Kubota KC100HD WORKSHOP MANUAL

Download

Page 1

WORKSHOP MANUAL

DUMPER

KC100HD

Page 2

Page 3

MECHANISM

1. SPECIFICATIONS

2. DIMENSIONS

3. ENGINE

4. TRANSMISSION

5. HYDRAULIC SYSTEM (HST)

6. HYDRAULIC SYSTEM (DUMPING)

7. FUEL SYSTEM

8. V-BELT

9. WIRING DIAGRAM

SERVICING

1. TIGHTENING TORQUE

CONTENTS

2. OILS AND FUEL

3. GREASING

4. CAUTION FOR DISASSEMBLING AND REASSEMBLING

5. ADJUSTMENT OF COMPONENT PARTS

6. TESTING OF PRESSURE (HST)

7. REPLACEMENT OF WEAR OUT PARTS

8. TROUBLESHOOTING AND COUNTERMEASURES

9. MAINTENANCE INTERVALS

Page 4

MECHANISM

1. SPECIFICATIONS

2. DIMENSIONS

3. ENGINE

4. TRANSMISSION

5. HYDRAULIC SYSTEM (HST)

6. HYDRAULIC SYSTEM (DUMPING)

7. FUEL SYSTEM

8. V-BELT

9. WIRING DIAGRAM

Page 5

1. SPECIFICATIONS

Model KC100HD

Machine weight (kg) 885

Max. loading capacity (kg) 1200

Engine Model KUBOTA Z482-E3B-CRYM-1

Type Vertical 4-cycle Liquid-Cooled Diesel

No. of cylinder 2

Bore and Stroke (mm) 67 x 68

Total Displacement (cc) 479

Output (KW/rpm) 8.3/3000

Starting system Electric

Dimensions Length (mm) 2640

Width (mm) 950

Height (mm) 2015

Min. ground clearance (mm) 145

Track center-to-center distance (mm) 720

Bed Length (mm) 1470

Width (mm) 855

Height (mm) 320

Capacity Struck / Heaped (

Undercarriage Crawler type Rubber track

Number of drive sprocket teeth 7

Crawler pitch (mm) 72

Track width (mm) 230

Number of track rollers 6 (one side)

Ground contact length (mm) 1180

Gradeability (° ) 25

Alignment Screw type with spring

Ground contact pressure w/o load (kgf/cm

Ground contact pressure w/t load (kgf/cm

Max. traction power (kgf) 1040

Transmission Type HST + Gear shift type transmission

Travelling speed 1st (km/h) 0 - 3.2 / 0 - 2.1

(Forward / Reverse) 2nd (km/h) 0 - 5.8 / 0 - 3.9

Main clutch Belt tension

Steering clutch Tooth clutch

Steering brake Wet multi-plate type

Parking brake Wet multi-plate type

Dumping performance Dumping type Hydraulic

Dumping direction Front / Right side / Left side

Max. Dumping angle (° ) 56 / 60 / 60

Raising time (at 3000rpm) (sec) 7.1

Lowering time (at 30900rpm) (sec) 4.0

Capacity Fuel tank (

Hydraulic oil tank (

Engine oil (

Coolant (

HST oil (

Transmission oil (main / sub) (

) 400 / 520

) 0.17

) 0.4

) 14.8

) 1.5

) 2.55

) Approx. 2.8

) 13.0

) 3.1 / 0.45

Page 6

2. DIMENSIONS

Page 7

3. ENGINE

Model : Z482-E3B-CRYM-1 / Code No : 1G317-51000

See the WSM / DIESEL ENGINE SM-E3B SERIES

Hard Copy - Code No 9Y121-00132

CD-ROM - Code No 9Y131-00132

Specications

Model Z482-E3B Z602-E3B

Number of Cylinders 2 Type Vertical, Water-cooled, 4 cycle IDI diesel engine Bore×Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) Total Displacement 479.0 cm

ISO Net Continuous

ISO/SAE Net Intermittent

SAE Gross Intermittent

8.10 kW / 3600 min

(10.9 HP / 3600 min

9.30 kW / 3600 min

(12.5 HP / 3600 min

9.90 kW / 3600 min

(13.3 HP / 3600 min Maximum Bare Speed 3800 min Minimum Bare Idling Speed 900 to 1000 min Combustion Chamber Spherical type (E-TVCS) Fuel Injection Pump Bosch MD type mini pump Governor All speed mechanical governor Direction of Rotation Counter-clockwise (viewed from ywheel side) Injection Nozzle Bosch “Throttle” type Injection Timing 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C. Firing Order 1-2 Injection Pressure 13.73 MPa (140.0 kgf/cm Compression Ratio 23.5 : 1 24 : 1 Lubricating System Forced lubrication by trochoid pump Oil Pressure Indicating Electrical Type Switch Lubricating Filter Full ow paper lter (Cartridge type) Cooling System

Pressurized radiator, forced circulation with water pump (not included in the basic engine) Starting System Electric starting with starter Starting Motor 12V, 0.8kW 12V, 1.0kW Starting Support Device By glow plug in combustion chamber EGR None Battery 12V, 28 AH equivalent 12V, 36 AH equivalent Charging Alternator 12V, 150W 12V, 480W Fuel Diesel Fuel No.2-D (ASTM D975)

Lubricating Oil

Class CF lubricating oil as per API classication is recommended.

