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    • Rears Mfg Engine Drive Shredder Operator's Manual (2005 Model Year)

      (Click to view pdf file for 2005 Model Year Engine Drive Shredder by Rears Mfg) The following operators manual is only for the year 2005 EDS05 Model Engine Drive Shredder, there may be parts differences between years. We are not responsible for ordering incorrect parts based on this information. The information provided is intended to help provide safe operations for the end user. The Rears Mfg EDS05 Manual has been converted to plain text for your convenience below: R E A R S Engine Drive Shredder ENGINE DRIVE SHREDDER READ THIS MANUAL BEFORE OPERATING 10.17.05 Engine Drive Shredder Flail Safety: Operator Training Safety is a primary concern in the design and manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by a single careless act of an operator. In addition to the design and con.guration of equipment, hazard control and ac­cident prevention are dependent upon the awareness, concern, prudence and proper training of personnel involved in the operation, transport, maintenance and storage of equipment. It has been said, the best safety device is an informed, careful operator. We ask you to be that kind of an operator. It is the operator’s responsibility to read and understand all safety and operating instructions in the manual and to follow these. Accidents can be avoided. Working with unfamiliar equipment can lead to careless injuries. Read this manual and the manual for your tractor before assembly or operation, to acquaint yourself with the machines. If this machine is used by any person other than the owner or is loaned or rented, it is the owner’s responsibility to make certain that the operator has instruction for the safe and proper use of the machinery and that the operator reads and understands the operator’s manuals. Know your controls and how to stop the tractor, engine, and implement quickly in an emergency. Read this manual and the one provided with the tractor. Train all new personnel and review instructions frequently with existing workers. A person who has not read and understood all operating and safety instructions is not quali.ed to operate the machine. An untrained operator exposes himself and bystanders to possible serious injury or death. Do not allow children to operate this machine. READ THE OPERATOR’S MANUAL READ THE OPERATOR’S MANUAL READ THE OPERATOR’S MANUAL Flail Safety: Preparation Never operate the tractor and implement until you read and completely understand this manual, the tractor operator’s manual, and each of the safety messages found on the safety decals on the tractor and the implement. Personal protection equipment, including a hard hat, safety glasses, safety shoes, and gloves are recommended during assembly, installation, operation, adjustment, maintenance, repair, removal, or transport of this implement. Do not allow long hair, loose .tting clothing or jewellery to be around moving parts. Tractors, with or without implements, can often be noisy enough to cause per­manent, partial hearing loss. We recommend that you wear hearing protection on a full-time basis if the noise in the operator’s position exceeds 80db. Long-term exposure to noise over 85db can cause severe hearing loss. Long-term exposure to noise over 90db may cause permanent, total hearing loss. NOTE: Hearing loss from loud noise (from tractors, chain saws, radio earphones) is cumulative over a lifetime without hope of natural recovery. Operate the implement only with a tractor equipped with an approved Roll-Over­Protection-System (ROPS). Always wear your seat belt. Serious injury or even death could result from falling off a tractor– particularly during a turnover, when the operator could be pinned under the tractor. Operate only in daylight or good arti.cial light. Ensure the implement is properly mounted and in good operating condition. Safety shielding and safety decals must be properly installed and in good condition. iii Flail Safety: Operation The use of this equipment is subject to certain hazards which cannot be protected against by mechanical means or product design. All operators of this equipment must read and understand this entire manual, paying particular attention to safety and operating instructions, prior to use. If there is something in this manual you do not understand, ask your supervisor, dealer, or call the manufacturer. Most accidents occur because of neglect or carelessness. Keep all helpers and bystanders at least several hundred feet away from the operating implement. Only properly trained people should operate this machine. Keep children away at all times. When the machine is operated in populated areas or in other areas where thrown objects could injure persons or property, standard equipment safety chain shielding (which is designed to reduce the possibility of thrown objects) must be installed. If the machine is not equipped with full chain shielding, operation must be stopped when anyone comes within several hundred feet. The majority of accidents invlolve entanglement on a driveline, injury of bystanders by objects thrown by rotating blades, and operators being knocked off the tractor by low hanging limbs and run over by the mower. Accidents are most likely to occur with untrained operators or machines that are loaned or rented to someone who has not read the owner’s manual and is not familiar with the mower. Always stop the tractor, set the brake, shut off the engine, remove the ignition key, lower the implement to the ground and allow cutter blades to come to a complete stop before dismounting the tractor. Never leave equipment unattended with the tractor running. Never place hands or feet under the mower with tractor engine running or before you are sure all motion has stopped. Stay clear of all moving parts. Do not reach or place yourself under equipment until it is blocked securely. Take all possible precautions when leaving unit unattended: set parking brake, stop engine, and remove key from ignition. Do not allow riders on the implement or tractor at any time. There is no safe place for any riders. Do not operate unless all personnel, livestock, and pets are several hundred feet away to prevent injury by thrown objects. Never direct discharge toward anyone. Keep children away at all times. Install and secure all guards and shields before starting or operating. Keep hands, feet, hair, and clothing away from all moving parts. Take care when operating tractor and implement under trees with low hanging limbs: the operator can be knocked off the tractor and run-over. The rotating parts of this machine have been designed and tested for rugged use. However, they could fail upon impact with heavy, solid objects, such as steel guard rails and concrete abutments. Such impact could cause the broken object to be thrown outward at a very high velocity. To reduce the possibility of property dam­age, serious injury, or even death, never allow the cutting blades to contact such obstacles. Frequently check blades. They should be free of nicks and cracks and securely fas­tened. Pick up rocks and other debris before operating. Enter new areas carefully. Never assume an area is clear. Always check. Stop mower and tractor immediately upon striking an obstruction. Turn off the trac­tor, remove the key, allow all moving parts to stop before leaving the tractor seat. Inspect and repair any damage before resuming operation. Keep wood dust and debris cleared from engine compartment to minimize .re dan­ger. The operator should always have a .re extinguisher immediately available. The chain guards, bands, .aps, driveline shields, and gearbox shields should be used and maintained in good working condition. They should be inspected carefully, at least daily, for missing or broken cable, chain links, shields, or guards. Missing, broken or worn items must be replaced at once to reduce the possibility of injury from thrown objects or entanglement. Stay alert for holes, rocks and roots in the terrain and other hidden hazards. Keep away from drop-offs. Use extreme care and maintain minimum ground speed when transporting on hill­side, over rough ground and when operating close to ditches or fences. Be careful when turning sharp corners. Reduce speed on slopes and sharp turns to minimize tipping or loss of control. Be careful when changing directions on slopes. Do not start or stop suddenly on slopes. Avoid operation on steep slopes. When using an implement, 20% of the combined tractor and implement weight (at a minimum!) must be on the tractor’s front wheels. Without this weight, the tractor could tip over, causing personal injury or death. The weight may be attained with a front end loader, front wheel weights, ballast in the tires or front tractor weights. When attaining this minimum 20% front wheel weight, you must not exceed the ROPS weight rating. Weigh the tractor and the implement. Do not guess or esti­mate! Inspect the entire machine periodically as indicated in the maintenance section of this manual. Look for loose fasteners, worn or broken parts, pinched hydraulic hoses, and leaky or loose .ttings. Make sure all pins have cotter pins and washers. Serious injury may occur from not maintaining this machine in good working order. Be careful when operating the tractor and implement on uneven ground to avoid upsetting. In extremely uneven terrain, front wheel weights, front tractor weights, and/or tire ballast should be used to improve stability. Pass diagonally through sharp dips and avoid sharp drops to prevent hanging up the tractor and implement. Practice improves skills in maneuvering rough terrain. Avoid sudden starts and stops while travelling up or downhill. Always travel down slopes, never across the face. Avoid operation on steep slopes. Slow down on sharp turns and slopes to prevent tipping and/or loss of control. Flail Safety: Maintenance Good maintenance is your responsibility. Poor maintenance is an invitation to trouble. Follow good shop practice. Keep service area clean and dry. Be sure electrical out­lets and tools are properly grounded. Use adequate light for the job at hand. Make sure there is plenty of ventilation. Never operate gas/diesel engines in a closed building. The exhaust fumes may cause asphyxiation. Before working on this machine shut off the engine, set the brakes and remove the key from the ignition. Be certain all moving parts on tractor and implement have come to a complete stop before attempting to perform maintenance. Never work under equipment unless it is blocked securely. When performing any service or maintenance, always use personal protection de­vices such as eye, hand and hearing protection. Frequently check mower blades. They should be free of nicks or cracks and securely fastened. Periodically tighten all bolts, nuts and screws and check that all cotter pins are properly installed to insure unit is in a safe condition. When completing a maintenance or service function, make sure all safety shields and devices are installed before placing the unit back in service. Remove hydraulic pressure prior to doing any maintenance. Block the implement securely and turn off the engine. Never use your hands or any part of your body to locate a hydraulic leak. Use a piece of cardboard or wood to pass along the hydraulic line and determine the loca­tion of any leak. Wear protective gloves and glasses. Hydraulic .uid escaping under pressure can penetrate the skin. Openings in the skin and minor cuts are suscep­tible to infection from hydraulic .uid. If injured by escaping hydraulic .uid, see a doctor at once. Gangrene and death can result. Without immediate medical treat­ment, serious infection and reactions can occur. When disconnecting hydraulic lines, shut off supply: relieve all hydraulic pressure. Before pressurizing system, inspect all components. Make sure .ttings are tight and lines are not worn, kinked or damaged. After servicing, be sure all tools, parts and service equipment are removed. Do not allow grease or oil build up on any deck or platform. Keep engine compartment clear of wood dust and debris to minimize .re danger. Never replace hex bolts with less than grade 5 bolts unless otherwise speci.ed, i.e. shear bolts. Refer to bolt torque chart for head identi.cation markings. Where replacement parts are necessary for periodic maintenance and servicing, gen­uine factory replacement parts must be used to restore your equipment to original speci.cations. The manufacturer will not claim responsibility for use of unapproved parts and/or accessories and other damages as a result of their use. If equipment has been altered in any way from the original design, the manufac­turer does not accept any liability for injury or warranty. A .re extinguisher and .rst aid kit should be kept readily accessible while perform­ing maintenance on this or any equipment. Flail Safety: Tires Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experi­ence to do the job. In.ating or servicing tires can be dangerous. Whenever possible, trained personnel should be called to service and/or mount tires. Always order and install tires and wheels with appropriate capacity to meet or exceed the anticipated weight to be placed on them. ix Flail Safety: Transport Comply with state and local laws governing highway safety and movement of farm machinery on public roads. re.ective red border The use of .ashing amber lights is acceptable in most localities. However, some localities prohibit their use. Local laws should be checked for all highway lighting and marking requirements. When driving the tractor and equipment on the road or highway under 20mph (32kph) at night or during the day, use .ashing amber warning lights and a slow moving vehicle identi.cation emblem (SMV). Plan your route to avoid heavy traf.c. slow moving vehicle emblem Always install transport locks, pins or brackets before transporting. Do not drink and drive. Watch out for traf.c when operating near or crossing roadways. When driving hills or curves, slow down and make gentle turns. Make certain that at least 20% of the total weight of tractor and implement is on the front wheels to maintain safe steerage. Slow down on rough or uneven surfaces. Use extreme care and maintain minimum ground speed when transporting on hill­sides, rough ground, or when travelling close to ditches and fences. Be careful when steering around sharp corners. Never allow riders on either the tractor or implement. Falling off can kill. Be a safe and courteous driver. Always yield to oncoming traf.c in all situations, including narrow bridges, intersections, etc. Do not exceed 20mph (32kph). Reduce speed on rough roads and surfaces. Use hardened hitch pins with retainers when attaching to pull-type machines. Use a safety chain to prevent unexpected separation with pull-type models. Flail Safety: Storage Do not work under an implement supported by a jack. Do not put any part of body under a raised implement unless it is blocked securely. Store the implement away from activity. Do not park equipment where it will be exposed to livestock. Damage to equipment or injury to livestock could result. Do not permit children to play on or around the implement. Make sure the parked unit is on a hard, level surface with all safety devices in place and in good working condition. xi Flail Safety: Safety Decals This is the SAFETY-ALERT symbol. This symbol is used to visibly mark operating hazards. YOU MUST FOLLOW THE DIRECTIONS POSTED BESIDE THE SAFETY-ALERT SYMBOL TO AVOID BODILY INJURY OR DEATH. Before you operate any machinery, read the operator’s manual. A copy of every SAFETY-ALERT decal on your implement is included in your operator’s manual with a map of each decal on your implement. With your operator’s manual in hand, walk around the implement: .nd, read, and UNDERSTAND every SAFETY-ALERT decal. EVERY OPERATOR OF THIS IMPLEMENT MUST DO THIS FOR THEIR OWN SAFETY. On Safety Decals, there is often a signal word: DANGER, WARNING, CAUTION. These signal words indicate the level of hazard or degree of seriousness for the described hazard on the decal. Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. Indicates a potentially hazardous situation that, if not avoided, may result in death or serious injury. Indicates an area of extreme danger- machine components and hazardous opera­tions that, for functional purposes, cannot be guarded and, if not avoided, could result in death or serious injury. Warns the operator of potential machine damage if indicated procedure is not fol­lowed. Keep safety decals clean and legible at all times and replace safety decals that are missing or have become illegible. When parts that bear safety decals are replaced, the replacement parts must have a current safety decal. Safety decals are available from your dealer or direct from the manufacturer. When applying a safety decal, be sure the application surface is clean (free of dirt and grease) and dry. The surface you are applying the decal to should be above 50°F (10°C). decals won’t help if you can’t read them install the decal properly and they’ll stick around WARNING CAUTION IMPORTANT Engine Drive Shredder Engine Drive Shredder Safety Decal Locations For the safety of operators, maintenance workers, and bystanders, familiarize yourself with the safety decals on the chopper. Decals indicated on the illustration, below, are reproduced on the previous page. Decal 93 can only be seen if a guard is removed. Item numbers with a * can be found on both the left and right side of the machine. Make certain all decals listed here are present on the shredder and in good condition. Replacement decals are available from your dealer or direct from Rears. (inside) 1. Top off the gearbox oil if needed. You will .nd instruc­tion for how to check the oil level and a list of recom­mended lubricants included on the parts page for your gearbox model in this manual. 2. Check your drive belt tension. New belts will stretch and become slack much more quickly than belts that have been broken in. Check new belts frequently. 3. Properly lubricate all grease points. 4. Check all fasteners - tighten as required. 5. In.ate tires to 36psi. Check tire pressure frequently. Tractor Setup 1. Tractor size: 85hp 4x4 tractor recommended. 2. Tire pressure: in.ate tractor tires as recommended in your tractor’s operator manual. 3. Front weights: the tractor must have a full rack of front weights to keep adequate front wheel traction-when pulling the shredder up a hill or onto a trailer. When the 3-point is raised above the center of the axle at the end of a row or when loading onto a trailer, the pull from the shredder will tend to lift the tractor front end. In operating conditions with the 3-point lowered, the pull from the shredder will have little effect on front end loading (see table, right) 4. Shielding: to minimize brush dragging under the tractor, full tractor belly plates are strongly recom­mended. The tractor belly plate needs to extend beyond the tractor rear axle to overlap the shielding on the shredder arch. Any gaps in the shielding are potential catch points for brush and may keep brush from feeding properly. 5. Wheel tread: increase wheel tread to maintain tractor stability when working on inclines or rough ground. Refer to your tractor’s operator manual for instruction. 6. Brakes: do not transport implements unless tractor brakes are in good condition. 7. Hydraulics: two sets of remotes are required to operate the lift axle and the upper feed roll independently. The hoses with orange ties are for the upper feed roll. Purple ties mark the axle lift hoses. A free .ow case drain connection is also required to allow the upper feed roll to .oat correctly. The case drain hose on the shredder is supplied with a 1/4” male quick connetor. A mating 1/4” female connector, also supplied, should be attached to the tractor. Operating Conditions Equivalent Tongue Weight @ 24” 3pt lowered, .eld operation 2700 lb 3pt raised, .at .eld 3200 lb 3pt raised, hilly .eld 3900 lb 3pt raised, trailer loading with long ramps- 50% grade 4300 lb 3pt raised, trailer loading with short ramps- 67% grade 4800 lb 8. Electrical: all electric controls for the operation of the shredder run off the electrical system on the shred­der. There is a 7-pin SAE J560 trailer plug for tail light operation. The plug conforms to the SAE J560 wiring standard: Terminal 1 Ground Terminal 3 Left Turn Signal, Brakes Terminal 5 Right Turn Signal, Brakes Terminal 6 Tail Lights Engine Drive Shredder Tractor Hook-Up The supplied 3-point arch is a tongue extension which connects to the standard tractor 3point. This extended pivot point allows the shredder to track better when turn­ing at the row head. The added brush shield beneath the arch helps to better feed the machine. 1. Connect 3-point arch to tractor: Wrap lower, hinged brush pan chain around the tractor 3-point arm and attach chain to keyhole pad on pan: .g ii. The chain in the center of the brush pan is for arch storage and should be secured out of the way during operation. To minimize brush dragging under the tractor, full trac­tor belly plates are strongly recommended. The tractor belly plate needs to extend beyond the tractor rear axle to overlap the 3-point arch brush pan. Any gaps in the shielding are potential catch points for brush and may keep brush from feeding properly: .g i. 2. Remove hitch jaw cross bolt on shredder tongue: the lower bolt which pins the hitch jaw shut. Pivot the hitch jaw retainer band up so the jaws are free to move. With the band elevated, slide the bolt back into the band holes to keep the retainer band out of the way when hooking up: .g iii. 3. Align hitch ball with hitch jaw: back the tractor up with the hitch ball level with the hitch jaws. As the ball enters the jaws, the jaws will close around the ball. Back up until the jaws are fully closed. 4. Lower retainer band over jaws and re-insert cross bolt through jaws to keep them together. 5. Loop safety chain from the back of the 3-point arch through the eye on the shredder tongue. Fasten with supplied shackle: .g iv. 6. Connect hydraulic hoses to tractor remotes: hoses marked with orange ties control the upper feed roll lift. Hoses with purple ties actuate the axle pantograph. The line marked yellow is the case drain. The feed roll lift function (orange ties) will be used most frequently and should be easily accessible. 7. Mount the shredder control box on the tractor. 8. Connect the trailer plug to the tractor for the rear tail lights. There are two basic adjustments on the machine: gauge wheel height and the side roller length. 1. Set gauge wheel height: the gauge wheels are typi­cally set to where the feed rolls just skim the ground. The gauge wheels are intended to be a safety stop, protecting the lower feed roll .ngers in uneven terrain. The gauge wheels in normal operation should .oat over the terrain, suspended from the tractor 3-point. The wheels are adjusted by loosening all the mount plate bolts, sliding the wheel to the desired height, and tightening all fasteners: .g i. 2. Adjust side roller length: the side rolls are set so the bottom of the lower pipe just clears the ground during operation. Align holes on the inner pipe with those on the outer pipe to select from a range of side roll lengths: .g ii. If necessary, cut the inner pipe to the desired length. The bottom hole on the outer pipe is to allow the inner pipes to act as jackstands when working on the machine. 7 Engine Drive Shredder The control at the rear of the shredder, .g i, monitors the engine operating conditions to minimize the risk of engine failure due to overheating, low oil pressure, excessive temperatures, etc. The panel displays the engine coolant temperature, operating speed, oil pressure, fuel tank level, and total hours while the engine is running. The panel will also display error messages for engine problems if they arise. This control has an engine protection program that will reverse feed rolls if lugged down below 1400 rpm. An overload condition will occur if the engine lugs down below 1400 rpm for 30 seconds. The control will reduce the engine speed to idle, 800 rpm, and disengage the clutch (see CAUTION, below). An overload lamp on the control handset, .g ii, will light if this occurs. NOTE: the overload lamp will also light during shut down because of the sudden speed change- this is normal. CAUTION! If the engine overload lamp lights during operation, immediately switch OFF the clutch at the handset or the control panel. If you do not switch the clutch OFF, the clutch will attempt to re-engage every 30 seconds. The overload cause should be cleared from the machine (see Shredder Operation: Rotor Jams). After 30 seconds the shredder can be brought back to operating speed. If the engine fails to reach the minimum operating speed within 30 seconds, the engine will kick down to idle again and cannot be brought back up to speed for another 30 seconds. If the clutch cannot engage after 4 tries (overload due to a jammed rotor) the system will prevent additional attempts for 5 minutes, allowing the clutch to cool. IMPORTANT! DO NOT attempt to bypass the 5 minute clutch cool­ing period. Mechanical damage can occur if the clutch is not allowed to cool. If the clutch fails to engage 4 times DO NOT shut down the engine until the 5 minute cool off period is complete. To prevent overload conditions, listen for shredder engine lugging during operation: be aware of shred material load. If you hear the engine laboring, slow your ground speed and allow the material to clear- reverse feed rolls if needed to relieve engine load. Engine Drive Shredder Engine Operation: Starting 1. Make certain the rotor cavity is clear of material. 2. Turn Key to RUN on control panel, .g i. 3. The display will power up and should read: Press & Hold ENTER to Crank. If there is no power at the panel, the handset engine stop switch, .g ii, may be in the STOP position. 4. There is a clutch engage switch, .g ii, on the hand­set and below the control panel, .g i. One of these switches must be OFF to start unit. 5. Press ENTER on the control panel. The engine will start and run at idle speed, 800 rpm. 6. Turn on BOTH cooler fans, .g. i. 7. After 30 seconds, the clutch can be engaged. Turn ON handset and control panel clutch switches to engage clutch. Both must be ON to engage the clutch. There is a delay when engaging the clutch. The control will cycle 3 times to bring the rotor up to speed. If the hydraulic pressure in the clutch circuit is below 200psi, the engine will not run above idle speed. A pressure gauge is located on top of the clutch housing. Engine Operation: Stopping Reduce engine speed to idle. Let idle for at least two minutes to allow components to cool. At the con­trol panel turn the key to OFF or at the handset, .ip the engine stop switch to STOP. If the engine overload lamp is lit, switch the clutch OFF immediately at the handset or control panel before shutting down the machine. If the engine is overloaded and you have not shut OFF the clutch, the system will try to re-engage the clutch every 30 seconds, overheating the clutch. After 4 clutch engage­ment cycles have failed, the clutch will need a cooling period before shutdown: allow the engine to idle for 5 minutes before shut-down. If you are stopping to clear a rotor overload, please see the following section, Shredder Operation: Rotor Jams. Operating, handset control: Engine speed is controlled by the engine speed control switch on the handset, .g ii. To run the engine at operating speed, 2000 rpm, push the toggle switch to rabbit. To reduce speed to idle, push the toggle to turtle. Engine shutoff .ip the engine stop switch to STOP. Operating, ECU panel control: Engine speed is controlled by the UP and DN but­tons on the panel, .g i. To run the engine at operating speed, 2000 rpm, push the UP button. To reduce speed to idle, push the DN button. Engine shutoff turn the key to OFF. Engine Drive Shredder Shredder Operation 1. Make certain rotor cavity is clear of material. 2. Lower shredder axle to minimum height. 2. Lower upper feed roll. 3. Lower tractor 3-point so the gauge wheels on the shredder just clear the ground. 4. Engage clutch. 5. Bring shredder engine up to operating speed. 6. Turn on feed rolls. 