Kubota kc250hr dumper service repair manual

WORKSHOP MANUAL

KUBOTA DUMPER

KC250H/HR

Code No. 97899-61750

GB

Ãœbersetzung

DANGER

DANGER

WARNING

WARNING

CAUTION

CAUTION

NOTICE

NOTICE

Note

Note

Important

Important

Contents

1. Introduction ......................................................... 1 1.1 Purpose of This Manual...................................................................... 1 1.2 Composition of This Manual ............................................................... 1 1.3 Notice to the Technician ..................................................................... 2

2. Service Data......................................................... 3 2.1 Component Names and Functions ..................................................... 3 2.2 Product Specifications ........................................................................ 5 2.2.1 Specifications of this Product ....................................................................... 5 2.2.2 Details of Tool Bag ....................................................................................... 8 2.2.3 Stroke and Operating Force of Controls....................................................... 8 2.2.4 Cylinder Speed ............................................................................................. 8 2.2.5 Falling Rate .................................................................................................. 8

2.3 Serial Number Position ....................................................................... 9 2.3.1 Product Model and Production Number ....................................................... 9 2.3.2 Engine Model Number.................................................................................. 9

2.4 Torque Settings for Fasteners .......................................................... 10 2.4.1 Standard Torque Settings for Hex Head Bolts and Nuts ............................ 10 2.4.2 Standard Torque Settings for Flange Bolts and Nuts ................................. 11 2.4.3 Standard Torque Settings for Hydraulic Hose Joints.................................. 11 2.4.4 Specific Fastening Requirements............................................................... 12

2.5 Fuel, Lubricant, and Cooling Water Chart ........................................ 12 2.6 Consumables (Replacement Parts) Chart ........................................ 13

3. Safety Covers .................................................... 14 3.1 Removing Safety Covers .................................................................. 14

4. Engine ................................................................ 16 4.1 Removing Engine ............................................................................. 16

5. Driveline and Chassis....................................... 17 5.1 Driveline Mechanism ........................................................................ 17 5.2 Chassis Mechanism ......................................................................... 18 5.3 Parts Diagrams and Summaries of Assembly and Adjustment ........ 18 5.3.1 Idler............................................................................................................. 18 5.3.2 Roller A (mobile roller) ................................................................................ 19 5.3.3 Roller B (fixed roller)................................................................................... 20 5.3.4 Upper roller (carrier roller) .......................................................................... 21 5.3.5 Track Tension Adjuster............................................................................... 22 5.3.6 Tips for Track Tension Adjustment ............................................................. 23 5.3.7 Rubber track ............................................................................................... 23

5.4 Maintenance Standard of the Parts .................................................. 24 5.4.1 Idler............................................................................................................. 24 5.4.2 Roller A (Mobile Roller)/Roller B (Fixed Roller) .......................................... 24 5.4.3 Upper Roller ............................................................................................... 25 5.4.4 Sprocket ..................................................................................................... 25 5.4.5 Rubber Track.............................................................................................. 25

6. Steering System ................................................ 26 6.1 Steering System Diagram................................................................. 26 6.2 Adjustment of the Steering System .................................................. 27 6.2.1 Neutrality Adjustment ................................................................................. 27 6.2.2 6.2.2 Linearity Adjustment .......................................................................... 27

7. Vessel................................................................. 29 7.1 Tail Gate Closing Mechanism........................................................... 29

8. Electrical Equipment......................................... 30 8.1 Electrical Diagram ............................................................................ 30 8.2 Tips for Mechanism, Functions, and Maintenance ........................... 32 8.2.1 Indicator...................................................................................................... 32 8.2.2 Fuel Level Sensor....................................................................................... 33 8.2.3 Ignition switch ............................................................................................. 33 8.2.4 Switch (Parking Brake, High/Low Speed, Light)......................................... 33 8.2.5 Horn Switch ................................................................................................ 34 8.2.6 Relay .......................................................................................................... 34

8.3 Tips for Operational Confirmation..................................................... 36

9. Hydraulic Equipment ........................................ 37 9.1 Circuit Diagram ................................................................................. 37 9.1.1 One-way Dump Model................................................................................ 37 9.1.2 Turn & Dump Model .................................................................................. 38

