Kubota r520a wheel loader service repair manual

WORKSHOP MANUAL

KUBOTA WHEEL LOADER

R420S, 520S R420α , 520α

KUBOTA Corporation

CONSTRUCTION MACHINERY DIVISION 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN

EDITOR:

CONSTRUCTION MACHINERY MANUFACTURING DEPT. SERVICE SECTION HIRAKATA PLANT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN PHONE :+81-72-840-1195 FAX :+81-72-890-2886

KUBOTA Corporation

Printed in Japan 0403.AK.e.10

Service Chapter

Code No.97899-60800

Code No.97899-60801

Service Chapter CONTENTS 1.

2.

3.

4.

5.

6.

General .................................................................................................................................1-1 Machine Body & Front Attachment .......................................................................................2-1 Engine...................................................................................................................................3-1 Hydraulic System ..................................................................................................................4-1 Brake System and power train..............................................................................................5-1 Electrical System ..................................................................................................................6-1

CONTENTS 1. General .................................................................................................................................1-1 [1] Body and engine identification marks .................................................................................1-1 [2] Safety precautions for servicing, disassembly and reassembly..........................................1-2 (1) Safety measures before starting work ........................................................................1-2 (2) Safety measures during work .....................................................................................1-2 (3) Preparation for disassembly .......................................................................................1-3 (4) Precautions for disassembly and reassembly ............................................................1-3 [3] Important safety process and critical functional process ....................................................1-4 [4] Important inspection items after reassembling ...................................................................1-5 (1) Operate the machine and check for unusual noise and vibrations.............................1-5 (2) Make sure the safety decals and wireharness clamps are in their specified positions. .........................................................................................1-5 (3) With the machine front in a specified posture, check the amount of hydraulic oil. .....1-5 [5] Service fundamentals .........................................................................................................1-6 (1) Service intervals .........................................................................................................1-6 (2) Lubricants ...................................................................................................................1-8 (3) Notices for servicing items..........................................................................................1-9 (4) Tightening torque......................................................................................................1-10

R420S( ), R520S( ), WSM

1. General

1. General [1] Body and engine identification marks Your dealer is interested in your new wheel loader and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find that you can do some of the regular maintenance yourself.

However, when in need of parts or major service, be sure to see your KUBOTA dealer.

For service, contact the KUBOTA dealer/Dealership from which you purchased your wheel loader or your local authorized KUBOTA dealer.

When in need of parts, be prepared to give your dealer both the machine and engine serial numbers. Locate the serial numbers now and record them in the space provided.

Model Wheel Loader Engine Date of Purchase Name of Dealer (To be filled in by purchaser)

(1) Machine serial No. (2) Engine serial No.

(3) Engine serial No.

1-1

Serial No.

R420S( ), R520S( ), WSM

1. General

[2] Safety precautions for servicing, disassembly and reassembly A Most accidents during servicing arise from carelessness. Please remember that safety involves both the welfare of the employees and improved work efficiency.

A Machines must be disassembled and assembled efficiently and safely.

It is very important to thoroughly understand the construction and function of the machine, to make all appropriate preparations, and start operations according to the specified working procedures.

(1) Safety measures before starting work [1] Work clothes 1. Wear specified work cap and clothed. (Under no circumstances may workers wear undershirts only.)

Cuffs must be kept buttoned, and any tears must be mended.)

2. Wear safety shoes.

3. Do not wear cotton gloves when working on the internal section of engine, reduction gears or hydraulic units for repair or others, or when using a hammer. Wear leather gloves, however, when hoisting wires.

[2] Inspecting equipment and tools 1. Prepare equipment (cranes, fork lifts, tool, etc.) requires for servicing and inspect for any problems before starting work.

2. Hammer heads (metal parts) must be firmly secured to their handles.

3. Check hosting tools (wire ropes, hosting chains, etc.) before use.

[3] Keep workshop in order 1. Secure appropriate space needed for disassembly to the job.

2. Secure a clean, safe place for arranging disassembled parts.

3. Store volatile substances (gasoline, light oil, thinner, oily articles, etc.) in appropriate containers at selected locations to prevent fire hazards.

(2) Safety measures during work [1] Protectors 1. Wear goggles when using chisels for chipping.

2. Use appropriate protectors during welding.

3. Wear a helmet when working with a crane or at elevated locations.

[2] Team work 1. When working with two or more people, divide the work and maintain close communication.

2. Clean work must be carried out using predetermined signals.

1-2

R420S( ), R520S( ), WSM

1. General

[3] Disassembly and assembly 1.

2.

3.

4.

Do not wear gloves when using hammers.

Use rods of the specified soft material for removing pins. Do not use a hammer as a pad.

Do not place fingers in holes when centering.

Heavy parts must be adequately supported before removing bolts.

[4] Cranes 1. In principle, use a crane for objects heavier than 44 lb (20 kg) 2. Crane operation and hoisting must be performed only by qualified personal.

3. Pay careful attention to the center of gravity when hoisting, and do not stand under the lifted objects.

[5] Others 1.

2.

3.

4.

To work under a jacked-up carrier, be sure to place wood pieces under it.

When charging batteries, make sure there are no open flames in the immediate vicinity.

All electric tools must be grounded.

Before welding the machine, remove the battery.

A When removing the battery, be sure to disconnect negative (-) cord first.

A When mounting the battery, be sure to connect the positive (+) cord first.

(3) Preparation for disassembly [1] Cleaning Remove mud and dirt from the body before disassembly.

[2] Acceptance inspection The machine must be checked before it is disassembled to record existing conditions, such as those listed below.

Model, serial number, and hourmeter reading A Reason for repair and repair history A Element stains A Fuel and oil condition A Parts damage *(Take photographs if necessary.)

[3] Equipment and tools Prepare equipment, tools, cranes and parts storage racks as required.

(4) Precautions for disassembly and reassembly [1] Disassembly 1. Follow the specified disassembly procedures.

2. Make alignment marks to insure correct reassembly.

3. Arrange disassembled parts in an orderly way, and attach identification tags or put marks if needed.

1-3

R420S( ), R520S( ), WSM

1. General

[2] Reassembly 1.

2.

3.

4.

Clean all parts before assembly. Repair any scratches or dents. Take special precautions against dirt and dust.

Parts with rust-preventive coatings must be assembles only after removing the corting.

Separated parts must be correctly reassembled using alignment marks.

As a rule, use a press to reassembled bearings, bushing and oil seals. Use pads when using a hammer.

[3] Important safety process and critical functional process The following instructions are related to essential adhesives, important safety process 㧿 and critical functional process 㧭 . Pay special attention in servicing these process. (Pay also close attention in reconnecting the electrical cables.)

(1) Important safety process 㧿 1. Assembling and adjustment of brake & inching components.

2. Reconnecting the fuel hose (clearance, hose routes, clamps, etc.)

3. Electrical cabling (engine, instrument panel, controls, etc.) (wiring routes, clamps and couplers)

(2) Important critical functional process 㧭 1.

2.

3.

4.

5.

Assembling and installing the differential assy.

Assembling the center shaft.

Fitting the pump couplings (tightening torque).

Installing the LST pump (tightening torque).

Installing the LST motor (tightening torque)

(3) Essential adhesives Type of screw adhesive Unless otherwise specified, use Three-Bond 1324 adhesive (medium-duty type).

Keep the screw threads free of oil and water.

Type of instantaneous adhesive Use Three-Bond 1733 or Three-Bond 1741E adhesive.

Keep the bond areas free of oil and water.

1-4

R420S( ), R520S( ), WSM

1. General

[4] Important inspection items after reassembling (1) Operate the machine and check for unusual noise and vibrations.

(2) Make sure the safety decals and wireharness clamps are in their specified positions.

(3) With the machine front in a specified posture, check the amount of hydraulic oil.