7. Begin driving into brush. Turning at row end: lift the tractor 3-point so the gauge wheels clear the ground. Keep the feed rolls running and the shredder engine at full operating speed. With the 3-point arch installed, the shredder will track be­hind the tractor. For best material feeding stack brush across the row, perpendicular to the direction of travel. Larger pieces of wood (greater than 3” dia.) tend to feed better if in line with the direction of travel. Brush piles should be no wider than 8’. Freshly pruned wood shreds more eas­ily than wood that has had time to dry. Dried brush can take 2-3 times more horsepower to shred. Feed roll speed will depend on brush load, ground condi­tions, and ground speed. The lower feed rolls have a 2-speed valve mounted on the right/front corner of the shredder frame, .g i. Run the valve in low speed (valve handle up) for most shredding. For light brush condi­tions and higher ground speeds, run the valve in high speed (valve handle down). Adjust speed for the upper and lower feed rolls independently at the handset. Feed roll jams: brush blockages in the feed rolls can be backed out by hitting the feed roll reverse button. Sometimes the brush can be forced into the shredder by lifting the upper feed roll and lowering it back down. Rotor jams: An overload condition will occur if the engine lugs down below 1400 rpm for 30 seconds. The control will reduce the engine speed to idle, 800 rpm. An overload lamp on the control handset, .g ii, will light if this occurs. NOTE: the overload lamp will also light during shut down because of the sudden speed change- this is normal. To prevent overload conditions, listen for shredder engine lugging during operation: be aware of shred material load. If you hear the engine laboring, slow your ground speed and allow the material to clear- reverse feed rolls if needed to relieve engine load. Reduce the frequency of engine rpm kick-downs and engine restarts to insure long clutch life. If the engine overload lamp lights, switch off the clutch to prevent overheating- Switch the clutch ON when the blockage is cleared. See previous Engine Operation section for more clutch information. If the engine overloads and idles the rotor, the feed rolls reverse to back out material. The upper feed roll may have to be raised to allow all the brush to clear. Once clear, the rotor can be restarted. If a jam still persists in the rotor, the engine will overload when starting up. If the rotor jam persists, shut off the engine and re­move the key. DO NOT CLEAR THE JAM BY HAND WITH THE ENGINE RUNNING! Lower the .ail head to the ground and block the shred­der wheels. Raise the top feed roll and install the cylinder blocks on each side (illustrated, right). The cylinder blocks are stored in the fender toolbox behind the battery cabinet when delivered from the factory. Turn off the tractor and clear the rotor jam. Once the jam is clear you may remove the cylinder locks, lower the top feed roll and start up the engine. Machine Vibration: Uneven blade wear or blade dam­age can unbalance rotor and cause harmful machine vibration. If extreme vibration develops, shut down the machine and examine rotor for damage. Engine Drive Shredder KEEP YOUR DRIVE CLUTCH HEALTHY ...prevent overload conditions, listen for shredder engine lugging during operation: be aware of shred material load. If you hear the engine laboring, slow your ground speed and allow the material to clear- reverse feed rolls if needed to relieve engine load. Reduce the frequency of engine rpm kick-downs and engine restarts to insure long clutch life. PREVENT MACHINE DAMAGE ...shut down machine immediately when vibration develops. PREVENT WOOD DUST FIRES ...keep the engine compartment clear of wood dust & debris. ...provide the operator with a .re extinguisher. KEEP YOUR OPERATORS SAFE ...do not clear rotor jams by hand with the engine running! Engine Drive Shredder Maintenance speci.cations & measures Flail Belt 6/5VX800 Oil Filter RE57394 Engine Oil See Deere Engine Manual 28.5L/30.1QT New units change break-in oil at 100HR Primary Fuel Filter RE522687 Final Fuel Filter RE522688 Hydraulic Filter Zinga ZEE-304-10 (New units change .lter at 100HR) Hydraulic Oil Tractor hydraulic .uid 48GAL, dipstick in reservoir cap Engine Coolant See Deere Engine Manual 41.5QT Fuel Diesel 125GAL Air Filter, Primary Donaldson P181041 Air Filter, Safety Donaldson P119370 Gearbox Oil Schaeffer’s #167 Moly Synthetic SAE75W140 150OZ Accumulator Charge with Nitrogen @250PSI Tire Pressure 36PSI Battery 8D ORM 850 Belt, Fan & Alternator R135593 (John Deere); 8PK1760 (generic) Clutch Filter Zinga ZHE-10L (New units change .lter at 100HR) Lubrication schedule All lube points have been made accessible. For .rst time use, grease all lube points as instructed Lubrication does not require disassembly. on the lubrication schedule, below, EXCEPT the rotor bearings. The pre-lubricated rotor bearings are ready to operate as delivered and should be greased every eight Always use a Lithium base NLGI Grade 2 EP hours of operation. grease. We recommend Texaco Multifak EP2, Shell Alvania 2EP, and Mobil Mobilux EP2. Lubrication points are illustrated on the facing page. pt. hours pumps 1 Driveline U-joint Each cross on engine driveline 16 2-4 2 Driveline-gearbox adapter Slip sleeve on gearbox 16 purge 3 Driveline U-joint Crosses on each jackshaft driveline 16 1-2 4 Feed Roll Lift Arms Access hole for pivot bearing on each arm Weekly Purge 5 Jackshaft Bearing Point on each tensioner housing 16 1-2 6 Tensioner Pivot Pivot on each tensioner housing Monthly Purge 7 Jackshaft Bearing Topmost point on belt housing, each side 16 1-2 8 Rotor Bearing Middle point on belt housing, each side 8 20 9 Rotor Labyrinth Lowest point on belt housing, each side 8 20 10 Top Feed Roll Access hole each end of feed roll Daily To Resist 11 Bottom Feed Roll Access hole each end of feed roll Daily To Resist 12 Axle Pantograph Arm Pivot bearing on each arm Weekly Purge 13 Wheel Hub Grease point on outer hub housing Monthly Purge 14 Castor Hub Repack annually Annual – 15 Side Roll Hub Repack annually Annual – 16 Hydraulic oil tank Check daily: use tractor hydraulic .uid Daily – 17 Engine oil reservoir Check daily: see John Deere manual Daily – 18 Engine coolant tank Check daily: see John Deere manual Daily – 13 Engine Drive Shredder 11 Engine Drive Shredder STG G140076 air cleaner maintenance 1. Check dust cup DAILY. Dust cup should be dumped when 2/3 full. When re-installing the dust cup, be sure it seals 360° around the air cleaner body. 2. Check tubes for plugging. When the dust cap is removed, check the tubes for plugging. Generally the tubes are self-cleaning and need no service. Visual inspection is adequate: if the tubes carry light dust, remove it with a stiff brush. If heavy plugging with fibrous material is evident, remove the tube section and clean with compressed air or water no hotter than 160°F/72°C. Never clean tubes with compressed air unless both the primary and safety filters are installed in the air cleaner. Never steam-clean tubes. 3. CHECK AIR CLEANER message on the engine control panel indicates a plugged filter. Loosen the wingnut behind the filter cover and remove the primary filter. Clean or replace the primary filter. If the filter is not going to be replaced immediately, cover the filter cav­ity with a cloth or replace the housing cover to prevent dirt from getting into the air system. The Safety Filter will need replacing less frequently. See safety filter instructions, right. Before installing a NEW filter, inspect it for shipping damage and gasket integrity. If there is damage, DO NOT install it. 4. System check. Inspect and tighten all air cleaner sys­tem connections. If there are holes or damage, replace immediately. Inspect all gaskets for worn spots or dam­age. Annual replacement of gaskets is recommended. safety filter P119370 safety element X004816 primary filter P181041 gasket washer P105740 clamp P100861 wingnut body gasket P017335 cover gasket P016972 cover & latch P017617 latch repair kit cup gasket X005555 P017335 clamp P100866 safety signal X004816 Engine Drive Shredder Engine Drive Shredder pump SPD3-44-27-1H1R motors TG0335AS030AAAA cooler ILLC01101U relief valve RV-2H-3000 return filter EF-10-25-1 flow control A EF-15-12 element EE-304-10 B EF-25-12 directional control D3W2CNKK base AD05HSPS12S series/parallel DS3B-4E Hydraulic hose list Hydraulic .tting list Part # Description Qty ESH1 3016-10-KW-12OF90T-12OFS-11.0”HL 1 ESH2 3016-10-KW-12OFS-12OR-84.0”HL 1 ESH3 3016-10-KW-12OFS-12OR-78.0”HL 1 ESH4 3016-12-KW-12OF90T-12OFS-10.0”HL 1 ESH5B 3016-10-KW-12OFS-10OFS-120.0”HL 2 ESH7B 3016-12-KW-12OFS-12OF45T-18.5”HL 1 ESH8B 3016-12-KW-12OFS-24.0”HL 1 ESH10B 3016-12-KW-12OFS-20.5”HL 2 ESH11B 3016-12-KW-12OR-12OFS-40.0”HL 1 ESH12B 3016-12-KW-12OFS-40.0”HL 1 ESH14B 3016-10-KW-10OFS-10OFS-138.0”HL 2 ESH15B 3016-10-KW-10OFS-10OFS-106.0”HL 2 ESH17B 3100-16-KW-16OF90T-16OFS-104.0”HL 1 ESH18B 3100-16-KW-16OFS-16MS-94.0”HL 1 ESH20 4200-04-KW-4MP-34.0”HL 1 ESH21 4200-04-KW-4MP-26.0”HL 1 Location Part # Description Qty Pump suction 4603-24-24 45° -24HB x -24SAE 1 Tank suction 4503-24-24 45° -24HB x -24MPT 1 Pump pressure outlet, small OFS6801-12-12 90° -12SAE x -12OFS 1 Pump pressure outlet, large OFS6801-12-16 90° -16SAE x -12OFS 1 Relief inlet OFS2503-12-12 45° -12OFS x -12MPT 2 Pump pressure OFS6602-12-12-12 run tee -12OFS 2 Speed to directional valve 12F5BU-S ferulok -12SAE straight 4 Upper feed OFS6801-12-12 90° -12SAE x -12OFS 1 Upper&Lower feed OFS6400-12-12 straight -12SAE x -12OFS 1 Directional valve return OFS6802-12-12 45° -12SAE x -12OFS 2 Speed return OFS6801-12-12 90° -12SAE x -12OFS 2 Selector RH & LH motor OFS6801-10-10 90° -10SAE x -10OFS 3 Selector inlet OFS6400-12-10 straight -10SAE x -12OFS 2 Selector LH motor 10F65OL str -10SAE x -10OFSswivel 1 Return manifold OFS6400-12-12 straight -12SAE x -12OFS 4 Return manifold/retn .lter OFS6400-16-16 straight -16SAE x -16OFS 2 Feed Cooler OFS6801-16-16 90° -16SAE x -16OFS 2 Upper Feed motors OFS6400-10-10 straight -10SAE x -10OFS 6 Bottom Feed motors OFS6802-10-10 45° -10SAE x -10OFS 6 Engine Drive Shredder Upper feed roll lift circuit: 11/2” x 6” cylinders Axle lift circuit: 3” x 8” cylinders 250psi pre-charge TRACTOR REMOTES pilot to close valve LODC-XDN-ECI relief valve RDDA-LAN-FAI accumulator 4.5AL-4 needle valve N400-S flow control valve F400-S Hydraulic hose list Hydraulic .tting list Part # Description Qty ESH22 4200-04-KW-4MP-20.0”HL 1 ESH23 4200-04-KW-4MP-12.0”HL 1 ESH24 4200-04-KW-4MP-8MP-228.0”HL 2 ESH30 4200-04-KW-4MP-67.0”HL 1 ESH31 4200-04-KW-4MP-30.0”HL 1 ESH32 4200-04-KW-4MP-102.0”HL 1 ESH33 4200-04-KW-4MP-22.0”HL 1 ESH34 4200-04-KW-4MP-13.0”HL 1 ESH35 4200-04-KW-4MP-7.0”HL 1 ESH36 4200-04-KW-4MP-8MP-156.0”HL 2 ESH37 4200-04-KW-4MP-156.0”HL 1 Location Part # Description Qty Tractor hose ends S71-4 1/2” QC tip 4 Lift cylinders 6901-06-04 90° -6SAE x -4FPS 7 Feed lift cylinder 6405-06-04 straight -6SAE x -4FPT 2 Feed lift cylinder PBG006A 1/4” gearbox vent 2 Feed lift cylinder SSSTL025 1/4” 90° street el 2 Feed lift 6401-06-04 -6SAE x -4MPT 2 Feed lift 1601-04-04-04 -4MPT x -4 tee 2 Feed lift 1603-04-04-04 -4 swivel tee 4 Feed lift 5404-04-04 -4 nipple 2 Feed lift 1501-04-04 90° -4MPT x -4FPS 1 Feed lift 1404-04-04 straight -4MPT x -4FPS 1 Directional valve 6409-04 -4SAE plug 4 Engine Drive Shredder Clutch hydraulics ESH7 ESH48 Hydraulic hose list Hydraulic .tting list Part # Description Qty ESH7 3016-12-KW-12OFS-12OF45T-20.0”HL 1 ESH8 3016-12-KW-12OFS-12OF90T-17.0”HL 1 ESH9 3016-12-KW-12OFS-12OF45T-16.0”HL 1 ESH41 3400-20-18”HL 1 ESH42 3400-24-24”HL 1 ESH43 3400-24-17”HL 1 ESH44 3400-16-18”HL 1 ESH47 3100-12-KW-12OFS-28.0”HL 1 ESH48 3100-12-KW-12OFS-12OF90T-52”HL 1 ESH49 3100-12-KW-12OFS-12FJ-98.0”HL 1 Location Part # Description Qty Scavenge pump outlet OFS6801-12-12 90° -12SAE x -12OFS 1 Scavenge pump outlet OFS6602-12-12-12 run tee -12OFS 1 Scavenge motor OFS6400-12-10 straight -10SAE x -12OFS 2 Clutch circuit relief valve OFS6801-12-12 90° -12SAE x -12OFS 1 Clutch circuit relief valve OFS6400-12-12 straight -12SAE x -12OFS 1 Clutch circuit .lter housing OFS6801-12-12 90° -12SAE x -12OFS 2 Clutch circuit relief @ tank OFS2404-12-12 straight -12MPT x -12OFS 1 Scavenge cooler OFS6801-12-16 90° -16SAE x -12OFS 2 Clutch upper drain 4503-24-24 45° -24HB x -24MPT 1 Engine Drive Shredder 1.25a FUSE BLACKORANGEBLUE WHITEGREENRED BLACKORANGEBLUE WHITEGREENRED BLACK WHITE GREEN (24') 16/6 CABLE (22') 16/6 CABLE WHITE-BLACKRED-BLACK BLUE ORANGEREDGREEN-BLACK 16/6 cable: valve cable black valve ground orange speed control blue speed control white solenoid B (front): reverse green solenoid A (rear): forward red n/a (41'6") 16/9 CABLE 16/9 cable: control box cable black ground white engine stop (022d) green engine stop (032) blue engine speed increase orange engine speed decrease white-black overload indicator light red 10A circuit breaker, ignition red-black clutch engage green-black feed reverse 12/2 CABLE (1’ 6”) 12/2 CABLE (4’ 6”) LIGHT SWITCH LIGHT SWITCHCOOLER COOLER 21 Engine Drive Shredder wiring diagram tail light harness CONNECT TO 7-PIN SAE J560 PLUG PIN WHITE 1 RED 3 GREEN 5 BLACK 6 (36’) 16/4 CABLE GROUND LH TURN RH TURN TAIL (4) TAIL LIGHT PIGTAIL 47723 Engine Drive Shredder Drive belt stretching Most belt damage occurs during the .rst hours of use. Check new belt tension after one hour of operation and make any required adjustments. Check the belt tension periodically during a new belt’s .rst day of use. Belt tension should be checked daily as a part of your lubrication schedule. Too little belt tension will cause belt and pulley wear. Too much tension will cause bearing wear. To loosen or remove belts: back the jam nuts off the tension­er body and turn the threaded tension rod counter clockwise- this will move the drive pulleys closer together. To remove the belt, continue to turn the tension rod until the belt can be lifted off the pulleys. To tighten belts: back the jam nuts off the tensioner body and turn the threaded tension rod clockwise to pull the drive pulleys apart. Tighten the tension rod until the belts are pulled to their proper tension, as described below. Tighten the jam nuts. Tensioning the drive belt Slack off the tension on the drive belt until the drive belt is loose. Wrap a non-elastic string or band around the outside of the drive belt (.g. 1a). Your measuring string or band should not stretch while measuring. The string should be snug to the belt. The string should be in contact with the belt all the way around. For accurate measurement, as illustrated in .g. 2, the string should be aligned with the edge of the drive belt. Mark the string where the end overlaps itself (.g. 2). Mark your target tension stretch on the string: select your jackshaft pulley/rotor pulley/belt combination on chart A, right, and .nd your target stretch. Add a new line to your measuring string: from the overlap line marked on your mea­suring string, mark the target stretch distance on the string, see .g. 2. Tighten the tension on the drivebelt until the string overlap reaches the target stretch line, see .g. 3. Do not re-use the measuring string the next time you tension the drive belt. Each time you tension the drive belt, you must re-measure the slack belt length and re-mark the target stretch. Rears Manufacturing Company Inc. 800 547 8925 measuring string or band should be snug to belt .g. 1a: slack drive belt .g. 1b: drive belt with proper tension jackshaft pulley rotor pulley belt size target tension stretch 9.75 9.75 800 1/2” -3/4” chart A mark target stretch mark slack length measuring string drive belt string parallel with belt edge .g. 2: mark slack belt length mark target stretch mark slack length .g. 3: pull belt to target stretch Engine Drive Shredder QD bushing removal 1. Remove cap screws as illustrated, right, and insert them into the threaded jack-screw holes, J. Do not use lubricants or anti-sieze compounds on threads or tapered surfaces. 2. With all three screws inserted into the bushing jack-screw holes: tighten each screw in small, equal amounts; alternately and progressively (start with the screw furthest from the split in the bushing) until the tapered surfaces release. Never use excessive or unequal pressure on the cap-screws. You may damage the bushing. QD bushing installation 1. The surfaces of the bushing tapered cone and the mating bore of the pulley must be clean and free of dirt, excess paint, metal chips, lubricant, etc. 2. On a clean work surface, line up the unthreaded holes of the bushing, C, as illustrated, with the threaded holes of the pulley, T. Insert cap screws with lock washers and tighten a few turns- engage only a few threads. Do not use lubricants or anti-sieze compounds on threads or tapered surfaces. 