WORKSHOP MANUAL

DUMPER

KC100HD
 CONTENTS

MECHANISM
1. SPECIFICATIONS
2. DIMENSIONS
3. ENGINE
4. TRANSMISSION
5. HYDRAULIC SYSTEM (HST)
6. HYDRAULIC SYSTEM (DUMPING)
7. FUEL SYSTEM
8. V-BELT
9. WIRING DIAGRAM

SERVICING
1. TIGHTENING TORQUE
2. OILS AND FUEL
3. GREASING
4. CAUTION FOR DISASSEMBLING AND REASSEMBLING
5. ADJUSTMENT OF COMPONENT PARTS
6. TESTING OF PRESSURE (HST)
7. REPLACEMENT OF WEAR OUT PARTS
8. TROUBLESHOOTING AND COUNTERMEASURES
9. MAINTENANCE INTERVALS

1
MECHANISM
1. SPECIFICATIONS
2. DIMENSIONS
3. ENGINE
4. TRANSMISSION
5. HYDRAULIC SYSTEM (HST)
6. HYDRAULIC SYSTEM (DUMPING)
7. FUEL SYSTEM
8. V-BELT
9. WIRING DIAGRAM

2
1. SPECIFICATIONS
Model KC100HD
Machine weight (kg) 885
Max. loading capacity (kg) 1200
Engine Model KUBOTA Z482-E3B-CRYM-1
Type Vertical 4-cycle Liquid-Cooled Diesel
No. of cylinder 2
Bore and Stroke (mm) 67 x 68
Total Displacement (cc) 479
Output (KW/rpm) 8.3/3000
Starting system Electric
Dimensions Length (mm) 2640
Width (mm) 950
Height (mm) 2015
Min. ground clearance (mm) 145
Track center-to-center distance (mm) 720
Bed Length (mm) 1470
Width (mm) 855
Height (mm) 320
Capacity Struck / Heaped ( ) 400 / 520
Undercarriage Crawler type Rubber track
Number of drive sprocket teeth 7
Crawler pitch (mm) 72
Track width (mm) 230
Number of track rollers 6 (one side)
Ground contact length (mm) 1180
Gradeability (° ) 25
Alignment Screw type with spring
Ground contact pressure w/o load (kgf/cm2) 0.17
Ground contact pressure w/t load (kgf/cm ) 2
0.4
Max. traction power (kgf) 1040
Transmission Type HST + Gear shift type transmission
Travelling speed 1st (km/h) 0 - 3.2 / 0 - 2.1
(Forward / Reverse) 2nd (km/h) 0 - 5.8 / 0 - 3.9
Main clutch Belt tension
Steering clutch Tooth clutch
Steering brake Wet multi-plate type
Parking brake Wet multi-plate type
Dumping performance Dumping type Hydraulic
Dumping direction Front / Right side / Left side
Max. Dumping angle (° ) 56 / 60 / 60
Raising time (at 3000rpm) (sec) 7.1
Lowering time (at 30900rpm) (sec) 4.0
Capacity Fuel tank ( ) 14.8
Hydraulic oil tank ( ) 1.5
Engine oil ( ) 2.55
Coolant ( ) Approx. 2.8
HST oil ( ) 13.0
Transmission oil (main / sub) ( ) 3.1 / 0.45

3
4
2. DIMENSIONS
3. ENGINE
Model : Z482-E3B-CRYM-1 / Code No : 1G317-51000
See the WSM / DIESEL ENGINE SM-E3B SERIES
Hard Copy - Code No 9Y121-00132
CD-ROM - Code No 9Y131-00132