Checking the oil level (For further details, refer to the Operator's Manual of each model.)

1) Park the machine on a level ground, stop engine and lower the bucket to the ground.

2) Make sure the hydraulic oil temperature is in the range of 10-30 (50-86 ) and see if the oil level is within the specified zone of the oil level gauge.

3) Keep the machine front as shown as following posture.

(1) Oil port (2) Oil level gauge

1-5

R420S( ), R520S( ), WSM

1. General

[5] Service fundamentals (1) Service intervals Service Interval Chart (Do all previous checks in addition to New checks.)

1-6

R420S( ), R520S( ), WSM

1. General

1-7

R420S( ), R520S( ), WSM

1. General

(2) Lubricants Select the Grade by Referring to the Table.

A In area where the temperature drops to -10 or lower, drain all oil in hydraulic oil tank and replace with all season type engine oil SAE 5W-30(CD) for the winter.

A Use engine oil API service classification CD, CE or CF. A It cannot be guaranteed against any problem caused by use of the fuel and lubricating oil and grease that are not specified.

Always use the specified gear oil, M80B or equivalent, which is permitted by KUBOTA. When engine oil is used to the LSD specification differential, paki-paki sounds are generated from differential gears during turning (especially when the steering wheel is maintained at a turned position). (This occurs due to wrong combination of LSD clutch plate and oil, causing change in the friction characteristics, which has no adverse effects including durability) Specified differential oil type M80B Shell Donax TD

Mobiland super Universal

Multipurpose Tcuban EP SAE 80W

1-8

Chevron Universal Gear Lubricant SAE 80W-90

Multi gear Lubricant EP SAE 80W-90

R420S( ), R520S( ), WSM

1. General

(3) Notices for servicing items [1] Air cleaner element cleaning pressure C Cleaning with compressed air Pressure of compressed air must be under 205 kPa (2.1 , 30 psi), and the cartridge should be blown clean from the inside to the outside until the dust deposits are remarkably reduced.

A If the air suction is still inadequate, or the color of the exhaust gases is abnormal even after the cleaning, the air filter cartridge must be replaced.

A Should the machine be used in extreme dusty areas, the air filter element must be inspected and cleaned more frequently than in the specified maintenance periods.

A The air filter has a dry element, keep free from oil.

A Do not run the engine without the air filter.

(1) Outer element (2) Inner element (3) Case (4) Dust cover

[2] Periodic parts replacement To ensure safety at all times, it is important to inspect and maintain the engine on a regular basis. For further safety, it is strongly recommended to periodically replace the following parts which are most essential to safe operation.

These parts tend to wear out or deteriorate with time and it is often difficult to determine their condition by periodic inspection. Therefore, even if no defect is found, they should be replaced at certain intervals to maintain their safe operation.

If any defect is found before the specified time, immediately replace or repair the part. Please understand that such periodic replacement is not covered by the maker's warranty.

Periodic parts of replacement

Replacement intervals

1

Brake rubber hose

every year

2

Rubber parts (piston packing of brake master cylinder etc.)

every two years

3

Brake fluid (Hydraulic oil ISO VG 32)

every two years

4

Fuel lines

every two years

5

Oil pressure hose for steering cylinder

every two years

6

Packing of steering cylinder, seal O ring

every four years

As for overall daily and periodical service items, refer to "Operator's Manual". Code No. R2411-8121-1 1-9

R420S( ), R520S( ), WSM

1. General

(4) Tightening torque [1] General precautions A Tightening the pipe socket to the specified torque. If too tight, the socket itself or a hydraulic component may get damaged. If too loose, an oil leak may result.

A In connecting a new hose or pipe, tighten its nut first to the specified torque and then turn it back (about 45 ).

Then tighten it again to the specified torque. (Do not this to the sealing tape-applied hose or pipe.)

A When disconnecting a vertical hose or pipe, separate its bottom connection first.

A In disconnecting and reconnecting the hose and pipe, be sure to use two wrenches. With one wrench, restrain the mating part to allow no twist.

A Check the mating connector's sleeve and the hose's taper for dust deposits and scratches.

A When the pipe socket has been tightened up, wipe the joint clean. Apply the maximum operating pressure 2 or 3 times to make sure there is no oil leak.

[2] Hydraulic hose Check the hydraulic hose for too tight a connect or twist. *Excessively tight contact condition is; Let's suppose that a hose is in contact with another hose or other part. If the hose is pulled away by a force of 2 kg but still in contact, it means the contact is too tight.

[3] Precautions in tightening the bolts and nuts A Use bolts of specified length.

A Do not over tighten the bolts: Its threads may get deformed or the fixed part may get damaged. Do not under tighten the bolt either: It may get loose.

A In other words, tighten the bolt to the specified torque.

A Tighten the bolts and nuts diagonally for even tightness.

1-10

R420S( ), R520S( ), WSM

1. General

[4] Hose screw Tightening torque N-m kgf-m ft-lbf

Thread size (piping screw)

Wrench size (reference)

Union nut section

Taper thread section

1/8"

7.8 ~ 11.8 N-m 0.8 ~ 1.2 kgf-m 5.8 ~ 8.7 ft-lbf

14.71 ~ 19.61 N-m 1.5 ~ 20 kgf-m 10.85 ~ 14.47 ft-lbf

17 mm 0.67 in

1/4"

24.5 ~ 29.4 2.5 ~ 3.0 18.1 ~ 21.7

36.3 ~ 44.1 3.7 ~ 4.5 26.8 ~ 32.5

19 mm 0.75 in

3/8"

49.0 ~ 53.9 5.0 ~ 3.0 18.1~21.7

49.0 ~ 68.6 5.0 ~ 7.0 36.2 ~ 50.6

22 mm 0.87 in

1/2"

49.0 ~ 53.9 5.0 ~ 5.5 36.2 ~ 39.8

83.4 ~ 88.3 8.5 ~ 9.0 61.5 ~ 65.1

27 mm 1.06 in

3/4"

58.8 ~ 63.7 6.0 ~ 6.5 43.4 ~ 47.0

127.5 ~ 147.1 13.0 ~ 15.0 94.0 ~ 108.5

36 mm 1.42 in

1"

137.3 ~ 147.1 14.0 ~ 15.0 101.3 ~ 108.5

147.1 ~ 166.7 15.0 ~ 17.0 108.5 ~ 123.0

41 mm 1.61 in

Metric Size Hose Thread size (piping screw)

Torque N-m kgf-m ft-lbf

M12 x 1.5

20 ~ 30 2.0 ~ 3.1 14.75 ~ 22.13

M14 x 1.5

20 ~ 30 2.0 ~ 3.1 14.75 ~ 22.13

M16 x 1.5

30 ~ 50 3.1 ~ 5.1 22.13 ~ 36.9

M18 x 1.5

30 ~ 50 3.1 ~ 5.1 22.13 ~ 36.9

M22 x 1.5

40 ~ 60 4.1 ~ 6.1 29.5 ~ 44.25

1-11

R420S( ), R520S( ), WSM

1. General

[5] Joint bodies Tightening torque N-m kgf-m ft-lbf

Thread size (piping screw)

Spanner size (reference)

Remarks Steel pipe (OD)

R (tapered thread)

G (straight thread)

1/8"

19.6 ~ 29.4 N-m 2.0 ~ 3.0 kgf-m 14.5 ~ 21.7 ft-lbf

---

17 mm 0.67 in

8 mm 0.31 in

1/4"

36.3 ~ 44.1 3.7 ~ 4.5 26.8 ~ 32.5

W/O-ring Joint Torque 58.8 ~ 78.5 6~8 43.4 ~ 57.9

19 mm 0.75 in

12 mm 0.47 in

3/8"

39.2 ~ 49.0 4.0 ~ 5.0 28.9 ~ 36.2

W/O-ring Joint Torque 78.5 ~ 98.1 8 ~ 10 57.9 ~ 72.3

23 mm 0.91 in

1/2"

49.0 ~ 68.6 5.0 ~ 7.0 36.2 ~ 50.6

W/O-ring Joint Torque 117.7 ~ 137.3 12 ~ 14 86.8 ~ 101.3

26 mm 1.02 in

When in steel pipe is in use.