3. With the key in the drive shaft keyway, slide the loosely assembled unit onto the shaft and align the pulleys using a straight edge. Note for alignment: when tightening the cap screws the pulley will move, drawn to the bushing. The bushing will not move on the shaft when the cap screws are tightened. 4. Carefully tighten cap screws alternately and progressively to half the recommended torque (see chart, right). Never use excessive or unequal pressure on the cap-screws. You may damage the bushing. 5. Use a straight edge to check pulley alignment and pulley runout (wobble)- correct as needed. 6. Continue careful alternate and progressive tightening of screws to recommended torque value (see chart, right). Properly installed assemblies will have a gap between the bushing .ange and the face of the pulley. 7. Some assemblies have a set screw over the bushing key-way. If this applies to your model, tighten to secure the shaft key. to remove bushing Do not use lubricants or anti-sieze compounds on threads or tapered surfaces. Never use excessive or unequal pressure on the cap-screws. You may damage the bushing. torque bushing cap (ft.lbs.) size screw 40jackshaft 1/2”- 13 thread 40rotor 1/2”- 13 thread Engine Drive Shredder Feed roll assembly Feed roll parts quantities listed per asssembly Slide bearing 3 onto feed roll stub shaft 4- do not tighten. Insert keyed motor drive shaft 1 into feed roll stub shaft as illustrated (if feed roll has no motor drive, skip ahead to stub shaft installation). Prepare groovelock bolt 5 with Loctite primer and Loctite 2760 as per Loctite instructions. Thread groovelock bolt into motor shaft and tighten by hand. Back off to align tab on bolt retainer 8 with keyslot in rotor stub shaft 4. Slide bolt retainer to shoulder of groovelock bolt and install snap-ring 9. Apply Loctite 2760 to threads of setscrew 2 and install. Bolt the feed roll stub shaft 4 to the feed roll 5 using fastners 7. Slide the completed feed roll assembly into position us­ing the provided access slot in the .ail housing and bolt the bearing mount plates to the .ail housing. Tighten the bearing eccentric lock collar 3 in the direc­tion of shaft rotation. No. Part # Description Qty 1 TG0335AS030AAAA hydraulic motor 1 2 0310025SET 5/16”-18UNC x 1/4” setscrew 1 3 TCJT-2-3/16 bearing 1 4 ES1017 feed roll stub shaft 1 5 ES1046 5/8”-18UNF x 3-1/2” groovelock bolt 1 6 ES1018 upper feed roll 1 ES1019 lower feed roll 1 7 0510150CH5 1/2”-20UNF x 1-1/2” gr5 bolt 6 05WS 1/2” lock washer 6 8 (see No.5) Groovelock keeper- included with No.5 1 9 (see No.5) Groovelock snap-ring- included with No.5 1 10 ESIN1237 Torque arm 1 11 0500175AHS 1/2”-13 x 1-3/4” .at head allen bolt 2 050NYS 1/2”-13 nylock nut 2 12 ES1051 Torque arm stop 1 13 0870150CH5 7/8”-9 x 1-1/2” gr5 bolt 1 087WS 7/8” lockwasher 1 Engine Drive Shredder Parts list: comer gearbox 1000 rpm 23 22 1 2 3 4 5 6 24 7 8 9 4 10 ratio 1:1 25 input shaft 1.75” 20 spline output shaft 1.75” 20 spline oil Schaeffer’s high temperature 169 moly synthetic gear lubricant SAE75W140. 150oz/4.4litre No. Part # Description FLGB85020 1000RPM Comer 1:1 gearbox 1 8.1.1.00061 bolt M10x25 8,8 2 0.703.7500.00 shim 99.7 3 8.0.9.00107 bearing 30309 4 0.252.7500.00 shim 65.3 5 0.301.0300.00 casing 6 0.121.7101.00 cap 7 0.132.7107.00 nut M40 x 1.5 8 8.4.7.01112 cotter pin B4 x 60 9 0.301.5003.00 pinion Z20 M7 10 8.6.5.00203 plug 1/2”GAS 11 0.301.3013.00 shaft 1-3/4” Z20 12 8.7.3.00331 oil seal 45 x 85 x 10 13 0.244.7510.00 shim 40.3 x 1.0 14 0.712.7500.00 shim 70.3 15 8.0.9.00268 bearing 30310 16 8.0.9.00469 bearing 30210 17 0.301.2202.00 shaft 1-3/4” Z20 18 8.7.3.01296 oil seal 55 x 90 x 10 19 0.301.1300.00 extension 20 8.6.5.00006 plug 3/8” GAS 21 0.301.1302.00 cover 22 8.3.3.01114 copper washer 23 8.6.0.01113 oil plug extension- not a dipstick 24 0.124.7101.00 plate 25 8.6.7.00269 oil .ller plug 2 11 Qty 12 12 21 3 18 2 9 13 2 1 14 2 15 1 1 1 19 20 1 20 2 18 16 1 17 1 2 1 1 1 OIL FILL POINT 1 not a dipstick 1 1 1 2 OIL FILL 1 INDICATOR 1 Level gearbox 1 1 Remove indicator plug Fill to opening 150oz/4.4 litres 1 gearbox mount bolts- M16 x 35 Engine Drive Shredder . . . . . . . . . . . . . . . . . Parts list: belt tensioner assembly No. Part # Description Qty OMT200 tensioner assy includes • parts OMT200KIT repair kit includes x parts 1 • tensioner housing 1 4 mount pin 1 5 OMT118 tension bolt for .ail chopper 1 6 062NF 5/8”NC nut 2 7 OMT111 eyebolt pivot shaft 1 8 FLT111 threaded eyebolt pivot shaft 1 9 LCT125 • dust shield 1 10 0250025K2ST x 1/4”-20 x 1/4” set screw 4 11 x nylon thread saver 4 Tensioner bearing removal 1. On a clean work surface, remove set screws 20 and set collar 19. Loosen set screws 10. 2. Using an adjustable spanner wrench, remove the bear­ing retainer 17. 3. Clean and insert jackshaft. 4. Reinstall set collar 19 and .rmly tighten set screws 20 to shaft through bearing holes. From the opposite end, press/drive the bearing cone 16 and extract outer bear­ing cup 15 from cavity. Remove components from the shaft. 5. Repeat steps 1-4 to remove opposing bearing assembly. 6. Use a drift with care to pull the grease retainer 22 and cup 15 from cavity. . . . 9 . No. Part # Description Qty 12 7200-98 x snap ring 2 13 OMT122 • x cast iron bushing 2 14 Z1641B • grease zerk 1/4”-28 1 15 362 • x timken bearing cup 4 16 367DE • x timken bearing cone 2 17 OMT104 • x bearing retainer 2 18 23035 • x outer grease seal 2 19 OMT102 • bearing collar 2 20 0370037K1NST • 3/8”-24 x 3/8” set screw 4 21 Z1688B • grease zerk 1/8”NPT 2 22 OMT103 • x inner grease retainer 2 Tensioner bearing installation 1. Clean the tensioner housing 1 and insert the grease retainer 22- the dished face of the retainer installs with the bevel at the same angle as the inner bearing cup 15, see .g.i, next page. Press inner bearing cup 15 into the housing cavity. 2. Insert bearing cone 16 into the housing well greased. Press outer bearing cup 15 against bearing cone 16. 3. Press seal 18 into retainer 17 as illustrated, below. The seal should be pressed in 1/32”-1/16” from the retainer’s top face. 1/32”-1/16” 4. Screw threaded bearing/retainer assembly tight against the outer bearing cup 15. Back off 1/8 turn. continued, next page Engine Drive Shredder CDE BA Tensioner bearing installation, continued 5. Adjust tensioner bearings individually: Insert jackshaft and install collar 19 at either B or D in .g i, above. The set screw holes are drilled offset and the collar should be installed with the set screws closer to the bear­ing. Tighten setscrews 20. Press/drive jackshaft from end opposite bearing to push bearing 15 against the retainer 17. Target clearance is .004”-.005” end play: tighten 17 until correct. 6. Use #242 Loctite to install both set screws 10 and thread savers 11-tightly securing the retainer 17 you just .nished adjusting. 7. Loosen the setscrews 20 for the bearing adjusted in step 6 and repeat steps 5 & 6 to set end play in the opposing bearing. 8. Loosen the setscrews 20. Move on to Jackshaft Installa­tion. Jackshaft installation 1. Insert jackshaft from the belt housing end A, .g i. Slide shaft through tensioner housing and install jack-shaft driveline yoke onto shaft. Drive rollpin to secure yoke to shaft at C. 2. Tighten both collar setscrews at B to secure bearing to jackshaft. 3. Thread both collar setscrews at D through collar and into inner bearing race BUT DO NOT TIGHTEN against jackshaft. 4. Bearing setting. Press jackshaft at A while simultane­ously prying collar at points E away from tensioner housing. Hold this force on the bearing/jackshaft as­sembly as you lock setscrews onto shaft at D. 5. Check shaft end play. Target clearance is .004”-.005” end play: repeat step 4 until target clearance is se­cured. If target clearance cannot be attained, return to the Tensioner Bearing Installation section, step 5, and check the end play of tensioner bearings individually. Adjust bearings as needed, then restart the Jackshaft Installation procedure. Rotor bearing lubrication The pre-lubricated rotor bearings are ready to operate as delivered and should be greased (20 pumps) every 8 hours of operation as per the lubrication schedule on page 7. Pump slowly. Excess grease is purged through a vented seal on the back of the assembly. The bearings can not be over-greased. Always use a lith­ium base NLGI grade 2 EP grease. We recommend Texaco Multifak EP2, Shell Alvania 2EP, and Mobilux EP2. Outer rotor bearing removal To prevent damage to the rotor anti-wraps, the rotors must each be supported with a jack prior to bearing removal. For ease of removal, the rotor shaft must be clean and smooth. File or sand burrs or gouges. To prevent damage to seals from wiggling the assembly off the shaft, grip opposite sides of the mount plate and exert equal force. Outer rotor bearing installation 1. Clean all bearing mount surfaces- thoroughly clean the shafting of all dirt, rough spots and burrs. This area must be smooth. Apply a light coat of oil or grease to mating surfaces. 2. Make certain to align the grease holes A in the bearing 1, adapter plate 4, and grease labyrinth 5 when assem­bling the complete bearing. 3. Slide entire bearing assembly onto the rotor shaft. DO NOT hammer on the bearing! If .t is snug, use emery cloth to smooth rough spots on shaft. To prevent damage to seals from wiggling the assembly onto the shaft, grip opposite sides of the mount plate and exert equal force. 4. Use original bolts or equivalent to mount the bearing assembly to the .ail housing and rotor anti-wraps. Mount bearing so grease .ttings are easily accessible. Fasten tightly. Check that the rotor spins freely- any friction will damage the bearing assembly. Mount bolts must be tight before proceeding to step 5. 5. Tighten the eccentric lock 2 by hand in the direction of shaft rotation. With the lock hand tight, insert a driv­ing tool into hole X and tap tool a few times to secure the collar. Tighten allen head screws 3. Check that the rotor spins freely- any friction will damage the bearing assembly. Engine Drive Shredder 1. Bolt only the bushing 2 between rotor pads using bolt assembly 4. 2. Torque to 113 ft-lbs. Verify that pads clamp bushing and prevent it from turning. If bushing is not clamped in place, remove fasteners and heat/straighten bent rotor pad. 3. If pads clamp bushing properly, remove bushing and slide it into hammer 1. Bolt the hammer/bushing as­sembly to rotor pads using fasteners 4. Torque to 113 ft-lbs. Rotor pad replacement 1. Damaged or missing rotor pads can be replaced. Contact Rears Mfg. Co. for welding instructions: 800.547.8925. 2. Welding on the rotor drum will change the rotor shape and can cause machine vibration. Rotors should be bal­anced after pad replacement. 3. Place shaft 8 on mount and .nger-tighten all bolts. 4. Torque bolts in sequence, illustrated below, to 20 ft-lbs. 5. Torque bolts in sequence to 50 ft-lbs. 6. Torque bolts in sequence to 90 ft-lbs 1 7 8 rotor torque pattern Engine Drive Shredder universal joint disassembly Remove all (4) snap rings in cross assembly 1. Position joint in loose vice 2. Strike top arm of unsupported yoke to drive the top cup up. Repeat on the opposite side. Grip loosened cup in vice 3 and strike yoke arm to drive yoke off cup. Repeat on opposite cup. Support cross in loose vice 4 and strike yoke arm to drive the top cup up. Repeat on opposite side. Repeat step 3 to remove the remaining two cups. Note: Yoke arms must be true. If a yoke arm is sprung by striking with excessive force, the cross will bind in operation. True yoke test- slide a machined rod (a few thousandths under cup diameter) through the yoke arms. The yoke must be replaced if the yoke won’t slide com­pletely onto the rod. 55 series rod diameter 1.530” 35 series rod diameter 1.247 universal joint reassembly Clean bearings 1 before assembling cross. Cups should be free from dirt- and be certain the seal from the previous cross does not remain in the cup. Smear grease in the clean bearing. Make certain all needle bearings are seated properly. Clean bearing seat in yoke arms. Check for burrs (in new yokes also). File out any burrs: bearing seat should be smooth and clean. Yoke arms must be true (see true yoke test, above). If a yoke arm is sprung by striking with excessive force, the cross will bind in operation. Rears Manufacturing Company Inc. 800 547 8925 Where a spacer is required, select a diameter that evenly distributes force around the outer edge of the bearing cup. Choosing a spacer of insuf.cient diameter or using no spacer at all will drive the bearings unevenly and cause the joint to bind in operation. You should assemble the joint in a clean area. Insert the cup and cross 2 and drive in with a spacer. Insert snap ring 3. Insert second cup 4 and hold cross in place to drive on cup. Drive cup down with spacer and insert snap ring. To loosen cross, strike yoke arm 5 and check cross for free rotation. Position second yoke on cross 6 and repeat steps 2 to 5. ENGINE DRIVE SHREDDER LIMITED WARRANTY Rears Manufacturing Company Incorporated, hereafter referred to as Rears, makes every effort to assure that its products meet high quality and durability standards subject to the provisions hereinafter set forth. Rears does hereby warrant to the original purchaser of an Engine Drive Shredder manufactured by Rears for a period of one (1) year from the date of purchase or .ve hundred (500) hours of operation, whichever occurs .rst, that such product will be free from defects in material and workmanship under normal use with normal maintenance service. This warranty does not cover component parts of products manufactured by Rears when such component parts are subject to a manufacturer’s warranty. In addition, this warranty does not cover pressure gauges. THE EXCLUSIVE REMEDY FOR ANY DEFECTS COVERED BY THIS WARRANTY SHALL BE THE OBLIGATION OF REARS TO REPAIR OR REPLACE ANY PARTS OF SAID PRODUCTS WHICH SHALL, WITHIN ONE (1) YEAR FROM THE DATE OF PURCHASE OR FIVE HUN­DRED (500) HOURS OF OPERATION, WHICHEVER OCCURS FIRST, BE DETERMINED TO THE SATISFACTION OF REARS UPON REARS’ EXAMINATION, TO HAVE BEEN THUS DEFECTIVE. In order to take advantage of this limited warranty the defective product must be returned for examination, freight pre­paid, to Rears or an authorized dealer designated by Rears. Proof of purchase date and explanation of the defect must accompany the returned product. REARS MAKES NO EXPRESSED OR IMPLIED WARRANTIES OF ANY KIND, INCLUDING THE IMPLIED WARRANTIES OF MERCHANT­ABILITY AND OF FITNESS FOR ANY PARTICULAR PURPOSE OTHER THAN STATED HEREIN. The limited warranty contained herein shall not apply to any product if it shall have been repaired or altered by personnel not authorized by Rears or if the product shall have been subject to misuse, negligence or accident. THE REMEDIES PROVIDED HEREIN ARE THE EXCLUSIVE REMEDIES TO THE PURCHASER AND REARS SHALL NOT BE LIABLE TO THE PURCHASER OR ANY OTHER PARTY FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OR ANY CAUSE, LOSS, AC­TION, CLAIM OR DAMAGE WHATSOEVER FOR INJURY TO PERSON OR PROPERTY OR ANY CONSEQUENTIAL ECONOMIC OR INCI­DENTAL LOSS RESULTING FROM ANY DEFECT IN MATERIALS OR WORKMANSHIP OF THE PRODUCT SOLD. Rears will assign to the original purchaser upon request all warranties on component parts if permitted by the manufacturer of such component parts. Purchaser Name Purchase Date Address Model City State/Zip Serial Number Dealer Name Address Sales person City Phone State/Zip #RearsMfg #OperatorsManual #Implements #PartsManual #Parts #Shredder