Specifications
Model Z482-E3B Z602-E3B
Number of Cylinders 2
Type Vertical, Water-cooled, 4 cycle IDI diesel engine
Bore×Stroke 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.)
Total Displacement 479.0 cm3 (29.23 cu.in.) 599.0 cm3 (36.55 cu.in.)
8.10 kW / 3600 min-1 (rpm) 10.1 kW / 3600 min-1 ( rpm)
ISO Net Continuous
(10.9 HP / 3600 min-1 (rpm)) (13.5 HP / 3600 min-1 (rpm))
9.30 kW / 3600 min-1 (rpm) 11.6 kW / 3600 min-1 ( rpm)
ISO/SAE Net Intermittent -
(12.5 HP / 3600 min (rpm)) 1
(15.5 HP / 3600 min-1 (rpm))
9.90 kW / 3600 min (rpm)- 1
12.5 kW / 3600 min-1 ( rpm)
SAE Gross Intermittent
(13.3 HP / 3600 min-1 (rpm)) (16.8 HP / 3600 min-1 (rpm))
Maximum Bare Speed 3800 min-1 (rpm)
Minimum Bare Idling Speed 900 to 1000 min-1 (rpm)
Combustion Chamber Spherical type (E-TVCS)
Fuel Injection Pump Bosch MD type mini pump
Governor All speed mechanical governor
Direction of Rotation Counter-clockwise (viewed from flywheel side)
Injection Nozzle Bosch “Throttle” type
Injection Timing 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C.
Firing Order 1-2
Injection Pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)
Compression Ratio 23.5 : 1 24 : 1
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical Type Switch
Lubricating Filter Full flow paper filter (Cartridge type)
Cooling System Pressurized radiator, forced circulation with water pump (not included in the basic engine)
Starting System Electric starting with starter
Starting Motor 12V, 0.8kW 12V, 1.0kW
Starting Support Device By glow plug in combustion chamber
EGR None
Battery 12V, 28 AH equivalent 12V, 36 AH equivalent
Charging Alternator 12V, 150W 12V, 480W
Fuel Diesel Fuel No.2-D (ASTM D975)
Class CF lubricating oil as per API classification is recommended.
Lubricating Oil
For details on recommended lubricating oils, see page G-6, 9
Oil Pan Depth
2.1 L (0.55 U.S.gals) 2.5 L (0.66 U.S.gals)
Lubricating Oil 101 mm (3.98 in.)
Capacity Oil Pan Depth
2.5 L (0.66 U.S.gals) –
121 mm (4.76 in.)
Weight (Dry) kg(lbs) 53.1 (117) 60.0 (132)
* The specification described above is of the standard engine of each model.
* Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW
W10336300

5
Performance curves
• Z482-E3B

3EEACABEP001A

(1) Brake Horsepower (6) Net Intermittent Torque (11) Net Intermittent B.S.F.C. (15) Gross B.H.P.
(2) Engine Speed (7) Net Continuous Torque (12) Gross Torque (16) Overload B.H.P.
(3) B.S.F.C. (8) Gross Intermittent B.H.P. (13) Overload Torque (17) Continuous B.H.P.
(4) Torque (9) Net Intermittent B.H.P. (14) Continuous Torque (18) Overload B.S.F.C.
(5) Gross Intermittent Torque (10) Net Continuous B.H.P.

Fuel consumption
Fuel consumption KC100HD
Fuel consumption(L/h)

Work load factor (%)

6
Dimension
• Z482-E3B
Uni : mm (in.)

3EEACABFP001A

Uni : mm (in.)

3EEACABFP002A

7
8
4. TRANSMISSION
[POWER TRAIN]

[GEARING]

[GEAR RATIO]

A HST E CLUTCH GEAR

B Hight (H) F BRAKE (STEERING/PARKING)
C Low (L) G OUTPUT SHAFT
D INPUT SHAFT
5. HYDRAULIC SYSTEM (HST)
HST unit

1 Housing
2 Cover
3 Hanger
4 Input shaft
5 Output shaft
6 Block, cylinder
Hydraulic pump : 0 ~ 18.2 cm3 7 Piston
Hydraulic motor : 18.2 cm3 8 Case, charge pump
Charge pump : 5.1cm3 9 Relief valve (Low pressure)
10 Relief valve (High pressure)
Relief valve set pressure : 18.5MPa+2.9MPa
11 Neutral valve (Backward)
Charge pressure : 5.0 kgf/cm2
12 Neutral valve (Forward)
13 Drain port
Pressure check port ( PF3/8 ) 14 Suction port
Suction port (PF1/2) [charge pump] 15 Pressure check port (Forward)
Discharge port (PF3/8) [charge pump] 16 Pressure check port (Backward)

E/G

B C
A D

T/M

C
B

A Pump (Adjustable)
B Piston
C Cylinder
D Flow of oil

9
Mechanism of drive pedal

K10H-D010

Flow of HST oil

E Oil cooler
F Oil filter cartridge K10H-D004

G HST oil tank

10
6. HYDRAULIC SYSTEM (DUMPING)
Hydraulic pump

Hydraulic pump : K82R

(Part no 89956-1559-0)
Discharge volume : 3cc/rev
Revolution : 500 ~ 2000rpm
Relief valve set pressure : 140+5/kgf/cm2 (13.7+0.5MPa)
(at 1800rpm)
Tank capacity : 1.6 ℓ
Pulley size (pump) : Dia 101.6mm
(Part no 89956-1298-0)
Pulley size (engine) : Dia 76.2mm
(Part no 89920-1157-0)

Flow of hydraulic oil

A B

K70E-U002
A Pull-Down port
B Push-up port

11
Hydraulic hose / Hydraulic cylinder

K10H-D002

1 : Hydraulic cylinder (Part no 89950-1154-0 / 1 pce)

Pressure : 170kgf/cm2 (16.7MPa)
Stroke : 300mm
2 : Hydraulic pump (Part no 89956-1559-0 / 1 pce)
3 : Hydraulic hose (Part no 89957-1233-0 / 2 pcs)
Length : 3000mm
4 : Elbow (Part no 89910-1188-0 / 2 pcs)
5 : Hose adapter with O-ring (Part no 89910-1189-0 / 2 pcs)
6 : Cylinder pin (Part no 89954-1159-0 / 2 pce)
7 : Cir-clip (E) (Part no 04613-00150 / 4 pcs)
8 : Vinyl tube (Part no 89957-1234-0 / 2 pcs)