15 mm 0.59 in

16 mm 0.63 in

[6] Tightening torque table for hose clamp (Screw type)

No.

Dia. (mm)

Code No.

1

ø12 ~ 16

09318-89016

2

ø19 ~ 25

09318-89024

3

ø31 ~ 40

09318-89039

4

ø36 ~ 46

09318-89045

5

ø15 ~ 25

RC101-64580

6

ø26 ~ 38

68311-72820

7

ø13 ~ 20

RB101-63630

8

ø40 ~ 55

RC411-63180

9

ø77 ~ 95

69284-63170

10

ø50 ~ 60

RC401-63190

11

ø32 ~ 44

RD411-63820

1-12

Tightening torque N-m kgf-m ft-lbf 2.5 ~ 3.4 25 ~ 35 1.84 ~ 2.51 4.9 ~ 5.9 50 ~ 60 3.61 ~ 4.35 3.4 ~ 4.4 35 ~ 45 2.58 ~ 3.31 4.9 ~ 5.9 50 ~ 60 3.61 ~ 4.35

R420S( ), R520S( ), WSM

1. General

[7] Nuts for piping Steel pipe size (O.D. x I.D. x Thickness)

Tightening torque N-m kgf-m ft-lbf

Spanner size (reference)

8 x 6 x 1 mm 0.31 x 0.24 x 0.04 in

29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9

17 mm 0.67 in

10 x 7 x 1.5 mm 0.39 x 0.28 x 0.06 in

39.2 ~ 44.1 4.0 ~ 4.5 28.9 ~ 32.5

19 mm 0.75 in

12 x 9 x 1.5 mm 0.47 x 0.35 x 0.06 in

53.9 ~ 63.7 5.5 ~ 6.5 39.7 ~ 47.0

21 mm 0.83 in

16 x 12 x 2 mm 0.63 x 0.47 x 0.08 in

88.3 ~ 98.1 9.0 ~ 10.0 65.1 ~ 72.3

29 mm 1.14 in

18 x 14 x 2 mm 0.71 x 0.55 x 0.08 in

127.5 ~ 137.3 13.0 ~ 14.0 94.0 ~ 101.3

32 mm 1.26 in

27.2 x 21.6 x 2.8 mm 1.07 x 0.85 x 0.11 in

235.4 ~ 254.97 24.0 ~ 16.0 173.6 ~ 188.1

41 mm 1.61 in

1-13

Remarks

When sleeve nut is in use.

R420S( ), R520S( ), WSM

1. General

[8] Tightening torque of bolts and nuts Refer to the tightening torque table below.

Bolts, Nuts Nominal Dia.

4T

㧠

7T

㧣

9T

㧥

SS41

S40C, S45C

SCr4

M6

7.8 ~ 9.3 N-m 0.80 ~ 0.95 kgf-m 5.8 ~ 6.9 ft-lbf

9.8 ~ 11.3 N-m 1.00 ~ 1.15 kgf-m 7.2 ~ 8.3 ft-lbf

12.3 ~ 14.2 N-m 1.25 ~ 1.45 kgf-m 9.0 ~ 10.5 ft-lbf

M8

17.7 ~ 20.6 N-m 1.80 ~ 2.10 kgf-m 13.0 ~ 15.2 ft-lbf

23.5 ~ 27.5 N-m 2.40 ~ 2.80 kgf-m 17.4 ~ 20.3 ft-lbf

29.4 ~ 34.3 N-m 3.00 ~ 3.50 kgf-m 21.7 ~ 25.3 ft-lbf

M10

39.2 ~ 45.1 N-m 4.00 ~ 4.60 kgf-m 28.9 ~ 33.3 ft-lbf

48.0 ~ 55.9 N-m 4.90 ~ 5.70 kgf-m 35.4 ~ 41.2 ft-lbf

60.8 ~ 70.6 N-m 6.20 ~ 7.20 kgf-m 44.8 ~ 52.1 ft-lbf

M12

62.8 ~ 72.6 N-m 6.40 ~ 7.40 kgf-m 46.3 ~ 53.5 ft-lbf

77.5 ~ 90.2 N-m 7.90 ~ 9.20 kgf-m 57.1 ~ 66.5 ft-lbf

103.0 ~ 117.7 N-m 10.50 ~ 12.00 kgf-m 75.9 ~ 86.8 ft-lbf

M14

107.9 ~ 125.5 N-m 11.00 ~ 12.80 kgf-m 79.6 ~ 92.6 ft-lbf

123.6 ~ 147.1 N-m 12.60 ~ 15.0 kgf-m 91.1 ~ 108.5 ft-lbf

166.7 ~ 196.1 N-m 17.00 ~ 20.00 kgf-m 123.0 ~ 144.7 ft-lbf

M16

166.7 ~ 191.2 N-m 17.00 ~ 19.50 kgf-m 123.0 ~ 141.0 ft-lbf

196.1 ~ 225.6 N-m 20.00 ~ 23.00 kgf-m 144.7 ~ 166.4 ft-lbf

259.9 ~ 304.0 N-m 26.50 ~ 31.00 kgf-m 191.7 ~ 224.2 ft-lbf

M18

245.2 ~ 284.4 N-m 25.00 ~ 29.0 kgf-m 180.8 ~ 209.7 ft-lbf

274.6 ~ 318.7 N-m 28.00 ~ 32.50 kgf-m 202.5 ~ 235.1 ft-lbf

343.2 ~ 402.1 N-m 35.00 ~ 41.00 kgf-m 253.2 ~ 296.5 ft-lbf

M20

333.4 ~ 392.2 N-m 34.00 ~ 40.00 kgf-m 245.9 ~ 389.3 ft-lbf

367.7 ~ 431.5 N-m 37.50 ~ 44.0 kgf-m 271.2 ~ 318.2 ft-lbf

519.8 ~ 568.8 N-m 53.00 ~ 58.00 kgf-m 383.3 ~ 419.5 ft-lbf

[9] Types and materials of bolts and nuts [Hex. bolts] Types

Material

Tensile strength

Hardness

4T

SS41

Over 392 MPa 4000 56892 lbf/in

HrB 62 ~ 98

㧠

No mark or marked 4

7T

S40C S45C

Over 686 MPa 7000 99561 lbf/in

HrC 20 ~ 28

㧣

Marked 7

9T

SCr4

Over 882 MPa 9000 128007 lbf/in

HrC 28 ~ 34

㧥

Marked 9

1-14

Bolts head marking

R420S( ), R520S( ), WSM

1. General

[10] Washer-equipped elbow Tightening torque Size

N-m

kgf-m

ft-lbs

G1/4

25 ~ 30

2.5 ~ 3.0

18 ~ 22

G3/8

49 ~ 54

5.0 ~ 5.5

36 ~ 40

G1/2

59 ~ 64

6.0 ~ 6.5

43 ~ 47

G3/4 G1

118 ~ 127

12.0 ~ 13.0

87 ~ 94

Tightening procedure 1) Connecting with the valve A Screw in the elbow by hand until the washer comes into contact.

Note: Clean up the mating seal beforehand.

2) Positioning A Turn the elbow back to its set position.

Note: Do not make any more than one turn back.

3) Fixing A Tighten up the lock nut with a wrench.