Oil Pan Depth Lubricating Oil Capacity

101 mm (3.98 in.)

Oil Pan Depth

121 mm (4.76 in.) Weight (Dry) kg(lbs) 53.1 (117) 60.0 (132)

* The specication described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW

(29.23 cu.in.) 599.0 cm3 (36.55 cu.in.)

(rpm)

(rpm))

(rpm)

(rpm))

(rpm)

(rpm))

10.1 kW / 3600 min

(13.5 HP / 3600 min

11.6 kW / 3600 min

(15.5 HP / 3600 min

12.5 kW / 3600 min

(16.8 HP / 3600 min

(rpm)

, 1991 psi)

( rpm)

(rpm))

( rpm)

(rpm))

( rpm)

(rpm))

For details on recommended lubricating oils, see page G-6, 9

2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals)

2.5 L (0.66 U.S.gals)

–

W10336300

Page 8

Performance curves

• Z482-E3B

3EEACABEP001A

(1) Brake Horsepower (6) Net Intermittent Torque (11) Net Intermittent B.S.F.C. (15) Gross B.H.P. (2) Engine Speed (7) Net Continuous Torque (12) Gross Torque (16) Overload B.H.P. (3) B.S.F.C. (8) Gross Intermittent B.H.P. (13) Overload Torque (17) Continuous B.H.P. (4) Torque (9) Net Intermittent B.H.P. (14) Continuous Torque (18) Overload B.S.F.C. (5) Gross Intermittent Torque (10) Net Continuous B.H.P.

Fuel consumption

Fuel consumption KC100HD

Fuel consumption(L/h)

Work load factor (%)

Page 9

Dimension

• Z482-E3B

Uni : mm (in.)

3EEACABFP001A

Uni : mm (in.)

3EEACABFP002A

Page 10

[GEARING]

[GEAR RATIO]

[POWER TRAIN]

4. TRANSMISSION

Low (L) G OUTPUT SHAFT

INPUT SHAFT

Hight (H) F BRAKE (STEERING/PARKING)

A HST E CLUTCH GEAR

Page 11

5. HYDRAULIC SYSTEM (HST)

HST unit

Hydraulic pump : 0 ~ 18.2 cm Hydraulic motor : 18.2 cm Charge pump : 5.1cm Relief valve set pressure : 18.5MPa Charge pressure : 5.0 kgf/cm

Pressure check port ( PF3/8 ) Suction port (PF1/2) [charge pump] Discharge port (PF3/8) [charge pump]

+2.9MPa

1 Housing

Cover

Hanger

Input shaft

Output shaft

Block, cylinder

Piston

Case, charge pump

Relief valve (Low pressure)

Relief valve (High pressure)

Neutral valve (Backward)

Neutral valve (Forward)

Drain port

Suction port

Pressure check port (Forward)

Pressure check port (Backward)

Pump (Adjustable)

Piston

Cylinder

Flow of oil

E/G

T/M

Page 12

Mechanism of drive pedal

Flow of HST oil

K10H-D010

E Oil cooler F

Oil lter cartridge

HST oil tank

K10H-D004

Page 13

6. HYDRAULIC SYSTEM (DUMPING)

Hydraulic pump

Hydraulic pump : K82R

(Part no 89956-1559-0)

Discharge volume : 3cc/rev

Revolution : 500 ~ 2000rpm

Relief valve set pressure : 140+5/kgf/cm

(at 1800rpm)

Tank capacity : 1.6 l

Pulley size (pump) : Dia 101.6mm

(Part no 89956-1298-0)

Pulley size (engine) : Dia 76.2mm

(Part no 89920-1157-0)

(13.7+0.5MPa)

Flow of hydraulic oil

A Pull-Down port B

Push-up port

K70E-U002

Page 14

Hydraulic hose / Hydraulic cylinder

1 : Hydraulic cylinder (Part no 89950-1154-0 / 1 pce)

Pressure : 170kgf/cm

(16.7MPa)

Stroke : 300mm

: Hydraulic pump (Part no 89956-1559-0 / 1 pce)

: Hydraulic hose (Part no 89957-1233-0 / 2 pcs)