12
7. FUEL SYSTEM
Fuel tank / Fuel hose

1) Fuel hose (Fuel tank ~ Fuel filter) Size : L : 1400mm x 1 pce / 09661-7140-0 / 1
Clip x 2pcs - Part no 14911-4275-0 / 4
Tube x 1pce - part no 89920-1265-0 / 7
2) Fuel hose (Fuel filter ~ Injection pump) Size : L : 750mm x 1 pce / 09661-7075-0 / 2
Clip x 2pcs - Part no 14911-4275-0 / 5
Tube x 1pce - part no 89920-1264-0 / 8
3) Fuel hose (Nozzle holder ~ Fuel tank) Size : L : 1150mm x 1 pce / 09661-4115-0 / 3
Clip x 2pcs - part no 14971-4275-0 / 6

K10H-D003

13
8. V-BELT
Size of V-belt

1) V-belt (Engine pulley ~ HST pulley)

Size : SC64 (Cog belt) x 1 pce / Part no 89920-1170-0
2) V-belt (Engine pulley ~ Hydraulic pump pulley)
Size : SB29 x 1 pce / Part no 89920-1175-0
3) Engine pulley
Part no 89920-1157-0
4) HST pulley
Part no 89920-1165-0

14
 9. WIRING DIAGRAM
Cord color
B Black
Br Brown
G Green
Ⓢ Ⓣ L Blue
P Pink
R Red
SB Sky blue
W White
Ⓡ Y Yellow
BL Black / Blue
BW Black / White
GB Green / Black
Ⓠ LB Blue / Black
PB Pink / Black
RW Red / White
WB Red / White
YB Yellow / Black
BR Black / Red

Ⓟ
Ⓐ Starter
Ⓑ Safety switch
Ⓒ Glow plug
Ⓓ Alternator
Ⓔ Regulator
Ⓕ Alarm lamp “Battery
Ⓘ Ⓙ Ⓛ Ⓝ charge”
Ⓞ Ⓔ Ⓖ Ⓖ Solenoid timer
Ⓗ Solenoid
Ⓠ Ⓘ Hour meter
Ⓙ Alarm lamp “Engine
oil pressure”
Ⓚ Oil switch
Ⓛ Horn
Ⓜ Horn switch
Ⓓ Ⓝ Electrical socket
Ⓕ Ⓞ Glow timer
Ⓟ Indicator lamp
Ⓠ “Glow”
Ⓐ Ⓑ Ⓒ Ⓒ Ⓗ Ⓚ Ⓜ Relay
Ⓡ Key switch
Ⓢ Fuse arrangement
Ⓣ Connector terminal
arrangement

15
SERVICING
1. TIGHTENING TORQUE
2. OILS AND FUEL
3. GREASING
4. CAUTION FOR DISASSEMBLING AND REASSEMBLING
5. ADJUSTMENT OF COMPONENT PARTS
6. TESTING OF PRESSURE (HST)
7. REPLACEMENT OF WEAR OUT PARTS
8. TROUBLESHOOTING AND COUNTERMEASURES
9. MAINTENANCE INTERVALS

