High-pressure side (2) : 1.96 to 2.45 MPa (20 to 25 kgf/cm2, 284.5 to 355.6 psi) • Either frost or heavy condensation on the low-pressure side line 2. Possible Causes • Problem with the expansion valve. • The flow volume adjustment is set improperly. 3. Solution Methods • Replace the expansion valve. (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0024US0

Faulty compression from compressor 1. Symptoms that appear in the refrigerant cycle • Low-pressure side (1) : 0.39 to 0.59 MPa (4 to 6 kgf/cm2, 56.9 to 85.3 psi) High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm2, 99.6 to 142.2 psi) 2. Possible Causes • Compressor is leaking. 3. Solution Methods • Replace the compressor. CAUTION • When the compressor is producing a faulty compression, it can be detected with a manifold gauge (figure at left). (1) Low Pressure Side

(2) High Pressure Side RY9212001CAS0025US0

5-S15

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[2] COLLECTION, VACUUMING AND CHARGING IMPORTANT • Follow 4. Precautions when Repairing the Refrigerant Cycle when discharging, vacuuming and charging the refrigerant system. RY9212001CAS0026US0

(1) Collecting Refrigerant Get a R134a refrigerant collection/recycling device ready to use. 1. Connect the low-pressure hose (blue) from the refrigerant collection/recycling machine to the low-pressure side charge valve. Connect the high-pressure hose (red) to the high-pressure charge valve. 2. Follow the instructions of the manufacturer and discharge the refrigerant from the cooling system. IMPORTANT • Do not use device except an R134a refrigerant collection and recycling machine. In order to prevent damage to the compressor, do not mix R134a equipment, refrigerant or compressor oil into an R12 system. CAUTION • When removing the charge valve hose, cover it with a rag to protect your fingers and eyes from frost bite from the refrigerant. (1) Refrigerant Charging Hose (Blue or Yellow) (2) Refrigerant Charging Hose (Red) (3) High-Pressure Valve (4) Low-Pressure Valve

(5) Manifold Gauge (6) Low-Pressure Side Charge Valve (7) High-Pressure Side Charge Valve

RY9212182CAS0002US0

(2) Vacuuming Out the System No.

Description of Work

Remarks

(1)

Check the connected parts and correct any problems

(2)

Start vacuuming

Approx 15 minutes, 750 mmHg (229 in.Hg) or greater

(3)

Stop vacuuming

Leave for five minutes

(4)

Check the concentration

If the gauge indicates abnormally, return to (1)

(5)

Charge with refrigerant

98 kpa (1.0 kgf/cm2, 14 psi)

(6)

Check for gas leaks

(7)

Charge with refrigerant RY9212001CAS0028US0

5-S16

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Manifold gauge connections and vacuuming 1. Close the high-pressure (HI) and low-pressure (LO) valves of the manifold gauge. 2. Connect the L-shaped side of 2 charging hoses to quick joints and connect them to the compressor and receiver service valves. Blue hose

Low-pressure side (L mark)

Red hose

High-pressure side (H mark)

3. Connect the charging hose (green) in the middle of the manifold gauge to the vacuum pump. 4. Open the high and low pressure valves of the manifold gauge. 5. Turn the vacuum pump switch on and vacuum the line until the low-pressure gauge reaches a reading of approximately –0.1 MPa (–750 mmHg). (about 15 minutes) 6. Once about –0.1 MPa (–750 mmHg) is reached, close the high and low pressure valves of the manifold gauge and stop the vacuum pump. 7. Let it set for at least five minutes and check to make sure the indicator needle of the low-pressure gauge does not approach 0. 8. If the needle of the gauge approaches 0, the system's airtightness is compromised somewhere, so after inspecting and repairing the line connections, run the vacuum again and check to make sure there are not any places that are not airtight. (1) (2) (3) (4) (5)

Vacuum Pump High-Pressure Valve Low-Pressure Valve High-Pressure Side (H Mark) Low-Pressure Side (L Mark)

(A) Inspection Line Connections (B) Low-Pressure Gauge (a) Valve Settings (L: Closed, H: Closed) (b) Leave for at Least Five Minutes (c) If the Needle Approaches 0, Inspecting and Repairing the Line Connections. RY9212001CAS0029US0

Connections with a refrigerant collector or service canister 1. Close the high-pressure (HI) and low-pressure (LO) valves of the manifold gauge. 2. Connect the charging hose (green) connected to the vacuum pump to the collector or service canister. (Air is in the charging hose, so do not open the high or low pressure valves.) 3. Discharge from the collector or open the service canister's valve. 4. Press on the valve core of the manifold gauge for three to five seconds to discharge any air from the hose. (1) (2) (3) (4) (5)

Service Canister Valve High-Pressure Valve Low-Pressure Valve High-Pressure Side (H Mark) Low-Pressure Side (L Mark)

(a) Press Valve Core to Expel Air

RY9212001CAS0030US0

5-S17

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(3) Charging from the High-Pressure Side Charging from the High-pressure Side

•

• • 1. 2. 3. 4.

CAUTION Important : do not start the engine. If the engine is running, the gas will flow back and burst either the service canister or a hose. IMPORTANT Do not open the low-pressure valve of the manifold gauge. If the service canister has been changed, be sure to expel any air out of the charging hose (green). Without starting the engine, open the high-pressure valve and charge with approx 500g of gas. While charging, once the low-pressure gauge indicates approx 0.10 MPa (approx 1.0 kgf/cm2), close the high-pressure valve and the service canister valve for the time being. Use a gas detector to check the hoses and pipe connections for gas leaks; if any exist, repair them. If there are no leaks, continue charging the refrigerant. When charging on the high-pressure side stops, close the high-pressure valve on the manifold gauge and the service canister valve, and then charge from the low-pressure side.

(1) Service Canister Valve (2) High-Pressure Valve (3) Low-Pressure Valve

(a) Press Valve Core to Expel Air

RY9212001CAS0031US0

(4) Charging from the Low-Pressure Side Charging from the Low-Pressure Side CAUTION • Never open the manifold gauge's high-pressure valve when charging refrigerant while the engine is running. (If the high-pressure valve is opened, high-pressure gas will flow back up the line and rupture the service canister or a charging hose.) • Always keep the service canister upright when charging. IMPORTANT • If the service canister has been changed, be sure to expel any air out of the charging hose (green). 1. Check and make sure the manifold gauge's high-pressure valve is closed. 2. After starting the engine, set it to approx 1500 rpms and open all of the doors. 3. Turn the AC switch on and set the temperature control to maximum cooling. 4. Open the manifold gauge's low-pressure valve and the service canister valve and charge with the specified amount of gas. 5. After completing refrigerant charging, close the manifold gauge's low-pressure valve and the service canister valve and stop the engine. 6. Check for any gas leaks with the gas leak tester. RY9212001CAS0032US0

5-S18

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(5) Inspections and Troubleshooting [A] Checking the Quantity of AC Gas Checking with a manifold gauge All the manifold gauge values indicated below are measurements taken under the specified conditions. Please note that the measurements you take will vary depending on the prevailing conditions. Conditions Doors

All open

Inside/outside air switch

Inside

Ambient air temperature

30 to 35 °C (86 to 95 °F)

Engine RPM

About 1,500

Temperature control

Max cooling position

Blower switch

1. After closing both the high and low-pressure valves of the manifold gauge, connect charging hoses (red/blue) to the compressor and the service canister valve of the receiver tank. 2. Loosen the low-pressure valve slightly to expel any air from the charging hose. After expelling the air, close the low-pressure valve again. 3. Expel air from the charging hose on the high-pressure side in the same way. 4. Start the engine and set it at approximately 1,500 rpms. 5. Turn the AC switch ON and set the temperature control to maximum cooling and the blower switch to HI. 6. Read the values on the low-pressure and high-pressure gauges.

When Normal

(1) (2) (3) (4) (5) (6) (7) (8) (9)

High-Pressure Gauge Low-Pressure Gauge High-Pressure Valve Low-Pressure Valve Valve Core Red Blue Quick Joint Green

Factory specification

Low pressure side

0.15 to 0.20 MPa 1.5 to 2.0 kgf/cm2 21 to 28 psi

Factory specification

High pressure side

1.27 to 1.66 MPa 13 to 17 kgf/cm2 185 to 242 psi

(a) High-Pressure Side (Compressor's H-Mark Side) (b) Low-Pressure Side (Compressor's L-Mark Side)

RY9212001CAS0033US0

5-S19

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Checking with the sight glass Conditions Doors

All open

Inside/outside air switch

Inside

Ambient air temperature

30 to 35 °C (86 to 95 °F)

Engine RPM

About 1500 rpm

Temperature control

Max cooling position

Blower switch

Criteria (a)

Overcharged

No air bubbles at all in the flow. In this case, both high and low-pressure sides are at high pressure and the cooling is ineffective.

(b)

Normal amount

Almost no air bubbles in the flow. If the engine rpm is raised gradually from idle to 1,500 rpm, the air bubbles disappear and the flow becomes transparent.

(c)

Undercharged

Air bubbles flow past constantly.

(1) Sight Glass RY9212001CAS0034US0

5-S20

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

6. INSPECTION AND DISASSEMBLY [1] CHECKS AND ADJUSTMENTS (1) Compressor Magnetic clutch 1. Start the engine. 2. With the AC switch on the AC control panel off, check and make sure that no scraping sounds or other noise comes from the pulley as it turns. 3. Turn the AC switch and the fan switch on to make the AC system operate. With the AC working, check and make sure the magnetic clutch is not slipping. 4. If there is any noise, repair or replace it. (1) Magnetic Clutch RY9212001CAS0035US0

Stator coil 1. Remove the magnetic clutch's 1P connector. 2. Measure the resistance between the 1P connector on the magnetic clutch side and the body of the stator. 3. If the measurement falls outside of the factory specification, replace the stator coil. Between stator body and harness side of stator coil

Factory specification

3 to 4 Ω RY9212001CAS0036US0

(2) Relays After turning the starter switch off, remove the cover under the seat, remove each relay and take the following measurements. (1) Fuse box

(A) (B) (C) (D)

Blower motor relay Compressor clutch relay Cab relay Cab work light relay RY9212182CAS0003US0

5-S21

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Harness-side checks Between battery and cab relay 1. Measure the voltage between terminal 1in the fuse box and ground on the body. 2. Set the starter switch to [RUN]. 3. Measure the voltage between terminals 3 and 5in the fuse box. 4. If the voltages of each are the same as the battery voltage (DC 11 to 14V), they are normal. Between battery and blower motor relay 1. Measure the voltage between terminal 1in the fuse box and ground on the body. 2. If the voltage is the same as the battery voltage (DC 11 to 14V), it is normal. Between battery and cab work light relay 1. Measure the voltage between terminal 1in the fuse box and ground on the body. 2. If the voltage is the same as the battery voltage (DC 11 to 14V), it is normal. Testing individual relays 1. Impress the battery voltage between terminals 3 and 5 of the relay. 2. Check for continuity between terminals 1 and 2 of the relay. 3. If there is continuity between the terminals, it is normal. (a) (b) (c) (d)

Terminal 5 Terminal 3 Terminal 2 Terminal 1

(A) Fuse Box Terminals (B) Individual Relay

RY9212001CAS0038US0

5-S22

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(3) Blower Motor Connector voltage 1. Remove the blower motor's 1P connector. 2. Switch the starter switch to [RUN] and the blower switch to [3] (HI). 3. Measure the voltage between terminal 1of the connector on the switch side and ground on the body. 4. If the voltage is different from the battery voltage (DC 11 to 14V), then there is a fault in the wire harness, blower motor relay, the fuse and/or the starter switch. (1) 1P Connector (A) 1P Connector (Main Harness (2) 1P Connector (Main Harness Side) Side) RY9212001CAS0039US0

Blower motor test 1. Turn the blower motor by hand and check whether it turns smoothly. 2. Remove the 2P connector from the blower motor. 3. Connect a jumper lead from the positive (+) terminal of the battery to terminal b of the connector. 4. Connect a jumper lead from the negative (-) terminal of the battery to terminal e of the connector for just a moment. 5. If the blower motor fails to turn, check the motor. (1) Blower Motor (2) 2P Connector (Blower Motor Side) (3) Battery (12V)

b : (+) Terminal e : (-) Terminal RY9212001CAS0040US0

5-S23

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(4) Blower Resistor 1. Remove the blower resistor's 3P connector. 2. Measure the resistance between terminals 2 and 3 and between 2 and 1 of the connector on the AC unit side. 3. If they differ from the factory specifications, the blower resistor is faulty. Terminal 3 – terminal 2 Terminal 1 – terminal 2

Factory specification

(1) 3P connector

About 0.9 Ω About 1.9 Ω

(2) 3P connector (AC unit side) RY9212001CAS0041US0

(a) Fuse (221 ± 10 °C, 430 ± 18 °F) A : 0.9 Ω B : 1.2 Ω (Reference)

<1> R1 terminal <2> E terminal <3> R2 terminal (A) 3P connector (AC unit side) RY9212001CAS0042US0

5-S24

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(5) Blower Switch Connector voltage 1. Remove the 6P connector from the blower switch. 2. Turn the starter switch to [RUN]. 3. Measure the voltage between terminals 3 and 6 of the connector on the harness side. 4. If the voltage is different from the battery voltage (DC 11 to 14V), then there is a fault in the wire harness, blower motor relay, the fuse and/or the starter switch. (1) Control Panel (2) 6P connector

(A) 6P connector (harness side) RY9212001CAS0043US0

Blower switch test 1. Check the continuity between each of the terminals according to the table below. 2. If continuity exists, it is normal.