    • Kubota RTV900 Operators Manual

      The Kubota RTV900 Utility Vehicle Owner and Operators Manual is available as a PDF or for purchase. (Click image to view or download as pdf) The Kubota RTV900 Operators Manual is posted below in plain text for your convenience. READ AND SAVE THIS MANUAL PRINTED IN U.S.A. © KUBOTA Corporation 2009 ABBREVIATION LIST Abbreviations Definitions 2WD Two Wheel Drive 4WD Four Wheel Drive API American Petroleum Institute ASABE American Society of Agricultural and Biological Engineers, USA ASTM American Society for Testing and Materials, USA DIN Deutsches Institut für Normung, GERMANY fpm Feet Per Minute HST Hydrostatic Transmission Km/h Kilometers Per Hour MPH Miles Per Hour m/s Meters Per Second PTO Power Take Off RH/LH Right-hand and left-hand sides are determined by facing in the direction of forward travel ROPS Roll-Over Protective Structures rpm Revolutions Per Minute r/s Revolutions Per Second SAE Society of Automotive Engineers, USA VHT Variable Hydro Transmission KUBOTA Corporation is ··· Since its inception in 1890, KUBOTA Corporation has grown to rank as one of the major firms in Japan. To achieve this status, the company has through the years diversified the range of its products and services to a remarkable extent, until today, 19 plants and 16,000 employees produce over 1,000 different items, large and small. All these products and all the services which accompany them, however, are unified by one central commitment. KUBOTA makes products which, taken on a national scale, are basic necessities. Products which are indispensable, products intended to help individuals and nations fulfill the potential inherent in their environment. For KUBOTA is the Basic Necessities Giant. This potential includes water supply, food from the soil and from the sea, industrial development, architecture and construction, transportation. Thousands of people depend on KUBOTA's know-how, technology, experience and customer service. You too can depend on KUBOTA. UNIVERSAL SYMBOLS As a guide to the operation of your vehicle, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning. Safety Alert Symbol Diesel Fuel Hourmeter/Elapsed Operating Hours Engine Coolant-Temperature Brake Fluid & Parking Brake Engine Intake/Combustion Air-Filter Battery Charging Condition Engine Oil-Pressure Turn Signal/Hazard Engine-Stop Engine-Run Starter Control Diesel Preheat/Glow Plugs(Low Temperature Start Aid) Engine Shut-Off Control Differential Lock Differential Lock Hold Lift Cylinder-Retract Lift Cylinder-Extend Lift Cylinder-Float Hazard Warning Lights Master Lighting Switch Audible Warning Device Fast Slow Lock Unlock FOREWORD You are now the proud owner of a KUBOTA Vehicle. This vehicle is a product of KUBOTA quality engineering and manufacturing. It is made of excellent materials and under a rigid quality control system. It will give you long, satisfactory service. To obtain the best use of your vehicle, please read this manual carefully. It will help you become familiar with the operation of the vehicle and contains many helpful hints about vehicle maintenance. This manual contains instructions for minor maintenance, but information about major repairs is outlined in the KUBOTA Work Shop Manual and should be performed only by a KUBOTA Dealer Technician. It is KUBOTA's policy to utilize as quickly as possible every advance in our research. The immediate use of new techniques in the manufacture of products may cause some small parts of this manual to become outdated. KUBOTA distributors and dealers will have the most up-to-date information. Please do not hesitate to consult with them. 3 SAFETY FIRST This symbol, the industry's ''Safety Alert Symbol'', is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit. 3DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. 3 WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. 3CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed. NOTE : Gives helpful information. CONTENTS SAFE OPERATION ................................................................................................. 1 SERVICING OF VEHICLE........................................................................................... 1 SPECIFICATIONS....................................................................................................... 2 SPECIFICATION TABLE ......................................................................................... 2 TRAVELING SPEEDS ............................................................................................. 3 VEHICLE LIMITATIONS.............................................................................................. 4 INSTRUMENT PANEL AND CONTROLS................................................................... 5 LOCATION OF PARTS............................................................................................ 5 PRE-OPERATION CHECK ......................................................................................... 9 DAILY CHECK ......................................................................................................... 9 OPERATING THE ENGINE....................................................................................... 10 STARTING THE ENGINE...................................................................................... 10 Cold Weather Starting ....................................................................................................13 Block Heater...................................................................................................................13 STOPPING THE ENGINE...................................................................................... 13 WARMING UP ....................................................................................................... 13 Warm-Up Transmission Oil in the Low Temperature Range..........................................13 JUMP STARTING .................................................................................................. 14 OPERATING THE VEHICLE..................................................................................... 15 OPERATING NEW VEHICLE ................................................................................ 15 Do not Operate the Vehicle at Full Speed for the First 50 Hours ...................................15 Changing Lubricating Oil for New Vehicles ....................................................................15 STARTING............................................................................................................. 15 Seat Belt.........................................................................................................................15 Head Light Switch...........................................................................................................16 Hazard Light Switch........................................................................................................16 Turn Signal Light Switch.................................................................................................16 Horn Button.....................................................................................................................17 Work Light (Front)...........................................................................................................17 Work Light (Rear) ...........................................................................................................17 Brake Pedal....................................................................................................................18 Range Gear Shift Lever..................................................................................................18 4WD Lever......................................................................................................................19 Parking Brake Lever.......................................................................................................19 Speed Control Pedal.......................................................................................................19 STOPPING............................................................................................................. 20 Stopping..........................................................................................................................20 CHECK DURING DRIVING ................................................................................... 20 Immediately Stop the Engine if:......................................................................................20 Easy Checker(TM)..........................................................................................................20 Fuel Gauge.....................................................................................................................21 Coolant Temperature Gauge..........................................................................................21 Hourmeter.......................................................................................................................21 CONTENTS Speedometer ..................................................................................................................22 PARKING............................................................................................................... 22 Parking Brake Lever.......................................................................................................22 ACCESSORY......................................................................................................... 23 12V Electric Outlet..........................................................................................................23 Utility Box........................................................................................................................23 OPERATING TECHNIQUES ................................................................................. 23 Differential Lock..............................................................................................................23 Directions for Use of Power Steering..............................................................................24 Unfamiliar Terrain...........................................................................................................24 Driving in Reverse ..........................................................................................................25 Driving in "4WD".............................................................................................................25 Turning the Vehicle.........................................................................................................26 Hills.................................................................................................................................26 Traversing Hillsides ........................................................................................................27 Sliding and Skidding.......................................................................................................27 Driving through Water.....................................................................................................27 OPERATING HAND THROTTLE........................................................................... 28 STATIONARY HYDRAULIC OUTLET ................................................................... 28 CARGO BED ............................................................................................................. 29 CARGO BED.......................................................................................................... 29 General Caution..............................................................................................................29 Max. Cargo Load............................................................................................................29 Cargo Bed Tailgate.........................................................................................................30 Raising and Lowering the Cargo Bed.............................................................................31 HYDRAULIC OUTLET............................................................................................... 32 HYDRAULIC OUTLET ........................................................................................... 32 Hydraulic Outlet Lever....................................................................................................32 Hydraulic Outlet Valve Coupler Connecting and Disconnecting.....................................33 TIRES AND WHEELS ............................................................................................... 34 TIRES..................................................................................................................... 34 Inflation Pressure............................................................................................................34 Tire Type and Use..........................................................................................................34 WHEELS................................................................................................................ 35 TOWING AND TRANSPORTING.............................................................................. 36 TOWING AND TRANSPORTING .......................................................................... 36 Rear Trailer Hitch............................................................................................................36 Front Trailer Hitch...........................................................................................................36 Winch Mount Bracket......................................................................................................37 Transporting Vehicle.......................................................................................................37 MAINTENANCE......................................................................................................... 38 SERVICE INTERVALS .......................................................................................... 38 LUBRICANTS, FUEL AND COOLANT .................................................................. 