A Lock nut tightening torque G1/4: 25 ~ 30 N-m (2.5 ~ 3.0 kgf-m, 18 ~ 22 ft-lbs) G3/8: 50 ~ 55 N-m (5.0 ~ 5.5 kgf-m, 36 ~ 40 ft-lbs) G1/2: 60 ~ 65 N-m (6.0 ~ 6.5 kgf-m, 43 ~ 47 ft-lbs) G3/4: 118 ~ 127 N-m (12.0 ~ 13.0 kgf-m, 87 ~ 94 ft-lbs) G1: 118 ~ 127 N-m (12.0 ~ 13.0 kgf-m, 87 ~ 94 ft-lbs)

1-15

R420S( ), R520S( ), WSM

1. General

[11] Tire maintenance

Tire pressure

Conservation of Tires If the air pressure in the tire is too high or too low, the life of the tire will be shortened.

Make routine checks of the air pressure in tires, and adjust so the pressure is correct.

Always measure the tire pressure, and check for damage to the tires or rims before starting operation.

(1) Deficient (2) Correct

(3) Excessive (4) Ground level

Type

R420S

R520S

Make sure the tire size marked on the R420 tire.

Then follow above chart.

Tire size

12.5 / 70-16-8PR

15.5 / 60-18-8PR

Front tire

0.26r0.01MPa (36.9r1.4psi)

0.22r0.01MPa (31.2r1.4psi)

Rear tire

0.26r0.01MPa (36.9r1.4psi)

0.22r0.01MPa (31.2r1.4psi)

1. Insufficient tire pressure Too small an amount of air in the tire can cause it to have excessive slack, which makes for faster wearing down of the tread.

2. Correct tire pressure 3. Excessively high tire pressure Too high a tire pressure causes the tractive force of the machine to decrease, or the tire to slip.

There is also the risk of a blow out.

Changing Tires Removal 1. Loosen the hub bolts each by one turn on the wheel to be removed.

2. Raise the wheel off the ground, then loosen and remove the hub bolts and change the tire to a new one.

Fitting 1. Mount wheel to axle and lightly tighten the hub bolts.

2. Lower the wheel to the ground, and tighten the hub bolts to the recommended torque in the order shown above.

Tightening torque

1-16

275 to 314 N-m (203 to 231 ft-lb)

R420S( ), R520S( ), WSM

1. General

Mounting the Tires Lug tires are used to provide strong traction and buoyancy on soft ground. When mounting them, take care to position their tread pattern in the proper direction.

(1) Correct (2) Incorrect (3) Forward

1-17

CONTENTS 2. Machine Body & Front Attachment .......................................................................................2-1 [1] Specifications ......................................................................................................................2-1 (1) Machine Specifications...............................................................................................2-1 (2) Main Specification: EU-version...................................................................................2-3 [2] Installing the frame-related parts (front) ............................................................................2-13 [3] Center pin (important functional component) ....................................................................2-14 [4] Rear frame, center pin ......................................................................................................2-18 [5] Assembly drawing of the control levers ............................................................................2-19 [6] Installing the control levers ...............................................................................................2-20 [7] Assembly drawing of accelerator and brake .....................................................................2-22 [8] Installing the brake and inching-related parts ...................................................................2-25 [9] Installing the accelerator-related parts..............................................................................2-27 [10] Installing the seat ..............................................................................................................2-28 [11] Fender...............................................................................................................................2-29 [12] Installing the canopy .........................................................................................................2-30 [13] Cabin.................................................................................................................................2-31 [14] Heater hose ......................................................................................................................2-32

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

2. Machine Body & Front Attachment [1] Specifications (1) Machine Specifications SPECIFICATION TABLE: Front loader With 1500 lbs Counter weight for R420S. Model name

R420S

Counter weight

1500 lbs

Type Operating weight (with Rops/Fops Canopy, CAB) Bucket capacity

kg (lbs.)

Canopy

CAB

3380 (7450)

3600 (7935)

(cu.yds.)

0.4 (0.5)

Tipping load Straight (SAE Rating)

kN (lbf)

20.4 (4585)

23.1 (5200)

Tipping load Full turn (SAE Rating)

kN (lbf)

17.1 (3850)

19.3 (4340)

Operating load

kN (lbf)

Manufacturer

KUBOTA

Model

Water cooled D1503-M-T-E2RP-1 diesel engine

Horsepower (SAE gross) Engine

Bucket

kW (HP)/rpm

Number of cylinders L (cu.in.)

1.499 (91.4)

Starter

V/kW

12 / 1.4

Battery

V/Ah

12 / 65

Overall length

mm (in.)

4210 (165.8)

Overall width (without bucket)

mm (in.)

1520 (59.8)

Overall height

mm (in.)

2510 (98.8)

Min. ground clearance

mm (in.)

285 (11.3)

Wheel base

mm (in.)

1775 (69.9)

Tread

mm (in.)

1180 (46.5)

Angle of articulation

Deg

40 each

Angle of oscillation

Deg

8 each

Loader clearance circle (center of tire)

mm (in.)

6170 (242.9)

Hinge pin height

mm (in.)

2810 (110.7)

Dump height

mm (in.)

2245 (88.4)

Reach fully raised

mm (in.)

780 (30.8)

Lift capacity to max. height

kN (lbf)

14.2 (3190)

Breakout force

kN (lbf)

29.2 (6570)

Drive system

4WD

Tire Traveling

Traveling speed Traction force

Others

32.1 (43) / 2600 3

Displacement

Dimensions

8.6 (1925)

12.5 / 70-16-8PR Forward

km/h (MPH)

0 to 20 (0 to 12.5)

Reverse

km/h (MPH)

0 to 20 (0 to 12.5)

kN (lbf)

23.5 (5290)

Fuel tank

L (U.S.gal.)

54 (14.3)

Hydraulic oil tank

L (U.S.gal.)

42 (11.1)

Hydraulic oil system

L (U.S.gal.)

60 (15.9)

2-1

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

With 1500 lbs and 2020 lbs Counter weight for R520S. Model name

R520S

Counter weight

1500 lbs

Type Operating weight (with Rops/Fops Canopy, CAB) Bucket capacity

kg (lbs.)

2020 lbs

Canopy

CAB

Canopy

CAB

4075 (8980)

4295 (9470)

4315 (9510)

4535 (10000)

(cu.yds.)

0.57 (0.75)

Tipping load Straight (SAE Rating)

kN (lbf)

23.1 (5190)

25.5 (5740)

25.4 (5710)

27.8 (6260)

Tipping load Full turn (SAE Rating)

kN (lbf)

19.6 (4410)

21.7 (4870)

21.6 (4850)

23.6 (5310)

Operating load

kN (lbf)

Manufacturer

Water cooled V2203-M-E2RP diesel engine

Horsepower (SAE gross)

Bucket

kW (HP)/rpm

Number of cylinders L (cu.in.)

2.197 (134.1)

Starter

V/kW

12 / 2.0

Battery

V/Ah

12 / 65

Overall length

mm (in.)

4685 (184.5)

Overall width (without bucket)

mm (in.)

1760 (69.3)

Overall height

mm (in.)

2580 (101.6)

Min. ground clearance

mm (in.)

325 (12.8)

Wheel base

mm (in.)

1950 (76.8)

Tread

mm (in.)

1360 (53.5)

Angle of articulation

Deg

40 each

Angle of oscillation

Deg

8 (each)

Loader clearance circle (center of tire)

mm (in.)

6770 (266.5)

Hinge pin height

mm (in.)

3310 (130.3)

Dump height

mm (in.)

2670 (105.2)

Reach fully raised

mm (in.)

860 (33.9)

Lift capacity to max. height

kN (lbf)

17.7 (3960)

Breakout force

kN (lbf)

33.1 (7440)

Drive system

4WD

Tire Traveling

15.5 / 60-18-8PR Forward

km/h (MPH)

0 to 20 (0 to 12.5)

Reverse

km/h (MPH)

0 to 20 (0 to 12.5)

kN (lbf)

31.4 (7055)

Fuel tank

L (U.S.gal.)