16
1. TIGHTENING TORQUE
1) GENERAL BOLTS AND NUTS

Bolt torque
Material Grade Standard Bolt Special Bolt Special Bolt
Nominal Dia. SS41, S20C S43C, S487C (Refined) SCR3, SCM3 (Refined)
7.8 - 9.3 N.m 9.8 - 11.3 N.m 12.3 - 14.2 N.m
M6 0.80 - 0.95 kgf-m 1.00 - 1.15 kgf-m 1.25 - 1.45 kgf-m
5.8 - 6.9 lb.ft. 7.2 - 8.3 lb.ft. 9.0 - 10.5 lb.ft.
17.7 - 20.6 N.m 23.5 - 27.5 N.m 29.4 - 34.3 N.m
M8 1.80 - 2.10 kgf-m 2.40 - 2.80 kgf-m 3.00 - 3.50 kgf-m
13.0 - 15.2 lb.ft. 17.4 - 20.3 lb.ft. 21.7 - 25.3 lb.ft.
39.2 - 45.1 N.m 48.0 - 55.9 N.m 60.8 - 70.6 N.m
M10 4.00 - 4.60 kgf-m 4.90 - 5.70 kgf-m 6.20 - 7.20 kgf-m
28.9 - 33.3 lb.ft. 35.4 - 41.2 lb.ft. 44.8 - 52.1 lb.ft.
62.8 - 72.6 N.m 77.5 - 90.2 N.m 103.0 - 117.7 N.m
M12 6.40 - 7.40 kgf-m 7.90 - 9.20 kgf-m 10.50 - 12.00 kgf-m
46.3 - 53.5 lb.ft. 57.1 - 66.5 lb.ft. 75.9 - 86.8 lb.ft.
107.9 - 125.5 N.m 123.6 - 147.1 N.m 166.7 - 196.1 N.m
M14 11.00 - 12.80 kgf-m 12.60 - 15.00 kgf-m 17.00 - 20.00 kgf-m
79.6 - 92.6 lb.ft. 91.1 - 108.5 lb.ft. 123.0 - 144.7 lb.ft.
166.7 - 191.2 N.m 196.1 - 225.5 N.m 259.9 - 304.0 N.m
M16 17.00 - 19.50 kgf-m 20.00 - 23.00 kgf-m 26.50 - 31.00 kgf-m
123.0 - 141.0 lb.ft. 144.7 - 166.4 lb.ft. 191.7 - 224.2 lb.ft.
245.2 - 284.4 N.m 274.6 - 318.7 N.m 343.2 - 402.0 N.m
M18 25.00 - 29.00 kgf-m 28.00 - 32.50 kgf-m 35.00 - 41.00 kgf-m
180.0 - 209.8 lb.ft. 202.5 - 235.1 lb.ft. 253.2 - 296.5 lb.ft.
333.4 - 392.2 N.m 367.7 - 431.5 N.m 490.3 - 568.7 N.m
M20 34.00 - 40.00 kgf-m 37.50 - 44.00 kgf-m 50.00 - 58.00 kgf-m
245.9 - 289.3 lb.ft. 271.2 - 318.2 lb.ft. 361.6 - 419.5 lb.ft.

Bolt material grades are shown

by numbers punched on the bolt
heads. Prior to tightening, be
sure to check out the numbers as
shown below.

Punched Bolt Material

Number Grade
Standard Bolts SS41,
None
S20C
Standard Bolts SS43,
7
S48C (Refined)
Special Bolts SCR3,
9
SCM3 (Refined)

17
2) Crawler adjusting bolt : 215 ~ 225kgf . cm (21.1N . m ~ 22.1N . m)

1 : Adjusting bolt (Part no 89954-1205-0)

2 : Snap pin (Part no 89910-1289-0)
3 : Stopper (Part no 89950-1372-0)

3) Hose adapter for hydraulic pump : 200 ~ 240kgf . cm (19.6N . m~23.5N . m)

4) Transmission
4-1 Brake case [BOLT] : 220 ~ 280kgf . cm (21.6N . m ~ 27.4N . m)

18
4-2 Brake case [BOLT] : 300 ~ 350kgf . cm (29.4N . m ~ 34.3N . m)

K10H-D013

4-3 Brake case cover [BOLT] : 220 ~ 280kgf . cm (21.6N . m ~ 27.4N . m)

4-4 Transmission case [NUT] : 400 ~ 450kgf . cm (39.2N . m ~ 44.1N . m)

4-5 Transmission case [NUT] : 120 ~ 170kgf . cm (11.8N . m ~ 16.7N . m)

19
 4-6 Axle pipe [BOLT] : 400 ~ 450kgf . cm (39.2N . m ~ 44.1N . m)

4-7 Brake joint [NUT] : 120 ~ 170kgf . cm (11.8N . m ~ 16.7N . m)

4-8 Shift lever comp [NUT] : 120 ~ 170kgf . cm (11.8N . m ~ 16.7N . m)

4-9 Plug [PT1/8] : 40 ~ 50kgf . cm (3.9N . m ~ 4.9N . m)

20
 4-10 Shifter support [BOLT] : 100 ~ 120kgf . cm (9.8N . m ~ 11.8N . m)

5) ENGINE PULLEY MOUTING BOLT : 440 ~ 480kgf . cm (43.2N . m ~ 47.0N . m)

(M10 x 55)

6) ENGINE MOUTING BOLT : 460 ~ 500kgf . cm (45.1N . m ~ 49.1N . m)

(M10 x 25)

K10H-D005

7) CUSHION : 445 ~ 455kgf . cm (43.7N . m ~ 44.6N . m)

K10H-D006

21
8) BOLT FOR HST NEUTRAL LEVER : 280 ~ 300kgf . cm (27.5N . m ~ 29.4N . m)
(M8 x 55)

K10H-D007

9) HST
9-1 Cover

1 Cover
2 Relief valve (Low pressure)
3 Relief valve (High pressure)
4 Neutral valve
8 Pin
9 Bolt
10 Bolt
11 Plug
12 Plug
16 Control plate (Pump)
17 Control plate (Motor)
18 Screw
(Apply the screw locking bond to screws)

22
 9-2 Relief valve [High pressure]

1 Poppet
2 Spring
3 Barrel
4 Plug
5 O-ring
6 Shim 13.5 x 22 x 1.0
7 Shim 13.5 x 22 x 0.7
8 Shim 13.5 x 22 x 0.5
9 Shim 13.5 x 22 x 0.3
10 Plug