41 PERIODIC SERVICE................................................................................................. 44 HOW TO OPEN THE HOOD AND TILT THE SEAT.............................................. 44 Hood ...............................................................................................................................44 Operator's Seat...............................................................................................................44 HOW TO RAISE THE CARGO BED...................................................................... 45 CONTENTS Raising and Lowering the Cargo Bed [if equipped with hydraulic dump]........................45 Raising and Lowering the Cargo Bed [without hydraulic dump].....................................46 JACK-UP POINT.................................................................................................... 46 Front End........................................................................................................................46 Rear End.........................................................................................................................46 DAILY CHECK ....................................................................................................... 47 Walk Around Inspection..................................................................................................47 Checking and Refueling..................................................................................................47 Checking Engine Oil Level..............................................................................................48 Checking Transmission Fluid Level................................................................................48 Checking Power Steering Oil Tank Level.......................................................................49 Checking Hydraulic Lift Oil Tank Level...........................................................................49 Checking Hydraulic Auxiliary Tank Oil Level..................................................................50 Cleaning Oil Cooler Net..................................................................................................50 Checking Coolant Level..................................................................................................51 Cleaning Radiator Screen...............................................................................................51 Checking Brake Fluid Level............................................................................................52 Checking Brake Pedal....................................................................................................52 Checking Parking Brake.................................................................................................53 Checking Gauges, Meter and Easy Checker(TM)..........................................................53 Checking Head Light, Turn Signal Light etc. ..................................................................53 Checking Seat Belt and ROPS.......................................................................................53 Checking Joint Boot........................................................................................................53 Checking Tire Inflation Pressure.....................................................................................54 Checking Backup Beeper...............................................................................................54 EVERY 50 HOURS................................................................................................ 55 Greasing .........................................................................................................................55 Oiling...............................................................................................................................56 Checking Engine Start System.......................................................................................56 EVERY 100 HOURS.............................................................................................. 57 Checking VHT Neutral Spring.........................................................................................57 Checking VHT Pressure Release...................................................................................57 Checking Wheel Bolt Torque..........................................................................................58 Cleaning Air Cleaner Primary Element...........................................................................59 Adjusting Alternator Belt Tension ...................................................................................59 Checking Fuel Line and Fuel Filter.................................................................................60 Checking Battery Condition............................................................................................61 Adjusting Toe-in..............................................................................................................62 Cleaning Muffler..............................................................................................................63 EVERY 150 HOURS.............................................................................................. 64 Cleaning Air Cleaner Primary Element...........................................................................64 EVERY 200 HOURS.............................................................................................. 65 Adjusting Parking Brake .................................................................................................65 Replacing Engine Oil Filter.............................................................................................65 Changing Engine Oil.......................................................................................................66 Replacing Transmission Oil Filter [HST].........................................................................67 Replacing Transmission Oil Filter [SUCTION]................................................................68 Changing Hydraulic Lift Oil.............................................................................................69 Changing Hydraulic Auxiliary Tank Oil ...........................................................................70 Checking Brake Pedal....................................................................................................71 Checking Brake Hose and Pipe......................................................................................71 Checking Front Brake Case............................................................................................72 CONTENTS Checking Brake Light Switch..........................................................................................72 Checking Radiator Hose and Clamp ..............................................................................72 Checking Power Steering Line .......................................................................................73 Changing Power Steering Oil .........................................................................................74 Checking Intake Air Line.................................................................................................75 Checking Hydraulic Auxiliary Oil Line.............................................................................75 EVERY 300 HOURS.............................................................................................. 76 Checking Tire..................................................................................................................76 EVERY 400 HOURS.............................................................................................. 76 Changing Knuckle Case Oil............................................................................................76 Changing Transmission Fluid.........................................................................................76 Replacing Hydraulic Auxiliary Tank Oil Filter..................................................................77 Changing Front Axle Case Oil........................................................................................78 EVERY 500 HOURS.............................................................................................. 79 Replacing Fuel Filter.......................................................................................................79 EVERY 800 HOURS.............................................................................................. 79 Adjusting Engine Valve Clearance .................................................................................79 EVERY 1500 HOURS............................................................................................ 79 Checking Fuel Injection Nozzle Injection Pressure.........................................................79 EVERY 3000 HOURS............................................................................................ 79 Checking Injection Pump................................................................................................79 EVERY 1 YEAR ..................................................................................................... 79 Replacing Air Cleaner Primary Element and Secondary Element..................................79 EVERY 2 YEARS................................................................................................... 79 Changing Brake Fluid.....................................................................................................79 Flushing Cooling System and Changing Coolant...........................................................79 Anti-Freeze .....................................................................................................................80 Replacing Radiator Hose (Water pipes).........................................................................81 Replacing Power Steering Hose.....................................................................................81 Replacing Fuel Hose ......................................................................................................81 Replacing Engine Breather Hose ...................................................................................81 Replacing Brake Master Cylinder (Inner Parts)..............................................................81 Replacing Front Brake Seal............................................................................................81 Replacing Rear Brake Cylinder Seal..............................................................................81 Replacing Intake Air Line................................................................................................81 Replacing Remote Hydraulic Hose.................................................................................81 EVERY 4 YEARS................................................................................................... 81 Replacing Brake Hose....................................................................................................81 SERVICE AS REQUIRED...................................................................................... 81 Bleeding Fuel System.....................................................................................................81 Replacing Fuse...............................................................................................................81 Replacing Slow-Blow Fuses...........................................................................................82 Replacing Light Bulb.......................................................................................................83 Cleaning Oil Cooler Net..................................................................................................83 STORAGE ................................................................................................................. 84 VEHICLE STORAGE ............................................................................................. 84 REMOVING THE VEHICLE FROM STORAGE..................................................... 84 TROUBLESHOOTING............................................................................................... 85 ENGINE TROUBLESHOOTING ............................................................................ 85 BATTERY TROUBLESHOOTING ......................................................................... 86 CONTENTS MACHINE TROUBLESHOOTING ......................................................................... 87 OPTIONS................................................................................................................... 88 SAFE OPERATION SAFE OPERATION Careful operation is your best insurance against an accident. Read and understand this Operator's Manual carefully before operating the vehicle. All operators, no matter how much experience they may have, should read this and other related manuals before operating the vehicle or any implement attached to it. It is the owner's obligation to instruct all operators in safe operation. 1. BEFORE OPERATING THE VEHICLE 1. Know your equipment and its limitations. Read this entire manual before attempting to start and operate the vehicle. 2. Pay special attention to the Danger, Warning and Caution labels on the vehicle. 3. Do not remove Roll-Over Protective Structures (ROPS) for any application and fasten seat belts at all times. This combination will reduce the risk of serious injury or death, should the vehicle be upset. If the ROPS is loosened or removed for any reason, make sure that all parts are reinstalled correctly before operating the vehicle. Never modify or repair a ROPS because welding, bending, drilling, grinding, or cutting may weaken the structure. A damaged ROPS structure must be replaced, not repaired or revised. If any structural member of the ROPS is damaged, replace the entire structure at your local KUBOTA Dealer. 4. Always use the seat belts. Check the seat belts regularly and replace if frayed or damaged. 5. Do not operate the vehicle or any implement attached to it while under the influence of alcohol, medication, controlled substances or while fatigued. 6. Carefully check the vicinity before operating the vehicle or any implement attached to it. Check for overhead clearance which may interfere with the CAB or ROPS. Do not allow any bystanders around or near the vehicle during operation. 7. Never allow anyone without a valid driver's license to operate this vehicle. 8. Before allowing other people to use your vehicle, explain how to operate and have them read this manual before operation. 9. Never wear loose, torn, or bulky clothing around the vehicle. It may catch on moving parts or controls, leading to the risk of an accident. Use additional safety items, e.g. helmet, safety boots or shoes, eye and hearing protection, gloves, etc., as appropriate or required. 10.This vehicle is for off road use only. KUBOTA does not recommend operating on public roads. 