54 (14.3)

Hydraulic oil tank

L (U.S.gal.)

42 (11.1)

Hydraulic oil system

L (U.S.gal.)

60 (16.4)

Traveling speed Traction force

Others

36.6 (49) / 2600 4

Displacement

Dimensions

10.8 (2420) KUBOTA

Model Engine

9.8 (2205)

2-2

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

(2) Main Specification: EU-version Model Operating Weight (Canopy / Cab) Bucket Capacity Manufacturer

kg ---

Model Engine

---

Others

KUBOTA D1503-M-T-E2RP-1 V2203-M-E2RP Water cooled diesel Water cooled diesel engine engine 29 / 2600 (40 / 2600)

33 / 2600 (45 / 2600)

--cc V/kW V/Ah mm mm mm mm mm mm Deg Deg mm mm mm mm

3 1499 12 / 1.4 12 / 65 4470 1520 2615 / 2570 280 1775 1180 40 (each) 8 (each) 6170 2810 2110 770

4 2197 12 / 2.0 12 / 65 4840 1760 2685 / 2640 325 1950 1360 40 (each) 8 (each) 6770 3310 2580 770

kg

2000 / 2370

2590 / 2920

kg

1700 / 2010

2200 / 2480

Max. Lifting Capacity (ISO 8313) Breakout Force (ISO 8313) Tipping Load, full turn (ISO 8313) (Canopy / Cab)

kN (kgf) kN (kgf)

17.7 (1800) 29.2 (2980)

23.2 (2370) 33.1 (3375)

kg

1240 / 1460

1420 / 1970

Max. Payload (EN474-3) 80% Max. Payload (EN474-3) 60% Drive System Tire Traveling Forward Speed Reverse Traction Force Fuel Tank Hydraulic Oil Tank Hydraulic Oil System

kg kg ----km/h km/h kN (kgf) L L L

950 / 1150 700 / 850 LST-4WD 12.5 / 70-16-8PR 0 ~ 20 0 ~ 20 23.5 (2400) 54 42 60

1100 / 1550 850 / 1150 LST-4WD 15.5 / 60-18-8PR 0 ~ 20 0 ~ 20 31.4 (3200) 54 42 62

Tipping Load, full turn (ISO 8313) (Canopy / Cab)

Traveling

R520 3980 / 4300 0.65

kW/rpm (PS/rpm)

Horsepower (DIN 70020)

Number of cylinders Displacement Starter Battery Overall length Overall width (without bucket) Overall height (Canopy / Cab) Min. Ground Clearance Dimensions Wheel Base Tread Angle of Articulation Angle of Oscllation Loader Clearance Circle (Center of tire) Hinge Pin Height Dump Height Reach Fully Raised Tipping Load, straight (ISO 8313) (Canopy / Cab) Bucket

Fork

R420 3040 / 3360 0.4

A Above dimensions are based on the machine with Quick Coupler, Standard Bucket, Weight and ROPS/FOPS Canopy and Cab (Made in Germany).

Mean Value and value for use on concreat roads are given for tipping load and operating load.

Specifications Subject to change without Notice.

2-3

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

2-4

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

SPECIFICATION TABLE: Backhoe Model name

R420S

Type

R520S

Canopy

CAB

Canopy

CAB

Operating weight (with ROPS/FOPS Canopy, CAB)

kg (lbs.)

3410 (7520)

3660 (8070)

3750 (8270)

4000 (8820)

Tipping Load (Full Turn)

kN (lbf)

20.6 (4630)

22.8 (5130)

22.1 (4960)

24.1 (5420)

Operating load

kN (lbf)

10.3 (2315)

11.0 (2480)

Overall length

mm (in.)

4695 (184.8)

5135 (202.2)

Max. digging depth

mm (in.)

2750 (108.3)

2750 (108.3)

Max. digging height

mm (in.)

3220 (126.8)

3220 (126.8)

Max. dumping height

mm (in.)

2040 (80.3)

2040 (80.3)

Max. digging radius

mm (in.)

3700 (145.7)

3700 (145.7)

Deg

180

180

mm (in.)

1000 (39.4)

1000 (39.4)

(cu.ft)

0.07 (2.4)

0.07 (2.4)

Bucket width

mm (in.)

450 (17.7)

450 (17.7)

Digging force bucket

kN (lbf)

18.2 (4100)

18.2 (4100)

Digging force dipperstick

kN (lbf)

12.3 (2755)

12.3 (2755)

Backhoe

Swing angle Width of boom slide Bucket capacity

Above dimensions are based on the machine with JPN Quick Coupler, Standard Loader, ROPS/FOPS Canopy, Backhoe and Standard Backhoe Bucket.

JPN = made in Japan Mean Value and value for use on concrete roads are given for tipping load and operating load.

Specifications subject to change without notice.

2-5

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

Parts Weight Table

kg (lb) Item

R420S,

R520S,

A-LST SYSTEM

1

LST pump

37 (82)

LST motor

30 (66)

LST filter flange

1.4 (3.1)

Parking valve

1.6 (3.5)

Suction filter

0.5 (1.1)

Return filter

1.0 (2.2)

Oil cooler

1.5 (3.3)

38 (84)

POWER TRAIN

2

Rear differential axle assy

135.0 (297.4)

Reduction gear case assy

40 (88.1)

Propeller shaft

10 (22)

Front differential axle assy

143 (315)

Tire assy

49 (108)

69 (152)

HYDRAULIC SYSTEM

3

Control valve assy

11 (24.2)

Steering controller assy

6.2 (13.6)

6.6 (14.5)

Lift cylinder

17 (37)

24 (53)

Tilt cylinder

18 (40)

26 (57)

Steering cylinder

10 (22)

15.0 (33.0)

Standard bucket (Coupler type)

149 (328)

224 (493)

Cutting edge

30 (66.1)

33 (72.7)

Tilt link assy

7.7 (16.9)

10.4 (22.9)

Tilt arm assy

33 (73)

28 (62)

149 (328)

224 (493)

Front frame

224 (493)

288 (634)

Rear frame

280 (616)

Center shaft

37 (81)

FRONT ATTACHMENT

4

Shovel frame assy MACHINE STRUCTURE

Bonnet

5

46 (101)

25 (55)

Seat assy

10 (22.0)

Rear fender

5 (11.0)

Counter weight

239 (256)

Canopy assy

100 (220)

Rops canopy roof

51.7 (114)

500 (1100)

Rops post (L)

22 (48)

Rops post (R)

22 (48)

Hydraulic oil tank

22 (48)

Step (L)

1.1 (2.4)

1.1 (2.4)

Step (R)

1.1 (2.4)

1.1 (2.4)

Cab (EU-version)

420 (924) 2-6

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[EU-version machine weight] Machine type

R420

Canopy

Weight 440

BH 780

R420

Cab

Weight 440

BH 780

R520

Canopy

Weight 960

BH 780

R520

Cab

Weight 960

BH 780

Weight

B.H.

Canopy

Cab

100

420

100

420

Machine weight

CE label

3380

3700

3980

4300

Catalog

3040

3380

3360

3700

2-7

3980

3800

4300

4120

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

Front pin, Front bush

&

.

.

F

&

9.4 42 #

mm (in.)