9.2 Mechanism, Function, and Specification .......................................... 39 9.2.1 HST Pump .................................................................................................. 39 9.2.2 HST Motor (Traveling Motor)...................................................................... 40

9.2.3 Control Valve .............................................................................................. 41 9.2.4 Solenoid Valve............................................................................................ 42

9.3 Tips and Maintenance Standards for HST Circuit ............................ 43 9.3.1 Pressure Setting Standards........................................................................ 43 9.3.2 Neutrality adjustment.................................................................................. 44

9.4 Towing .............................................................................................. 46

10. Troubleshooting ............................................. 47 10.1 The Engine does not Start .............................................................. 47 10.2 Vehicle does not Move with Lever Engagedand Parking Brake Unhitched. .............................................................................................. 48 10.3 Lever Response is Slow. ............................................................... 49 10.4 Unable to Make a Pivot Turn (Unable to Lock One Track). ............ 49 10.5 Unable to Travel Straight. .............................................................. 50 10.6 Unable to Turn to Either Side. ........................................................ 50

1

Introduction

1. Introduction 1.1

Purpose of This Manual

The purpose of this manual is to provide the technician with detailed information so that they will know the structure and proper method of servicing concerning this machine.

This manual has been prepared for people who are familiar with how to operate and control this machine.

1.2

Composition of This Manual

This manual gives information by dividing it into the following chapters: 1.

Introduction This Chapter describes the purpose and formation of this manual and information and data necessary for the maintenance of this vehicle.

2.

Service Data This Chapter describes the names and functions of the parts, specification, and product number position of this vehicle.

3.

Removal and Installation of Covers This Chapter describes the formation of the safety covers installed in this vehicle.

4.

Engine This Chapter describes the information on the dismounting of the engine.

5.

Driveline and Chassis This Chapter describes the information on the structure and maintenance (disassembly, reassembly, adjustment) of the driveline and chassis.

6.

Steering System This Chapter describes the information on the maintenance (adjustments) of the steering system.

7.

Vessel This Chapter describes the information on the structure and maintenance (disassembly, reassembly, adjustment) of the vessel.

8.

Electrical Equipment This Chapter describes the information on the electrical parts.

9.

Hydraulic Equipment This Chapter describes the information on the structure and maintenance (disassembly, reassembly, adjustment) of the parts of the hydraulic devices.

10. Troubleshooting This Chapter describes the causes of troubles and remedial measures for each trouble.

-1-

Introduction 1.3

1

Notice to the Technician

This manual explains the "structure" of this product and "procedure for assembling" it. Please read this "service manual" carefully so that you will perform proper servicing, before carrying out any servicing.

The technician must know that this machine can be potentially dangerous. Always follow the instructions in this manual when operating or inspecting the machine.

This manual has been prepared for people who are familiar with how to operate and use this machine. Before reading this manual, be sure to read the OPERATOR'S MANUAL (52345101000) to familiarize yourself with how to operate and control this machine.

It is illegal to operate this machine on public roads and roads which are regarded as public roads. Kubota Corporation. will not assume responsibility for any accidents and violations attributable to operation of this machine on such roads.

Do not modify the machine and do not operate when safety covers, etc. are removed. Also, do not use this machine for purposes other than operation.

-2-

2

Service Data

2. Service Data 2.1

Component Names and Functions Seat Tail gate

Idler Head lamp Upper roller

Track

Sprocket

Roller

Roller bracket

High/low speed selector switch

Lamp switch

Parking brake switch

Horn button

Accelerator lever

Ignition switch One-way Dump Model Turn lever Lock plate Steering lever Turn lever Dump lever

Lock plate

Fuel gauge

Engine oil lamp

Cooling water temperature lamp

Hour meter

Charge lamp

Parking brake lamp

-3-

Turn & Dump Model

Service Data

2

Accelerator lever . . . . . . . . . . . . Increases and decreases the engine revolutions.

Ignition switch . . . . . . . . . . . . . . Starts and stops the engine and used for glow. Turning the key to the “ | ” position breaks the electrical circuit of the truck.