Length : 3000mm

: Elbow (Part no 89910-1188-0 / 2 pcs)

: Hose adapter with O-ring (Part no 89910-1189-0 / 2 pcs)

: Cylinder pin (Part no 89954-1159-0 / 2 pce)

: Cir-clip (E) (Part no 04613-00150 / 4 pcs)

: Vinyl tube (Part no 89957-1234-0 / 2 pcs)

K10H-D002

Page 15

7. FUEL SYSTEM

Fuel tank / Fuel hose

1) Fuel hose (Fuel tank ~ Fuel lter) Size : L : 1400mm x 1 pce / 09661-7140-0 / 1

Clip x 2pcs - Part no 14911-4275-0 / 4

Tube x 1pce - part no 89920-1265-0 / 7

2) Fuel hose (Fuel lter ~ Injection pump) Size : L : 750mm x 1 pce / 09661-7075-0 /

Clip x 2pcs - Part no 14911-4275-0 / 5

Tube x 1pce - part no 89920-1264-0 / 8

3) Fuel hose (Nozzle holder ~ Fuel tank) Size : L : 1150mm x 1 pce / 09661-4115-0 / 3

Clip x 2pcs - part no 14971-4275-0 /

K10H-D003

Page 16

8. V-BELT

Size of V-belt

1) V-belt (Engine pulley ~ HST pulley)

Size : SC64 (Cog belt) x 1 pce / Part no 89920-1170-0

2) V-belt (Engine pulley ~ Hydraulic pump pulley)

Size : SB29 x 1 pce / Part no 89920-1175-0

3) Engine pulley

Part no 89920-1157-0

4) HST pulley

Part no 89920-1165-0

Page 17

Cord color

B Black

Br Brown

G Green

L Blue

P Pink

R Red

SB Sky blue

W White

Y Yellow

BL Black / Blue

BW Black / White

GB Green / Black

LB Blue / Black

PB Pink / Black

RW Red / White

WB Red / White

YB Yellow / Black

BR Black / Red

Starter

Safety switch

Glow plug

Alternator

ⒶⒷⒸⒹⒺ

Regulator

Alarm lamp “Battery

charge”

Solenoid timer

Solenoid

Ⓕ

ⒼⒽⒾ

Ⓝ

Ⓛ

Ⓙ

Hour meter

Alarm lamp “Engine

oil pressure”

Oil switch

Horn

Ⓙ

ⓀⓁⓂⓃⓄⓅⓆ

Horn switch

Electrical socket

Glow timer

Indicator lamp

“Glow”

Relay

Ⓜ

Ⓚ

Key switch

Fuse arrangement

Connector terminal

arrangement

ⓇⓈⓉ

Ⓢ Ⓣ

Ⓘ

Ⓖ

Ⓗ

Ⓕ

Ⓔ

Ⓠ

Ⓓ

Ⓟ

Ⓞ

Ⓡ

9. WIRING DIAGRAM

Ⓠ

Ⓐ Ⓑ Ⓒ Ⓒ

Page 18

SERVICING

1. TIGHTENING TORQUE

2. OILS AND FUEL

3. GREASING

4. CAUTION FOR DISASSEMBLING AND REASSEMBLING

5. ADJUSTMENT OF COMPONENT PARTS

6. TESTING OF PRESSURE (HST)

7. REPLACEMENT OF WEAR OUT PARTS

8. TROUBLESHOOTING AND COUNTERMEASURES

9. MAINTENANCE INTERVALS

Page 19

1. TIGHTENING TORQUE

1) GENERAL BOLTS AND NUTS

Bolt torque

Material Grade Standard Bolt Special Bolt Special Bolt

Nominal Dia.

M10

M12

M14

M16

M18

M20

SS41, S20C S43C, S487C (Rened) SCR3, SCM3 (Rened)

7.8 - 9.3 N.m

0.80 - 0.95 kgf-m

5.8 - 6.9 lb.ft.

17.7 - 20.6 N.m

1.80 - 2.10 kgf-m

13.0 - 15.2 lb.ft.

39.2 - 45.1 N.m

4.00 - 4.60 kgf-m

28.9 - 33.3 lb.ft.

62.8 - 72.6 N.m

6.40 - 7.40 kgf-m

46.3 - 53.5 lb.ft.

107.9 - 125.5 N.m

11.00 - 12.80 kgf-m

79.6 - 92.6 lb.ft.

166.7 - 191.2 N.m

17.00 - 19.50 kgf-m

123.0 - 141.0 lb.ft.

245.2 - 284.4 N.m

25.00 - 29.00 kgf-m

180.0 - 209.8 lb.ft.

333.4 - 392.2 N.m

34.00 - 40.00 kgf-m

245.9 - 289.3 lb.ft.