Reference pin dimensions

Reference bushing dimensions

Pin diameter D x Length L

Inside diameter D x Outside diameter d x Length L

R420S,

R520S,

R420S,

R520S,

(1)

45 x 144 (1.77 x 5.67)

45 x 55 x 65 (1.77 x 2.17 x 2.56)

(2)

40 x 145 (1.57 x 5.71)

40 x 50 x 75 (1.57 x 1.97 x 2.95)

(3)

40 x 145 (1.57 x 5.71)

(4)

40 x 117 (1.57 4.61)

40 x 50 x 50 (1.57 x 1.97 x 1.97)

(5)

40 x 117 (1.57 4.61)

40 x 50 x 50 (1.57 x 1.97 x 1.97)

(6)

35 x 96 (1.38 x 3.78)

40 x 107 (1.57 x 4.21)

35 x 45 x 43 (1.38 x 1.77 x 1.69)

40 x 50 x 52 (1.57 x 1.97 x 2.05)

(7)

35 x 143 (1.38 x 5.63)

40 x 146 (1.57 x 5.75)

35 x 45 x 43 (1.38 x 1.77 x 1.69)

40 x 50 x 50 (1.57 x 1.97 x 1.97)

(8)

50 x 211 (1.97 x 8.31)

50 x 60 x 30 (1.97 x 2.36 x 1.18)

(9)

40 x 117 (1.57 x 4.61)

40 x 50 x 50 (1.57 x 1.97 x 1.97)

40 x 50 x 50 (1.57 x 1.97 x 1.97)

(10)

35 x 96 (1.38 x 3.78)

---

---

(11)

35 x 110 (1.38 x 4.33)

35 x 45 x 45 (1.38 x 1.77 x 1.77)

40 x 50 x 50 (1.57 x 1.97 x 1.97)

Service limit

45 x 145 (1.77 x 5.71)

Up to -1.0 mm (-0.039 in.) of pin diameter

2-8

40 x 50 x 65 (1.57 x 1.97 x 2.56)

45 x 55 x 65 (1.77 x 2.17 x 2.56)

Up to +1.0 mm (+0.039 in.) of inside diameter

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

mm (in.)

R420S,

9.4 42 #

a

589 (23.2)

b

68 (2.68)

c

52 (2.05)

d

102 (4.02)

(A)

ø45 (1.77)

(B)

ø35 (1.38)

(C)

ø40 (1.57)

R520S,

(1) Front frame (2) Bushing

mm (in.)

R420S,

9.4 42 #

(3) Shovel frame (4) Shim (5) Bushing

(6) Bushing (7) Bushing (8) Dust seal

2-9

R520S,

e

65 (2.56)

f

972 (38.27)

1168 (45.98)

g

1880 (74.02)

2200 (86.61)

h

130 (5.12)

(D)

ø50 (1.97)

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

mm (in.)

R420S,

R520S,

i

520 (20.47)

580 (22.83)

j

466.7 (18.4)

450 (17.7)

k

128 (5.04)

l

400 (15.75)

m

75 (2.95)

(E)

ø40 (1.57)

500 (19.69)

9.4 42 #

(13) Bushing (14) Dust seal (15) Bushing (16) Shim

(9) Tilt arm (10) Bushing (11) Shim (12) Tilt link

mm (in.)

R420S,

9.4 42 #

(17) Shovel (18) Cutting edge

2-10

R520S,

n

1580 (62.20)

1690 (66.5)

o

125 (4.92)

150 (5.91)

p

16 (0.63)

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

Center Pins and Bushing

9.4 42 #

2-11

(1) Center pin (2) Bushing (3) Center shaft (4) Bushing (5) Dust seal (6) Thrust collar (7) O-ring (8) Thrust collar (9) Dust seal (10) Collar (11) Thrust collar (12) End plate (13) Plate spring (14) Bolt (15) Collar (16) Bushing

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

Unit: mm (inch) R420S,

R520S,

(1)

475 (10.7)

520 (20.4)

(2)

40 (1.57)

54 (2.13)

(3)

90 (3.54)

(4)

125 (4.92)

150 (5.91)

(5)

347 (13.66)

379 (14.92)

(6)

445 (17.52)

463 (18.23)

(7)

570 (22.44)

613 (24.13)

(8)

130 (5.12)

144 (5.67)

(9)

210 (8.29)

240 (9.45)

Section B-B

Unit: mm (inch) R420S,

R520S,

(A)

110 (4.33)

109 (4.29)

(B)

9 (0.35)

(C)

77 (3.03)

(D)

16.5 (0.65)

16 (0.63)

(E)

ø65 (2.56)

ø70 (2.76)

(F)

ø40 (1.57)

ø45 (1.77)

Section C-C

2-12

Unit: mm (inch) R420S,

R520S,

(A)

110 (4.33)

109 (4.29)

(B)

9 (0.35)

(C)

77 (3.03)

(D)

16.5 (0.65)

16 (0.63)

(E)

ø65 (2.56)

ø65 (2.76)

(F)

ø40 (1.57)

ø40 (1.77)

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[2] Installing the frame-related parts (front) Spanners 14, 17, 22, 27 and 37 Pin puller, Plastic hammer 1. Apply grease after installing each part.

2. Adjust each pin portion clearance with the shim to 1.0 mm or less.

3. The inclination of the bucket bottom should be 10mm or less when the bucket is in contact with the ground.

4. Adjusting the auto leveler.

A Adjust the auto leveler so that there is a clearance of 5 to 10 mm between the bar and the sensor section when the bucket bottom is in contact with the ground horizontally.

A The bucket should be horizontalize after the auto leveler works.

Clearance: 5 ~ 10 mm (0.20 ~ 0.40 inch)

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9.44##$2 #

(1) Sensor (auto leveler) (2) Bracket (auto leveler) (3) Bar (sensor)

2-13

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[3] Center pin (important functional component) [1] Removing and installing Spanners 10, 14, 17, 22 and 27, Long-nose pliers Jack 2, Crane Two plugs 1/2, Four plugs 3/8

A This work is very dangerous because the front frame and rear frame are separated. Be sure to comply strictly with the following.

A The jack and crane used for supporting the machine should be able to bear the weight and safe to use.

A The work should be performed carefully by at least three persons, who should give signals to one another for safety.

A It is advisable to place a slippery thing under the shovel bucket in order to make it easy to move the front frame forward after pulling out the center pin.

(In the photo shown to the left, a rubbercrawler-replacing jig is used.)

1. Disconnect the control cable.

Refer to Control valve 2. Remove the wire harness from the front frame.

A Remove the front cover.

3. Remove the propeller shaft.

Remove the propeller shaft on the front axle side.

A Tightening torque: 77.5 ~ 90.2 N-m (7.9 ~ 9.2 kgf-m) (Apply a screw-fixing compound.)

2-14

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

4. Disconnect the hoses.

A Disconnect the hydraulic hoses for the operating machine and steering equipment.

5. While supporting the rear frame at two places with jacks, raise the front frame with a garage jack or lift the shovel frame with a crane.

A Make sure that the jack is stable.

9.44##$2 #

6. Remove the end plate.

A Take care not to lose the collar and dust seal.

Installing the end plate 196 ~ 225 N-m (20 ~ 23 kgf-m) 145 ~166 ft-lbs

2-15

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

7. Remove the front frame.

A Do this work carefully so as not to allow the jack supporting the frame to be disengaged.

A Remove the front frame while rolling the right and left front tires at the same time.

Installing Move the frame while keeping it horizontal with a jack.

A After separating the frames.

8. Remove the dust seal, collar and O-ring.

(1) Dust seal (2) Collar (3) O-ring A When installing the frame, do not forget to attach the dust seal and collar.

2-16

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

A Component

A Take care not to lose the dust seal, collar and O-ring.