(A) 6P connector (Switch side) RY9212001CAS0044US0

5-S25

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(6) Servo Motor (for Temp Control) Servo motor test 1. Switch the starter switch to [RUN] and the blower switch to ON. 2. Press the AC switch to turn the AC on. 3. Turn the Temperature control dial to the (B), (C), and (D) positions in turn as indicated in the figure at left and measure the resistance in (A). 4. When making the measurements, first turn the starter switch to OFF and then disconnect the servo motor's 8P connector. 5. If the resistance measured between terminals 2 and 3 of the connector on the AC unit side differs from the factory specifications, then either the AC unit harness or the servo motor is faulty. (B) (C)

Approx. 1.2 kΩ Factory specification

(D) (1) (2) (3) (4) (5)

8P connector 8P connector (AC unit side) Temperature control dial AC switch Fan switch

Approx. 2.9 kΩ Approx. 4.6 kΩ

(A) (B) (C) (D)

8P connector (AC unit side) Left end (blue side, max cool) Center (white center) Right end (red side, max hot) RY9212001CAS0045US0

5-S26

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(7) Pressure Switch When a pressure switch (inside the high-pressure/low-pressure switch) is operating normally, electricity is conducted (ON) and when an abnormal pressure occurs, it trips the switch, blocking the electricity (OFF). RY9212001CAS0046US0

Manifold gauge connections 1. Close the HI (high-pressure side) valve (3) and the LO (low-pressure side) valve (2) of the manifold gauge (1) securely. 2. Connect the red charging hose (4) to the HI (high-pressure side) charge valve (1) and the blue charging hose (5) to the LO (low-pressure side) charge valve (2). 3. Open the manifold gauge's HI (high-pressure side) valve (3) a little and press on the valve core to expel any air inside its charging hose (4). Then close the HI (high-pressure side) valve (3) tightly. 4. Open the manifold gauge's LO (low-pressure side) valve (2) a little and press on the valve core to expel any air inside its charging hose (5). Then close the LO (low-pressure side) valve (2) tightly. (1) Manifold Gauge (2) Low-Pressure Valve (3) High-Pressure Valve

(4) Red Charging Hose (5) Blue Charging Hose RY9212001CAS0047US0

When refrigerant pressure is rising (OFF) 1. Start the engine and set it at 1500 rpms. Turn the AC switch on the control panel on, set the fan switch to HI and set the temperature control lever to the max cool position. 2. Cover the front of the condenser with cardboard or the like and raise the pressure on the high-pressure side of the AC cycle. 3. Once the pressure on the high-pressure side rises, the high-pressure switch operates, turning the magnetic clutch of the compressor off. When it does so, read the HI (high-pressure) gauge of the manifold gauge and if it reads higher than the pressure setting, replace the pressure switch. • Pressure setting on the high-pressure side of the switch: Switches off at approximately 3.14 MPa (32 kgf/cm2, 460 psi) or higher RY9212182CAS0004US0

When refrigerant pressure is dropping (OFF)

1. Remove the connector of the pressure switch (1). 2. Measure the resistance between the terminals of the pressure switch with a circuit tester. It should register 0 Ω unless there is insufficient gas due to a leak or unless the pressure switch is faulty. • Pressure setting on the low-pressure side of the switch: Switches off at approximately 0.196 MPa (2.0 kgf/cm2, 28 psi) RY9212001CAS0049US0

5-S27

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[2] DISASSEMBLY AND ASSEMBLY Diagram of AC Unit

(1) (2) (3) (4) (5) (6) (7) (8)

Top Case Evaporator Bottom Case Linkage Cover Intake Cover Evaporator O-Ring O-Ring

(9) Expansion Valve (10) Expansion Bolt (11) Thermistor ASSY (12) Thermistor Clamp (13) AC Amp (14) Heater Core (15) Pipe (16) Water Valve

(17) Clip (18) Washer Screw (19) O-Ring (20) Servo Motor (21) Linkage Lever (22) Blower Resistor (23) Tapping Screw (24) Tapping Screw

(25) Cap (Plug) (26) Blower Fan (27) Wire Harness (28) AC Collar (29) Flat Washer (30) Bolt (31) Air Conditioning Unit RY9212001CAS0050US0

5-S28

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(1) Connecting / Disconnecting AC Hoses Fastening torques for A/C hoses Compressor M6 bolt (1) Tightening torque

Condenser M6 bolt (2) Receiver M6 bolt (3) A/C unit M6 bolt (4)

7.9 to 11.8 N·m 0.8 to 1.2 kgf·m 5.9 to 8.7 lbf·ft 4.0 to 6.8 N·m 0.4 to 0.7 kgf·m 3.0 to 5.0 lbf·ft

(When removing) 1. Collect the refrigerant from the A/C system. 2. Disconnect the negative (-) cable from the battery and disconnect the 1P connector of the magnetic clutch. 3. Remove the A/C hose(s). CAUTION • After removing hose(s), immediately seal the A/C system so no moisture or water gets into it. (When attaching) • Pay attention to whether each hose is for high or low pressure. • Pay attention to whether each hose is an inlet or outlet hose. • Attach each bolt and tighten to its specified torque. • Tighten the aluminum pipe nuts with two wrenches, holding one side from turning and tightening the other nut to it. (The mating side is soft, so be careful when tightening.) • Tighten carefully so as to avoid twisting the pipe. • Apply some compressor oil to pipes that have O-rings and press the tip into the stepped surface. (1) (2) (3) (4)

Compressor M6 bolt Condenser M6 bolt Receiver M6 bolt A/C unit M6 bolt

(A) (B) (C) (D)

Discharge hose Suction hose Rigid pressure hose Liquid hose RY9212182CAS0020US0

5-S29

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CABIN

U35-4, WSM

A/C hose routing

(1) (2) (3) (4)

Compressor Condenser Receiver Air Conditioning Unit

(A) (B) (C) (D)

Discharge hose Suction hose Rigid pressure hose Liquid hose RY9212182CAS0021US0

5-S30

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(2) Mounting and Removing the Compressor (1) (2) (3) (4) (5) (6) (7) (8) (9)

A/C Drive Belt Tensioner Pulley Compressor ASSY Pulley Mounting Bolt Lock Nut Adjustment Bolt Compressor Bracket Tensioner Pulley Bracket

(L) Belt Tension Checking Position

(When removing) 1. Collect the refrigerant from the AC system. 2. Disconnect the negative (–) cable from the battery and the 1P connector of the magnetic clutch. 3. Remove the low-pressure pipe and the high-pressure pipe from the compressor, then immediately cap them so no water or moisture gets into the AC system. 4. Remove the AC drive belt and then the compressor. (When attaching) • Adjust the tension of the compressor drive belt. If you press down on the L part of the belt with your fingertips [68.6 N (7 kgf, 20 lbf)] and it displaces 12 to 15 mm (0.47 to 0.59 in.), it is correct. • Attach each bolt and tighten to its specified torque. • Apply compressor oil to the O-rings. • Connect the low-pressure hose to the side of the compressor marked "S" (suction). Be careful of the orientation of bolts when installing them. • Connect the high-pressure hose to the side of the compressor marked "D" (discharge). Be careful of the orientation of bolts when installing them. • Be careful of the orientation of bushing (compressor) when installing it. RY9212182CAS0005US0

5-S31

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Filling the compressor with oil When replacing the compressor • The amount of oil required by the new compressor is enclosed within the AC cycle. A certain amount of compressor oil circulates along with the gas in the AC system. • When replacing the compressor, remove the excess oil from the new compressor. • Compressor oil (ND-OIL8) readily absorbs moisture, so seal it immediately. Compressor Oil

(1) New Compressor (2) Old Compressor

Type: ND-OIL8

Capacity (reference value): 60 cc, 0.06 U.S.qts

A : Amount of Oil for New Compressor B : Amount of Oil from Old Compressor (a) Remove Excess Oil (A-B) RY9212001CAS0053US0

(1) Low-Pressure Pipe (2) High-Pressure Pipe (3) Bolt

(A) Bolt Mounting Orientation

RY9212001CAS0054US0

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Adjusting clearance 1. Use a feeler gauge to check the clearance. 2. If the measurement is outside the factory specification, adjust the clearance. Clearance

Factory specification

0.30 to 0.65 mm 0.0118 to 0.0255 in.

[NOTE] Shim Thickness

Part No.

0.10 mm (0.0039 in.)

T1065-87340

0.15 mm (0.0059 in)

T1065-87350

0.40 mm (0.016 in.)

T1065-87360

0.60 mm (0.024 in.)

T1065-87370

1.0 mm (0.0394 in.)

T1065-87380

(1) (2) (3) (4) (5)

Magnetic Clutch Mounting Screw Hub Plate Shim Snap Ring Rotor

(6) Snap Ring (7) Stator (8) Compressor Body L : Clearance RY9212148CAS0010US0

5-S33

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(3) Connecting / Disconnecting Hoses

(1) Engine side (2) Joint installation angle (3) Pipe joint (45, R3-14)

(4) Hose clamp (with spring) (5) Joint (pipe, water) (6) Hose clamp (with spring)

(7) A/C unit side (8) Bottom of machine

(a) 15 °

(When removing) 1. Stop the engine and allow the radiator to cool before starting work. 2. Drain the coolant (hot water) from the engine side. 3. Simultaneously remove the heater hose from the water flange side and drain the coolant (hot water). 4. Remove the heater hose on the heater core side. (When attaching) • Be careful not to mistake the inlet and outlet hoses. • Apply compressor oil to the O-rings. • Joint mounting angle (a): 15 ° Pipe joint (3)

≥ 20 N·m ≥ 2.0 kgf·m ≥ 15 lbf·ft

Joint (pipe, water) (5)

24.5 to 29.4 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft

Tightening torque

RY9212182CAS0006US0

5-S34

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Handling engine coolant (when draining) 1. Stop the engine and start working once the radiator has cooled. 2. Remove the reserve tank hose from the radiator. 3. Remove the drain plug from the radiator, then remove the radiator cap and drain out all of the coolant. (When filling) 1. Tighten the drain plug securely and replace the reserve tank hose to the radiator. 2. Fill the radiator and the reserve tank with coolant. 3. After filling, tighten the cap, start the engine, let it idle for five minutes, stop the engine and check and make sure it has the specified amount of coolant. (1) Coolant drain plug

(2) Radiator cap RY9212182CAS0007US0

5-S35

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(4) Removing and Mounting the Receiver (1) Condenser (2) Condenser cushion (3) Condenser grommet (4) Thrust collar (5) Bolt (6) Plate (7) Bolt (8) Receiver (9) Receiver holder (10) Bolt (11) Wing bolt (12) Condenser support (13) Bracket

(When removing) 1. Remove the receiver and receiver holder. 2. Remove the wing bolt. Raise the support slightly and turn to the lock position. 3. Remove the condenser cushion from the support. 4. Remove the cushion from the plate. 5. Remove the plate from the condenser. CAUTION • The receiver has a desiccant in it, so do not remove the rubber cap until just before connecting the hoses. Be careful not to damage the fins of the condenser. (When attaching) • Make sure the thrust collar (condenser) is installed in the right direction. • Be careful not to mistake the inlet and outlet hoses. • Attach each bolt and tighten to its specified torque. (To be continued)

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(Continued) NOTE Part Replaced

Fill Capacity

Condenser

40 cc 0.042 U.S.qts 0.035 lmp.qts

Evaporator

40 cc 0.042 U.S.qts 0.035 lmp.qts

Receiver

10 cc 0.011 U.S.qts 0.009 lmp.qts

Hose

20 cc 0.022 U.S.qts 0.018 lmp.qts

Brand Name

ND-OIL8 <PAG* oil>

*PAG: Polyalkylene glycol (synthetic oil) RY9212182CAS0008US0

(5) Removing and Mounting AC Ducts (1) Duct ASSY (1, AC) (2) Duct (3) Seal (4) Seal (5) Seal (6) Duct ASSY (2, AC) (7) Duct (8) Seal (9) Seal (10) Seal (11) Seal (12) Bolt (13) Duct ASSY (3, AC) (14) Duct (15) Duct (16) Seal (17) Seal (18) Insulation (2, AC) (19) Air Conditioning Unit RY9212001CAS0059US0

5-S37

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CABIN

U35-4, WSM

(When removing) 1. Remove the two bolts and then the duct cover (1). 2. Remove the two bolts and then the switch cover. 3. Remove the four bolts and then the duct cover (3). 4. Remove the duct ASSY (3, AC) from the duct ASSY (1, AC). 5. Remove just the one bolt and then remove the duct ASSY (2, AC) from the duct ASSY (1, AC). 6. Remove the duct ASSY (1, AC) from the air conditioning unit. (When attaching) • All the duct assemblies fit together. • Press the parts that fit together in firmly until the seal is hidden. • Attach the bolts and tighten them to the specified torque. (1) (2) (3) (4)

Duct Cover Switch Cover Duct Cover Duct ASSY (3, AC)

(5) Bolt (6) Duct ASSY (2, AC) (7) Duct ASSY (1, AC) RY9212001CAS0060US0

5-S38

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CABIN

U35-4, WSM

(6) Removal and Installation of AC Cabin Outside Sir

(1) (2) (3) (4) (5) (6)

Duct ASSY (1, fresh air, A/C) Duct Seal Seal Duct Duct ASSY (fresh air, base)

(7) Duct (8) Seal (9) Seal (10) Seal (11) Filter (12) Cover (13) Washer (14) Plastic bolt

(15) Flat spring (16) Nut (17) Seal (18) Plate (19) Seal (20) Bolt (21) Bolt

(22) Duct ASSY (3, fresh air, A/C) (23) Duct (24) Seal (25) Heat insulation (26) Bracket (27) Bolt (28) Outer RY9212182CAS0027US0

5-S39

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

(When removing) 1. Remove the two bolts and then the duct cover. 2. Remove the two bolts and then the switch cover. 3. Remove the two bolts and then the duct ASSY (fresh air, base). 4. Remove the duct ASSY (3, fresh air, A/C) and the duct (2, fresh air, A/C) 5. Remove the duct ASSY (1, fresh air A/C) from the air conditioning unit. Changing the filter 1. Loosen the knob bolt. 2. Lift the right end of the cover and remove the hook from the flat spring. 3. Unhook the catch on the left edge of the cover. 4. Remove the filter. (When attaching) • Insert the filter into the duct slit hose (part ). • Insert the cover into the duct slit holes (part , 2 places) and fix at part . 1. To install the duct ASSY (3, fresh air, A/C), insert between the duct assembly (fresh air, base) and the bracket (duct, fresh air). 2. To install the duct assembly (1, fresh air, A/C), insert it into the A/C unit. 3. To install the duct (2, fresh air, A/C) insert it between the duct assembly (1, fresh air, AC) and the duct assembly (fresh air, base). (5) Duct (6) Duct assembly (fresh air, base) (7) Duct (11) Filter (12) Cover

(14) Plastic bolt (23) Duct (26) Bracket (29) Duct cover (30) Switch cover RY9212182CAS0010US0

5-S40

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CABIN

U35-4, WSM

7. CABIN REMOVAL AND MOUNTING [1] REMOVING THE CABIN 1. Put the bucket on the ground, stop the engine, and slide the seat forward of the machine. 2. Remove the cover (1), (2), (3) and the filter. (1) Cover (2) Cover

(3) Cover (4) Filter RY9212182CAS0026US0

3. Disconnect the harness for cabin and the coupler connecting the main harness. 4. Remove the cover (1). (1) Cover (2) Main Harness Coupler

(3) Harness Coupler for Cabin RY9212032CAS0004US0

5. Remove the floor mat and the two nuts (1) at the front of the machine to attach the cabin. Tightening torque

107 to 127.4 N·m 11.0 to 13.0 kgf·m 79.69 to 92.6 lbf·ft

Nut (1)

(1) Nut RY9212032CAS0006US0

6. Remove the two nuts (1) at the rear of the machine to attach the cabin. Tightening torque

107 to 127.4 N·m 11.0 to 13.0 kgf·m 79.69 to 92.6 lbf·ft

Nut (1)

(1) Nut RY9212032CAS0007US0

7. Remove the air duct (1) and (2). (1) Air Duct

(2) Air Duct RY9212032CAS0005US0

5-S41

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Tightening torque

78 to 127 N·m 8.0 to 13.0 kgf·m 58 to 94 lbf·ft

Stud (front) (6) Stud (rear) (7)

Spread the screw fixation medicine (Loctite 271). (1) Nut (2) Washer (3) Shock Absorber Rubber (Cabin, Upper) (4) Shock Absorber Rubber (Cabin, Lower) (5) Collar

(6) Stud (Front) (7) Stud (Rear) (A) Two Points at the Front of the Machine (B) Two Points at the Rear of the Machine RY9212032CAS0008US0

8. Suspend the nylon sling at the top of the cabin. RY9212182CAS0015US0

9. Lift the cabin gently and remove it. Cabin weight

approx. 230 kg (507 lbs) RY9212182CAS0016US0

5-S42

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

8. WINDOW WASHER [1] WIPER SWITCH Connector voltage 1. Remove the 6P connector from the wiper switch. 2. Switch the starter switch to [RUN] and the wiper switch to ON. 3. Measure the voltage between terminal 1of the connector on the harness side and ground on the body. 4. If is the same as the battery voltage (DC 11 to 14 V), it is normal. (1) Wiper switch

A : 6P connector (harness side) RY9212182CAS0017US0

Checking the wiper switch 1. Check the continuity between each of the terminals according to the table below. 2. If continuity exists, it is normal.