9.8 - 11.3 N.m

1.00 - 1.15 kgf-m

7.2 - 8.3 lb.ft.

23.5 - 27.5 N.m

2.40 - 2.80 kgf-m

17.4 - 20.3 lb.ft.

48.0 - 55.9 N.m

4.90 - 5.70 kgf-m

35.4 - 41.2 lb.ft.

77.5 - 90.2 N.m

7.90 - 9.20 kgf-m

57.1 - 66.5 lb.ft.

123.6 - 147.1 N.m

12.60 - 15.00 kgf-m

91.1 - 108.5 lb.ft.

196.1 - 225.5 N.m

20.00 - 23.00 kgf-m

144.7 - 166.4 lb.ft.

274.6 - 318.7 N.m

28.00 - 32.50 kgf-m

202.5 - 235.1 lb.ft.

367.7 - 431.5 N.m

37.50 - 44.00 kgf-m

271.2 - 318.2 lb.ft.

10.50 - 12.00 kgf-m

17.00 - 20.00 kgf-m

26.50 - 31.00 kgf-m

35.00 - 41.00 kgf-m

50.00 - 58.00 kgf-m

12.3 - 14.2 N.m

1.25 - 1.45 kgf-m

9.0 - 10.5 lb.ft.

29.4 - 34.3 N.m

3.00 - 3.50 kgf-m

21.7 - 25.3 lb.ft.

60.8 - 70.6 N.m

6.20 - 7.20 kgf-m

44.8 - 52.1 lb.ft.

103.0 - 117.7 N.m

75.9 - 86.8 lb.ft.

166.7 - 196.1 N.m

123.0 - 144.7 lb.ft.

259.9 - 304.0 N.m

191.7 - 224.2 lb.ft.

343.2 - 402.0 N.m

253.2 - 296.5 lb.ft.

490.3 - 568.7 N.m

361.6 - 419.5 lb.ft.

Bolt material grades are shown

by numbers punched on the bolt

heads. Prior to tightening, be

sure to check out the numbers as

shown below.

Punched

Number

None

Bolt Material

Grade

Standard Bolts SS41,

S20C

Standard Bolts SS43,

S48C (Rened)

Special Bolts SCR3,

SCM3 (Rened)

Page 20

2) Crawler adjusting bolt : 215 ~ 225kgf . cm (21.1N . m ~ 22.1N . m)

1 : Adjusting bolt (Part no 89954-1205-0)

: Snap pin (Part no 89910-1289-0)

: Stopper (Part no 89950-1372-0)

3) Hose adapter for hydraulic pump : 200 ~ 240kgf . cm (19.6N . m~23.5N . m)

4) Transmission

4-1 Brake case [BOLT] : 220 ~ 280kgf . cm (21.6N . m ~ 27.4N . m)

Page 21

4-2 Brake case [BOLT] : 300 ~ 350kgf . cm (29.4N . m ~ 34.3N . m)

K10H-D013

4-3 Brake case cover [BOLT] : 220 ~ 280kgf . cm (21.6N . m ~ 27.4N . m)

4-4 Transmission case [NUT] : 400 ~ 450kgf . cm (39.2N . m ~ 44.1N . m)

4-5 Transmission case [NUT] : 120 ~ 170kgf . cm (11.8N . m ~ 16.7N . m)

Page 22

4-6 Axle pipe [BOLT] : 400 ~ 450kgf . cm (39.2N . m ~ 44.1N . m)

4-7 Brake joint [NUT] : 120 ~ 170kgf . cm (11.8N . m ~ 16.7N . m)

4-8 Shift lever comp [NUT] : 120 ~ 170kgf . cm (11.8N . m ~ 16.7N . m)

4-9 Plug [PT1/8] : 40 ~ 50kgf . cm (3.9N . m ~ 4.9N . m)

Page 23

4-10 Shifter support [BOLT] : 100 ~ 120kgf . cm (9.8N . m ~ 11.8N . m)

5) ENGINE PULLEY MOUTING BOLT : 440 ~ 480kgf . cm (43.2N . m ~ 47.0N . m)

(M10 x 55)

6) ENGINE MOUTING BOLT : 460 ~ 500kgf . cm (45.1N . m ~ 49.1N . m)

(M10 x 25)

7) CUSHION : 445 ~ 455kgf . cm (43.7N . m ~ 44.6N . m)

K10H-D005

K10H-D006

Page 24

8) BOLT FOR HST NEUTRAL LEVER : 280 ~ 300kgf . cm (27.5N . m ~ 29.4N . m)

(M8 x 55)

K10H-D007

9) HST

9-1 Cover

1 Cover

Relief valve (Low pressure)

Relief valve (High pressure)

Neutral valve

Bolt

Plug

Control plate (Pump)

