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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

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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

Machine weight

Max. loading capacity

Engine

(kg) Model

67 x 68

Output

(KW/rpm)

8.3/3000

Length

(mm)

2640

Height

(mm)

2015

(mm)

720

(cc)

Starting system Width

(mm)

Track center-to-center distance Bed

(mm)

Height

(mm)

Width

Crawler type

Number of drive sprocket teeth Track width

Ground contact length

Ground contact pressure w/o load Ground contact pressure w/t load Max. traction power

(Forward / Reverse) Main clutch

Lowering time (at 30900rpm) Hydraulic oil tank Engine oil

230

6 (one side) 1180

1st

2nd

25

(kgf/cm ) (kgf)

(km/h) (km/h)

Screw type with spring 0.17 0.4

1040

HST + Gear shift type transmission 0 - 3.2 / 0 - 2.1 0 - 5.8 / 0 - 3.9 Belt tension

Tooth clutch

Wet multi-plate type Wet multi-plate type

Dumping type

Fuel tank

7

72

2

Parking brake

Raising time (at 3000rpm)

Rubber track

(kgf/cm2)

Steering brake

Max. Dumping angle

400 / 520

(mm)

Steering clutch

Dumping direction

320

( )

(° )

Alignment

Travelling speed

855

(mm)

Gradeability

Type

1470

(mm)

Number of track rollers

Electric

145

(mm)

Capacity Struck / Heaped

479

950

(mm)

Length

Crawler pitch

Capacity

2

(mm)

Min. ground clearance

Dumping performance

KUBOTA Z482-E3B-CRYM-1

Vertical 4-cycle Liquid-Cooled Diesel

Total Displacement

Transmission

1200

Type

No. of cylinder

Undercarriage

885

(kg)

Bore and Stroke

Dimensions

KC100HD

Hydraulic

(° )

(sec)

(sec)

Front / Right side / Left side 56 / 60 / 60 7.1

4.0

( )

14.8

( )

2.55

( )

1.5

Coolant

( )

Approx. 2.8

Transmission oil (main / sub)

( )

3.1 / 0.45

HST oil

( )

13.0

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 Number of Cylinders Type Bore×Stroke Total Displacement ISO Net Continuous ISO/SAE Net Intermittent SAE Gross Intermittent Maximum Bare Speed Minimum Bare Idling Speed Combustion Chamber Fuel Injection Pump Governor Direction of Rotation Injection Nozzle Injection Timing Firing Order Injection Pressure Compression Ratio Lubricating System Oil Pressure Indicating Lubricating Filter Cooling System Starting System Starting Motor Starting Support Device EGR Battery Charging Alternator Fuel Lubricating Oil

Z482-E3B

2 Vertical, Water-cooled, 4 cycle IDI diesel engine 67.0 × 68.0 mm (2.64 × 2.68 in.) 72.0 × 73.6 mm (2.83 × 2.90 in.) 599.0 cm3 (36.55 cu.in.) 479.0 cm3 (29.23 cu.in.) 10.1 kW / 3600 min-1 ( rpm) 8.10 kW / 3600 min-1 (rpm) (10.9 HP / 3600 min-1 (rpm)) (13.5 HP / 3600 min-1 (rpm)) 11.6 kW / 3600 min-1 ( rpm) 9.30 kW / 3600 min-1 (rpm) 1 (12.5 HP / 3600 min (rpm)) (15.5 HP / 3600 min-1 (rpm)) 1 12.5 kW / 3600 min-1 ( rpm) 9.90 kW / 3600 min (rpm) (13.3 HP / 3600 min-1 (rpm)) (16.8 HP / 3600 min-1 (rpm)) 3800 min-1 (rpm) 900 to 1000 min-1 (rpm) Spherical type (E-TVCS) Bosch MD type mini pump All speed mechanical governor Counter-clockwise (viewed from flywheel side) Bosch “Throttle” type 0.37 rad (21 °) before T.D.C. 0.35 rad (20 °) before T.D.C. 1-2 13.73 MPa (140.0 kgf/cm2, 1991 psi) 23.5 : 1 24 : 1 Forced lubrication by trochoid pump Electrical Type Switch Full flow paper filter (Cartridge type) Pressurized radiator, forced circulation with water pump (not included in the basic engine) Electric starting with starter 12V, 0.8kW 12V, 1.0kW By glow plug in combustion chamber None 12V, 28 AH equivalent 12V, 36 AH equivalent 12V, 150W 12V, 480W Diesel Fuel No.2-D (ASTM D975) Class CF lubricating oil as per API classification is recommended. For details on recommended lubricating oils, see page G-6, 9