A : 6P Connector (Switch Side) RY9212001CAS0072US0

5-S43

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Checking the cab wiper power harness 1. Disconnect the 6P connector from the wiper switch and the 4P connector from the cab wiper power harness. 2. Check the continuity between the terminals on both sides of the harness. 3. If continuity exists, it is normal. (1) Cab Wiper Power Harness

A: B: (a) (b)

6P Connector 4P Connector Wiper Motor Line Washer Motor Line RY9212001CAS0073US0

[2] COMPONENT SCHEMATIC (1) Wiper Motor ASSY (2) Nut (3) Wiper Cap (4) Nut (5) Washer (6) Wiper Seal (7) Wiper Plate (8) Wiper Cover (9) Bolt (10) Cushion (11) Flange Nut (12) Wiper Arm ASSY (13) Wiper Blade (14) Nozzle ASSY (15) Gasket (16) Gasket (17) Elbow Joint (18) Tube Joint (19) Screw (20) Washer Tank (21) Bracket (22) Bolt (23) Tube (24) Clamp (25) Washer motor

The wiper is installed on the front and is composed of a wiper motor, wiper arm, wiper blade, etc. RY9212001CAS0074US0

5-S44

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[3] WIPER MOTOR Connector voltage 1. Remove the wiper cover. 2. Remove the 4P connector from the wiper motor. 3. Switch the starter switch to [RUN] and the window washer to ON. 4. Measure the voltage between terminals 2 and 3 of the connector on the harness side. 5. If is the same as the battery voltage (DC 11 to 14 V), it is normal. (1) Wiper motor

A : 4P connector (harness side) RY9212001CAS0075US0

Testing the motor separately 1. Raise the wiper blade so there is no load on it. 2. Switch the starter switch to [RUN] and the wiper switch to ON. 3. If the rpm and wiping angle are as indicated in the table, it is normal. No load wiper rpm

Factory specification

No load wiping angle

Tightening torque

25 to 43 rpm 87 to 93 °

Flange nut (11)

3.43 to 4.41 N·m 0.35 to 0.45 kgf·m 2.53 to 3.25 lbf·ft

Nut (4)

2.94 to 3.92 N·m 0.30 to 0.40 kgf·m 2.17 to 2.89 lbf·ft

Nut (2)

6.37 to 9.32 N·m 0.65 to 0.95 kgf·m 4.70 to 6.87 lbf·ft RY9212182CAS0018US0

[4] WASHER MOTOR The window washer operates via a small, electric hi-speed motor and consists of a tank, pump and nozzle. The washer pump is linked to the shaft of the motor and is installed below the tank. Tank Capacity

1.6 L (0.42 U.S.gal)

(1) Washer motor (2) Tank

A : 2P connector (harness side) RY9212182CAS0019US0

Connector voltage 1. Remove the 2P connector from the washer motor. 2. Press in on the [OFF] side of the wiper switch. (so only the window washer operates.) 3. Measure the voltage between terminals 1 and 2 of the connector on the harness side. 4. If is the same as the battery voltage (DC 11 to 14V), the connector voltage is normal. A : 2P connector (harness side) RY9212001CAS0078US0

5-S45

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

9. LIGHTING DEVICES (CAB WORK LIGHT, INTERIOR LIGHT) (1) Wire Harness (Cabin) (2) Wire Harness (3) Grommet (4) Bolt (Earth) (5) Cabin Working Light (6) Light Bulb (7) Lamp Cover (8) Wiper Cover (9) Bolt (10) Lamp Bracket Assy (11) Bolt (12) Room Light Assy (13) Light Bulb (14) Screw RY9212032CAS0011US0

Connector voltage 1. Disconnect the cab power 8P connector from the wire harness (cabin). 2. Measure the voltage between terminal 3 of the connector on the cabin power harness side and ground on the body. (interior light) 3. Turn the starter switch to [RUN]. 4. Measure the voltage between terminal 4 of the connector on the cabin power harness side and ground on the body. (cab work light) 5. If is the same as the battery voltage (DC 11 to 14 V), the connector voltage is normal. (1) Cab Power Harness

A : 8P Connector (Cab Power Harness Side) B : 8P Connector (Cab Harness Side) RY9212001CAS0080US0

5-S46

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Terminal voltage (cab work light) 1. Remove the grommet and pull the work light terminal out of the frame of the cabin. 2. Remove the two work light terminals. 3. Switch the starter switch to [RUN] and the cab work light switch to ON. 4. Measure the voltage between GND and the work light terminal (+) on the harness side. 5. If is the same as the battery voltage (DC 11 to 14 V), the terminal voltage is normal. (1) Work Light (2) Grommet

(a) (+) Terminal (b) GND Terminal RY9212001CAS0081US0

Terminal voltage (interior light) 1. 2. 3. 4.

Remove the cover of the interior light. Remove the bulb. (pull it out) Switch the interior light switch to [ON]. Measure the voltage between GND and the interior light terminal (+). 5. If is the same as the battery voltage (DC 11 to 14 V), the terminal voltage is normal. (1) Interior Light ASSY (2) Interior Light Switch

(a) (+) Terminal (b) GND Terminal RY9212001CAS0082US0

5-S47

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

Cab work light switch Connector voltage 1. Turn the starter switch to [OFF] and disconnect the 10P connector from the cab work light switch. 2. Turn the starter switch to [RUN]. 3. Measure the voltage between terminal 7 of the connector on the harness side and ground on the body. (switch voltage) 4. Measure the voltage between terminal 4 of the connector on the harness side and ground on the body. (LED voltage) 5. If is the same as the battery voltage (DC 11 to 14 V), it is normal. (1) Cab work light switch (2) 10P connector (harness side)

(A) 10P connector (harness side) RY9212182CAS0024US0

Checking the cab work light switch 1. Check the continuity between each of the terminals according to the table below. 2. If continuity exists, it is normal.

(1) Cab work light switch (2) 10P connector (switch side)

(a) (free) RY9212182CAS0025US0

5-S48

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

10. REMOVAL AND INSTALLATION OF GLASS [1] PREPARATION Items required • • • • • • •

Cleaner : Equivalent of Seeker Cleaner 205 Adhesive : Equivalent of Seeker Flex 250PC-JM Primer : Equivalent of Seeker Primer 206 Scraper Awl Adhesive cutter Glass suction cups (use if needed) NOTE • The cleaner and adhesive have a short shelf-life (9 to 12 months), so obtain them immediately before use from a nearby manufacturer or a shop that handles auto glass products. (1) Glass Suction Cups

(2) Adhesive Cutter RY9212001CAS0085US0

[2] REMOVING GLASS 1. Mask off painted surface around the glass to protect them from scratching while removing/installing glass. 2. Remove the glass. [When using piano wire (damages parts of the glass)] • Pierce and make a hole in the adhesive with an awl (or knife of glass cutter, etc.). • Pass the piano wire (or steel wire) through the hole. • Wrap both ends of the piano wire around a wood block or the like. • Pull the piano wire along the edge of the window, sawing through the adhesive between the cab and the glass; then remove the glass from the cab. [When using an adhesive cutter (completely ruins the glass)] • Insert the adhesive cutter into the adhesive. • Pull on part (a) of the cutter and cut the glass out. CAUTION • If the piano wire gets very hot in one place, it may break. Avoid rubbing it with much force against the edge of the glass. • Be careful not to cut yourself on fragments of glass or the blade of the cutter. (1) (2) (3) (4)

Cab Frame Glass Awl Adhesive

(5) Piano Wire (6) Wood (7) Adhesive Cutter RY9212001CAS0086US0

5-S49

KiSC issued 10, 2022 A

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[3] INSTALLING GLASS 1. Completely eliminate all old adhesive on the frame of the cab. 2. Use the cleaner to clean the cab frame and the surface of the new glass where adhesive will be applied to get rid of any dirt or oil. 3. Affix the windshield dam to the surface of the new glass where the adhesive will be applied. 4. Apply primer uniformly around the circumference of the windshield dam. 5. Apply adhesive uniformly along the outer circumference of the windshield dam. 6. Apply primer uniformly around the entire circumference of the flange of the cab frame. (Application width: 18 mm (0.71 in.) or more) 7. Make and install a spacer for in between the edge of the glass and the cab's frame so that the glass does not slide down during installation. (holds position and prevents slipping) 8. Press lightly all the way around the edge of the glass from the outside, so the glass touches the shield dam and they stick together. 9. Hold the glass in place with packing tape until the adhesive hardens so the glass does not shift or come off. (1) (2) (3) (4)

Glass Windshield Dam (W/Adhesive) Primer (Apply) Adhesive (Apply)

(a) (b) (c) (A)

At Least 7 mm (0.28 in.) At Least 12 mm (0.47 in.) 12 mm (0.47 in.) Start Affixing Dam Here RY9212001CAS0087US0

• For the front window (1) (2) (3) (4)

Glass (a) At Least 7 mm (0.28 in.) Windshield Dam (W/Adhesive) (b) At Least 12 mm (0.47 in.) Adhesive (Apply) Fastener (Affix as Male/Female Set) (A) Line Up with the Edge of the Frame RY9212001CAS0088US0

• Recommended shape of triangular bead NOTE • Cut the tip of the nozzle of the adhesive cartridge in the shape of a V. • Apply the adhesive to the glass so it forms a uniform triangular bead. (1) Nozzle Tip (2) Windshield Dam (W/Adhesive) (3) Adhesive (Apply)

(a) At Least 8 mm (0.31 in.) (b) At Least 12 mm (0.47 in.) RY9212001CAS0089US0

5-S50

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[4] GLASS TRIM TYPE (When removing) 1. Lift the rubber core by its seam and remove it. 2. Remove the glass to the outside. (When attaching) 1. From the outside, insert the glass into the glass trim. 2. Insert the rubber core into the groove all the way around the trim. 3. Start inserting the rubber core at the bottom center. (to prevent rain from getting in) (1) (2) (3) (4)

Panel Glass Trim Rubber Core Glass

(a) Inside (b) Start Here

RY9212001CAS0090US0

[5] HOW TO REPLACE THE GLASS OF THE RIGHT-SIDE WINDOW Put something like a piano wire into the outer window frame, pull it along the frame, remove the adhesive agent and cut it off from the cab frame. Replace the window glass followed by the next procedure. RY9212032CAS0012US0

How to replace the glass 1. Lift the pin up with a flat-head driver. For RD451-46041, remove the sealant first and lift the pin. 2. Open the window to the point as shown in the figure. 3. Push down to widen up the window frame within elastic deflection not enough to deform itself permanently and replace the glass. And the same way when you install the glass. 4. Put the pin back. Apply sealant on this part of RD451-46041. NOTE • Use same brand of an adhesive agent and a primer E.g.) – Cleaner: TK cleaner made in Daishin Chemistry – Adhesive agent: Sikaflex-260AP (SikaTack-Go!) or MSI made Sunrise U90 – Primer: Sika Coating Activator or MSI made Sunrise Primer 24 (1) Pin (2) Window

(A) Push Down to Widen Up the Window Frame RY9212032CAS0013US0

5-S51

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

How to apply primer on the cab side 1. Remove dirt and grease on the opening surface of the glass sash's flange with a cleaner such as white gasoline. Avoid using an alcoholic cleaner. 2. Apply body primer evenly all around of flange from the end. NOTE • You have to finish the glass installation within 3 min. to 6 hours after coating the primer. (1) Primer (Apply)

(a) 18 mm (0.71 in.) or more RY9212032CAS0014US0

How to install the glass spacer 1.

Remove dirt and grease on the surface of glass spacer with a cleaner such as white gasoline. 2. Apply the primer to the glass spacer. 3. Install the glass spacer in the glass sash. (4 spots) (1) Glass Spacer

(a) (b) (c) (d) (e)

100 mm (3.9 in.) Cross Section of the Spacer Install in the Sash Inclined Surface Cab Side RY9212032CAS0015US0

How to install the sealant dam and apply the primer 1. Remove dirt and grease on the surface of the circumference at the back of the sash glass to apply an adhesive agent and on the surface of applying a sealant dam with a cleaner such as white gasoline. Avoid using an alcoholic cleaner. 2. Put a sealant dam on the position as shown in the figure and evenly apply the primer peripherally. [ How to apply adhesive ] 1. Apply the adhesive along the circumference of the sealant dam. NOTE • You have to finish the glass installation within 3 min. to 6 hours after coating the primer. • In order to keep water-tightness, the adhesive must be applied unbrokenly. • Installation of glass needs to be done within 3 min. after the adhesive is applied. (1) Sealant Dam (W/Adhesive) (2) Primer (Apply) (3) Adhesive (Apply)

(a) 12 mm (0.47 in.) (b) 12 mm (0.47 in.) or more (c) 7 mm (0.27 in.) or more (A) Starting Point of Installation RY9212032CAS0016US0

5-S52

KiSC issued 10, 2022 A

CABIN

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How to install the glass sash 1. Set the glass in the sash on which the adhesive has been already applied and install to attach on the cabin frame. NOTE • Adhesive should not be run off the edge of the sash after the glass sash is set. • Need to maintain that state for about 24 hours after the glass sash is set. (1) Glass Sash RY9212032CAS0017US0

5-S53

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

11. FRONT WINDOW [1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP) When water leaks in the cabin or it rattles 1. Close the front window (top) and lock it securely. 2. Remove the trim on the top edge of the front window (top) about half way along the frame and measure the clearance between the glass and the cab frame. NOTE • If you remove the trim too far, the glass may shift out of position, preventing a reliable measurement of the clearance. (1) (2) (3) (4)