10) ROPS
[M10 x 20 / 10.9T - 6 pcs, M12 x 20 / 10.9T - 8 pcs]

[M10 x 20 / 10.9T - 6 pcs / Approx. 640kgf . cm (62.6N . m)]

[M12 x 20 / 10.9T - 8 pcs / Approx. 1100kgf . cm (109N . m)]

23
2. OILS AND FUEL
1) TRANSMISSION OIL
Type of oil Quantity
Main Automatic transmission fluid (ATF) [DEXRON] 3.1L
Sub Automatic transmission fluid (ATF) [DEXRON] 0.45L

1 Oil port (main)

3
2 Oil port (sub)
3 Drain plug

2) HYDRAULIC PUMP OIL

Type of oil Viscosity Quantity
Shell Tellus T46 or
Hydraulic oil ISO46 1.5
equivalent oil
NOTE
Total capacity of hydraulic pump oil with new cylinder and hoses : Approx. 1.9L.
Proper oil level A : Approx. 50mm / distance from oil port
(Hydraulic cylinder completed contacted)

K70E-U007

4 Oil port
4 5 5 Drain plug
24
3) HST OIL
Type of oil Viscosity Quantity
Shell Tellus T46 or
Hydraulic oil ISO46 13
equivalent oil

5
6

7
5 Tank cap
6 Drain plug
7 Drain port

IMPORTANT
If HST oil is filled to HST unit first, add the HST oil (approx. 1.5L)
through drain port of HST unit.
Shell Mobil
Transmission oil
Super ATF Mobil ATF
(Automatic transmission fluid / ATF)
HST oil Mobil DTE-Oil 15
Shell Tellus T46
(Hydraulic oil / ISO : 46)
Hydraulic pump oil Mobil DTE-Oil 15
Shell Tellus T46
(Hydraulic oil / ISO : 46)
New machine is used Shell oil.

25
4) ENGINE OIL
[Engine oil quantity : 2.55 L]
Temperature Type of oil
SAE30 or SAE10W-30
Above 25˚C
SAE10W-40
SAE20 or SAE10W-30
0˚C to 25˚C
SAE10W-40
SAE10 or SAE10W-30
Below 0˚C
SAE10W-40

NOTE
Engine Oil :
• Refer to the following table for the suitable American Petroleum Institute (API)
classification of engine oil according to the engine type (with internal EGR, external EGR
or non-EGR) and the Fuel Type Used :
(Low Sulfur, Ultra Low Sulfur or High Sulfur Fuels).
Engine oil classification (API classification)
Fuel Type Engines with non-EGR
Engines with external EGR
Engines with internal EGR

CF
High Sulfur Fuel
(If the "CF-4, CG-4, CH-4, or CI-4" engine
[0.05 % (500 ppm) ≤
oil is used with a high-sulfur fuel, change -
Sulfur Content <
the engine oil at shorter intervals.
0.50 % (5000 ppm)]
(approximately half))

Low Sulfur Fuel

CF or CI-4
[Sulfur Content <
(Class CF-4, CG-4 and CH-4
0.05 % (500 ppm)] or
CF, CF-4, CG-4, CH-4 or CI-4 engine oils
Ultra Low Sulfur Fuel
cannot be used on EGR type
[Sulfur Content <
engines.)
0.0015 % (15 ppm)]

EGR : Exhaust Gas Re-circulation

W1024941
• CJ-4 classification oil is intended for use in engines equipped with DPF (Diesel Particulate
Filter) and is
Not Recommended for use in Kubota E3 specification engines.
• Oil used in the engine should have API classification and Proper SAE Engine Oil Viscosity
according to the ambient temperatures where the engine is operated.
• With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils
have been developed for use with low sulfur fuels, for On-Highway vehicle engines.
When a Non-Road engine runs on high sulfur fuel, it is advisable to use a "CF or better"
26
 classification engine oil with a high Total Base Number
(a minimum TBN of 10 is recommended).

5) FUEL
Type Capatity
over -5˚, use No.2-D diesel fuel 14.8 L

NOTE
Fuel :
• Cetane Rating : The minimum recommended Fuel Cetane Rating is 45. A cetane rating
greater than 50 ispreferred, especially for ambient temperatures below −20 °C (−4 °F) or
elevations above 1500 m (5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with
all applicable emission regulations for the area in which the engine is operated.
• Use of diesel fuel with sulfur content less than 0.10 % (1000 ppm) is strongly
recommended.
• If high-sulfur fuel (sulfur content 0.50 % (5000 ppm) to 1.0 % (10000 ppm)) is used as a
diesel fuel, change the engine oil and oil filter at shorter intervals. (approximately half)
• DO NOT USE Fuels that have sulfur content greater than 1.0 % (10000 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile
service. (SAE J313 JUN87)
• Since KUBOTA diesel engines of less than 56 kW (75 hp) utilize EPA Tier 4 and Interim
Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory for these
engines, when operated in US EPA regulated areas. Therefore, please use No.2-D S500 or
S15 diesel fuel as an alternative to No.2-D, and use No.1-D S500 or S15 diesel fuel as an
alternative to No.1-D for ambient temperatures below −10 °C (14 °F).
1) SAE : Society of Automotive Engineers
2) EN : European Norm
3) ASTM : American Society of Testing and Materials
4) US EPA : United States Environmental Protection Agency
5) No.1-D or No.2-D, S500 : Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No.1-D or No.2-D, S15 : Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%