(6) Disc spring (7) Bolt (8) Shaft (9) Center pin

(1) Dust seal (2) Collar (3) O-ring (4) Collar (5) End plate

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9.44##$2 $

Unit: mm (inch) Outside diameter of shaft

Model

R420S R420

R520S R520

(mm)

110

(inch)

4.33

(mm)

130

(inch)

5.12

Recommended limit for replacement: Pin Bush

Inside diameter of rear frame bush

Outside diameter of center pin

Inside diameter of bush

110 +0.035 0

70 -0.05 -0.08

70 +0.20 +0.05

4.33 +0.0014 0

2.76 -0.002 -0.003

2.76 +0.008 +0.002

130 +0.035 -0.005

80 -0.05 -0.07

80 +0.20 +0.05

5.12 +0.0014 -0.0002

3.15 -0.002 -0.003

3.15 +0.08 +0.002

-0.5 mm (-0.02 inch) +1.0 mm (+0.04 inch)

2-17

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[4] Rear frame, center pin

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No.

Part name and section

Qty.

1.

Bolt

4

2.

Disc spring

4

3.

Plate (end)

1

4.

Bushing

1

5.

Grease nipple

1

6.

Grease nipple

1

7.

Hexagon socket bolt

4

8.

Cushion (frame)

2

9.

Grease nipple installation

---

10.

Shim

11.

Steering cylinder

1, 2

Remarks (A) M16 x 40L, 196 ~ 225 N-m (20 ~ 23 kgf-m) Apply a screw-fixing compound (locktite 271).

1/4 x 1/8

M12 x 25L, 27 ~ 29 N-m (2.8 ~ 3.0 kgf-m) Apply a screw-fixing compound (locktite 271).

Install the grease nipple at an angle of 45 degrees.

The clearance should be 1.0 mm or less.

(If the clearance is more than 1.0 mm, rattling noise will be caused.)

1

12.

2-18

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[5] Assembly drawing of the control levers

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Standard value

M6 bolt

(3) (11) Bolt tightening torque

9.8 ~ 11.3 N-m (1.0 ~ 1.15 kgf-m)

M8 bolt

(9) Bolt tightening torque

23.5 ~ 27.5 N-m (2.4 ~ 2.8 kgf-m)

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2-19

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[6] Installing the control levers Spanners 10, 14 and 22, Long-nose pliers

2-20

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

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Sample: without service port (1) Grommet (2) Label (black) (3) Base (valve) (4) Cable (control) (5) Crimp (6) The protective tube should be installed so that the crimped portion is located on the c/v side.

(7) Should be adjusted so that the detent works without fail.

(8) Lever grip (9) Lever (1, operation) (10) Taping (11) Should be crimped after the wiring is passed.

(12) Terminal 2 assembly

2-21

(13) Terminal 1 assembly (14) Tube (Should be taped so as not to be dislocated.)

(15) Cable for lifting (16) Cable for tilting (17) Lock lever: The neutral status should be maintained when the lever is locked.

When removing the fuse box, relay, etc., disconnect the (-) battery terminal.

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[7] Assembly drawing of accelerator and brake

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No.

Part name

Qty 1

Cautions SS400

No. 23

Part name Rubber cap

Qty

1

Bracket (brake)

2

Bush

1

DU

24

Switch (PTO)

1

3

Bush

1

DU

25

Pedal cover

2

4

Bush

2

DU

26

Push rod

1

5

Bolt

1

M8 x 35L 7T

27

Nut

1

6

Nut

1

M8 7T

28

Cylinder assembly

1

7

Pedal (brake L)

1

SS440

29

Bolt

4

8

Pedal (brake R)

1

30

Cable

1

Cautions

1

M8 4T M8 x 20L 7T

9

External snap ring

1

31

Snap pin

2

SN-C

10

Spring

1

32

Snap pin

1

SN-C

11

Link (brake)

1

33

Cable (accelerator)

1

12

Bush

2

34

Missing number

13

Stopper

1

35

Missing number

14

Arm (brake)

1

15

Yoke

16 17 18

DU SS400

36

Pedal (accel)

1

1

37

Headed pin

1

Headed pin

1

38

Missing number

Cotter pin

1

39

Missing number

Pedal

1

40

Snap pin

1

SM-C

19

Bolt

1

41

Pedal rubber

1

A610

20

Link

1

42

Roller (accelerator)

1

POM

21

Spring pin

1

43

Flat washer

2

22

Spring

1

44

Cotter pin

1

SS400

2-22

SS400

SMAM10

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

2-23

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

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(1) Link (brake) (2) Arm (brake) (3) Switch (PTO) Pushing-in tip: 3 0.5 mm If the pushing-in tip is large, the switch will be damaged.

If the pushing-in tip is small, the stop lamp will not go on.

(4) Push rod Clearance between link (brake) and arm (brake): 8 ~ 10 mm If the clearance is large, the brake will take hold late.

If the clearance is small, the brake will take hold too early to cause seizing up of the brake plate.

(5) Cylinder assembly (master) (6) Bracket (brake) (7) First braking (8) Braking area (9) Inching area (10) Pedal (brake, L)

(11) Inching closed (play) (12) Inching area (13) Inching open (14) Cable (inching) Cable protrusion (portion A in drawing): 1 ~ 2 mm The machine should not move during idling.

If the protrusion is too large, the cable will reach the stroke end as soon as the pedal is pressed.

Vehicle starting revolution: 1150 100 rpm (Oil temperature: 50 5 ) If the vehicle starting revolution is high, the movement will be felt to be slow. If the vehicle starting revolution is low, the machine will move when the forward/reverse lever is operated during idling.

(15) Snap pin (16) Bracket assembly (inching) (17) Snap pin (18) Rod assembly (inching) (19) Not adjusted (20) LST Pump side

2-24

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[8] Installing the brake and inching-related parts Ô™ Ô˜

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(1) Pedal (brake L) (2) Spline section Portion A Adjust the spline section so that the right and left pedals are aligned.

(3) Pedal (brake R) (4) Link (brake) Install the link (brake) so that it is placed 90 degrees (portion B) from the pedal (brake).

(5) Pedal (brake R) (6) Pipe (1, brake) Leave a clearance of 10 mm or more between another part and it.

(7) Cable (inching) Install the cable according to the dimension shown in portion C. (8) Arm (brake) (9) Should strike against the stopper.

2-25

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

1. This component should be an equivalent to 47200-1700 manufactured by Aisin Seiki Co., Ltd. The oil to be used should be Daphne Super Hydraulic Fluid 32 Mataha 46 (Idemitsu Kosan).

2. The maximum allowable working pressure should be 150 kg/ .

3. This component differs from 68811-32202 only in union installing angle.

(1) A diameter of the compensating port

(2) Stroke

(3) Port idle

Component list No.

Aisin part name

Material

Qty.

1

Union

2

Piston, Master cylinder

A5056 BD-H12

1

3

Boot, Master cylinder

CR

1

4

Cup, Cylinder

NBR

1

5

Ring, Snap

SK5M

1

6

Bolt, Union

S45C

1

7

Gasket

TCUP1-0

2

1

8

Spacer, Master cylinder, Piston cup

SK5M

1

9

Cup, Cylinder

NBR

1

10

Retainer, Piston return spring

Polyacetal resin

1

11

Ring, Shaft snap

SK5M

1

12

Spring, Conical

SWPA

1

13

Body, Master cylinder

FC20

1

2-26

(4) Apply silicon grease on this part.

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[9] Installing the accelerator-related parts Spanners 10, 12 and Long-nose pliers

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(1) Split port The spring driving direction should be such that the splitting direction is perpendicular to the shaft. If the installing direction is wrong, the spring pin will come off.

(2) Shaft center (3) Shaft (accelerator) (4) Link (accelerator) (5) Accelerator pedal Portion C At idling: 140 mm, At maximum no-load speed: 115 mm (6) The upper part should be passed through. The lower part is for fixed acceleration.

(7) Cable (accelerator) Install the cable so that the dimension of portion C is 15 mm.

Idling speed: 980 ~ 1050 rpm No abnormal rattling noise should be caused.

Travelling should not be started.

