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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9.44##$2 #
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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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