Cab ASSY Front Window (Top) Trim Cab Frame

(a) Clearance

RY9212001CAS0091US0

3. Remove the clip and then the lock cover. (1) Lock Cover

(2) Clip RY9212001CAS0092US0

4. Remove the lock of the front window (top) and loosen the lock's mounting bolts. 5. Leave the rear bolt as is and lift up the front bolt 1.0 to 1.5 mm (0.04 to 0.06 in.). NOTE • Lifting the bolt more than 1.5 mm (0.06 in.) may prevent the lock from working. 6. Re-tighten the bolts to the specified torque. 7. Close the front window (top) and lock it securely. 8. Recheck the clearance between the glass and the cab frame and make sure the clearance is smaller. 9. Operate the mini-excavator and make sure the rattling has stopped while driving. 10. Spray some water on the window and make sure it does not leak. (1) Lock (2) Bolt (Front)

(3) Bolt (Rear) RY9212001CAS0093US0

5-S54

KiSC issued 10, 2022 A

CABIN

U35-4, WSM

[2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP) When it rattles on the cabin 1. Lift the front window (top) and lock it securely to the ceiling. 2. While pulling down on the handle, check whether there is a gap between the glass and the cushion. 3. If the glass is up against the cushion without a gap, it is OK. 4. If there is a gap between the glass and the cushion, it causes the rattling. Loosen the nut and stretch the cushion until it is against the surface of the glass. 5. After adjusting the cushion, re-tighten the nut. 6. Lift the front window (top) and lock it securely to the ceiling. 7. Operate the mini-excavator and make sure the rattling has stopped while driving. (1) Cabin (2) Nut

(3) Cushion (4) Handle RY9212001CAS0094US0

5-S55

KiSC issued 10, 2022 A

W/H30 CORD,BATTERY(+) N_

BASE: 3 B

W/H33 CORD,BATTERY(-)

BASE: 20.00

B/Y

BASE: 20.00

+ BATTERY -

BATTERY

B/Y

BASE: 20.00

B/Y

B/W

RD451-54311

ACA: 3 W

CAB: 3 W

BASE: 5 R

BASE: 3 B/W

R/W

BASE: 3 B/W

BASE: 3 R/W

BCN: 5 R

BASE: 3 R

5 R N_BI:

CNP: CAB: 5 R

KEY_SWITCH BASE: 3 R/W

START

OFF

BASE: 5 R

8.00

AUX1: 5 R

SBF-BOX N_BI: 3

BASE: 5 R

SWITCH,STARTER

BASE: 5 R

MAIN(POWER) N_BI: 8.00 1 W/H30

CAB: 3 W

SBF_BOX

SBF(ALTERNATOR) 80 Bolt-in_type

BATTERY(POWER) N_BI: 8.00 W 1 W/H00

BASE: 3 R

SBF-BOX BASE: 8.00 R

Composition Specification Code

ACA: 5 R/Y

BASE: 5 R

SBF(MAIN1) 50 Plug-in_type

ACA: 5 R/Y

SBF 2

GND3

1 BODYEARTH(ENGINE)

W/H34 CORD,BODY EARTH SBF(MAIN2) 50 Plug-in_type

SWING_FRAME ENGINE

GND1 GND2 GND1:POWER GND2:ECU,SENSOR GND3:SHIELD(SENSOR)

GND3

GND1 GND2 GND3

BATTERY

BASE: 3 B

RELAY(40A,ISO)

RELAY(POWER) BASE: 5 R BASE: 0.50

RELAY(POWER) BASE: 3 W BASE: 0.30

GND2

FUSE(ALTERNATOR) BASE: 3 R/W

FUSE(ALTERNATOR) 10 MiniFuses RD451-54101

ASSY_ALTERNATOR

ALTERNATOR(+B) +B BASE: 8.00 R B-1 BASE: 1.25 f Y/R IG A-1 BASE: 1.25 f W/R L A-2 ALTERNATOR(IG,L)

FUSE(ALTERNATOR) BASE: 1.25 f Y/R

RELAY(STARTER)

Null

RELAY(STARTER) BASE: 3 B/W 30 3 BASE: 0.50 R/B 86 1

BASE: 3

B/W

RELAY(GLOW)

BASE: 0.50 FUSE(ENGINE,STOP) BASE: 3 R

RELAY(GLOW) NULL

R/B

RELAY(20A,MICRO-ISO)

STOP_SWITCH R

RELAY(ECU_MAINPOWER) RELAY(ECU_MAINPOWER)

FUSE(ECU_MAIN(POWER)) BASE: 3 Y/R

BASE: 3 Y/R BASE:2 f

Y/R

NULL

Null

RELAY(ENGINE_STOP) BASE: 3 R

SWITCH,ASSY.ENGINE_STOP

FUSE(ECU_MAIN(POWER)) 30 MiniFuses

CAB

CAB (8+4)

ACA

Foreign-A/C

ACM

A/C-mode

CNP

Canopy

AutoIdle

Anti-Theft

N_AT

No.Anti-Theft

N_BI

No.Battery Isolator

AT&BI

Anti-Theft & Battery Isolator

AT&N_BI

Anti-Theft & No.Battery Isolator

Engine Stop

BCN

Beacon

TRB

Travel Alarm

AUX1

Grip (R)

AT&AUX1

Anti-Theft & Grip (R)

AT&HS

Anti-Theft & Horn SW

Normal Blade

Angel Blade

Blade Cap

COMMON

ALL-USE

W/H00:RC788-53420 W/H,MAIN,CAB,AC RC788-53410 W/H,MAIN,CAB,ACAB RC788-53320 W/H,MAIN,CNP RC788-53310 W/H,MAIN,CNP,AB RC788-53430 W/H,MAIN,CAB,ACAB,AT RC788-53330 W/H,MAIN,CNP,AB,AT W/H05:RD809-53333 W/H,FUELSENSOR W/H06:RC788-53390 W/H,BLOWER,A/C W/H12:RC788-53360 W/H,FRONT W/H19:RD451-46902 W/H,MAIN,CAB W/H20:RD451-46913 W/H,WIPERCODE W/H23:RD451-53380 W/H,CANOPY,4P W/H30:RC788-53220 CORD,BATTERY(+) W/H33:RC788-53230 CORD,BATTERY(-) W/H34:RC411-53241 CORD,BODY EARTH

ASSY_STARTER

RELAY(GLOW) BASE: 3 R

FUSE(ECU_MAIN(POWER)) BASE: 5 R

ALL-USE

STARTER(50) BASE: 3 B/W 50 A-1 W/H00 30_+B N_BI: 30 R/B B-1 W/H31 STARTER(+B) N_BI:

FUSE(ENGINE,STOP) 30 MiniFuses

BASE

MIC

RELAY(20A,MICRO-ISO)

FUSE(ENGINE,STOP) BASE: 5 R

Notes

STOP_SWITCH ES: 0.50 O/B

4 5 2

3-Cylinder GLOW_PLUG

GLOW

BASE: 3 R/B

BASE: 0.50

B/R

SOLENOID,ASSY

RELAY(ENGINE_STOP) 4

JOINT-ES water-proof

BASE: 3 R/W

ENGINE_STOP_SOL BASE: 2 f R/W

BASE: 0.50 B

BASE: 2 f R/W

B/Y

232C Y/R

BASE: 0.50

B/Y

GND2

MAGNET

GND3

BASE: 0.50

N_BI: 0.50

BASE: 0.50 BASE: 0.50

HOLD

AT&N_BI: 0.50

Y/G

W/B

AT: 0.30

SWITCH,LIMIT B

f G/W

FUSE(STARTER_SIGNAL) BASE: 0.30 Y/B

(+)

BASE: 0.50

B/O

RxD(MAIN-ECU)

CAN-L

TxD(RF-UNIT)

AT: 0.30 G

RxD(RF-UNIT)

AT: 0.30

TRAVEL_PRESSURE_SWITCH CR: TRB: 0.50 G/W NO 1

TRAVEL_ALARM(FRONT,+) TRB: 0.50 L/B TRB: 0.50

GND1

TRB: 0.50

AI_PRESSURE_SW AI: 0.50 G/W

AI:

AT: 0.50 W/B

TRAVEL_PRESSURE_SWITCH TRB: 0.50 L/B

0.5R(+)

A-1

0.5B(-)

750ohm,0.5W

BUZZER,BACK

750ohm,0.5W 150ohm,2W

0.5R(+)

A-1

150ohm,2W

0.5B(-)

B-1 TRAVEL_ALARM(REAR,GND)

COMPRESSOR-CRUTCH-SW

MOTOR-GND

WORKLIGHT-SW

AUX1-SOL(R)

Y/B

STARTER-SW

AUX1-SOL(L)

44 46

ENGINE-STOP-SW

24 23

Y/R

BASE: 0.50

G/R

BASE: 2 f

Y/G

AI:

1.25

AI:

1.25

INOUT RF

GND

AI_MOTOR MOTOR,ASSY(AI) AI: 1.25 G CCW(G) 1 PTC

AI:

0.30

AI:

0.50

B/Y

AI:

0.50

R/B

AI:

0.30

AI:

0.30

L/W

AI:

0.30

B/R

AI:

0.30

AI: 0.30

PUSH_SW(W)

LEFT_SW(Y)

NB:

0.50

AB:

0.50 Y/

Y/B

R/W W/B

AUX1: 0.30

EF-SOL

ACM: 0.50

TRAVEL-SPEED-SW

EF-SOL-FEEDBACK

ACM: 0.50

G/B

TRAVEL-SPEED-SOL

BASE: 0.50

Y/B

AB: 0.50

R/Y

W/B

22 21

Y/R

AUX1-HOLD-SW

SOL(AUX1-L) AUX1: 0.50 R/W 1

SW1

SW2

SOL(AUX1-R) AUX1: 0.50 W/B 2

SW2

SOL(AUX1-L) AUX1: 0.50 W/B 2

SOLENOID

ANGLE(R)-SOL

AB: 0.50

L/Y

ANGLE(R)-SW

AB: 0.50

R/Y

ANGLE(L)-SW

BASE: 0.50

G/W

LEVER-LOCK-SW

SOLENOID

MULITIPURPOSE-SOL

AB: 0.50

SW1

MULTIPURPOSE-LEVER-SW

AUX2-HOLD-SW

Y/B

SOLENOID

SOL(AUX1-R) AUX1: 0.50 W 1

AI-CHANGE-SW

ANGLE(l)-SOL

ANTITHEFT-HORN-RELAY

LEVER-LOCK-SOL

CHARGE-INPUT

AB: 0.50

G/W

AB: 0.50

R/B

AT:

L/R

0.50

BASE: 0.50

Y/B

SOL(E/F) ACM: 0.50 G

SOL(E/F)

(+)

(-)

SOLENOID

SOL(TRAVEL_SPEED) (+) BASE: 0.50 Y 1

ACM:0.50

L/Y

SOL(TRAVEL_SPEED) BASE: 0.50 B 2

(-)

GND3

OIL-SW BUZZER-OUT

AB: 0.50

SOL(ANGLE-R) (+) G/W 1

AB: 0.50

SOL(ANGLE-L) R/B 1

ANTITHEFT-RELAY

AI:

0.50

R/B

AUX1: 0.50

R/B

DISPLAY-CHANGE-SW

STARTER-RELAY

USER-CHANGE-SW

AI: 0.30

R/B

AI: 0.50

B/Y

+5V-OUT

GLOW-RELAY

GND(Sensor-Use)

BASE: 0.50

B/R

AUX1: 0.50

B/Y

AT:

ANTITHEFT-FLASHER-LED

BOOM-ROD-PRESS-SENSOR

0.30

AI-MODE-LED

AI:

0.30

L/W

BOOM-POT

AI: 0.50

BASE: 0.30

AI-SELFHOLD-RELAY

26 AI: 0.30

39 12

ACCEL-POT

GND

SENSOR_WATER_TEMP BASE: 0.75 f W

LCD_METER BASE: 0.50 R

Y/G

7 AI-MOTOR-POT

BASE: 0.50

G/R

BASE: 0.50

Y/R

BASE: 0.50

R/B

BASE: 0.50

AUX1-POT1

7 5 6 8

BASE: 0.75

f Y

AUX1-POT2

BASE: 0.75

f W

AUX2-POT2

W/B

AUX1: 0.30

f AI: 0.75

0.75

f G

WAKEUP-SIGNAL

W/B

+12V-OUT

ANALOG_GND

R/B 0.50

GND1

AI:

R/B 0.50 AI:

R/B

R/B BASE: 0.50

BASE: 0.50

FUSE(ECU-MAIN(AC)) BASE: 0.50 R/B

SIGNAL

GND(+)

FUSE(ECU-MAIN(+B)) N_BI: 0.50 Y/R

BASE: 0.50

R/B

AC-SW(KEY-SW)

N_BI:

Y/R

+B(DIRECT)

FUSE(HORN-MAIN) BASE: 5 R

FUSE(HORN-MAIN) 10 MiniFuses FUSE(HORN-SW) 5 MiniFuses

FUSE(HORN-MAIN) BASE: 0.50 L/W

BASE: 0.75

GND(POWER)

0.50

BASE: 0.50

ENGINE_REV._SENSOR AI: 0.75 f G

1 W/H05

AUX1: 0.30

2 LED(GND) 10

3 1

GND1

FUSE(FRONT-WORKLIGHT) BASE: 2 f Y

RELAY(WORKLIGHT)

NULL 30

4 5 2

BASE: 2 f

BASE: 0.50

GND2

FUSE(CAB-WORKLIGHT) BASE: 2 f Y

BCN: 0.30

R/Y W/H00 [main]_to_cab BASE: 2 f Y 4

W/H19 main_to_[cab] BASE: 0.85 R 4

BCN: 0.30

BCN: 1.25

GND1

BASE: 0.50

mo(+1)(G/R) S(G/W) Null

1 6

BASE: 0.50

CAN Y/R

BASE: 0.50

G/R

CAN 1 2

CAN(H) CAN(L)

2 to_J/C(CAN,MAIN)

BASE: 1.25

GND2

DIODE(7321-9822) D_7321-9822 1

400V

HORN(+) ASSY_HORN T1 L A-1 B T2 B-1 HORN(-)

DIODE(HORN) BASE: 0.50 B

CA_R(+) A-1

CAB_WORKLIGHT,FL BASE: 0.85 R

CB_B(-) B-1

MAIN_HARNESS BASE: 1.25 R 1 W/H23

CB_B(-) B-1

LIGHT,WORK

CANOPY_WORKLIGHT,R BASE: 1.25 R CA_R(+) A-1

CB_B(-) B-1

CA_R(+) A-1

CB_B(-) B-1

LAMP(BEACON) 1

ROOM_LIGHT BASE: 0.50 O

SPEAKER,ASSY

CAB_WORKLIGHT,B BASE: 0.85 B

BEACON BASE: 0.85

(-)

com

ROOM_LIGHT

DOOR 1 ON 3

CNP: CAB: 3 B

CAB: 1.25 W

CAB: 1.25 G/W

1.25

G G

CNP: CAB: 3 B

GND2 CNP: CAB: 0.85 B GND(RADIO)

