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.
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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
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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
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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.
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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.
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