Control plate (Motor)

Screw

(Apply the screw locking bond to screws)

Page 25

9-2 Relief valve [High pressure]

10) ROPS

[M10 x 20 / 10.9T - 6 pcs, M12 x 20 / 10.9T - 8 pcs]

1 Poppet

Spring

Barrel

Plug

O-ring

Shim 13.5 x 22 x 1.0

Shim 13.5 x 22 x 0.7

Shim 13.5 x 22 x 0.5

Shim 13.5 x 22 x 0.3

Plug

[M10 x 20 / 10.9T - 6 pcs / Approx. 640kgf . cm (62.6N . m)]

[M12 x 20 / 10.9T - 8 pcs / Approx. 1100kgf . cm (109N . m)]

Page 26

2. OILS AND FUEL

1) TRANSMISSION OIL

Main Automatic transmission uid (ATF) [DEXRON] 3.1L

Sub Automatic transmission uid (ATF) [DEXRON] 0.45L

Type of oil Quantity

1 Oil port (main)

Oil port (sub)

Drain plug

2) HYDRAULIC PUMP OIL

Type of oil Viscosity Quantity

Hydraulic oil ISO46

NOTE

Total capacity of hydraulic pump oil with new cylinder and hoses : Approx. 1.9L.

Proper oil level A

: Approx. 50mm / distance from oil port

(Hydraulic cylinder completed contacted)

Shell Tellus T46 or

equivalent oil

1.5

K70E-U007

4 Oil port

Drain plug

Page 27

3) HST OIL

Type of oil Viscosity Quantity

Hydraulic oil ISO46

Shell Tellus T46 or

equivalent oil

5 Tank cap

Drain plug

Drain port

IMPORTANT

If HST oil is lled to HST unit rst, add the HST oil (approx. 1.5L)

through drain port of HST unit.

Shell Mobil

Transmission oil

(Automatic transmission uid / ATF)

HST oil

(Hydraulic oil / ISO : 46)

Hydraulic pump oil

(Hydraulic oil / ISO : 46)

Super ATF Mobil ATF

Shell Tellus T46

Mobil DTE-Oil 15

New machine is used Shell oil.

Page 28

4) ENGINE OIL

[Engine oil quantity : 2.55 L]

Temperature Type of oil

Above 25˚C

0˚C to 25˚C

Below 0˚C

NOTE

Engine Oil :

• Refer to the following table for the suitable American Petroleum Institute (API)

classication of engine oil according to the engine type (with internal EGR, external EGR

or non-EGR) and the Fuel Type Used :

(Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).

Fuel Type

Engines with non-EGR Engines with internal EGR

SAE30 or SAE10W-30

SAE10W-40

SAE20 or SAE10W-30

SAE10W-40

SAE10 or SAE10W-30

SAE10W-40

Engine oil classication (API classication)

Engines with external EGR

High Sulfur Fuel [0.05 % (500 ppm) ≤ Sulfur Content <

0.50 % (5000 ppm)]

Low Sulfur Fuel [Sulfur Content <

0.05 % (500 ppm)] or Ultra Low Sulfur Fuel [Sulfur Content <

0.0015 % (15 ppm)]

CF (If the "CF-4, CG-4, CH-4, or CI-4" engine oil is used with a high-sulfur fuel, change the engine oil at shorter intervals. (approximately half))

CF, CF-4, CG-4, CH-4 or CI-4

CF or CI-4 (Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR type engines.)

EGR : Exhaust Gas Re-circulation

W1024941

• CJ-4 classication oil is intended for use in engines equipped with DPF (Diesel Particulate

Filter) and is

Not Recommended for use in Kubota E3 specication engines.

• Oil used in the engine should have API classication and Proper SAE Engine Oil Viscosity

according to the ambient temperatures where the engine is operated.

• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils

have been developed for use with low sulfur fuels, for On-Highway vehicle engines.

When a Non-Road engine runs on high sulfur fuel, it is advisable to use a "CF or better"

Page 29

classication engine oil with a high Total Base Number

(a minimum TBN of 10 is recommended).

5) FUEL

Type Capatity

over -5˚, use No.2-D diesel fuel 14.8 L

NOTE

Fuel :

• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating

greater than 50 ispreferred, especially for ambient temperatures below −20 °C (−4 °F) or

elevations above 1500 m (5000 ft).

• Diesel Fuel Specication Type and Sulfur Content % (ppm) used, must be compliant with

all applicable emission regulations for the area in which the engine is operated.

• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly

recommended.

• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a

diesel fuel, change the engine oil and oil lter at shorter intervals. (approximately half)

• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).

• Diesel fuels specied to EN 590 or ASTM D975 are recommended.

• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile

service. (SAE J313 JUN87)

• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim

Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these

engines, when operated in US EPA regulated areas. Therefore, please use No.2-D S500 or

S15 diesel fuel as an alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an

alternative to No.1-D for ambient temperatures below −10 °C (14 °F).

1) SAE : Society of Automotive Engineers

2) EN : European Norm

3) ASTM : American Society of Testing and Materials

4) US EPA : United States Environmental Protection Agency

5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%

No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

Page 30

3. GREASING

• Greasing

CAUTION

To avoid personal injury:

• First stop the engine.

Apply a small amount of multipurpose grease or oil to the following points every 50 hours.

1 Cylinder lower (oil)

Cylinder upper (oil)

Cylinder upper (grease)

Deck body support fulcrum (grease)

Opening/closing kit (right & left) (oil)

Lower roller (grease)

Upper roller (grease)

Idler (grease)

Bogie roller (grease)

0 Wire (Brake, accelerator etc) (oil)

1 Steering lever (grease)

Dump lever joint (oil)

Brake pedal (grease)

Accelerator lever (oil)

Drive pedal shaft (grease)

Main clutch tension arm (grease)

Dump lever (grease)

Lever, dump support (grease)

Link arm, drive pedal (grease)

0 Speed change lever (grease)

1 Neutral plate (grease)

2 Parking brake lever (oil)

Page 31

Page 32

⑭

⑩

⑯

○

⑲

⑫

⑳

○

Page 33

4. CAUTION FOR DISASSEMBLING AND REASSEMBLING

1) SPROCKET

Before tting the sprocket to shaft of transmission, apply the grease to the spline of shaft.

Grease

K70E-U008

Sprocket

2) ADJUSTING BOLT FOR CRAWLER

Apply the grease to adjusting bolt to prevent the rust of bolt and nut.

Grease

3) BOLTS FOR FRAME (UPPER / UNDER)

Apply the screw locking bond to bolts.

K10H-D008

Page 34

4) ANGLE OF DRAIN PORT (HST UNIT)

When remove the hose from drain port for HST unit, check the angle of drain port.

1 About 45˚

K10H-D009

5) DUST COVER FOR TRANSMISSION (FINAL SHAFT)

Before tting the sprocket to nal shaft of transmission, apply the grease to the surface of oil seal

and dust cover.

6) CHARGE PUMP (HST)

Face the mark toward plate side.

Grease

Marks

Plate

Page 35

5. ADJUSTMENT OF COMPONENT PARTS

5-1 MAIN CLUTCH ADJUSTMENT

• Check and adjustment of V-belt tension (main clutch)

CAUTION

To avoid personal injury:

• First stop the engine.

• After servicing, make sure the function of main clutch.

1. When the main clutch (V-belts) slips.

1) Loosen the lock nut

by tightening the adjust nut

1 , then adjust the V-belt tension

2 .

2) After the adjustment, tighten up the lock nut.

Adjust nut

Lock nut

Reference for proper belt tension

1) Depress the center of V-belt with thumb pressure.

[8 to 10 mm / 5 kgf]

IMPORTANT

• After the adjustment, tighten up the lock nuts

5-2 BRAKE PEDAL ADJUSTMENT

• Check and adjustment of brake pedal

CAUTION

To avoid personal injury:

• First stop the engine.

• Be sure to check the braking force of parking

brake after adjustment.

1. Check the brake pedal free travel.

2. If the brake pedal free travel exceeds the limit, loosen

the lock nuts and move the adjust bolt toward

A .

3. After adjustment, tighten up the lock nut.

Brake pedal

Adjust bolt

Lock nut

[Proper brake pedal free travel/1mm]

2 3

Page 36

IMPORTANT

• If you turn the turn buckle toward A

too much, the brake is applied at all times.

This will cause the damage of transmission.

5-3 STEERING LEVER ADJUSTMENT

• Check and adjustment of steering lever

CAUTION

To avoid personal injury:

• First stop the engine.

• After servicing, make sure the function of

steering lever.

If it is difcult to disengage or engage the steering clutch,

check the following below.

1. Check the steering lever free travel.

2. If steering lever free travel exceeds the limit, loosen the

lock nuts and adjust the rod.

3. After the adjustment, tighten up the lock nut.

[Proper steering lever free travel / 3mm]

Steering lever

Rod

Lock nut

• Check and adjustment of steering brake

CAUTION

To avoid personal injury:

• First stop the engine.

• Be sure to check the braking force after adjustment.

1. When the steering brake is too weak, loose the lock nuts and move the adjust plate toward B

~ 6mm)

2. Check that adjust plate contact the brake lever, when move

the Lever C toward A

approx. 17 mm

3. After the adjustment, tighten up the lock nuts

Lock nut

Adjust plate

Brake lever

Lever C

Page 37

IMPORTANT

• If you move the adjust plate toward B

too much, the steering brake is applied at all times.