11.In addition to the driver, only one passenger should ride in the vehicle. Minimum age for passenger is 5 years old. 12.Keep all shields in place and stay away from all moving parts. 13.Check brakes, speed control pedal, and other mechanical parts for improper adjustment and wear. Replace worn or damaged parts promptly. Check the tightness of all nuts and bolts regularly. (For further details, see "MAINTENANCE" section.) 14.Keep your vehicle clean. Dirt, grease, and trash build up may contribute to fires and lead to personal injury. 15.Use only implements meeting the specifications listed under "VEHICLE LIMITATIONS" in this manual or implements approved by KUBOTA. 16.The maximum cargo capacity of this vehicle is 500kg. Reduce cargo capacity to match operating conditions. Do not carry anything which raises the center-of­gravity and sticks outside the cargo bed. 17.Do not modify the vehicle. Unauthorized modification may affect the function of the vehicle, which may result in personal injury. SAFE OPERATION 2. OPERATING THE VEHICLE C Starting 1. Always sit in the operator's seat when starting engine or operating levers or controls. 2. Before starting the engine, make sure that all levers are in their neutral positions, that the parking brake is engaged, and that the hydraulic outlet (if equipped) is OFF. And make sure the engine hand throttle (if equipped) is in its idle engine speed position. 3. Do not start engine by shorting across starter terminals or bypassing the safety start switch. The vehicle may start in gear and move if normal starting circuitry is bypassed. 4. Be sure that the operator (and passenger) seat belts are fastened. 5. Do not operate or idle engine in a non-ventilated area. Carbon monoxide gas is colorless, odorless, and deadly. C Operating 1. Do not wear headphones while operating. 2. Pull only from the trailer hitch (if equipped). Never hitch to axle housing or any other point except trailer hitch; such arrangements will increase the risk of serious personal injury or death due to a vehicle upset. 3. Keep all shields and guards in place. Replace any that are missing or damaged. 4. Avoid sudden starts. To avoid rollovers, slow down when turning, on uneven ground, and before stopping. While increasing engine speed with the engine hand throttle (if equipped), operate the speed control pedal with great care to avoid sudden starts. 5. The vehicle cannot turn with the differential locked and attempting to do so could be dangerous. 6. Do not operate near ditches, holes, embankments, or other ground surface features which may collapse under the vehicle's weight. The risk of vehicle upset is even higher when the ground is loose or wet. 7. Watch where you are going at all times. Watch for and avoid obstacles. Be alert at row ends, near trees, and other obstructions. 8. When working in groups, always let the others know what you are going to do before you do it. 9. Never try to get on or off a moving vehicle. C Safety for children Tragedy can occur if the operator is not alert to the presence of children. Children generally are attracted to vehicles and the work they do. 1. Never assume that children will remain where you last saw them. 2. Keep children out of the work area and under the watchful eye of another responsible adult. 3. Be alert and shut your vehicle down if children enter the work area. 4. Never carry children in the cargo bed. There is no safe place for them to ride. No person under the age of 5 may ride as a passenger in this vehicle. A passenger under 5 years of age requires special restraints which are not available with this vehicle. 5. Never allow children to operate the vehicle even under adult supervision. 6. Never allow children to play on the vehicle or on the implement. 7. Use extra caution when backing up. Look behind and down to make sure area is clear before moving. 8. Whenever possible, park your vehicle on a firm, flat and level surface. If this is not possible, park it across the slope. Set the parking brake(s), lower the implements to the ground, remove the key from the ignition and lock the cab door (if equipped) and chock the wheels. C Operating on slopes Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. All slopes require extra caution. 1. Travel straight up or down hill. 2. Reduce load when operating on hilly or over rough terrain. 3. Keep front wheels straight at crest of hill or going over bumps. 4. Do not stop or start suddenly when going uphill or downhill. Be especially cautious when changing direction on slopes. 5. If vehicle stops or loses power going up a hill, lock parking brake to hold vehicle on slope. Maintain direction of travel and release brake slowly. Back straight downhill while maintaining control. Do not turn vehicle sideways. Vehicle is more stable in a straight forward or rearward position. 6. When riding on soft terrain, turn front wheels slightly uphill to keep vehicle on a straight line across the hill. 7. If the vehicle begins to tip, turn front wheels downhill to gain control before proceeding. SAFE OPERATION (1) To avoid upsets, always back up steep slopes. If you cannot back up the slope or if you feel uneasy on it, do not operate on it. Stay off slopes too steep for safe operation. (2) Driving forward out of a ditch, mired condition or up a steep slope increases the risk of a vehicle to be upset backward. Always back out of these situations. Extra caution is required with four-wheel drive mode because the increased traction can give the operator false confidence in the vehicle's ability to climb slopes. (3) Keep all movement on slopes slow and gradual. Do not make sudden changes in speed or direction. C Operation in inclement conditions 1. Only operate during daylight or with good artificial light. 2. Operate vehicle in an open, unobstructed area. 3. Use helmet and/or protective gear for certain operating conditions. 4. Reduce speed according to trail, terrain and visibility conditions. 5. Never drive exceeding the limit of visibility. Slow down near crest of hill until getting a clear view of the other side. 6. Stay alert for holes, rocks and other hidden hazards in the terrain. 7. Never cross any body of water where depth may be unknown to the operator (Deep water is considered anything in excess the bottom edge of the axle cap). Choose a course within the waterway where both banks have a gradual incline. Cross at a point known to be safe. C Driving the vehicle at high speeds 1. Check the front wheel engagement. The braking characteristics are different between two and four wheel drive. Be aware of the difference and use carefully. 2. Always slow the vehicle down before turning. Turning at high speed may tip the vehicle over. 3. Turn the headlights on. 4. Drive at speeds that allow you to maintain control at all times. 5. Do not apply the differential lock while traveling at high speeds. The vehicle may run out of control. 6. Avoid sudden motions of the steering wheel as they can lead to a dangerous loss of stability. The risk is especially great when the vehicle is traveling at high speeds. C Other miscellaneous 1. Clean platform if dirty and remove any debris from around foot controls. 2. Always keep both hands on the steering wheel. 3. Always keep arms and legs inside the operating compartment. 4. Never operate the vehicle while standing. 5. Do not tow a cart with any riders on it. 6. Never attempt wheelies, jumps or other stunts. 3. HAULING LOADS IN THE CARGO BED 1. No riders in cargo bed or anywhere else. 2. Do not overload vehicle. Securely anchor all loads. 3. Be sure load is evenly distributed. 4. Reduce cargo capacity when operating on rough or hilly terrain. 5. Balance loads evenly and secure them. Braking could shift the load and affect vehicle stability. 6. Never operate vehicle with the cargo bed raised. 7. Operate cargo bed dump with vehicle stationary and parking brake locked. Do not dump while moving. 8. Operate hydraulic dump (if equipped) on level ground only. 9. Operate dump from operator's seat only. 10.Do not place hands or body under the cargo bed when lowering bed. 4. OPERATING HYDRAULIC OUTLET DRIVEN EQUIPMENT (IF EQUIPPED) 1. Before installing or using hydraulic outlet driven equipment, read the manufacturer's manual and review the safety labels attached to the equipment. 2. Wait until all moving components have completely stopped before getting off the vehicle, connecting, disconnecting, adjusting, cleaning, or servicing any hydraulically driven equipment. 3. When operating stationary hydraulically driven equipment, always apply the vehicle parking brake and place chocks behind and in front of the rear wheels. Stay clear of all rotating parts. Never step over rotating parts. SAFE OPERATION 5. Keep first aid kit and fire extinguisher handy at all 5. PARKING THE VEHICLE times. 6. Disconnect the battery's ground cable before working 1. Disengage the HYDRAULIC OUTLET (if equipped), lower all implements to the ground, place all control levers in their neutral positions, set the parking brake, stop the engine, and remove the key. 2. Make sure that the vehicle has come to a complete stop before dismounting. 3. Avoid parking on steep slopes, if possible park on flat ground, if not, park across a slope, always with attachment on the ground. 1. Disengage power to attachment(s) when transporting or not in use. 2. Do not tow this vehicle. Use a suitable truck or trailer when transporting on public roads. 3. Use extra care when loading or unloading the vehicle into a trailer or truck. 7. SERVICING THE VEHICLE Before servicing the vehicle, park it on a firm, flat and level surface, set the parking brake, lower all implements to the ground, place the range gear shift lever in neutral, stop the engine and remove the key. 1. Allow the vehicle time to cool off before working on or near the engine, muffler, radiator, etc. 2. Always stop the engine before refueling. Avoid spills and overfilling. 3. Do not smoke when working around battery or when refueling. Keep all sparks and flames away from battery and fuel tank. The battery presents an explosive hazard, because it gives off hydrogen and oxygen especially when recharging. 4. Before "jump starting" a dead battery, read and follow all of the instructions. (See "JUMP STARTING" in "OPERATING THE ENGINE" section.) on or near electric components. 7. To avoid the possibility of battery explosion, do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark. Check the fluid level regularly and add distilled water as required so that the fluid level is between the UPPER and LOWER marks. 8. To avoid sparks from an accidental short circuit, always disconnect the battery's ground cable (-) first and reconnect it last. 9. Do not remove radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. This vehicle has a coolant recovery tank, add coolant or water to the tank, not the radiator. (See "Checking Coolant Level" in "DAILY CHECK" in "PERIODIC SERVICE" section.) 10.Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. 11.Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure shown in the operator's manual. SAFE OPERATION 13.Make sure that wheel bolts have been tightened to the specified torque. 14.Do not work under any hydraulically supported devices. They can settle, suddenly leak down, or be accidentally lowered. If it is necessary to work under the vehicle or any vehicle elements for servicing or adjustment, securely support them with stands or suitable blocking beforehand. 15.Escaping hydraulic fluid under pressure has sufficient force to penetrate skin causing serious personal injury. Before disconnecting hydraulic lines, be sure to release all residual pressure. Before applying pressure to the hydraulic system, make sure that all connections are tight and that all lines, pipes, and hoses are free of damage. "High pressure fluid - Injection into body" hazard warning. 16.Fluid escaping from pinholes may be invisible. Do not use hands to search for suspected leaks; use a piece of cardboard or wood. Use of safety goggles or other eye protection is also highly recommended. If injured by escaping fluid, see a medical doctor at once. This fluid will produce gangrene or severe allergic reaction. (1) Cardboard (2) Hydraulic line (3) Magnifying glass SAFE OPERATION 8. DANGER, WARNING AND CAUTION LABELS SAFE OPERATION SAFE OPERATION SAFE OPERATION 9. CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth. 3. Replace damaged or missing danger, warning and caution labels with new labels from your local KUBOTA Dealer. 4. If a component with danger, warning and caution label(s) affixed is replaced with new part, make sure new label(s) is(are) attached in the same location(s) as the replaced component. 5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressing any bubbles to outside edge. SERVICING OF VEHICLE Your dealer is interested in your new vehicle 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 by yourself. However, when in need of parts or major service, be sure to see your KUBOTA Dealer. For service, contact the KUBOTA Dealership from which you purchased your vehicle or your local KUBOTA Dealer. When in need of parts, be prepared to give your dealer both the vehicle and engine serial numbers. Locate the serial numbers now and record them in the space provided. (1) Vehicle identification plate (2) Product identification number (1) Engine serial number (2) Transmission assy serial number Type Serial No. Vehicle Engine Product Identification Number Date of Purchase Name of Dealer (To be filled in by purchaser) SPECIFICATIONS SPECIFICATIONS SPECIFICATION TABLE Model General Purpose Worksite /Orange Worksite /Camo Worksite /Utility Turf Utility Engine Make KUBOTA D902-E3-UV Type 3 cylinders, 4-cycle, diesel, OHV Displacement L (cu. in.) 0.898 (54.802) Horsepower kW (HP) 16.1 (21.6) Rated revolution rpm 3200 Low idling revolution rpm 1300 to 1400 Fuel Capacity L (U.S.gals) 28 (7.4) Transmission Continuously variable hydro transmission (VHT) Wheels, Drive system 4, Rear 2WD or 4WD Differential lock Standard; foot operated with mechanical holder Gear selection Hi-Med-Lo range forward, neutral, reverse Brakes Front / Rear Wet disk brake Parking brake Rear wheel, hand lever Steering Hydrostatic power Suspension Front Independent, macpherson strut-type Rear Semi-independent, DeDion axle w/leaf springs and shock absorber Dimensions Length mm (in.) 2990 (117.7) 3030 (119.3) Width mm (in.) 1550 (61.0) Height, overall mm (in.) 2010 (79.1) Front tread centers mm (in.) 1150 (45.3) HDWS, ATV 1180 (46.5) Turf Rear tread centers mm (in.) 1180 (46.5) HDWS, ATV 1210 (47.6) Turf Wheelbase mm (in.) 1965 (77.4) Ground clearance front axle mm (in.) 210 (8.3) rear axle 190 (7.5) Turning diameter m (ft) 7.8 (25.6) Max. rolling weight (Towing Capacity) kg (lbs.) 590 (1300) Payload capacity kg (lbs.) 775 (1708) 750 (1653) 755 (1664) 720 (1587) 715 (1576) Weight kg (lbs.) 845 (1863) 870 (1918) 865 (1907) 900 (1984) 905 (1995) SPECIFICATIONS