27
3. GREASING
• Greasing
CAUTION
To avoid personal injury:
• First stop the engine.
Apply a small amount of multipurpose grease or oil to the following points every 50 hours.
1 Cylinder lower (oil)
2 Cylinder upper (oil)
3 Cylinder upper (grease)
4 Deck body support fulcrum (grease)
5 Opening/closing kit (right & left) (oil)
6 Lower roller (grease)
7 Upper roller (grease)
8 Idler (grease)
9 Bogie roller (grease)
10 Wire (Brake, accelerator etc) (oil)
11 Steering lever (grease)
28
12 Dump lever joint (oil)
13 Brake pedal (grease)
14 Accelerator lever (oil)
15 Drive pedal shaft (grease)
16 Main clutch tension arm (grease)
17 Dump lever (grease)
18 Lever, dump support (grease)
19 Link arm, drive pedal (grease)
20 Speed change lever (grease)
21 Neutral plate (grease)
22 Parking brake lever (oil)
 9

11
11

13

15

7 8 17

20

29
 ⑭

⑩ ⑲

○
21

○
22

30
4. CAUTION FOR DISASSEMBLING AND REASSEMBLING
1) SPROCKET
Before fitting the sprocket to shaft of transmission, apply the grease to the spline of shaft.
1

1 Grease
2 2 Sprocket
K70E-U008

2) ADJUSTING BOLT FOR CRAWLER

Apply the grease to adjusting bolt to prevent the rust of bolt and nut.

3 Grease

3) BOLTS FOR FRAME (UPPER / UNDER)

Apply the screw locking bond to bolts.

K10H-D008

31
4) ANGLE OF DRAIN PORT (HST UNIT)
When remove the hose from drain port for HST unit, check the angle of drain port.

1 About 45˚

K10H-D009

5) DUST COVER FOR TRANSMISSION (FINAL SHAFT)

Before fitting the sprocket to final shaft of transmission, apply the grease to the surface of oil seal
and dust cover.

2 Grease

6) CHARGE PUMP (HST)

Face the mark toward plate side.

3 Marks
4 Plate

3 4
32
5. ADJUSTMENT OF COMPONENT PARTS
5-1 MAIN CLUTCH ADJUSTMENT
• Check and adjustment of V-belt tension (main clutch)
CAUTION
To avoid personal injury:
• First stop the engine.
• After servicing, make sure the function of main clutch.
1. When the main clutch (V-belts) slips.
1) Loosen the lock nut 1 , then adjust the V-belt tension
by tightening the adjust nut 2 .
2) After the adjustment, tighten up the lock nut.
1 Adjust nut
2 Lock nut 1
2
Reference for proper belt tension
1) Depress the center of V-belt with thumb pressure.
[8 to 10 mm / 5 kgf]
IMPORTANT
• After the adjustment, tighten up the lock nuts

5-2 BRAKE PEDAL ADJUSTMENT

• Check and adjustment of brake pedal
1
CAUTION
To avoid personal injury:
• First stop the engine.
• Be sure to check the braking force of parking
brake after adjustment.
1. Check the brake pedal free travel.
2. If the brake pedal free travel exceeds the limit, loosen
the lock nuts and move the adjust bolt toward A .
3. After adjustment, tighten up the lock nut.
A
1 Brake pedal
2 Adjust bolt
3 Lock nut
[Proper brake pedal free travel/1mm] 2 3 3

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 IMPORTANT
• If you turn the turn buckle toward A too much, the brake is applied at all times.
This will cause the damage of transmission.

5-3 STEERING LEVER ADJUSTMENT

• Check and adjustment of steering lever
CAUTION
To avoid personal injury:
• First stop the engine.
• After servicing, make sure the function of
steering lever.
1
If it is difficult to disengage or engage the steering clutch,
1
check the following below.
1. Check the steering lever free travel.
2. If steering lever free travel exceeds the limit, loosen the
3
lock nuts and adjust the rod. 3
3. After the adjustment, tighten up the lock nut.
[Proper steering lever free travel / 3mm] 2
1 Steering lever 3 2
2 Rod
3
3 Lock nut

• Check and adjustment of steering brake

CAUTION
To avoid personal injury:
• First stop the engine.
• Be sure to check the braking force after adjustment.
1. When the steering brake is too weak, loose the lock nuts and move the adjust plate toward B . (4
~ 6mm)
2. Check that adjust plate contact the brake lever, when move
the Lever C toward A approx. 17 mm.
3. After the adjustment, tighten up the lock nuts
1 Lock nut
2 Adjust plate
3 Brake lever
4 Lever C
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 IMPORTANT
• If you move the adjust plate toward B too much, the steering brake is applied at all times.
This will cause the damage of transmission.