This will cause the damage of transmission.

5-4 NEUTRAL SYSTEM ADJUSTMENT

• Check and adjustment of drive pedal

CAUTION

To avoid personal injury:

• First stop the engine.

• After servicing, make sure the function of

drive pedal.

If abnormal operation (the machine moves at a very slow

speed, even if remove the foot from drive pedal)

is found, check and adjust the following below.

1) Move the adjusting bolt toward A

machine does not move.

2) After adjustment lock the the adjusting bolt.

When the machine move forward, move the adjusting bolt

or B until the

toward A

adjusting bolt toward B

When the machine move backward, move the

Adjusting bolt

Lock nut

Drive pedal locking bolt

IMPORTANT

• Do not adjust the height of the drive pedal locking bolts.

5-5 BELT TENSION ADJUSTMENT

• Check and adjustment of V-belt tension (hydraulic pump)

CAUTION

To avoid personal injury:

• First stop the engine.

1. Loosen the V-belt tension by loosening adjusting nut and lock nut for tension bolt after a little

loosening two of bolts for hydraulic pump.

2. Adjust the V-belt tension by tightening adjusting nut.

3. After the adjustment, tighten up the lock nut and two of bolts for hydraulic pump. Reference

for proper belt tension.

Page 38

Depress the center of V-belt with thumb pressure.

Displacement at center of belt / load to belt.

[8 to 10 mm / 5 kgf]

Lock nut

Adjust nut

• Check and adjustment of fan belt tension

CAUTION

To avoid personal injury:

1. Be sure to stop the engine and remove the key before checking the belt tension.

2. Be sure to reinstall the detached safety shield after maintenance or checking.

Proper fan belt tension

A deection of between 7 to 9 mm when the belt is pressed in the middle of the span.

1. Stop the engine and remove the key.

2. Apply moderate thumb pressure to belt between pulleys.

3. If tension is incorrect, loosen the alternator mounting bolts and, using a lever placed between

the alternator and the engine block, pull the alternator out until the deection of the belt falls

within acceptable limits.

4. Replace fan belt if it is damaged.

IMPORTANT

• If belt is loosen or damaged and the fan is damaged,

it could result in overheats or insufcient charging.

Correct or replace belt.

Fan belt

Bolt and nut

7 to 9 mm (under load of 10 kgf)

5-6 CRAWLER ADJUSTMENT

• Check and adjustment of rubber crawler tension

CAUTION

To avoid personal injury:

• If the crawler tension is too high, abnormal stress will be applied to the idler,

sprocket and crawler, causing serious accidents or excessive wear to occur.

Adjust the crawler tension by turning adjusting bolt after detach the snap pin and stopper to make

clearance A

between 25~35mm when pushed with the thumb.

Page 39

1 Adjusting bolt

Snap pin

Stopper

IMPORTANT

• Be sure to move the machine forward before

the adjustment. This is because, after backward

movement of the machine, the crawler is tensed on

the upper side, making correct adjustment impossible.

• The adjusting bolt will become difcult to turn when the sticking mud hardens.

•

After work, always grease the thread.

• Excessive tension results in trouble such as:

•

Increase of running resistance and reduction of driving power.

•

Excessive wear of crawler.

• Insufcient tension results in trouble such as:

•

Disengagement of crawler.

•

Defective engagement of sprocket.

•

Excessive wear of crawler.

• After completing the work, clean the crawler units, removing sticking soil completely.

Page 40

6. TESTING OF PRESSURE (HST)

Please check the pressure of HST by check port A or B .

Pressure check port (PF3/8) - FORWARD

Pressure check port (PF3/8) - BACKWARD

Input shaft

Suction port (PF3/8)

Drain port (PF3/8)

Charge pump

Suction port (PF1/2)

Discharge port (PF3/8)

Page 41

7. REPLACING OF WEAR OUT PARTS

1) Friction plate

If the measurement is less than the allowable limit, replace the parts.

Friction plate thickness

Factory spec. 2.53 ~ 2.67mm

Allowable limit 2.35mm

2) Clutch plate

If the measurement is less than the allowable limit, replace the parts.

Clutch plate thickness

Factory spec. 0.95 ~ 1.05mm

Allowable limit 0.85 mm

Page 42

8. TROUBLESHOOTING AND COUNTERMEASURES

1. Engine is difcult to start (Self-starter does not operate).

Safety switch (brake pedal) is broken.

Check and replace.

2-1. The machine does not stop, even if remove the foot from drive pedal.

(Both side / Forward and Backward)

The bolt for lever (HST) is loosed.

Check and tighten up the bolt.

See “8. BOLTS FOR HST NEUTRAL LEVER” under “TIGHTENING TORQUE”.