CAB: 1.25 G/W

.25

CAB: 1.25 R/W CAB: 1.25 L/W

5 4

CAB: 1.25

G/W

CAB: 1.25

R/W

CAB: 1.25

L/W

CAB: 1.25

4 [main]_to_cab(wiper) W/H00

BASE: 1.25

(+)

ASSY_LIGHT,ROOM 2

MAIN_HARNESS BASE: 1.25 B W/H23 1

CANOPY_WORKLIGHT,R BASE:1.25 B

BASE: 0.50 O RADIO(+B) BASE: 1.25 Y RADIO(AC) BASE: 0.50 B RADIO(GND) BASE: 1.25 B RADIOFRAME(GND) BASE: 0.50 W SPEAKER(R-) BASE: 0.50W/B SPEAKER(R-) BASE: 0.50 Y SPEAKER(L+) BASE: 0.50Y/B SPEAKER(L-)

CAB_WORKLIGHT,FL BASE: 0.85 B

LIGHT,WORK

CAB_WORKLIGHT,B BASE: 0.85 R

CANOPY_WORKLIGHT,L

SUB_WORK_LIGHT CNP: 1.25 B 1 W/H00

GND2

CAB_WORKLIGHT,FR BASE: 0.85 B

LIGHT,WORK

CA_R(+) A-1

GND2

LIGHT,WORK CANOPY_WORKLIGHT,L

LIGHT,WORK CA_R(+) A-1

[MAIN]TO_WORKLIGHT BASE: 1.25 B 2 W/H00

W/H12 W/H(FRONT)

BASE: 1.25

SPEAKER,ASSY (-)

(+)

BASE: 1.25

SPEAKER(R) BASE: 0.50

W/B

BASE: 0.50

SPEAKER(L) BASE: 0.50

Y/B

BASE: 0.50

RADIO RADIO(+B)

RADIO(AC)

RADIO(GND)

RADIOFRAME(GND)

SPEAKER(R+)

SPEAKER(R-)

SPEAKER(L+)

CAB_POWER_SOURCE

SPEAKER(L-)

8 BASE: 1.25

GND(RADIO)

GND(RADIO,CAB)

ROOM_LIGHT(+B)

BASE:0.85

CAB_WORK_LIGHT

BASE: 3

BASE:1.25

RADIO(AC)

BASE:1.25 BR

BEACON

3 4

GND(CAB)

5 6

GND(CABFRAME)

BASE: 1.25

BASE: 0.85

BASE: 0.50

BASE:0.50 O

8 CAB_POWER_SOURCE

BASE: 3 B BASE: 0.50 B

WASH1

OFF

CAB:

SWITCH(WIPER)

W/H00

P:1

SWITCH,ASSY(WIPER)

Vcc(R)

BASE: 1.25 BR

2 LED(GND) 10

Vcc_wash(Y/B)

BASE: 1.25

MAIN_TO_[WORKLIGHT] MAIN_TO_[WORKLIGHT] LIGHT,WORK FRONT_WORKLIGHT(+) FRONT_WORKLIGHT(-) BASE: 1.25 Y BASE: 1.25 f B CA_R(+) CB_B(-) 1 W/H12 A-1 B-1 W/H12 2

[MAIN]TO_WORKLIGHT

SUB_WORK_LIGHT CNP: 1.25 R W/H00 1

BEACON BASE: 1.25 BR

FUSE(RADIO(AC)) CAB: 1.25 G

FUSE(CAB-WORKLIGHT) BASE: 2 f Y

R B

GND3

LED(+) 4

WASHER(B)

FUSE(CAB-WORKLIGHT) 20 MiniFuses RD451-54101

CAB_WORKLIGHT,FR BASE: 0.85 R

BASE: 0.85

BEACON_SWITCH OFF 9 ON BCN: 0.50 6

CNP: CAB: 0.50 O

FUSE(WIPER/WASHER) CAB: 1.25 G/W

FUSE(FRONT-WORKLIGHT) BASE: 1.25 Y

BCN: 1.25

WASH2

FUSE(WIPER/WASHER) CAB: 3 W

GND2

BASE: 0.50

BEACON_SWITCH Vcc 7

FUSE(ROOM_LIGHT) CNP: CAB: 0.50 O

FUSE(FRONT-WORKLIGHT) 15 MiniFuses RD451-54101

BASE: 0.85

FUSE(RADIO(AC)) CAB: 3 W

FUSE(ROOM_LIGHT) 5 MiniFuses FUSE(RADIO(AC)) 15 MiniFuses FUSE(WIPER/WASHER) 15 MiniFuses RD451-54101

DIODE(HORN) BASE: 0.50 L

FUSE(ROOM_LIGHT) CNP: CAB: 5 R

400V

W/H23 W/H(CANOPY,4P)

BCN: 0.50

CNP: 1.25 R

OFF ON SWITCH(BEACON) R/Y

DIODE(ANTITHEFT_HORN_PROTECT) AT: 0.50 L/R C 1

RELAY(BEACON) NULL

RELAY(BEACON) 30 3 R/B 86 1 W

RELAY(WORKLIGHT) BASE: 3 R BASE: 0.30 R

BASE: 0.30

BCN: 0.30

DIODE(7321-9822) D_7321-9822

DIODE(ANTITHEFT_HORN_PROTECT) AT&AUX1: 0.30 L/W 2

BASE: 0.85

BCN: 0.30

L/R

BCN: 1.25

RELAY(WORKLIGHT)

ACA: 0.30

FUSE(BEACON) BCN: 1.25 W

W/B

0.50

0 L : 0.3 N_AT

BASE: 0.85

FUSE(BEACON) 15 MiniFuses RD451-54101

8 Vcc_SW1(G) 7 Vcc_SW2(Gy) 5

AT:

JS_CONTROL(R) GND(B) AUX1: 0.30 B/Y 2 OUTPUT(W) AUX1: 0.30 W 3 .30 L/W N_AT: 0 HORN_SW1(L) AT&AU 4 X1: 0.30 L /W TRIG_SW2(Y) 6 AUX1: 0.30 Y/R

LED(+) 4

BASE: 0.50

SENSOR_FUEL BASE: 0.50 B 2 W/H00

RELAY(HORN) NULL

RELAY(HORN) BASE: 0.50 L/W

R/W

RELAY(BEACON) FUSE(BEACON) BCN: 5 R

BASE: 0.50

Y/R

R/B

BASE: 0.85

WORKLIGHT_SWITCH OFF 9 ON BASE: 0.30 6

R/W

BASE:0.50

FUSE(RELAY) BASE: 0.50

W/H05

SWITCH(WORKLIGHT)

FUSE(RELAY) 5 MiniFuses RD451-54101

WORKLIGHT_SWITCH Vcc L 7

BCN: 0.50

FUSE(RELAY) BASE: 3 R/W

BASE: 0.50

BASE: 0.30

OFF ON

SENSOR,FUEL BASE: 0.50 B 2 MAIN

EARTH

GND3

VALVE,ASSY(PL,R,AX)

JS_CONTROL(R) +5V(R) AUX1: 0.30 R/B 1

RD451-54101

SWITCH,OIL

OIL_SWITCH f L 1 JOINT-CHARGE water-proof

DUMMY

W/H05 W/H(FUEL)

RELAY(HORN)

AUX1: 0.30

GND

SENSOR,FUEL FUEL_SENSOR BASE: 0.50 L 1

FUSE(HORN-SW) AUX1: 0.30 L

SENSOR,FUEL

MAIN

0.50 Y/R

BASE: 0.50 O

FUSE(HORN-SW) AUX2: HS: AUX1: 5 R

BASE: 3 B

FUSE(METER(+B)) BASE: 0.50 R

WAKEUP_OUT

GND3

BASE: 0.50 B

FUSE(METER(+B)) 5 MiniFuses RD451-54101

B/W

BASE: 0.50

J/C(CAN,MAIN)

FUSE(METER(+B)) BASE: 5 R

OLS_SW

CHARGE_SW

R/B

FUSE(ECU-MAIN(+B)) N_BI: 5 R

FUSE(ECU-MAIN(AC)) 5 MiniFuses FUSE(ECU-MAIN(+B)) 5 MiniFuses RD451-54101

0.75

VCC

CN_VSS

AT&N_BI: 0.50 Y/R

N_BI:

SENSOR(ROTATION)

BCN: 0.30

FUSE(ECU-MAIN(AC)) BASE: 3 R/W

AI:

CCW

N_BI:

ASSY_METER

AC_SW

REMOTE_WAKE_UP

B/W

GND1

GOVERNER_SENSOR AI: 0.50 B/Y GND 1 AI: 0.50 BR OUTPUT 2

W/R

BASE: 0.50

SENSOR_FUEL BASE: 0.50 L W/H00 1

SENSORACCEL

BASE:0.75

CAN(H)

WATER_TEMP_SENSOR

BASE: 0.50

BASE: 2 f B

f L

ENGINE-REV-SIGNAL

BASE: 0.50

0.50

BASE: 0.75

+B CAN(L)

FUEL_SENSOR

AUX2-POT1

AI:

GND3

AV0.5B(-)

8 W

ARM-POT

AUX1: 0.30

SOL(ANGLE-L) AB: 0.50 2

AV0.5R(+)

SENSOR_WATER_TEMP BASE: 0.75 f Y 1

AI:

MULTI-PURPOSE-LED

25 BOOM-BOT-PRESS-SENSOR

0.30

(-)

GND3

SENSOR,WATER_TEMP.

WATER-TEMP-SENSOR OIL-TEMP-SENSOR

JOINT-BUZ water-proof

DPF-INHIBIT-INDICATOR

B/Y

SOL(ANGLE-R) AB: 0.50 2

SOLENOID

(+)

BASE: 0.50 Y/B

EF-MODE-INDICATOR

0.50

(-)

BUZZER,BACK

N_BI: 0.50 Y/R

TRAVEL-PRESSURE-SENSOR

AI:

SOLENOID

ELECTRICAL_BUZZER

BACKETLOCK-SOL-RELAY

FUEL-SENSOR

ENGINE_REV._SENSOR AI: 0.75 f W/B

G/B

TRAVEL-ALARM-BUZZER

FUEL-FILTER-SW

GOVERNER_SENSOR AI: 0.50 R/B PW 3

DPF-INHIBIT-SW

AB: 0.50

RIGHT_SW(Y)

AI_MOTOR AI: 1.25

AUX2-SOL-FEEDBACK MULTIPURPOSE-SW

ANGLEBLADE&TRAVEL_HIGH_LOW AB: 0.50 W/B

Vcc(B)

B/R

AI: 0.30

TRAVEL_SPEED_SW NB: 0.50 W/B NB: 0.50

AUX2-SOL(L)

BOOM-RAISE-SW

GND1

AUX1: 0.50

EF-MODE-SW

CW(R)

0.1μ F

BASE: 2 f B

AUX1: 0.50

AUX1-SOL-FEEDBACK

BASE: 0.50

BASE: 2 f B

AI-PRESSURE-SW

R/W

W/B

AI-MOTOR(-)

BASE: 0.30

GRIP(ANGLE)

BASE: 0.30

AI_CONSOLE AI: 0.30 R/B

Vcc(W) 1 PUSH_SW(B) 2

GRIP(2SPEED)

AUX2-SOL(R)

+5V 8 AI_POT 7 GND 4 +12V 2 AUX_LED 5 AI_LED 1 AUX_SW 3 AI_SW 6

1kohm,0.4W

WATERSEPARATOR-SW

PANEL,ASSY(AI)

BUZZER,BACK

0.50 G/W

BASE: 0.50

B-1 TRAVEL_ALARM(FRONT,GND)

TRAVEL_ALARM(REAR,+) TRB: 0.50 L/B

GND1

AI-MOTOR(+)

SWITCH(PRESSURE,25.0K)

SWITCH(PRESSURE,7.5K)

TX RX

ECU(MAIN) CAN-H

ACA: 0.50 AI_PRESSURE_SW AI: 0.50 R/B

ECU(MAIN)

ECU(MAIN) TxD(MAIN-ECU)

BASE: 0.50

FUSE(STARTER_SIGNAL) 5 MiniFuses RD451-54101

SOLENOID(LEVER_LOCK) (-) BASE: 0.50 G 2

G/W

SOLENOID

SOLENOID(LEVER_LOCK)

SW(LEVER_LOCK) BASE: 0.50 2

G/W

LED +12V

AI-MOTOR-POWER-SUPPLY

SW(LEVER_LOCK)

FUSE(LEVER_LOCK) BASE: 0.50 f L/W

CR: TRB: 0.50

FUSE(STARTER_SIGNAL) BASE: 3 B/W

FUSE(LEVER_LOCK) 5 MiniFuses

LED+

GND1 FUSE(LEVER_LOCK) BASE: 3 R/W

Rxd

Y/R

AT: 0.50

JOINT-AIM water-proof

BASE: 3 Y/G BASE:0.30

Txd

B/O

ANTITHEFT_ANTENNA ANTENNA(ANTITHEFT)

RELAY(ECU_MAINPOWER)

GND

AT: 0.30

232C 4

TANK(WASHER)

WASHER_TANK (+) BASE: 0.50 W 2

4 main_to_[cab](wiper) W/H19

W/H19 W/H,CAB

(-)

WASHER_TANK BASE: 0.50 1

W/H19 BASE: 0.85 G 1 WIPERMOTOR

W/H20 BASE: 0.50 B 1 CAB(WIPERMOTOR)

W/H19 BASE: 0.85 W WIPERMOTOR 3 BASE: 0.85 R 4 WIPERMOTOR W/H19 BASE: 0.85 B 2 WIPERMOTOR W/H19

W/H20 BASE: 0.50 R 3 CAB(WIPERMOTOR) 4 CAB(WIPERMOTOR) W/H20 BASE: 0.50 G 2 CAB(WIPERMOTOR) W/H20

BASE: 0.50 W

WIPER,F

MOTOR_WIPER

(+B) (S)

(+1)

(-)

WIPER,F BASE: 0.50 G

BASE: 1.25

GND(WIPER,F)

W/H20 W/H,WIPERCODE

ASSY_SWITCH,AIR-CON A/C_HEATER_CONTROLER +B ACA: 0.50 R 16 ACA: 0.50 W/R IG 8

FUSE(COMPRESSOR) ACA: 0.85 W/R

RELAY(20A,MICRO-ISO) RELAY(BLOWER) 30 ACA: 3 R 3 ACA: 0.85W/R 86 1

Null 87 85

RELAY(20A,MICRO-ISO) RELAY(COMPRESSOR) ACA: 0.85 W/R 30 3 ACA: 0.85 W/R 86 1

Null 87 85

RELAY(BLOWER) 4 5 2

ACA: 0.50 ACA: 3 L/W ACA:

0.50

ACA: 0.50 L

RELAY(COMPRESSOR) 4 5 2

ACA:1.25

ACA:0.50

G/R

COMPRESSOR_ASSY COMPRESSOR_CLUTCH(A/C) RD451-93901 ACA:1.25

DUAL_PRESSURE_SWITCH

DUAL_PRESSURE_SWITCH ACA: 0.50 G/R 1

ACA: 0.30 R/W

DIODE(6098-0061) D_6098-0061

DIODE(COMPRESSOR) ACA: 0.50 Y

G/B

OUT A/C_SW

THERMO_SW

FAN

10 13 15

ILL(+)