Parking brake switch . . . . . . . . Parks the truck. When the switch is at “P” position, the truck does not move if you move the steering lever. The switch should be placed at “P” position when you start the engine.

High/low speed selector switch. Switches the speed (high or low).

Light switch . . . . . . . . . . . . . . . . Turns on the head lamp.

Horn button . . . . . . . . . . . . . . . . Sounds the horn.

Dump lever . . . . . . . . . . . . . . . . Lifts or lowers the vessel.

Turn lever . . . . . . . . . . . . . . . . . Rotates the vessel (for the turn & dump model).

Lock plate . . . . . . . . . . . . . . . . . Locks the dump and turn levers.

Steering lever . . . . . . . . . . . . . . Switches the traveling direction (forward or backward) and rotates the truck.

Fuel gauge . . . . . . . . . . . . . . . . Indicates how much the fuel is left.

Hour meter . . . . . . . . . . . . . . . . Indicates the accumulated operation hours of the machine by 0.1 hour units.

Engine oil lamp . . . . . . . . . . . . . Turns on during ignition and when engine oil pressure is too low.

Coolant temperature lamp . . . . Turns on when the engine coolant temperature is too high.

Charge lamp . . . . . . . . . . . . . . . Turns on when battery is sufficiently charged.

Parking brake lamp . . . . . . . . . . Turns on when the parking brake switch is at “P” position.

-4-

2

Service Data 2.2

Product Specifications

2.2.1

Specifications of this Product

Payload

Weight

Machine model, type Mass in working order

kg

Max. Payload

kgf

Struck

payload*1

Heaped payload* Velocity

Performance

Gradability

Size

One-way Dump

Turn & Dump

2,230

2,430 2,500

m³

0.89

1.03

m³

1.26

1.40

Low

km/h

0 - 6.0

High

km/h

0 - 11.0

Empty

degree

30

degree

15

Front

degree

30

Rear

degree

30

Left

degree

25

Right

degree

25

Empty

kPa (kgf/cm²)

24.7 (0.25)

26.9 (0.26)

Loaded

kPa (kgf/cm²)

51.6 (0.52)

53.8 (0.54)

Vessel dump degree

degree

60

85

Lenght

mm

3280

3650

Width

mm

1775

Height

mm

2370

Ground clearance

mm

295

Ground contact length

mm

1960

Track length

mm

1230

Track width

mm

3456

Length (inner)

mm

Width (inner)

mm

890

Depth

-

495

Model

-

Kubota V2203

Type

-

In-line water-cooled vertical four-cycle swirl-chamber diesel engine

Cylinder - bore × stroke

mm

4 - 87 × 92.4

Vessel

Engine

KC250HR

Loaded

Stability

Ground Pressure

1

KC250H

1315

1340

Total displacement

L(cc)

2.197(2,197)

Max. output

kW(PS)/rpm

34.1(46.4)/2,800

Max. torque

Nm(kgfm)/rpm

139.6(14.2)/1,600 to 1,800

Max. engine speed

rpm

3,000

Idling engine speed

rpm

950±50

Starter

-

12V, 1.4 kW

Alternator

-

12V, 35A

Battery

-

100E41R, 12V, 80Ah×1

-5-

2

Service Data KC250HR Turn & Dump

piece/side

1

Track roller

piece/side

6

Track

Type

-

Built-in rubber track

Pitch

mm

90

Width

mm

320

Type × unit

-

Triple pump (piston × 2 + gear) × 1

Discharge rate

L/min

Set pressure

MPa (kgf/cm²)l

Piston:64.4 × 2 Gear:31

Hydraulic motor (type × unit)

DUMP:15.7(160)

DUMP:11.8(120)

Piston, integral reducer in the parking brake × 2 -

Spooled × 1

Operating method

-

Spooled direct pulling

Type

-

Double-acting piston

Cylinder bore

mm

80

Rod diameter

mm

40

Stroke

mm

407

Max. pin distance

mm

1,072

Min. pin

mm

665

Size

Type Turn cylinder

Traveling:34.3(350)

Type × unit

Size

Dump cylinder

Operating valve

Hydraulic equipment

KC250H One-way Dump

Carrier roller (upper roller)

Hydraulic pump

Chassis

Machine model, type

-

-

Double-acting piston

Cylinder bore

mm

-

60

Rod diameter

mm

-

30

Stroke

mm

-

250

Max. pin distance

mm

-

685

Min. pin

mm

-

435

Hydraulic oil tank

-

Box sealed

Hydraulic oil filter

-

Pump suction side

Hydraulic oil cooler

-

Air-cooled

1

* Payloads are measured as per ISO 6483.