2-2. The machine does not stop, even if remove the foot from drive pedal.

(one side only / Forward or Backward)

The neutral system of HST is not correctly adjusted.

Check and adjust the neutral system of HST.

See “4. NEUTRAL SYSTEM ADJUSTMENT” under “ADJUSTMENT OF COMPONENT

PARTS”.

3. The machine does not drive

HST pump is broken.

Check and replace.

4-1. The machine does not drive powerful.

The crawler tension is too high.

Check and adjust the crawler tension.

See “6. CRAWLER ADJUSTMENT” under “ADJUSTMENT OF COMPONENT PARTS”.

Page 43

4-2. The machine does not drive powerful.

The main clutch (V-belts) slips.

Check and adjust of V-belt tension (main clutch)

See “1. MAIN CLUTCH ADJUSTMENT” under “ADJUSTMENT OF COMPONENT

PARTS”.

4-3. The machine does not drive powerful.

Pressure of HST unit is not enough.

Check the pressure of HST unit.

See “TESTING OF PRESSURE (HST)”.

4-4. The machine does not drive powerful.

The parking brake is applied at all time.

Check and adjust of parking brake

See “2. BRAKE PEDAL ADJUSTMENT” under “ADJUSTMENT OF COMPONENT

PARTS”.

4-5. The machine does not drive powerful.

The brake pedal does not return correct position by lack of lubrication.

Check and apply a grease.

4-6. The machine does not drive powerful.

The friction between clutch plate and friction plate for transmission is big.

The friction will be decrease after 30 minutes or 1 hour operation.

Page 44

5. The operating force for steering lever is heavy.

The lubrication of rod, side clutch lever is not enough.

Check and apply a grease

6-1. The steering lever does not return smoothly.

The lubrication of rod, side clutch lever is not enough.

Check and apply a grease.

7. The speed change lever does not move smoothly.

The lubrication of rod is not enough.

Check and apply a grease

Page 45

9 MAINTENANCE INTERVALS

[EVERY 25 SERVICE HOURS]

• Check of steering lever

• Check of V-belt tension (main clutch)

[EVERY 50 SERVICE HOURS]

• Check of steering brake

• Check of parking brake

• Greasing

• Draining water of the fuel tank

• Check of rubber crawler tension

• Check of fuel pipes and clamp bands

[EVERY 100 SERVICE HOURS]

• Check of speed change lever

• Check of roller and idler

• Check of V-belt tension (hydraulic pump)

[after rst 25 service hours]

• Cleaning of air cleaner element

• Cleaning of fuel lter

• Check of battery electrolyte level

• Check of fan belt tension

• Change of engine oil

[after rst 50 service hours]

• Check of hydraulic hoses and clamp bands [HST]

[EVERY 200 SERVICE HOURS]

• Check of radiator hoses and clamp bands

• Check of hydraulic hoses and clamp bands (hydraulic pump)

• Replacement of oil lter cartridge

[after rst 50 service hours]

• Check of intake air line

[EVERY 300 SERVICE HOURS]

• Change of transmission oil

[after rst 50 service hours]

Page 46

[EVERY 400 SERVICE HOURS]

• Replacement of fuel lter element

• Cleaning of radiator

[EVERY 500 SERVICE HOURS]

• Replacement of fan belt

• Change of hydraulic pump oil

• Change of HST oil

[after rst 50 service hours]

• Replacement of oil lter cartridge [HST]

[after rst 50 service hours]

• Replacement of suction lter [HST]

[after rst 50 service hours]

[EVERY ONE OR TWO MONTHS]

• Recharging of battery

[EVERY ONE YEAR]

• Replacement of air cleaner element

[every year or every 6 times at cleaning]

• Check of the electrical circuit and looseness of the coupler

[EVERY 800 SERVICE HOURS]

• Check of valve clearance

[EVERY 1500 SERVICE HOURS]

• Check fuel injection nozzle injection pressure

[EVERY 2000 SERVICE HOURS]

• Check of alternator and starter motor

[EVERY TWO YEARS]

• Replacement of battery

• Replacement of radiator hoses and clamp bands

• Replacement of fuel pipes and clamps

• Change of radiator coolant (L.L.C.)

• Replacement of intake air line

• Replacement of hydraulic hoses and clamp bands

Page 47

Page 48

EDITOR:

KUBOTA CORPORATION CONSTRUCTION MACHINERY DIVISION CUSTOMER TECHNICAL SUPPORT DEPARTMENT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, 753-0004 JAPAN PHONE : (81)72-890-2888 FAX : (81)72-890-2886 E-mail : [email protected]

KUBOTA Corporation

Printed in Japan 2010. 01, H, H, H, e Code No.RY921-20440