GND2

HOT_IN

COOL_IN

MOTOR DRIVE CIRCUIT

HOT_OUT

SERVO_OUT2:HOT

ACA: 0.50

COOL_OUT

SERVO_OUT1:COOL

ACA: 0.50

ILL(-) GND

9 4

ACA: 0.50 G

ACA: 0.50

G/B

2 3

A/C

THERMISTOR

MGC

THERMISTOR

Null

4 5 THERMOSTAT

2 1

com

LO MID HI

GND1

ACA:3 B

GND1

RESISTOR_BLOWER

RESISTOR_BLOWER ACA: 3 L/Y

1 2

ACA: 3 B GND

P-ON

ACA: 3 B

THERMISTOR 1

ACA:3 L/B

ACA: 3 L/B

ACA:3 L/Y

GND1

Null GND

OFF Lo A/C_FAN_SWITCH ACA: 3 B ACA:0.50 L ACA:0.50 L ACA:0.50 L ACA: 0.50 L

GND1

THERMOSTAT THERMOSTAT ACA: 0.85 W/R

A/C_FAN_SWITCH

SERVO_MOTOR SERVO_MOTOR MAXCOOL ACA: 0.50 W 1 MAXHOT ACA: 0.50 Y 2 ACA: 0.50 BR/W Pt 3 null 4 ACA: 0.50 R/Y GND 5 null 6 ACA: 0.50 W/R Vz 7

A/C_HEATER_CONTROLER ACA: 0.50 R/Y POT_Vcc 2 ACA: 0.50 BR/W POT_Vout 1 ACA: 0.50 W/R POT_GND 3

DIODE(COMPRESSOR) ACA: 0.50 B 2

DUAL_PRESSURE_SWITCH ACA: 0.50 G 2

CONSTANT VOLTAGE CIRCUIT

CPU

ACA: 0.50 Y

FUSE(BLOWER) ACA: 3 R

ACA: 3 L/B

R W/R

ACA: 0.50

ACA: 0.85

FUSE(COMPRESSOR) ACA: 3 W

FUSE(A/C_CONTROLER)

ACA: 0.50

FUSE(BLOWER) ACA: 5 R/Y

FUSE(A/C_CONTROLER) 5 MiniFuses FUSE(BLOWER) 30 MiniFuses FUSE(COMPRESSOR) 10 MiniFuses RD451-54101

W/R

FUSE(A/C_CONTROLER) ACA: 5 R/Y

3 4

2 [MAIN]to_BLOWER_MOTOR ACA: 3 L/B W/H00 2

MAIN_to[BLOWER_MOTOR] BASE: 3 L/B 2 W/H06

[MAIN]to_BLOWER_MOTOR ACA: 3 L/W W/H00 1

BLOWER_MOTOR MAIN_to[BLOWER_MOTOR] BASE: 3 L/W BLOWER 1 W/H06 1

M1 HI

221 ℃± 10 ℃

LO M2

W/H06 W/H,BLOWERMOTOR,AC BLOWER_MOTOR

BLOWER 2

BLOWER_MOTOR BASE: 3 L/B

FUSE(ELECTRICAL_OUTLET) FUSE(ELECTRICAL_OUTLET) BASE: 3 W

FUSE(FUEL_PUMP) BASE: 3 R/W

FUSE(ELECTRICAL_OUTLET) 15 MiniFuses RD451-54101 FUSE(FUEL_PUMP) 5 MiniFuses RD451-54101

CNP:

1.25

ELECTRICAL_OUTLET BASE: 1.25 G BASE: 2 B

1 2

GND2 FUSE(FUEL_PUMP) BASE: 0.50 Y/R

(+)

(-)

GND

CIGARETTE_SOCKET

FUEL_PUMP BASE:0.50

GND1

1 2

ASSY_PUMP,FUEL_BOOT

Electrical Circuit Diagram (U35-4 US, AU, CA)

KiSC issued 10, 2022 A

232C

2 1 4 3 C_WF04_7123-7740-40_1

A/C_FAN_SWITCH

3 2 1 6 5 4 C_OF06_7123-2865-70_1

ALTERNATOR(IG,L)

1 2 C_OF02_7123-2820 _1

ANGLEBLADE&TRAVEL_ HIGH_LOW

2 1 4 3 C_WF04_6180-4181 _1

ANTITHEFT_ANTENNA A/C_HEATER_CONTROLER

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 C_OF16_MX34016SF1_1

1 2 3 4 5 6 C_WM06_6189-6171 _1

BATTERY

CAB(WIPERMOTOR)

2 1

1 2 3 4 C_OM04_7282 -1042_1

AI_CONSOLE

4 3 2 1 8 7 6 5

C_LAF01_M8_1

BATTERY(POWER)

1 C_WF08_FW-C-8F_1

AI_MOTOR

2 1 C_WF02_6189-0176_1

ELECTRICAL_ OUTLET C_CAM01_1

AI_PRESSURE_SW

1 2

CAB_POWER_ SOURCE

1 5

C_OF08_7123 -6083-30_1

C_WF03_7 283-8732 -40_1 C_CAM01_1

FRONT_ WORKLIGHT(+)

CANOPY_WORKLIGHT,R

C_CBF01_1

CAB_WORKLIGHT,B

COMPRESSOR_CLUTCH(A/C) FRONT_ WORKLIGHT(-)

C_WF01_FW-C-1F_1

DIODE(COMPRESSOR)

C_CAM01_ 1

2 1

C_OF10_7123-8307 _1

FUEL_PUMP

C_CBF01_1

ECU(MAIN)

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 2

1 2

FUSE (ECU-MAIN(+B))

FUSE (ECU_MAIN (POWER))

C_OF02_M iniFuses _1

FUSE(A/C_ CONTROLER)

C_OF02_M iniFuses _1

FUSE(LEVER_ LOCK)

C_OF02_M iniFuses _1

FUSE (RADIO(AC))

C_OF02_M iniFuses _1

FUSE(ENGINE, STOP)

C_OF02_M iniFuses _1

C_OF02_M iniFuses _1 C_CAM01_1

FUSE (BEACON)

C_OF02_M iniFuses _1

GND(RADIO, CAB)

C_OF02_M iniFuses _1

FUSE (STARTER_ SYGNAL)

GND(WIPER,F)

1 M8 C_LAF01_ M8_1

C_LAF01_ 7009-183 6_1

C_OF02_M iniFuses _1

2 1 3 C_WF03_7123-6234-40 _1

LCD_METER

7 6 5 4 3 2 1 14 13 12 11 10 9 8

MAIN

1 2 C_WM02_7222-1424-40 _1

1 M8

C_CBF01_1

C_OF02_M iniFuses _1

C_OF04_P-ISO_1

1 2 C_OF02_ 7123-28 20_1

3 5 1 4 2 C_OF05_M-ISO_1

RELAY(WORKLIGHT)

3 5 1 4 2 C_OF05_M-ISO_1

2 1 4 3 C_OF04_6098-05 14_1

3 5 1 4 2 ROOM_LIGHT

OIL_SWITCH

1 C_OF01_ 1723202_1

RADIO(+B)

RADIO(AC)

C_OF05_M -ISO_1

RELAY(ECU_ MAINPOWER)

3 5 1 4 2 C_OF05_M -ISO_1

RELAY (ENGINE_ STOP)

3 5 1 4 2

3 2 1 C_OF03_6130-23 30_1

SBF

2 1 C_OF02_7323-32 20_1

RELAY(GLOW)

RADIO(GND)

3 5 1 4 2

C_CAM01_1

C_OF05_M -ISO_1

2 1 4 3 M6 M5 C_OF06_7357-51 55-30_1

RELAY(HORN)

3 5 1 4 2 C_OF05_M -ISO_1

SW(LEVER_LOCK)

TRAVEL_SPEED_SW

2 1

1 2 3

C_WF02_6195-0 003_1 C_CAM01 _1

C_WF03_7283-87 30-30_1

SENSOR_WATER_ TEMP

C_WF02_1783926_1

4 3 2 1 8 7 6 5

C_WM03_6092-0013 _1

C_WF08_7283 -1081-10_1

WASHER_TANK SOL (ANGLE-R)

SOL (AUX1-L)

2 1 C_WF0 2_174 352-2 _1

3 2 1 6 5 4 C_OF06_7123-2 860_1

2 1 C_WF0 2_728 3-209 0-30_ 1

C_CAM01 _1

2 1

1 2 C_OF02_7123-2820 _1

SPEAKER(R)

1 2 C_OF02_ 7123-28 20_1

TRAVEL_ALARM (FRONT,+)

4 3

SPEAKER(R-)

1 TRAVEL_ALARM (FRONT,GND)

2 1

10 9 8 7 6 5 C_OF10_7123-8307 _1

SOL(E/F)

TRAVEL_ALARM (REAR,+)

C_OF08_7123-6083 -30_1

C_CAM01 _1

STARTER(+B)

1 M8

SPEAKER(L)

1 2 C_OF0 2_712 3-282 0_1

[main]_to_cab

1 5

1 main_to_[cab] C_CBF01_1

TRAVEL_ALARM (REAR,GND)

1 5

2 3 4 6 7 8

C_OM08_7122-6083 -30_1

1 C_LAF01 _M8_1

[main]_to_cab(wiper) C_CAM01_1

STARTER (+B)

TRAVEL_PRESSURE_ SWITCH

2 1 4 3 C_OF04_7123-6040 _1

2 C_LAF01 _M8_1

2 1 C_WF0 2_728 3-209 0-30_ 1

WORKLIGHT_SWITCH

4 3 2 8 7 6

SOLENOID (LEVER_ LOCK)

6 7

C_CAM01_1

C_WF0 2_728 3-209 0-30_ 1

C_OF04_6090-1011 _1

SPEAKER(R-)

2 1

2 1 4 3

SOL (TRAVEL_ SPEED)

2 3

5 4 3 2 1 C_OF05_7283-1 050_1

C_CAM01 _1

C_WF0 2_728 3-209 0-30_ 1

WIPER,F

C_WF0 2_174 352-2 _1

2 1

J/C(CAN,MAIN)

C_WM08_7382 -1481-10_1

THERMOSTAT

C_CBF01_1

SOL (AUX1-R)

to_J/C(CAN,MAIN)

SWITCH(WIPER) SPEAKER(L-)

3 2 1

2 1 C_CAM01 _1

C_WF0 2_728 3-209 0-30_ 1

SPEAKER(L+)

SBF-BOX

M5 M5

C_OF05_M -ISO_1

C_CBF01 _1

2 1

RELAY(STARTER)

RESISTOR_BLOWER

GOVERNER_ SENSOR

C_OF05_M -ISO_1

RELAY (COMPRESSOR)

SOL (ANGLE-L)

3 1

SENSOR,FUEL

GND3

C_LAF01_ 7009-183 6_1

3 5 1 4 2

[MAIN]TO_ WORKLIGHT

C_LEF01_ M4_1

C_OM02_ 7122-28 20_1

C_CBF01 _1

MAIN_HARNESS

C_OF05_M -ISO_1

C_OF14_7283-5832_1

GND2

C_LAF01_ 7009-183 6_1

3 5 1 4 2

MAIN_TO_ RELAY [WORKLIGHT] (BLOWER)

C_WF02_7123-1424-40 _1

GLOW

C_CBF01 _1

KEY_SWITCH

2 1

C_OF02_M iniFuses _1

FUSE(WIPER/ WASHER)

RELAY (BEACON)

1 2

1 M8

SUB_WORK_ LIGHT

C_WF08_6195-0051_1

SUB_WORK_LIGHT

FUSE(FUEL_ PUMP)

JS_CONTROL(R)

C_LEF01_ M5_1

RELAY(POWER)

4 C_CAM01_ 1

C_OF01_7123-2010_1

4 3 2 1 8 7 6 5

C_OF02_M iniFuses _1

C_LAF01_ M8_1

FUSE(ROOM_ LIGHT)

C_CAM01 _1

SENSOR_FUEL

2 FUSE(FRONTWORKLIGHT)

GND1 FUSE(RELAY)

RADIOFRAME (GND)

HORN(-)

C_CBF01_1

FUSE (ALTERNATOR)

GND(RADIO)

C_OF02_M iniFuses _1

C_OF01_7123-2010_1

C_OF02_M iniFuses _1

CAB_WORKLIGHT, FR

MAIN_ HARNESS

FUSE (HORN-SW)

C_OF02_M iniFuses _1

C_WF81_1473244-1_1

CAB_WORKLIGHT, FR

C_OF02_M iniFuses _1

HORN(+)

FUSE (METER(+B))

FUSE (ELECTRICAL_ OUTLET)

C_OF02_7 123-2820 _1

C_LEF01_M3_1

4 3 2 1 10 9 8 7 6 5

C_OF02_M iniFuses _1

C_CAM01_1

CAB_WORKLIGHT, FL

FUSE (ECU-MAIN (AC))

C_CBF01_ 1

C_OF02_M iniFuses _1

C_CBF01_1

C_LAF01_M6_1

3 2 1

CAB_WORKLIGHT,B

BEACON_SWITCH

FUSE (COMPRESSOR)

ENGINE_REV._ SENSOR

C_OF02_6098-0017_1

ALTERNATOR(+B)

C_OF02_7 123-8322 _1

CANOPY_WORKLIGHT,R

1 C_WF02_6189-0156_1

C_OF02_M iniFuses _1

C_CBF01_1

MAIN(POWER)

BEACON

1 2

C_CAM01_1

C_OF01_7123-4113 -30_1

FUSE(CABWORKLIGHT)

CANOPY_WORKLIGHT,L

C_OF04_7283 -1040_1

GND (CABFRAME)

C_LAF01_ M8_1

C_OM01_7122-4113 -30_1

C_OF02_M iniFuses _1

WIPERMOTOR

4 3 2 8 7 6

C_OF02_7 123-2820 _1

CANOPY_WORKLIGHT,L

2 1 4 3

FUSE(BLOWER) FUSE(HORNMAIN)

2 1 2

C_WF02_7123-8520-40_1

1 M8

ELECTRICAL_ BUZZER

CAN

STARTER(50)

C_WF02_6189-0 156_1

main_to_[cab](wiper)

1 2 3 4 C_OM04_7122-6040 _1

C_OF01_ 1723201_1

STOP_SWITCH

1 2 C_WM02_ 6187-28 01_1

3 2 1 C_WF03_6 098-0142 _1

CONNECTOR CHART (U35-4 US, AU, CA) KiSC issued 10, 2022 A

R REVISED CONTENTS

KiSC issued 10, 2022 A

REVISED CONTENTS CONTENTS 1. [5] FRONT PIN DIMENSIONS.......................................................................................................R-1 2. (1) Weight Disassembly/Assembly ................................................................................................R-2 3. (2) Fuel Tank Assembly/Disassembly ...........................................................................................R-3 4. [1] PUMP REMOVAL AND INSTALLATION..................................................................................R-4 5. [2] DELIVERY HOSE ROUTING ...................................................................................................R-5 6. [3] FRONT HOSE ROUTING.........................................................................................................R-6 7. [4] ROUTING OF TRAVEL, SWIVEL AND BLADE HOSES (ANGLE BLADE) ............................R-7 8. [6] PILOT HOSE ROUTING (P).....................................................................................................R-8 9. (3) Fuel Hose Routing....................................................................................................................R-9 10. SPECIFICATIONS.......................................................................................................................R-10 11. Swivel motor adapter angles .......................................................................................................R-11 12. Swivel Joint Adapter Angle (Angle Blade Specification)..............................................................R-12 13. Performance reference list (Quality standard values)..................................................................R-13 14. [K] Model Setting .........................................................................................................................R-14 15. [6] FRONT BUSHING DIMENSIONS ..........................................................................................R-15 16. [1] SWIVEL BEARING .................................................................................................................R-16 17. (3) Track Dimensions...................................................................................................................R-18 18. PUMP / SPECIFICATION............................................................................................................R-19

KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

1. [5] FRONT PIN DIMENSIONS

(a) Pin diameter No.