Rated speed: 2400 rpm Maximum no-load speed: 2600 rpm (8) Accelerator pedal The pedal-side clearance (portion D) should be 0.5 mm or less when the engine-side governor lever is in contact with the stopper.

(9) 0.5 mm or less (10) Engine side

2-27

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[10]Installing the seat Spanner 12

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(1) Seat assembly 4 post canopy and Rops/Fops Cab: Seat belt provided The seat should slide smoothly and can be fixed securely.

(2) Hood (3) Frame (hood) (4) Flange nut (four) M8

2-28

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[11]Fender Spanners 14 and 36 㧔(KI #㧕

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(1) Fender (L) (2) Two cushions (pedal) (3) Cover (4) Hinge (5) Bolt M10 x 20L (6) Lock assembly (cylinder) After installing it, check that locking and unlocking can be performed securely (7) Adjusting shim 0.5 (8) Lever (9) Flat washer (10) Flat washer (11) Spring washer (12) Nut Tightening torque: 9.8 N-m (1.0 kgf-m) (13) Cushion (14) Mud guard Should be placed on the stay.

(15) Bolt flat washer M10 x 25L (16) Should be placed on the stay.

9.44##$2 #

2-29

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R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[12]Installing the canopy Spanners 14 and 22 Ԙ

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(1) Canopy roof (2) Bolts (eight) M10 x 25L Tightening torque: 48 ~ 55 N-m (4.9 ~ 5.7 kgf-m) (3) Post (right) (4) Post (left) (5) Post fastening bolts (eight) M16 x 35L Tightening torque: 196 ~ 225 N-m (20 ~ 23 kgf-m) 145 ~ 166 ft-lbs (6) Label (7) Rear frame

2-30

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[13]Cabin

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No.

Part name

Qty.

No.

Part name

Qty.

1

Cabin weight

9

Flat washer

2

Front installation position

10

Bolt

M10 x 45L Tightening torque: 23.5 ~ 27.5 N-m (2.4 ~ 2.8 kgf-m)

3

Front installation position

11

Nut

M10 Tightening torque: 23.5 ~ 27.5 N-m (2.4 ~ 2.8 kgf-m)

4

Rear installation position

12

Cabin

5

Cabin

13

Cushion

6

Cushion

14

Rear frame

7

Brake bracket

15

Turn lock nut

M16 x 1.5P Tightening torque: 77.5 ~ 90.2 N-m (7.9 ~ 9.2 kgf-m)

8

Bolt

16

Label

Attach the label.

Outside only

M10 x 40L Tightening torque: 23.5 ~ 27.5 N-m (2.4 ~ 2.8 kgf-m)

2

2-31

R420S( ), R520S( ), WSM

2. Machine Body & Front Attachment

[14]Heater hose

No.

Part name

Qty.

No.

Part name

Qty.

1

Body front

---

9

Adapter

PT1/2 x PT1/2

2

Cabin

---

10

Hose clamp

Innerspring

1

3

Grommet

2

11

Joint

Pipe, Water OUT R3/8

1

4

Tube protector

1

12

Hose clamp

Innerspring

1

5

Heater hose

1

13

Pipe joint

S, 13.8 13.8 x t2.3

1

6

Hose clamp

1

14

Hose clamp

Innerspring

2

7

Bolt

M8 x 20L

1

15

Cord band

R420D

1

8

Valve

PT1/2

1

16

Valve

Turbo specification

1

2-32

1

CONTENTS 3.

[1] [2] [3]

Engine ...............................................................................................................................3-1 Specifications ..................................................................................................................3-1 Engine assy dismounting ................................................................................................3-2 Engine accessories .........................................................................................................3-7 (1) Engine rubber mount ..............................................................................................3-7 (2) Radiator, oil cooler ..................................................................................................3-9 (3) Air cleaner.............................................................................................................3-10 (4) Muffler ...................................................................................................................3-12 (5) Fuel hose route (S) ...............................................................................................3-13 (6) Engine oil drain hose ............................................................................................3-14 [4] New emissions control engines .....................................................................................3-15 (1) Outline...................................................................................................................3-15 (2) Engine list for minor change .................................................................................3-16 (3) Major engine specification for Tier 4 / Interim Tier 4 Engine.................................3-17 (4) Performance curve................................................................................................3-18 (5) New engine structure ............................................................................................3-23 (6) Boost compensator and governor.........................................................................3-24 [5] Turbo-charger................................................................................................................3-27 (1) Specifications .......................................................................................................3-27 (2) Structure ...............................................................................................................3-28 (3) Installation of turbo-charger ..................................................................................3-33 (4) Turbo charger system ...........................................................................................3-34 (5) Disassembling / Assembling ................................................................................3-39 (6) Tightening torque ..................................................................................................3-42 (7) Trouble diagnosis..................................................................................................3-42 (8) Servicing reference table ......................................................................................3-42 (9) Checking ...............................................................................................................3-43

R420S( ), R520S( ), WSM

3. Engine

3. Engine [1] Specifications R420S,

R520S,

Model

D1503-M-T-E2RP-1

V2203-M-E2RP

Type

Vertical, water-cooled, 4-cycle diesel engine, 3-cylinder with turbo-charger

Vertical, water-cooled, 4-cycle diesel engine, 4-cylinder

Bore x stroke, displacement

83 x 92.4 mm (3.3 x 3.6 in.)

1.499 L (0.4 usgal)

87 x 92.4 mm (3.4 x 3.6 in.)

2.197 L (0.6 usgal)

Output (SAE J1349 Gross)

32.1 kW (43.0 HP) / 2600 rpm

36.6 kW (49.0 HP) / 2600 rpm

Output (DIN 70020)

29.0 kW (39.5 ps) / 2600 rpm

32.6 kW (44.3 ps) / 2600 rpm

No-load maximum speed

rpm

2800 or less

No-load minimum speed

rpm

1000 ~ 1050

Combustion chamber

E-TVCS

Fuel injection pump

PFR3M

Governor

Centrifugal ball mechanical governor Certrifugal ball mechanical governor

Injection nozzle Fuel injection timing

PFR4M

deg

OPD mini-nozzle

OPD mini-nozzle

B. T. D. C17 ~ 19

B. T. D. C17 ~ 19

Injection pressure

13.7 ~ 14.7 MPa (140 ~ 150 ) (1991 ~ 2133 psi)

Compression ratio

22

23

Water-cooled radiator system (Forced circulation by cooling water pump)

Water-cooled radiator system (Forced circulation by cooling water pump) Cell motor system (12V 2.0 kW)

Cooling system Starting system

V, kW

Cell motor system (12V 1.4 kW)

Charging system

V, W

Alternator system (12V 720W)

Applicable fuel

Diesel gas oil or Kubota diesel oil

Diesel gas oil or Kubota diesel oil

CD1 or above Ambient temperature at 15 or above: D30 super or D10W-30 super Ambient temperature at below 15 : D10W-30 super

CD1 or above Ambient temperature at 15 or above: D30 super or D10W-30 super Ambient temperature at below 15 : D10W-30 super

kg

152 kg (330.7 lbs)

180 k (396.8 lbs)

V, AH

12V x 55 AH (80D-26R)

Applicable lubricating oil

Dry weight Applicable battery

3-1

R420S( ), R520S( ), WSM

3. Engine

[2] Engine assy dismounting 1. Overview of engine room.

2. Remove muffler pipe flange bolts.

3. Disconnect fuel hoses.

4. Pull off harness coupler of engine oil pressure switch.

3-2

R420S( ), R520S( ), WSM

3. Engine

5. Disconnect radiator hose.

6. Remove muffler mounting bolts and leave the muffler assy down.

7. Dismount the engine bonnet and rear cover.

8. Dismount the radiator assy.

9. Loosen engine bracket bolts.

3-3

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