5-4 NEUTRAL SYSTEM ADJUSTMENT

• Check and adjustment of drive pedal
CAUTION
To avoid personal injury:
• First stop the engine.
• After servicing, make sure the function of
2 1
drive pedal.
If abnormal operation (the machine moves at a very slow
speed, even if remove the foot from drive pedal)
is found, check and adjust the following below. B A

1) Move the adjusting bolt toward A or B until the

machine does not move.
2) After adjustment lock the the adjusting bolt.
3
When the machine move forward, move the adjusting bolt
toward A When the machine move backward, move the
adjusting bolt toward B .
1 Adjusting bolt
2 Lock nut
3
3 Drive pedal locking bolt
IMPORTANT
• Do not adjust the height of the drive pedal locking bolts.

5-5 BELT TENSION ADJUSTMENT

• Check and adjustment of V-belt tension (hydraulic pump)
CAUTION
To avoid personal injury:
• First stop the engine.
1. Loosen the V-belt tension by loosening adjusting nut and lock nut for tension bolt after a little
loosening two of bolts for hydraulic pump.
2. Adjust the V-belt tension by tightening adjusting nut.
3. After the adjustment, tighten up the lock nut and two of bolts for hydraulic pump. Reference
for proper belt tension.
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Depress the center of V-belt with thumb pressure.
Displacement at center of belt / load to belt.
[8 to 10 mm / 5 kgf]
1 Lock nut
2 Adjust nut
1
2
• Check and adjustment of fan belt tension
CAUTION
To avoid personal injury:
1. Be sure to stop the engine and remove the key before checking the belt tension.
2. Be sure to reinstall the detached safety shield after maintenance or checking.
Proper fan belt tension
A deflection of between 7 to 9 mm when the belt is pressed in the middle of the span.
1. Stop the engine and remove the key.
2. Apply moderate thumb pressure to belt between pulleys.
3. If tension is incorrect, loosen the alternator mounting bolts and, using a lever placed between
the alternator and the engine block, pull the alternator out until the deflection of the belt falls
within acceptable limits.
4. Replace fan belt if it is damaged.
IMPORTANT
• If belt is loosen or damaged and the fan is damaged,
it could result in overheats or insufficient charging.
Correct or replace belt.
1 Fan belt
2 Bolt and nut
A 7 to 9 mm (under load of 10 kgf)

5-6 CRAWLER ADJUSTMENT

• Check and adjustment of rubber crawler tension
CAUTION
To avoid personal injury:
• If the crawler tension is too high, abnormal stress will be applied to the idler,
sprocket and crawler, causing serious accidents or excessive wear to occur.
Adjust the crawler tension by turning adjusting bolt after detach the snap pin and stopper to make
clearance A between 25~35mm when pushed with the thumb.
36
 1 Adjusting bolt
2 Snap pin
3 Stopper
IMPORTANT
• Be sure to move the machine forward before
the adjustment. This is because, after backward
movement of the machine, the crawler is tensed on
the upper side, making correct adjustment impossible.
• The adjusting bolt will become difficult to turn when the sticking mud hardens.
• After work, always grease the thread.
• Excessive tension results in trouble such as:
• Increase of running resistance and reduction of driving power.
• Excessive wear of crawler.
• Insufficient tension results in trouble such as:
• Disengagement of crawler.
• Defective engagement of sprocket.
• Excessive wear of crawler.
• After completing the work, clean the crawler units, removing sticking soil completely.

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6. TESTING OF PRESSURE (HST)
Please check the pressure of HST by check port A or B .

4
5
1
7

2 8

1 Pressure check port (PF3/8) - FORWARD

2 Pressure check port (PF3/8) - BACKWARD
3 Input shaft
4 Suction port (PF3/8)
5 Drain port (PF3/8)
6 Charge pump
7 Suction port (PF1/2)
8 Discharge port (PF3/8)

38
7. REPLACING OF WEAR OUT PARTS
1) Friction plate
If the measurement is less than the allowable limit, replace the parts.
Friction plate thickness
Factory spec. 2.53 ~ 2.67mm
Allowable limit 2.35mm

2) Clutch plate
If the measurement is less than the allowable limit, replace the parts.
Clutch plate thickness
Factory spec. 0.95 ~ 1.05mm
Allowable limit 0.85 mm

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8. TROUBLESHOOTING AND COUNTERMEASURES
1. Engine is difficult to start (Self-starter does not operate).

Safety switch (brake pedal) is broken.

Check and replace.