(b) Length Pin dia. × length

Diameter tolerance

No.

Pin dia. × length

Diameter tolerance

(1)

70 × 147 mm (2.8 × 5.79 in.)

-0.05 -0.08

(9)

45 × 185 mm (1.8 × 7.28 in.)

-0.05 -0.07

(2)

70 × 128 mm (2.8 × 5.04 in.)

-0.05 -0.08

(10)

45 × 162 mm (1.8 × 6.38 in.)

-0.05 -0.07

(3)

40 × 132 mm (1.6 × 5.2 in.)

-0.05 -0.07

(11)

40 × 162 mm (1.8 × 6.38 in.)

-0.05 -0.07

(4)

40 × 107 mm (1.6 × 4.21 in.)

-0.03 -0.05

(12)

40 × 193 mm (1.8 × 7.6 in.)

-0.05 -0.08

(5)

50 × 286 mm (2.0 × 11.3 in.)

-0.05 -0.08

(13)

40 × 193 mm (1.8 × 7.6 in.)

-0.05 -0.08

(6)

45 × 157 mm (1.8 × 6.18 in.)

-0.05 -0.07

(14)

40 × 161 mm (1.8 × 6.34 in.)

-0.05 -0.08

(7)

45 × 193 mm (1.8 × 7.6 in.)

-0.05 -0.07

(15)

45 × 131 mm (1.8 × 5.16 in.)

-0.05 -0.08

(8)

40 × 230 mm (1.6 × 9.06 in.)

-0.05 -0.08

• The pin usage limit is when the wear exceeds 1.0 mm (0.039 in.) from the factory spec. from new. RY92121844REV0001US0

R-1

KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

2. (1) Weight Disassembly/Assembly Removing the rear bonnet 1. Remove the bolts and then the rear bonnet. (1) Rear bonnet

(2) Bolt (M10 × 20) RY9212182MBS0026US0

Removing the left bonnet 1. Remove the four mounting bolts of the left bonnet and the fuel tank cap, and then take off the left bonnet. (1) Cap, ASSY (2) Bolt (M8 × 20)

(3) Left bonnet RY92121844REV0002US0

Removing the bracket and the partition plate 1. Detach the rear bonnet fixing bracket and the partition plate. (1) Bracket

(2) Partition plate RY9212182MBS0024US0

Removing the weight 1. Attach two eyebolts to the weight, connect a nylon sling to these and support the weight using a crane. (1) Weight (2) Eyebolt (M24 × P3)

(3) Nylon sling (4) Bolts (M20 × 90 × P2.5) RY9212182MBS0027US0

Weight (1)

367.7 to 431.5 N·m 37.5 to 44.0 kgf·m 271.2 to 318.2 lbf·ft

Apply thread lock (Loctite 271). RY9212182MBS0028US0

R-2

KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

3. (2) Fuel Tank Assembly/Disassembly Removing the left bonnet 1. Remove the four mounting bolts of the left bonnet and the fuel tank cap, and then take off the left bonnet. (1) Cap, ASSY (2) Bolt (M8 × 20)

(3) Left bonnet RY92121844REV0003US0

Removing the side cover 1. Remove the five bolts and the side cover. (1) Bolt (M10 × 25) (2) Bolt (M10 × 25)

(3) Side cover RY9212182MBS0030US0

Removing the fuel tank 1. Remove the two bolts and the blade 1. Remove the two bolts and the blade 2. (1) Blade 1 (2) Blade 2

(3) Bolt (M10 × 20) RY9212182MBS0032US0

(3) Bolt (4) Fuel drain main body RY9212182MBS0033US0

3. Detach the fuel sensor harness connector. RY9212182MBS0114US0

R-3

KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

4. [1] PUMP REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the machine, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot and under high pressure immediately after operating the machine. If the hydraulic oil reached a high operating temperature, it may cause a burn. • Oil gushing out under pressure has enough force to pierce your skin and may cause you injury. Always allow the temperature to drop and relieve any remaining pressure prior to working to remove any hydraulic equipment. RY9212001MBS0004US0

Removing the rear bonnet 1. Remove the bolts and then the rear bonnet. (1) Rear bonnet

(2) Bolt (M10 × 20) RY9212182MBS0026US0

Removing the left bonnet 1. Remove the four mounting bolts of the left bonnet and the fuel tank cap, and then take off the left bonnet. (1) Cap, ASSY (2) Bolt (M8 × 20)

(3) Left bonnet RY92121844REV0004US0

Removing the side cover 1. Remove the five bolts and the side cover. (1) Bolt (M10 × 25) (2) Bolt (M10 × 25)

(3) Side cover RY9212182MBS0030US0

R-4

KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

5. [2] DELIVERY HOSE ROUTING

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

RC787-6321-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

1980 mm 77.95 in.

White

G1/2 Straight

–

Pump - C/V P2

(2)

RC787-6322-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

1950 mm 76.77 in.

Green

G1/2 Straight

–

Pump - C/V P1

(3)

RC787-6323-1

20.5 MPa 209 kgf/cm2 2970 psi

1/2

2160 mm 85.04 in.

Pink

G1/2 Straight

–

Pump - C/V P3

(20)

RC787-6451-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

810 mm 31.9 in.

Gray

G3/8 Straight

–

C/V - Swivel motor Swivel left

(21)

RC787-6452-1

20.5 MPa 209 kgf/cm2 2970 psi

1/2

790 mm 31.1 in.

Aqua

G3/8 Straight

–

C/V - Swivel motor Swivel right

(37)

RC787-6324-1

7.0 MPa 70 kgf/cm2 1000 psi

3/8

500 mm 19.7 in.

Yellow

G3/8 Straight

–

Pump P4 - Line filter

(38)

RC787-6325-1

7.0 MPa 70 kgf/cm2 1000 psi

3/8

1290 mm 50.79 in.

–

G3/8 · 90°

G3/8 Straight

Corrugated

Line filter - Unload valve

No.

Part number

(1)

Guard

Point used

RY92121844REV0005US0

R-5

KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

6. [3] FRONT HOSE ROUTING

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

No.

Part number

Guard

Point used

(4)

RC787-6411-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1620 mm 63.78 in.

Green

G3/8 Straight

Plastic tube

C/V - Boom CYL Lift boom

(5)

RC787-6412-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1740 mm 68.50 in.

Yellow

G3/8 Straight

Plastic tube

C/V - Boom CYL Lower boom

(6)

RC787-6413-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1890 mm 74.41 in.

Black

G3/8 Straight

Plastic tube

C/V - Boom back Arm CYL dump

(7)

RC787-6414-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1895 mm 74.61 in.

Blue

G3/8 Straight

Plastic tube

C/V - Boom back Arm CYL rake

(8)

RC787-6415-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1930 mm 75.98 in.

Red

G3/8 Straight

Plastic tube

C/V - Boom back Bucket CYL dump

(9)

RC787-6416-1

24.5 MPa 250 kgf/cm2 3550 psi

3/8

1885 mm 74.21 in.

White

G3/8 Straight

Plastic tube

C/V - Boom back Bucket CYL rake

(26)

RC787-6491-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

2095 mm 82.48 in.

Pink

G1/2 Straight

Plastic tube

C/V - Pipe SP discharge side

(27)

RC787-6492-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

1910 mm 75.2 in.

Green

G1/2 Straight

Plastic tube

Third line valve - Pipe SP return side

(28)

RC787-6493-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

550 mm 21.7 in.

Green

G1/2 Straight

G1/2 · 90°

–

Third-line valve - C/V AUX1 return RY92121844REV0006US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

7. [4] ROUTING OF TRAVEL, SWIVEL AND BLADE HOSES (ANGLE BLADE)

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

No.

Part number

Guard

Point used

(16)

RC787-6441-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

700 mm 27.6 in.

Blue

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Left forward

(17)

RC787-6442-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

690 mm 27.2 in.

Red

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Left backward

(18)

RC787-6443-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

680 mm 26.8 in.

Green

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Right forward

(19)

RC787-6444-1

24.5 MPa 250 kgf/cm2 3550 psi

1/2

690 mm 27.2 in.

Yellow

G1/2 Straight

G1/2 · 90°

–

C/V - R/J Travel Right backward

(20)

RC787-6451-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

810 mm 31.9 in.

Gray

G3/8 Straight

–

C/V - Swivel motor Swivel left

(21)

RC787-6452-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

790 mm 31.1 in.

Aqua

G3/8 Straight

–

C/V - Swivel motor Swivel right

(24)

RC787-6471-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

820 mm 32.3 in.

Pink

G3/8 Straight

G3/8 · 90°

Protective tube

C/V - R/J Blade up

(25)

RC787-6472-1

20.5 MPa 209 kgf/cm2 2970 psi

3/8

890 mm 35.0 in.

Green

G3/8 Straight

G3/8 · 90°

Protective tube

C/V - R/J Blade down

(35)

RC787-7418-1

20.5 MPa 209 kgf/cm2 2970 psi

1/4

1030 mm 40.6 in.

Greenish yellow

G1/4 Straight

G1/4 · 90°

–

C/V - R/J Angle left

(36)

RC788-6385-1

20.5 MPa 209 kgf/cm2 2970 psi

1/4

930 mm 36.6 in.

Orange

G1/4 Straight

G1/4 · 90°

–

C/V - R/J Angle right RY92121844REV0007US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

8. [6] PILOT HOSE ROUTING (P)

Hose

Fitting

Max. operating pressure

Size

Total length

Tape color

Left

Right

No.

Part number

Guard

Point used

(20)

RC788-6326-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

680 mm 26.8 in.

C/V PP1 Nothing

G1/4 · 90°

G1/4 Straight

–

C/V (Pp1) - Swivel M (SM-P5) (P)

(21)

RC788-6327-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1620 mm 68.78 in.

Nothing C/V-PP2

G1/4 Straight

Corrugated tube

Unload valve (P) C/V (Pp2)

(22)

RC788-6328-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

740 mm 29.1 in.

Nothing C/V-PP1

G1/4 Straight

–

Unload valve - C/V [Pp1]

(23)

RC788-6329-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1400 mm 55.12 in.

Nothing 2S

G1/4 · 90°

G1/4 Straight

–

Unload valve - R/J (2-speed)

(34)

RC787-6324-1

7.0 MPa 70 kgf/cm2 1000 psi

3/8

500 mm 19.7 in.

Yellow 1 - Nothing

G3/8 Straight

–

Pump (4) - Pilot filter

(35)

RC787-6325-1

7.0 MPa 70 kgf/cm2 1000 psi

3/8

1290 mm 51.79 in.

–

G3/8 · 90°

G3/8 Straight

–

Pilot filter - Unload valve (P)

(36)

RC788-6385-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

570 mm 22.4 in.

AC-P SM-P4

G1/4 · 90°

G1/4 Straight

–

A/C Solenoid valve Swivel M (SM-P4) (P)

(38)

RC788-6387-1

7.0 MPa 70 kgf/cm2 1000 psi

1/4

1660 mm 65.35 in.

White

G1/4 Straight

G1/4 · 90°

–

A/C Solenoid valve Pump (Pc) RY92121844REV0008US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

9. (3) Fuel Hose Routing

(1) Drain Cock (2) Fuel Tank

(3) Water Separator (4) Fuel Pump

(5) Fuel Filter

Fuel tube Part No.

(6) Engine

Protective tube Length

Part No.

Hose clamp Length

IN / OUT side

(A)

RC788-51331

150 mm (5.91 in.)

–

09318-88125

(B)

09664-81600

1600 mm (62.99 in.)

RC788-51441

1500 mm (59.06 in.)

14911-42751

(C)

09664-80400

400 mm (15.7 in.)

RC788-51451

300 mm (11.8 in.)

14911-42751

(D)

RC788-51411

–

14911-42751

(E)

RC788-51421

Molded hose

–

14911-42751

(F)

RB238-51362

–

14911-42751

(G)

09664-40550

550 mm (21.7 in.)

RC461-51641

45 mm (17.7 in.)

14971-42751

(H)

09664-41650

1650 mm (64.96 in.)

RC788-51461

1550 mm (61.02 in.)

14911-42751

RY92121845REV0001US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

10. SPECIFICATIONS U35-4 Model

D1703-M-DI-E4-BH-US1

No. of cylinders

D1703-M-DI-E4-BH-US2 3

Cylinder Bore × Stroke

87 × 92.4 mm (3.4 × 3.64 in.) 1647 cm3 (100.5 cu.in.)

Total displacement Idling RPM

1300 to 1350 min-1

Rated RPM

2200 min-1

Compression ratio

20.5 : 1 Net

17.8 kW / 2200 min-1 (23.9 HP / 2200 min-1)

Gross

18.5 kW / 2200 min-1 (24.8 HP / 2200 min-1)

Net

95.2 N·m / 1500 min-1 (9.7 kgf·m / 1500 min-1) (70.2 lbf·ft / 1500 min-1 )

Gross

97.4 N·m / 1500 min-1 (9.9 kgf·m / 1500 min-1) (71.8 lbf·ft / 1500 min-1 )

Rated output/RPM

Max torque/RPM

Machine dimensions (LxWxH)

604 × 486 × 679 mm (23.8 × 19.1 × 26.7 in.)

Dry weight

610 × 486 × 679 mm (24 × 19.1 × 26.7 in.)

148 kg (326 lbs)

Valve clearance

0.18 to 0.22 mm (0.0071 to 0.0087 in.)