-6-

2

1560

1420

Service Data

1685

One-way Dump Model One-way Dump Model

320

440

54

295

770

370

2370

60

1775

1960 3280

1230 1550

1300

Turn & Dump Model Turn & Dump Model

2155

1775

295

32

55

768

(1410)

495

2370

2945

85

1960 3650

320 1230 1550

-7-

2

Service Data 2.2.2

Details of Tool Bag

No. 1 2

2.2.3

Part Name Operation and Maintenance Manual Instruction manual for engine

Q’ty 1 1

Remarks

Stroke and Operating Force of Controls Item

Steering Lever

Throttle Lever

Unit

Value

Stroke (forward)

mm

110±5 mm

Stroke (backward)

mm

110±5 mm

Force

N (kgf)

49 (5)

Stroke

mm

30

Force

N (kgf)

24.5 (2.5)

Note

at the base of the lever.

Dump Lever (One-way)

Stroke (up)

mm

48

at the tip of the lever.

Stroke (down)

mm

48

at the tip of the lever.

Dump Lever (Turn & Dump)

Stroke

mm

55

at the stopper pin.

Dump Lever (Turn & Dump)

Stroke

mm

59

at the stopper pin.

*Figures herein are standard values on a new machine.

2.2.4

Cylinder Speed Item

Dump Cylinder (One-way) Dump Cylinder (Turn & Dump) Turn Cylinder

Unit

Value

Extend

sec

3-6

Contract

sec

3-4

Extend

sec

6-8

Contract

sec

6-8

180°

sec

8-9

* These figures are obtained with the engine at maximum speed, oil temperature is at 50°C,and with no load in the loading deck or bucket.

2.2.5

Falling Rate Item

Unit

Use Limit

Note

Dump Cylinder (One-way)

mm/min.

1

Unloaded

Dump Cylinder (Turn & Dump)

mm/min.

1

Unloaded

* These figures are obtained with the engine at maximum speed, oil temperature is at 50°C,and with no load in the loading deck or bucket.

-8-

2

Service Data 2.3

Serial Number Position

When inquiring of our company about this machine, confirm in advance the relevant items, such as product model, production number for this machine, engine model, transmission production number, and front differential production number.

2.3.1

Product Model and Production Number

View from left side front

Location Locationofof production label product label

< Product label >

2-47, Shikitsuhigashi 1-Chome, Naniwa-ku, Osaka Japan, 556-8601

MODEL: MODELE: MODELL:

KC250H/KC250HR

MASS: MASSE: GEWICHT:

2100kg/2350kg

POWER: PUISSANCE LEISTUNG:

33.8kw

CONSTRUCTION YEAR: ANNEE DE FABRICATION: BAUJAHR:

2.3.2

Engine Model Number

View from right side

Location of engine model number

-9-

SERIAL No. NO DE SERIE SERIEN-NR.

KC250- 1 0 0 0 1 MADE IN JAPAN: FABRIQUE AU JAPON HERGESTELLT IN JAPAN

2007

2

Service Data 2.4

Torque Settings for Fasteners

When fastening a threaded fastener, torque it to an appropriate torque setting. Some fasteners are provided with specific torque settings; fasten them to these settings. For the fasteners with no settings specified, follow the standard torque settings shown below and in the next page.