Oil Pan Depth 2.1 L (0.55 U.S.gals) 101 mm (3.98 in.) Oil Pan Depth 2.5 L (0.66 U.S.gals) 121 mm (4.76 in.) Weight (Dry) kg(lbs) 53.1 (117) * The specification described above is of the standard engine of each model. * Conversion Formula : HP = 0.746 kW, PS = 0.7355 kW Lubricating Oil Capacity

Z602-E3B

2.5 L (0.66 U.S.gals) – 60.0 (132)

W10336300

5


Performance curves • Z482-E3B

3EEACABEP001A (1) Brake Horsepower (6) Net Intermittent Torque (2) Engine Speed (7) Net Continuous Torque (3) B.S.F.C. (8) Gross Intermittent B.H.P. (4) Torque (9) Net Intermittent B.H.P. (5) Gross Intermittent Torque (10) Net Continuous B.H.P.

(11) Net Intermittent B.S.F.C. (12) Gross Torque (13) Overload Torque (14) Continuous Torque

Fuel consumption

Fuel consumption(L/h)

Fuel consumption KC100HD

Work load factor (%)

6

(15) Gross B.H.P. (16) Overload B.H.P. (17) Continuous B.H.P. (18) Overload B.S.F.C.


Dimension • Z482-E3B Uni : mm (in.)

3EEACABFP001A

Uni : mm (in.)

3EEACABFP002A

7


8

A B C D

HST Hight (H) Low (L) INPUT SHAFT

[POWER TRAIN]

4. TRANSMISSION

E CLUTCH GEAR F BRAKE (STEERING/PARKING) G OUTPUT SHAFT

[GEAR RATIO]

[GEARING]


5. HYDRAULIC SYSTEM (HST) HST unit

Hydraulic pump : 0 ~ 18.2 cm3 Hydraulic motor : 18.2 cm3 Charge pump : 5.1cm3 Relief valve set pressure : 18.5MPa+2.9MPa Charge pressure : 5.0 kgf/cm2 Pressure check port ( PF3/8 ) Suction port (PF1/2) [charge pump] Discharge port (PF3/8) [charge pump]

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Housing Cover Hanger Input shaft Output shaft Block, cylinder Piston Case, charge pump Relief valve (Low pressure) Relief valve (High pressure) Neutral valve (Backward) Neutral valve (Forward) Drain port Suction port Pressure check port (Forward) Pressure check port (Backward)

E/G

A

B

D

C T/M

C A B C D

B

Pump (Adjustable) Piston Cylinder Flow of oil 9


Mechanism of drive pedal

K10H-D010

Flow of HST oil

E Oil cooler F Oil filter cartridge G HST oil tank 10

K10H-D004


6. HYDRAULIC SYSTEM (DUMPING) Hydraulic pump Hydraulic pump

Discharge volume

Revolution

: 3cc/rev

: 140+5/kgf/cm2 (13.7+0.5MPa)

(at 1800rpm)

Tank capacity

: 1.6 â„“

Pulley size (engine)

(Part no 89956-1559-0)

: 500 ~ 2000rpm

Relief valve set pressure

Pulley size (pump)

: K82R

: Dia 101.6mm

(Part no 89956-1298-0)

: Dia 76.2mm

(Part no 89920-1157-0)

Flow of hydraulic oil

A

B

A Pull-Down port B Push-up port

K70E-U002

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Hydraulic hose / Hydraulic cylinder

K10H-D002

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

Pressure Stroke

: 170kgf/cm2 (16.7MPa) : 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)

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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

Size : SB29 x 1 pce / Part no 89920-1175-0

Part no 89920-1157-0

Part no 89920-1165-0

2) V-belt (Engine pulley ~ Hydraulic pump pulley) 3) Engine pulley 4) HST pulley

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15

Ⓑ Ⓒ

9. WIRING DIAGRAM

Ⓡ Ⓢ Ⓣ

Ⓚ Ⓛ Ⓜ Ⓝ Ⓞ Ⓟ Ⓠ

Ⓖ Ⓗ Ⓘ Ⓙ

Ⓐ Ⓑ Ⓒ Ⓓ Ⓔ Ⓕ

B Br G L P R SB W Y BL BW GB LB PB RW WB YB BR

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

Cord color Black Brown Green Blue Pink Red Sky blue White Yellow Black / Blue Black / White Green / Black Blue / Black Pink / Black Red / White Red / White Yellow / Black Black / Red


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


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Kubota kc100hd dumper service repair manual  
Kubota kc100hd dumper service repair manual  
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