Fuel injection order

1-2-3

Combustion chamber

Direct injection

Compression pressure

2.95 to 3.23 MPa (30.0 to 33.0 kgf/cm2) (427 to 469 psi)

Fuel consumption (at rated RPM)

Net

261.3 g/kW·h (192.2 g/HP·h, 0.568 lb/HP·h)

Gross

251.4 g/kW·h (184.9 g/HP·h, 0.564 lb/HP·h) 18.6 MPa (190 kgf/cm2, 13.3 psi)

Fuel injection pressure

294 to 441 kPa (3.0 to 4.5 kgf/cm2) (0.21 to 0.32 psi)

Engine oil pressure (at rated RPM) Engine oil consumption (at rated RPM)

0.68 g/kW·h (0.50 g/PS·h, 0.0015 lb/HPh)

Fan belt Alternator

12 V, 720 W

Charging current

60 A

Regulator adjusted voltage Battery

14.2 to 14.8 V JIS

80D26R

Battery fluid ratio

1.28 ± 0.01

Mol meter

12 V, 1.4 W

Glow plug

0.9 Ω RY92121845REV0002US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

11. Swivel motor adapter angles

(1) (2) (3) (4) (5) (6) (7)

Straight Pipe Joint Straight Pipe Joint Pipe Joint Straight Pipe Joint Pipe Joint Pipe Joint Pipe Joint (T, G2)

(A) (B) (C) (D) (E) (F)

Control Valve Swivel Left Control Valve Swivel Right Makeup Drain Left Pilot Valve (P) Port Right Pilot Valve (P) Port

(G) Travel Pilot Valve (P) Port (H) AUX1 (P) Port (I) Control Valve (PP1) (J) AC (P) Port (K) AUX1 (P) Port (L) Control Valve (PP1)

(a) (b) (c) (d) (e)

5° 10 ° 45 ° 90 ° Canopy Spec.

RY92121845REV0003US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

12. Swivel Joint Adapter Angle (Angle Blade Specification)

(A) (B) (C) (D)

2-Speed Pilot Blade (Down) Blade (Up) Travel Left (Forward)

(E) Travel Right (Forward) (F) Travel Left (Backward) (G) Travel Right (Backward)

(H) Drain (I) Angle (Left) (J) Angle (Right)

G1/4

24.5 to 29.4 N·m 2.5 to 3.0 kgf·m 18.1 to 21.7 lbf·ft

G3/8

49.0 to 53.9 N·m 5.0 to 5.5 kgf·m 36.0 to 39.8 lbf·ft

G1/2

58.8 to 63.7 N·m 6.0 to 6.5 kgf·m 43.4 to 47.0 lbf·ft

3/4 UNF

44.1 to 53.9 N·m 4.5 to 5.5 kgf·m 32.5 to 39.8 lbf·ft

Tightening torque

(a) 5 ° (b) 15 ° (c) 60 °

RY92121845REV0004US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

13. Performance reference list (Quality standard values) Performance reference list (Quality standard values) Item

Boom (CAB)

Arm

Bucket Hydraulic cylinder operation time Swing

Blade

Angle (Angle spec.)

U35-4 Ground to max. lift

2.4 ± 0.3 sec

Max. lift to ground

2.8 ± 0.3 sec

Crowd

3.0 ± 0.3 sec

Dump

2.5 ± 0.3 sec

Crowd

2.6 ± 0.3 sec

Dump

1.6 ± 0.3 sec

Left

5.9 ± 0.5 sec

Right

4.4 ± 0.5 sec

Max down to Max up

2.1 ± 0.3 sec

Max up to Max down

2.8 ± 0.3 sec

Left

± 0.3 sec

Right

± 0.3 sec

Std. when new

≤ 20.0 mm ≤ 0.79 in.

Usage limit

≤ 100.0 mm ≤ 3.94 in.

Std. when new

≤ 20.0 mm ≤ 0.79 in.

Usage limit

≤ 100.0 mm ≤ 3.94 in.

Std. when new

≤ 10.0 mm ≤ 0.39 in.

Usage limit

≤ 50.0 mm ≤ 1.97 in.

Std. when new

≤ 20.0 mm ≤ 0.79 in.

Usage limit

≤ 70.0 mm ≤ 2.76 in.

When stopped

≤ 33.0 mm ≤ 1.30 in.

When Idling

≤ 201.0 mm ≤ 7.91 in.

Boom

Arm Hydraulic cylinder drift Bucket

Blade

Swivel Block Performance

Swivel speed

Notes

3 revs

19.1 to 23.3 sec / 3 revs 0 mm 0 in.

Travel block performance Rubber Travel speed Steel

1st

10.9 to 13.3 sec / 10 m (394 in.)

2nd

7.1 to 8.6 sec / 10 m (394 in.)

1st

11.3 to 13.8 sec / 10 m (394 in.)

2nd

7.1 to 8.6 sec / 10 m (394 in.) ≤ 600.0 mm ≤ 23.6 in.

Amount of travel drift

RY92121845REV0005US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

14. [K] Model Setting Setup procedure required when changing the ECU or meter (1)

Press and hold switch 5, and turn the starter key to [RUN]. (A)STOP, (B)RUN, (C)START Select "English" and press switch 5.

(2) Select "Setting" and press switch 5. (3)

(4)

Press switch 2 to select "Model Set" and then press switch 5.

(5)

Press switch 2 to select "Model" and then press switch 5. Select "Country name" and press switch 5.

(6) Select "AI YES or NO" and press switch 5. (7)

(8)

Select "Over load warning YES or NO" and press switch 5.

(9)

Select AUX1 spec. "Hand (Yes)" and press switch 5.

(10)

Select AUX2/Thumb spec. "Hand (Yes)" and press switch 5.

(11) *1

Select the Arm control spec. "YES or NO" and press switch 5.

(12)

Select "YES" if there is an angle blade and "NO" if there is no angle blade, and then press switch 5.

(13)

Select "YES" if there is a tilt blade and "NO" if there is no tilt blade, and then press switch 5.

(14)

(15)

(16)

(17)

(18)

(19) *1: Before using AUX ,make sure the arm control spec is "YES". (ECU default setting of the arm control spec is "NO") RY92121845REV0006US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

15. [6] FRONT BUSHING DIMENSIONS (I.D. × O.D. × Length)

Material

Bushing ID tolerance

<1>

70 × 82 × 41 mm (2.8 × 3.2 × 1.6 in.)

STKM16A, S43C, S45C

+0.12 +0.09

<2>

70 × 82 × 34 mm (2.8 × 3.2 × 1.3 in.)

STKM16A, S43C, S45C

+0.12 +0.09

STKM16A, S43C, S45C

<3> 70 × 82 × 34 mm (2.8 × 3.2 × 1.3 in.)

STKM16A, S43C, S45C

<6>

40 × 50 × 50 mm (1.6 × 2.0 × 2.0 in.)

S45C

<7>

40 × 50 × 25 mm (1.6 × 2.0 × 0.98 in.)

STKM16A, S43C, S45C

+0.12 +0.09

<8>

50 × 60 × 42 mm (2.0 × 2.4 × 1.7 in.)

STKM16A, S43C, S45C

+0.12 +0.09

<9>

50 × 60 × 60 mm (2.0 × 2.4 × 2.4 in.)

STK16A, S43C

+0.13 +0.10

<10>

45 × 55 × 45 mm (1.8 × 2.2 × 1.8 in.)

STK16A, S43C

+0.07 +0.05

<11>

45 × 55 × 45 mm (1.8 × 2.2 × 1.8 in.)

STK16A, S43C

+0.07 +0.05

<12>

45 × 55 × 60 mm (1.8 × 2.2 × 2.4 in.)

S45C

<13>

40 × 50 × 60 mm (1.6 × 2.0 × 2.4 in.)

STK16A, S43C

<14>

45 × 55 × 60 mm (1.8 × 2.2 × 2.4 in.)

STKM16A, S45C

―

<15>

40 × 50 × 50 mm (1.6 × 2.0 × 2.0 in.)

STKM16A, S45C

―

<16>

40 × 50 × 40 mm (1.6 × 2.0 × 1.6 in.)

STKM16A, S43C

+0.20 +0.17

<17>

40 × 50 × 32 mm (1.6 × 2.0 × 1.3 in.)

STKM16A, S43C, S45C

+0.12 +0.09

<4>

+0.12 +0.09

<5> ―

― +0.13 +0.10

• The usage limit for bushings is when the wear exceeds 1.0 mm (0.039 in.) from the factory spec. from new. (a) I.D. (b) O.D.

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

16. [1] SWIVEL BEARING Measuring Swivel Gear Backlash Purpose • Measure the degree of overall wear in the front and replace pins and/or bushings or add shims as needed. • When there is a great deal of play, it may cause wear in the swivel bearing teeth, swivel motor pinion gear and front pins and bushings. RY92121845REV0002US0

Measurement preparation 1. To make the measurements, position the machine so the arm cylinder and bucket cylinder are fully compressed with the end of the arm at a height of 1.0 m (40 in.) off the ground. 2. Stop the engine. [Left play measurement] 1. Push to the right with 50 N (5.0kgf, 11 lbs) of pressure, making that position the zero point; then press to the left with 300 N (30 kgf, 67.4 lbs) of pressure and take a reading at that point. 2. Take three measurements, determine the average and take that as the measured value. Factory Spec

50 mm (2.0 in.)

Allowable limits

Less than 70 mm (2.8 in.)

[Right play measurement] 1. Push to the left with 50 N (5.0 kgf, 11 lbs) of pressure, making that position the zero point; then press to the right with 300 N (30 kgf, 67.4 lbs) of pressure and take a reading at that point. 2. Take three measurements, determine the average and take that as the measured value. Factory Spec

50 mm (2.0 in.)

Allowable limits

Less than 70 mm (2.8 in.)

(1) 1.0 m (40 in.) (2) 50 N (5.0 kgf, 11 lbs)

(3) 300 N (30 kgf, 67.4 lbs) (4) Amount of Play RY92121845REV0003US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

(L): Point 50 mm (2.0 in.) from the swivel race

Factory Spec

U35-4

1.04 mm 0.04 in.

Allowable limits

U35-4

2.08 mm 0.08 in.

(L) Point to measure RY9212182MBS0130US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

17. (3) Track Dimensions Rubber track Item

U35-4

Crawler ASSY part no.

RP471-2231-1

Manufacturer's name

Sumitomo Rubber (Co., Ltd.)

(1) Lug height

25 mm (0.98 in.)

(2) Roller side height

23.5 mm (0.925 in.)

(3) Track width

300 mm (11.8 in.)

(4) Track height

79 mm (3.1 in.)

(5) Track tension

10 to 15 mm (0.39 to 0.59 in.)

Core pins

Track central circumference Pitch between pins

4452 mm (175.3 in.) 53 mm (2.1 in.) RY92121845REV0004US0

Steel Track Item

U35-4 Std. when new

Usage limit

Crawler ASSY part no.

RC541-2210-2

Manufacturer's name

TOPY Enterprises (Ltd.)

Track width

300 mm (11.8 in.)

(1) Length

406.4 mm (16 in.)

416.5 mm (16.4 in.)

(2) Tread height

68 mm (2.7 in.)

63 mm (2.5 in.)

(3) Track height

16.5 mm (0.65 in.)

8 mm (0.3 in.)

(4) Bush length

55 mm (2.2 in.)

–

(5) Bush inner diameter

17 mm (0.67 in.)

19 mm (0.75 in.)

(6) Bush outer diameter

28 mm (1.1 in.)

26.46 mm (1.042 in.)

(7) Master pin length

96.5 mm (3.8 in.)

–

(8) Master pin outer diameter

16.8 mm (0.661 in.)

15.5 mm (0.61 in.)

(9) Pin length

97 mm (3.8 in.)

–

(10) Pin outer diameter

17 mm (0.67 in.)

15.5 mm (0.61 in.)

(11) Track tension No. of links (A) Track (B) Bushing

75 to 80 mm (3.0 to 3.1 in.) 43 (C) Master pin (D) Pin RY9212182MBS0104US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

18. PUMP [1] SPECIFICATIONS Piston Pump Horsepower Control Curve

(1) P3 = 0.49 MPa (5.0 kgf/cm2, 71 psi)

(2) P3 = 19.6 MPa (200 kgf/cm2, 2840 psi)

(a) Discharge Flow: q1 = q2 (cc/rev)

(b) Discharge Pressure: P1 + P2 (MPa)

Pump input RPM: 2200 rpm At gear pump pressure: P3 = 0.49 MPa Pressure (MPa)

Delivery flow (cc/rev)

At gear pump pressure: P3 = 19.6 MPa Pressure (MPa)

Delivery flow (cc/rev)

QB1 = 17.82 (Target value)

PA0 = 0.00

QA0 = 18.00 (Target value)

PA1 = 16.99

QA1 = 17.51 (Target value)

PB1 = 6.07

PA2 = 28.60

QA2 = 11.30 (Target value)

PB2 = 23.44

QB2 = 8.42 (Target value)

PA3 = 49.00

QA3 = 6.34 (Target value)

PB3 = 43.11

QB3 = 3.69 (Target value)

PB4 = 49.00

QB4 = 3.45 (Target value) RY92121845REV0005US0

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KiSC issued 10, 2022 A

REVISED CONTENS

U35-4, WSM

Piston Pump Horsepower Control Curve (AC Mode Specification)

(a) Discharge Flow: q1 = q2 (cc/rev)

(b) Discharge Pressure: P1 + P2 (MPa)

At gear pump pressure: P3 = 0.49 MPa

At AC mode pressure: Pc = 0 MPa

At AC mode pressure: Pc = 3.9 MPa

Pressure (MPa)

Delivery flow (cc/rev)

PA0 = 0.00

QA0 = 18.0 (Target value)

Pressure (MPa)

Delivery flow (cc/rev)

PA1 = 16.9

QA1 = 17.5 (Target value)

PB1 = 10.4

QB1 = 17.7 (Target value)

PA2 = 28.5

QA2 = 11.3 (Target value)

PB2 = 23.3

QB2 = 10.6 (Target value)

PA3 = 49.0

QA3 = 6.4 (Target value)

PB3 = 49.0

QB3 = 4.4 (Target value)

Pump input RPM: 2200 rpm At gear pump pressure: P3 = 19.6 MPa

At gear pump pressure: P3 = 19.6 MPa

At AC mode pressure: Pc = 0 MPa

At AC mode pressure: Pc = 3.9 MPa

Pressure (MPa)

Delivery flow (cc/rev)

Pressure (MPa)

Delivery flow (cc/rev)

PA0 = 0.00

QA0 = 18.0 (Target value)

PD0 = 0.00

QD0 = 16.2 (Target value)

PC1 = 3.1

QC1 = 17.9 (Target value)

PD1 = 15.6

QD1 = 7.7 (Target value)

PC2 = 20.7

QC2 = 8.4 (Target value)

PD2 = 31.3

QD2 = 4.0 (Target value)

PC3 = 41.0

QC3 = 3.6 (Target value)

PD3 = 49.0

QD3 = 3.3 (Target value)

PC4 = 49.0

QC4 = 3.3 (Target value) RY92121845REV0006US0

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KiSC issued 10, 2022 A

KUBOTA Corporation

Printed in Japan 2022. 10, H, EI, EI, engusa Printed in Japan 2013. 03, H, EI, EI, engusa

Code No. RY911-21846 Code No. RY911-21843