2.4.1

Standard Torque Settings for Hex Head Bolts and Nuts

property class

4T

7T

8T

9T

11T

0.3~0.5 0.03~0.05) 0.8~1 (0.08~0.1) 2.5~3.4 (0.25~0.35) 4.9~6.9 (0.5~0.7) 11.8~16.7 (1.2~1.7) 20.6~29.4 (2.1~3) 44.1~53.9 (4.5~5.5) 63.7~78.5 (6.5~8) 88.3~107.9 (9~11) 117.7~137.3 (12~14) 147.1~166.7 (15~17) 176.5~205.9 (18~21) 235~264.8 (24~27)

(-) (-) 5.4~6.4 (0.55~0.65) 9.8~11.8 (1~1.2) 24.5~29.4 (2.5~3) 39.2~44.1 (4~4.5) 83.4~93.2 (8.5~9.5) 117.7~132.4 (12~13.5) 152~171.6 (15.5~17.5) 205.9~235.4 (21~24) 235.4~274.6 (24~28) 421.7~451.1 (43~46) 539.4~568.8 (55~58)

(-) (-) 6.4~7.4 (0.65~0.75) 11.8~13.7 (1.2~1.4) 29.4~34.3 (3~3.5) 49~53.9 (5~5.5) 93.2~107.9 (9.5~11) 132.4~147.1 (13.5~15) 176.5~196.1 (18~20) 245.2~274.6 (25~28) 313.8~353 (32~36) 539.4~578.6 (55~59) 706.1~745.3 (72~76)

(-) (-) 6.4~7.4 (0.65~0.75) 11.8~13.7 (1.2~1.4) 29.4~34.3 (3~3.5) 49~53.9 (5~5.5) 93.2~107.9 (9.5~11) 147.1~166.7 (15~17) 215.7~245.2 (22~25) 313.8~343.2 (32~35) 441.3~480.5 (45~49) 608~647.2 (62~66) 784.5~823.8 (80~84)

(-) (-) 8.8~9.8 (0.9~1) 14.7~16.7 (1.5~1.7) 36.3~41.2 (3.7~4.2) 72.6~82.4 (7.4~8.4) 122.6~137.3 (12.5~14) 205.9~225.6 (21~23) 313.8~343.2 (32~35) 441.3~470.7 (45~48) 617.8~657 (63~67) 843.4~882.6 (86~90) 1098.3~1137.6 (112~116)

nominal size

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24

Units in Nâ&#x20AC;˘m (kgfâ&#x20AC;˘m)

- 10 -

2

Service Data 2.4.2

Standard Torque Settings for Flange Bolts and Nuts property class

4T

7T

without serration

1.5~2 (0.15~0.2)

(-)

without serration

3.9~4.4 (0.4~0.45)

6.9~7.8 (0.7~0.8)

with serration

2.9~3.4 (0.3~0.35)

5.4~6.4 (0.55~0.65)

without serration

6.4~8.3 (0.65~0.85)

13.7~15.7 (1.4~1.6)

with serration

4.9~6.9 (0.5~0.7)

10.8~12.7 (1.1~1.3)

without serration

16.7~21.6 (1.7~2.2)

26.5~31.4 (2.7~3.2)

with serration

12.3~17.2 (1.25~1.75)

20.6~25.5 (2.1~2.6)

without serration

34.3~39.2 (3.5~4)

50~54.9 (5.1~5.6)

with serration

33.3~38.2 (3.4~3.9)

48~52.9 (4.9~5.4)

nominal size, Type

M4

M5

M6

M8

M10

Units in N•m (kgf•m)

2.4.3

Standard Torque Settings for Hydraulic Hose Joints mm

6

8

9

12

15

19

25

-

-04

-05

-06

-08

-10

-12

-16

Nominal size

PT

1/4

3/8

3/8

1/2

3/4

1

Torque

N•m (kgf•m)

25 (2.5)

34 (3.5)

34 (3.5)

59 (6)

118 (12)

118 (12)

137 (14)

Nominal size

UNF

7/16 - 20

1/2 - 20

9/16 - 16

3/4 - 16

7/8 - 14

Torque

N•m (kgf•m)

25 (2.5)

29 (3)

39 (4)

49 (5)

69 (7)

- 11 -

2

Service Data 2.4.4

Specific Fastening Requirements Thread Locking Adhesive

Tightening Torque

Note

Sprocket Axle Nut

Three-Bond 1324 or Equivalent

Standard

Align slot on the nut with hole on the axle at the specified torque.

