WORKSHOP MANUAL
DUMPER
KC100HD
CONTENTS 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 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
1
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
2
1. SPECIFICATIONS Model
Machine weight
Max. loading capacity
Engine
(kg) Model
67 x 68
Output
(KW/rpm)
8.3/3000
Length
(mm)
2640
Height
(mm)
2015
(mm)
720
(cc)
Starting system Width
(mm)
Track center-to-center distance Bed
(mm)
Height
(mm)
Width
Crawler type
Number of drive sprocket teeth Track width
Ground contact length
Ground contact pressure w/o load Ground contact pressure w/t load Max. traction power
(Forward / Reverse) Main clutch
Lowering time (at 30900rpm) Hydraulic oil tank Engine oil
230
6 (one side) 1180
1st
2nd
25
(kgf/cm ) (kgf)
(km/h) (km/h)
Screw type with spring 0.17 0.4
1040
HST + Gear shift type transmission 0 - 3.2 / 0 - 2.1 0 - 5.8 / 0 - 3.9 Belt tension
Tooth clutch
Wet multi-plate type Wet multi-plate type
Dumping type
Fuel tank
7
72
2
Parking brake
Raising time (at 3000rpm)
Rubber track
(kgf/cm2)
Steering brake
Max. Dumping angle
400 / 520
(mm)
Steering clutch
Dumping direction
320
( )
(° )
Alignment
Travelling speed
855
(mm)
Gradeability
Type
1470
(mm)
Number of track rollers
Electric
145
(mm)
Capacity Struck / Heaped
479
950
(mm)
Length
Crawler pitch
Capacity
2
(mm)
Min. ground clearance
Dumping performance
KUBOTA Z482-E3B-CRYM-1
Vertical 4-cycle Liquid-Cooled Diesel
Total Displacement
Transmission
1200
Type
No. of cylinder
Undercarriage
885
(kg)
Bore and Stroke
Dimensions
KC100HD
Hydraulic
(° )
(sec)
(sec)
Front / Right side / Left side 56 / 60 / 60 7.1
4.0
( )
14.8
( )
2.55
( )
1.5
Coolant
( )
Approx. 2.8
Transmission oil (main / sub)
( )
3.1 / 0.45
HST oil
( )
13.0
3
4
2. DIMENSIONS
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
Specifications Model Number of Cylinders Type Bore×Stroke Total Displacement ISO Net Continuous ISO/SAE Net Intermittent SAE Gross Intermittent Maximum Bare Speed Minimum Bare Idling Speed Combustion Chamber Fuel Injection Pump Governor Direction of Rotation Injection Nozzle Injection Timing Firing Order Injection Pressure Compression Ratio Lubricating System Oil Pressure Indicating Lubricating Filter Cooling System Starting System Starting Motor Starting Support Device EGR Battery Charging Alternator Fuel Lubricating Oil
Z482-E3B
2 Vertical, Water-cooled, 4 cycle IDI diesel engine 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) 599.0 cm3 (36.55 cu.in.) 479.0 cm3 (29.23 cu.in.) 10.1 kW / 3600 min-1 ( rpm) 8.10 kW / 3600 min-1 (rpm) (10.9 HP / 3600 min-1 (rpm)) (13.5 HP / 3600 min-1 (rpm)) 11.6 kW / 3600 min-1 ( rpm) 9.30 kW / 3600 min-1 (rpm) 1 (12.5 HP / 3600 min (rpm)) (15.5 HP / 3600 min-1 (rpm)) 1 12.5 kW / 3600 min-1 ( rpm) 9.90 kW / 3600 min (rpm) (13.3 HP / 3600 min-1 (rpm)) (16.8 HP / 3600 min-1 (rpm)) 3800 min-1 (rpm) 900 to 1000 min-1 (rpm) Spherical type (E-TVCS) Bosch MD type mini pump All speed mechanical governor Counter-clockwise (viewed from flywheel side) Bosch “Throttle” type 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C. 1-2 13.73 MPa (140.0 kgf/cm2, 1991 psi) 23.5 : 1 24 : 1 Forced lubrication by trochoid pump Electrical Type Switch Full flow paper filter (Cartridge type) Pressurized radiator, forced circulation with water pump (not included in the basic engine) Electric starting with starter 12V, 0.8kW 12V, 1.0kW By glow plug in combustion chamber None 12V, 28 AH equivalent 12V, 36 AH equivalent 12V, 150W 12V, 480W Diesel Fuel No.2-D (ASTM D975) Class CF lubricating oil as per API classification is recommended. For details on recommended lubricating oils, see page G-6, 9
Oil Pan Depth 2.1 L (0.55 U.S.gals) 101 mm (3.98 in.) Oil Pan Depth 2.5 L (0.66 U.S.gals) 121 mm (4.76 in.) Weight (Dry) kg(lbs) 53.1 (117) * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW Lubricating Oil Capacity
Z602-E3B
2.5 L (0.66 U.S.gals) – 60.0 (132)
W10336300
5
Performance curves • Z482-E3B
3EEACABEP001A (1) Brake Horsepower (6) Net Intermittent Torque (2) Engine Speed (7) Net Continuous Torque (3) B.S.F.C. (8) Gross Intermittent B.H.P. (4) Torque (9) Net Intermittent B.H.P. (5) Gross Intermittent Torque (10) Net Continuous B.H.P.