2-1. The machine does not stop, even if remove the foot from drive pedal.
(Both side / Forward and Backward)
The bolt for lever (HST) is loosed.

Check and tighten up the bolt.

See “8. BOLTS FOR HST NEUTRAL LEVER” under “TIGHTENING TORQUE”.

2-2. The machine does not stop, even if remove the foot from drive pedal.
(one side only / Forward or Backward)
The neutral system of HST is not correctly adjusted.

Check and adjust the neutral system of HST.

See “4. NEUTRAL SYSTEM ADJUSTMENT” under “ADJUSTMENT OF COMPONENT
PARTS”.

3. The machine does not drive

HST pump is broken.

Check and replace.

4-1. The machine does not drive powerful.

The crawler tension is too high.

Check and adjust the crawler tension.

See “6. CRAWLER ADJUSTMENT” under “ADJUSTMENT OF COMPONENT PARTS”.

40
4-2. The machine does not drive powerful.

The main clutch (V-belts) slips.

Check and adjust of V-belt tension (main clutch)

See “1. MAIN CLUTCH ADJUSTMENT” under “ADJUSTMENT OF COMPONENT
PARTS”.

4-3. The machine does not drive powerful.

Pressure of HST unit is not enough.

Check the pressure of HST unit.

See “TESTING OF PRESSURE (HST)”.

4-4. The machine does not drive powerful.

The parking brake is applied at all time.

Check and adjust of parking brake

See “2. BRAKE PEDAL ADJUSTMENT” under “ADJUSTMENT OF COMPONENT
PARTS”.

4-5. The machine does not drive powerful.

The brake pedal does not return correct position by lack of lubrication.
Check and apply a grease.

4-6. The machine does not drive powerful.

The friction between clutch plate and friction plate for transmission is big.

The friction will be decrease after 30 minutes or 1 hour operation.

41
5. The operating force for steering lever is heavy.

The lubrication of rod, side clutch lever is not enough.

Check and apply a grease

6-1. The steering lever does not return smoothly.

The lubrication of rod, side clutch lever is not enough.

Check and apply a grease.

7. The speed change lever does not move smoothly.

The lubrication of rod is not enough.

Check and apply a grease

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9 MAINTENANCE INTERVALS
[EVERY 25 SERVICE HOURS]
• Check of steering lever
• Check of V-belt tension (main clutch)

[EVERY 50 SERVICE HOURS]

• Check of steering brake
• Check of parking brake
• Greasing
• Draining water of the fuel tank
• Check of rubber crawler tension
• Check of fuel pipes and clamp bands

[EVERY 100 SERVICE HOURS]

• Check of speed change lever
• Check of roller and idler
• Check of V-belt tension (hydraulic pump)
[after first 25 service hours]
• Cleaning of air cleaner element
• Cleaning of fuel filter
• Check of battery electrolyte level
• Check of fan belt tension
• Change of engine oil
[after first 50 service hours]
• Check of hydraulic hoses and clamp bands [HST]

[EVERY 200 SERVICE HOURS]

• Check of radiator hoses and clamp bands
• Check of hydraulic hoses and clamp bands (hydraulic pump)
• Replacement of oil filter cartridge
[after first 50 service hours]
• Check of intake air line

[EVERY 300 SERVICE HOURS]

• Change of transmission oil
[after first 50 service hours]

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[EVERY 400 SERVICE HOURS]
• Replacement of fuel filter element
• Cleaning of radiator

[EVERY 500 SERVICE HOURS]

• Replacement of fan belt
• Change of hydraulic pump oil
• Change of HST oil
[after first 50 service hours]
• Replacement of oil filter cartridge [HST]
[after first 50 service hours]
• Replacement of suction filter [HST]
[after first 50 service hours]

[EVERY ONE OR TWO MONTHS]

• Recharging of battery

[EVERY ONE YEAR]

• Replacement of air cleaner element
[every year or every 6 times at cleaning]
• Check of the electrical circuit and looseness of the coupler

[EVERY 800 SERVICE HOURS]

• Check of valve clearance

[EVERY 1500 SERVICE HOURS]

• Check fuel injection nozzle injection pressure

[EVERY 2000 SERVICE HOURS]

• Check of alternator and starter motor

[EVERY TWO YEARS]

• Replacement of battery
• Replacement of radiator hoses and clamp bands
• Replacement of fuel pipes and clamps
• Change of radiator coolant (L.L.C.)
• Replacement of intake air line
• Replacement of hydraulic hoses and clamp bands

44
 EDITOR:
KUBOTA CORPORATION
CONSTRUCTION MACHINERY DIVISION
CUSTOMER TECHNICAL SUPPORT DEPARTMENT
1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, 753-0004 JAPAN
PHONE : (81)72-890-2888
FAX : (81)72-890-2886
E-mail : ce-sv@kubota.co.jp

KUBOTA Corporation Printed in Japan 2010. 01, H, H, H, e Code No.RY921-20440