Steering Lever Ball-joint (upper)

Three-Bond 1324 or Equivalent

Standard

Apply a small amount of adhesive on the thread of the ball-joint stud and secure with a nut.

2.5

Fuel, Lubricant, and Cooling Water Chart Item

Interval

Recommended product

Capacity

Fuel

Whenever needed

Diesel fuel

Engine oil

Filling: Check every day, add when level is low.

Change: 1st time: 50 hours.

2nd time on: every 200 hours.

API category: CD class or higher SAE category: 10W-30

Change: 1st time: 500 hours.

2nd time on: every 200 hours.

High viscosity index hydraulic fluid VG46 or engine oil API category : CD class or above SAE category : 10W-30 * When using in cold areas (below -15°C), use wear resistant hydraulic fluid VG32.

36 liters

0.6 liters

HST fluid (used also as hydraulic fluid)

9.7 liters

Traveling motor lubricating fluid

Change: 1st time: 200 hours.

2nd time on: every 1000 hours.

Gear oil API category: GL4 SAE category: # 90

Cylinder pin, roller support shaft

Every 100 hours

Lithium all-round grease (NLG No.2 or equivalent)

Engine cooling water

Adding: Check every day, add when level is low.

Change: Every 2 years.

Long Life Coolant (LLC) and pure water mixture

Check every 50 hours, add when level is low.

Distilled water

Battery electrolyte

- 12 -

45.0 liters

–

7.2 liters

–

2

Service Data 2.6

Consumables (Replacement Parts) Chart Item

Part number

Replacement interval

Quantity

Air cleaner element (outer)

R1401-4227-0

Every 1000 hours or more often, when you are working in dusty areas.

1

Air cleaner element (inner)

R2401-4228-0

Every 1000 hours

1

Fuel filter element

36640221500

Every 500 hours

1

Engine oil filter cartridge

36610001300

Every 200 hours (first time: 50 hours)

1

HST filter element

36616036300

Every 500 hours

1

Suction filter element

36636029000

Every 1000 hours

1

Battery

36610502000

1

Track

36632111999

2

Push-pull wire (for engine control)

37073321000

1

Wire (for engine control)

36550105100

1

Sprocket 15T

366321060X0

Track roller A assembly

52322201000

8

Track roller B assembly

52322211000

4

Carrier roller assembly

364022180X0

2

Idler assembly

364023310X0

2

Replace if there is any problem

2

Hydraulic hose

Piping conncetion port HST pump front right A1

HST motor top left P1

52296101000

1

HST pump front left B1

HST motor bottom left P2

52296102000

1

HST pump front left B2

HST motor bottom right P2

36646101200

1

HST pump front right A2

HST motor top right P1

52296104000

HST motor left drain bottom T1

Oil tank

52296111000

1

HST motor right drain bottom T1

Oil tank

52296112000

1

Pump top front drain

Oil cooler top

52296115000

1

Replace every 2 years (or replace if there is any problem)

1

NOTICE

Rubber parts such as hydraulic hoses will deteriorate even when not used. Replace them every 2 years, or whenever damaged.

- 13 -

Safety Covers

3

3. Safety Covers 3.1

Removing Safety Covers Engine Hood

Control Panel

1. Start the engine and raise the vessel. Hold the vessel with the safety prop (dump body support rod) securey. Stop the engine.

2. Unfasten bolts on the hinges to remove the engine hood.

3. Undo elecrtical couplers from the control panel.

Remove the throttle wire from the lever. Remove the hydraulic control valve from the control panel. Unfasten mount bolts to remove the Control panel. Then, unfasten mount bolts on the lower side to remove the side panels.

Side Panels Air Hose

4. Undo hose clamp to remove the air hose from the front panel.

Front panel Side Panel

Back Panel

5. Remove the front panel.

6. Remove the side panel.

7. Remove the back panel.

Front Panel

- 14 -

3

Safety Covers Pump Cover

Radiator

8. Undo radiator drain bolt to drain engine cooling water. Remove the radiator.

9. Remove the pump cover.

- 15 -

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