(11) Net Intermittent B.S.F.C. (12) Gross Torque (13) Overload Torque (14) Continuous Torque
Fuel consumption
Fuel consumption(L/h)
Fuel consumption KC100HD
Work load factor (%)
6
(15) Gross B.H.P. (16) Overload B.H.P. (17) Continuous B.H.P. (18) Overload B.S.F.C.
Dimension • Z482-E3B Uni : mm (in.)
3EEACABFP001A
Uni : mm (in.)
3EEACABFP002A
7
8
A B C D
HST Hight (H) Low (L) INPUT SHAFT
[POWER TRAIN]
4. TRANSMISSION
E CLUTCH GEAR F BRAKE (STEERING/PARKING) G OUTPUT SHAFT
[GEAR RATIO]
[GEARING]
5. HYDRAULIC SYSTEM (HST) HST unit
Hydraulic pump : 0 ~ 18.2 cm3 Hydraulic motor : 18.2 cm3 Charge pump : 5.1cm3 Relief valve set pressure : 18.5MPa+2.9MPa Charge pressure : 5.0 kgf/cm2 Pressure check port ( PF3/8 ) Suction port (PF1/2) [charge pump] Discharge port (PF3/8) [charge pump]
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
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)
E/G
A
B
D
C T/M
C A B C D
B
Pump (Adjustable) Piston Cylinder Flow of oil 9
Mechanism of drive pedal
K10H-D010
Flow of HST oil
E Oil cooler F Oil filter cartridge G HST oil tank 10
K10H-D004
6. HYDRAULIC SYSTEM (DUMPING) Hydraulic pump Hydraulic pump
Discharge volume
Revolution
: 3cc/rev
: 140+5/kgf/cm2 (13.7+0.5MPa)
(at 1800rpm)
Tank capacity
: 1.6 â„“
Pulley size (engine)
(Part no 89956-1559-0)
: 500 ~ 2000rpm
Relief valve set pressure
Pulley size (pump)
: K82R
: Dia 101.6mm
(Part no 89956-1298-0)
: Dia 76.2mm
(Part no 89920-1157-0)
Flow of hydraulic oil
A
B
A Pull-Down port B Push-up port
K70E-U002
11
Hydraulic hose / Hydraulic cylinder
K10H-D002
1 : Hydraulic cylinder (Part no 89950-1154-0 / 1 pce)
Pressure Stroke
: 170kgf/cm2 (16.7MPa) : 300mm
2 : Hydraulic pump (Part no 89956-1559-0 / 1 pce)
3 : Hydraulic hose (Part no 89957-1233-0 / 2 pcs)
Length
: 3000mm
4 : Elbow (Part no 89910-1188-0 / 2 pcs)
5 : Hose adapter with O-ring
(Part no 89910-1189-0 / 2 pcs)
6 : Cylinder pin (Part no 89954-1159-0 / 2 pce)
7 : Cir-clip (E) (Part no 04613-00150 / 4 pcs) 8 : Vinyl tube (Part no 89957-1234-0 / 2 pcs)
12
7. FUEL SYSTEM Fuel tank / Fuel hose 1) Fuel hose (Fuel tank ~ Fuel filter) 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 filter ~ Injection pump) Size : L : 750mm x 1 pce / 09661-7075-0 / 2 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 / 6
K10H-D003
13
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
Size : SB29 x 1 pce / Part no 89920-1175-0
Part no 89920-1157-0
Part no 89920-1165-0
2) V-belt (Engine pulley ~ Hydraulic pump pulley) 3) Engine pulley 4) HST pulley
14
15
Ⓐ
Ⓑ Ⓒ
Ⓠ
Ⓡ
Ⓒ
Ⓞ
9. WIRING DIAGRAM
Ⓟ
Ⓓ
Ⓠ
Ⓕ
Ⓔ
Ⓗ
Ⓖ
Ⓘ
Ⓢ
Ⓙ
Ⓚ
Ⓛ
Ⓣ
Ⓜ
Ⓝ
Ⓡ Ⓢ Ⓣ
Ⓚ Ⓛ Ⓜ Ⓝ Ⓞ Ⓟ Ⓠ
Ⓖ Ⓗ Ⓘ Ⓙ
Ⓐ Ⓑ Ⓒ Ⓓ Ⓔ Ⓕ
B Br G L P R SB W Y BL BW GB LB PB RW WB YB BR
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
Cord color Black Brown Green Blue Pink Red Sky blue White Yellow Black / Blue Black / White Green / Black Blue / Black Pink / Black Red / White Red / White Yellow / Black Black / Red
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
16
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