Model General Purpose Worksite /Orange Worksite /Camo Worksite /Utility Turf Utility Cargo bed Width mm (in.) 1320 (52) Length mm (in.) 1180 (46.7) Depth mm (in.) 290 (11.4) Volume m (cu.ft.) 0.455 (16) Bed height (unloaded) mm (in.) 800 (31.5) Cargo bed load kg (lbs.) 500 (1102) Sound level, operator ear db (A) 87 89 Tires Front 25x10-12 ATV, 6PLY 25x10-12 HDWS, 6PLY 25x12-12 Turf, 4PLY 25x10-12 ATV, 6PLY 25x10-12 HDWS, 6PLY 25x10-12 HDWS, 6PLY 25x12-12 Turf, 4PLY Rear 25x11-12 ATV, 6PLY 25x10-12 HDWS, 6PLY 25x12-12 Turf, 4PLY 25x11-12 ATV, 6PLY 25x10-12 HDWS, 6PLY 25x10-12 HDWS, 6PLY 25x12-12 Turf, 4PLY Front deluxe guard - Std. Std. Std. Std. Body color Orange Orange Camo Orange Orange Bed lift - Std. Std. Std. Std. Speedometer - - Std. Std. Std. Aux. control valve - - - Std. Std. A The company reserves the right to change the specifications without notice. A The values in "Ground clearance" and "Weight" are those of the machine equipped with the tires in the table above. TRAVELING SPEEDS Range gear shift lever km/h (mph) Low 16 (10) Medium 29 (18) High 40 (25) Reverse 20 (12) VEHICLE LIMITATIONS The KUBOTA Vehicle has been thoroughly tested for proper performance with implements sold or approved by KUBOTA. Use with implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Vehicle may result in malfunctions or failures of the vehicle, damage to other property and injury to the operator or others. [Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty] Max. Cargo loading weight (W1) Rear trailer hitch Front trailer hitch Max. Cargo load should not exceed "500 kg (1100 lbs.)" or "PCL". [General Purpose model] PCL = 775 kg (1708 lbs.) - (operator + passenger + opt. + acc. + cabin) weight [Worksite/Orange model] PCL = 750 kg (1653 lbs.) - (operator + passenger + opt. + acc. + cabin) weight [Worksite/Camo model] PCL = 755 kg (1664 lbs.) - (operator + passenger + opt. + acc. + cabin) weight [Worksite/Utility model] PCL = 720 kg (1587 lbs.) - (operator + passenger + opt. + acc. + cabin) weight [Turf Utility model] PCL = 715 kg (1576 lbs.) - (operator + passenger + opt. + acc. + cabin) weight PCL: Permissible Cargo Load opt.: option acc.: accessory Max. rolling weight (W2) 590 kg (1300 lbs.) Max. rolling weight (W4) 295 kg (650 lbs.) Max. tongue weight (W3) 50 kg (110 lbs.) Max. tongue weight (W5) 50 kg (110 lbs.) Rolling weight: Trailer weight + Cargo Load A Above mentioned specifications are based on level ground condition. INSTRUMENT PANEL AND CONTROLS INSTRUMENT PANEL AND CONTROLS LOCATION OF PARTS ILLUSTRATED CONTENTS (1) Work light (if equipped)................................... 17, 17 (2) ROPS............................................................. -­ (3) Hazard / Turn signal light (if equipped)........... 16, 16 (4) Front hood...................................................... 44 (5) Headlights...................................................... 16 (6) Winch mount bracket...................................... 37 (7) Front trailer hitch bracket................................ 36 (8) Battery........................................................... 61 (9) Front trailer hitch (if equipped)........................ 36 INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS (1) Steering wheel................................................. -­ (2) Cup holder........................................................ -­ (3) Horn button...................................................... 17 (4) Key switch........................................................ -­ (5) Turn signal light switch (if equipped)................. 16 (6) Head light switch.............................................. 16 (7) Hazard light switch (if equipped)....................... 16 (8) Brake pedal...................................................... 18 (9) Speed control pedal......................................... 19 ILLUSTRATED CONTENTS (10) 4WD lever...................................................... 19 (11) Range gear shift lever..................................... 18 (12) Speedometer (if equipped)............................. 22 (13) Hourmeter...................................................... 21 (14) Coolant temperature gauge............................ 21 (15) Hazard / Turn signal indicator (if equipped).... 16, 16 (16) Fuel gauge..................................................... 21 (17) Easy Checker(TM)......................................... 20 (18) 12V accessory plug........................................ 23 INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS (1) Seat belts....................................................... 15 (2) Seat............................................................... 44 (3) Differential lock pedal..................................... 23 (4) Differential lock holder.................................... 23 (5) Parking brake lever........................................ 22 (6) Hydraulic lift cylinder lever (if equipped)......... 31 (7) Hydraulic outlet lever (if equipped)................. 32 (8) Engine hand throttle (if equipped)................... 28 INSTRUMENT PANEL AND CONTROLS ILLUSTRATED CONTENTS (1) Cargo bed........................................................ 29 (2) Tailgate............................................................ 30 (3) Tail lamp (Combination lamp if equipped)......... 16 (4) Muffler.............................................................. 63 (5) Rear trailer hitch bracket................................... 36 (6) Handgrip.......................................................... -­ ILLUSTRATED CONTENTS (7) Fuel tank cap.................................................... 47 (8) Remote hydraulic outlet (if equipped)............... 32 (9) Hydraulic outlet for lift cylinder (if equipped)...... 31 (10) Rear trailer hitch (if equipped)......................... 36 (11) Backup beeper (if equipped)........................... 54 PRE-OPERATION CHECK DAILY CHECK To prevent trouble from occurring, it is important to know the condition of the vehicle well. Check it before starting. A Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake "ON" and implement lowered to the ground if equipped. Check item - Walk around inspection -Check engine oil level - Check transmission fluid level - Check brake fluid level - Check hydraulic auxiliary tank oil level (if equipped) - Clean hydraulic oil cooler net (if equipped) -Check coolant level -Clean grill, radiator screen (When used in a dusty place) -Check brake pedal - Check parking brake - Check indicators, gauges and meters - Check lights - Check seat belt and ROPS - Check front and rear joint boots - Check drive shaft boots - Check tire inflation pressure - Check backup beeper (if equipped) -Refuel (See "DAILY CHECK" in "PERIODIC SERVICE" section.) -Care of danger, warning and caution labels (See "DANGER, WARNING AND CAUTION LABELS" in "SAFE OPERATION" section.) OPERATING THE ENGINE To avoid personal injury A Read "Safe Operation" in front of this manual. A Read the danger, warning and caution labels located on the vehicle. A To avoid the danger of exhaust fume poisoning, do not operate the engine in a closed building without proper ventilation. A Never start engine while standing on ground. Start engine only from operator's seat. A Make it a rule to set range gear shift lever to the "NEUTRAL" position and to place the Hydraulic Outlet lever (if equipped) in "OFF" position and to place the hydraulic lift cylinder lever (if equipped) to the "NEUTRAL" position before starting the engine. A Make sure the engine hand throttle (if equipped) is in its idle engine speed position. A Do not use starting fluid or ether. A To protect the battery and the starter, make sure that the starter is not continuously turned for more than 10 seconds. STARTING THE ENGINE 1. Make sure the parking brake is set. A The parking brake indicator comes on while parking brake is applied and goes off when it is released. (1) Parking brake indicator 2. Set the range gear shift lever to the "NEUTRAL" position. (1) Range gear shift lever (L) LOW Range (H) HIGH Range (R) "REVERSE" (M) MEDIUM Range (N) "NEUTRAL" POSITION 3. Lock the hydraulic lift cylinder lever to the "NEUTRAL" position with a restricting plate by tightening knob bolt (if equipped). (1) Hydraulic lift cylinder lever (if equipped) (A) "LOCK" (2) Restricting plate (if equipped) (3) Knob bolt (if equipped) 4. Lock the hydraulic lift cylinder lever and the hydraulic outlet lever to the "NEUTRAL" position with restricting plate (if equipped). (1) Hydraulic outlet lever (if equipped) (A) "LOCK" (2) Hydraulic lift cylinder lever (if equipped) (3) Restricting plate (if equipped) (4) Knob bolt (if equipped) A The hydraulic outlet warning lamp comes on while hydraulic outlet lever is engaged "ON" and goes off when disengaged "OFF". 5. Push the speed control pedal down about 1/2 way. ( )"OFF" (Engine-Stop) ( )"GLOW" (Preheat) ( )"ON" (Engine-Run) ( )"START" (Engine-Start) C Check Easy Checker(TM) Lamps: 1. When the key is turned "ON", lamps(2)(3) should come on. If trouble should occur at any location while the engine is running, the warning lamp corresponding to that location comes on. 2. The parking brake warning lamp(1) comes on while parking brake is applied and goes off when it is released. If the parking brake is released but the lamp stays on, it means that the brake fluid may be low or the brake system may be damaged. (See "Checking Brake Fluid Level" in "DAILY CHECK" in "PERIODIC SERVICE" section.) 3. The hydraulic outlet warning lamp(5) comes on while hydraulic outlet lever is engaged "ON" and goes off when disengaged "OFF" (if equipped). A Daily checks with the Easy Checker(TM) only, are not sufficient. Never fail to conduct daily checks carefully by referring to "DAILY CHECK" in "PERIODIC SERVICE" section. 7. Turn the key to "PREHEAT" position and hold it for the preheating. For the appropriate preheating time, refer to the table below: Temperature Preheating Time Over 0 (32 ) 2 to 3 sec. 0 to -5 (32 to 23 ) 5 sec. -5 to -15 (23 to 5 ) 10 sec. Limit of continuous use 30 sec. A Glow plug indicator(4) comes on while key switch is in the "GLOW" position or "START" position. 8. Turn the key to "START" position and release when the engine starts. A Because of safety devices, the engine will not start except when the range gear shift lever is placed in the "NEUTRAL" position and (if equipped) the hydraulic outlet lever is placed in the "OFF" position. BCold Weather Starting When the ambient temperature is below 0 (32 ) and the engine is very cold. If the engine fails to start after 10 seconds, turn off the key for 30 seconds. Then repeat steps 6 and 7. To protect the battery and the starter, make sure that the starter is not continuously turned for more than 30 seconds. BBlock Heater [if equipped] A block heater is available as an option from your dealer. It will assist you in starting your vehicle when the ambient temperature is below -20 (-4 ). 9. Check to see that all the lamps on the Easy Checker(TM) are "OFF". If any lamp stays on, immediately stop the engine and determine the cause. STOPPING THE ENGINE 1. After slowing the engine to idle, turn the key to "OFF". 2. Remove the key. 3. Return the engine hand throttle (if equipped) to its idle engine speed position. WARMING UP To avoid personal injury: A Be sure to set the parking brake during warm-up. A Be sure to set the range shift lever to the "NEUTRAL" position and lock both the hydraulic lift cylinder and the hydraulic outlet levers to the "NEUTRAL" position with restricting plate (if equipped) during warm-up. For 5 minutes after engine start-up, allow the engine to warm up without applying any load. This is to allow oil to reach every engine part. If load should be applied to the engine without this warm-up period, trouble such as seizure, breakage or premature wear may develop. BWarm-Up Transmission Oil in the Low Temperature Range Hydraulic oil serves as transmission fluid. In cold weather, the oil may be cold with increased viscosity. This can cause delayed oil circulation or abnormally low hydraulic pressure for some time after engine start-up. This in turn can result in trouble in the hydraulic system. To prevent the above, observe the following instructions: Warm up the engine at about 50% of rated rpm according to the table below: Ambient temperature Warm-up time requirement Above 0 (32 ) Approx. 5 minutes -10 to 0 (14 to 32 ) 5 to 10 minutes -20 to -10 (-4 to 14 ) 10 to 15 minutes Below -20 (-4 ) More than 15 minutes A Do not operate the vehicle under full load condition until it is sufficiently warmed up. JUMP STARTING To avoid personal injury: A Battery gases can explode. Keep cigarettes, sparks, and flames away from battery. A If vehicle battery is frozen, do not jump start engine. A Do not connect other end of negative jumper cable to negative terminal of vehicle battery. A The parts such as the muffler may be hot. Be careful not to get burned in connecting jumper cables. When jump starting engine, follow the instructions below to safely start the engine. 1. Bring helper vehicle with a battery of the same voltage as disabled vehicle within easy cable reach. "THE VEHICLES MUST NOT TOUCH". 2. Engage the parking brake of both vehicles and put the shift lever in neutral. Shut the engine off. 3. Put on safety goggles and rubber gloves. 4. Ensure the vent caps are securely in place. (if equipped) 5. Cover vent holes with damp rags. Do not allow the rag to touch the battery terminals. 6. Attach the red clamp to the positive (red, (+) or pos.) terminal of the dead battery and clamp the other end of the same cable to the positive (red, (+) or pos.) terminal of the helper battery. 7. Clamp the other cable to the negative (black, (-) or neg.) terminal of the helper battery. 8. Clamp the other end to the engine block or frame of the disabled vehicle as far from the dead battery as possible. 9. Start the helper vehicle and let its engine run for a few moments. Start the disabled vehicle. 10.Disconnect the jumper cables in the exact reverse order of attachment. (Steps 8, 7 and 6). 11.Remove and discard the damp rags. (1) Dead battery (2) Lay a damp rag over the vent caps (3) Jumper cables (4) Helper battery A This vehicle has a 12 volt negative (-) ground starting system. A Use only same voltage for jump starting. A Use of a higher voltage source could result in severe damage to vehicle's electrical system. Use only matching voltage source when "Jump starting" a low or dead battery. OPERATING THE VEHICLE OPERATING NEW VEHICLE How a new vehicle is handled and maintained determines the life of the vehicle. A new vehicle just off the factory production line has been, of course, tested, but the various parts are not accustomed to each other, so care should be taken to operate the vehicle for the first 50 hours at a slower speed and avoid excessive work or operation until the various parts become "broken-in." The manner in which the vehicle is handled during the "breaking-in." period greatly affects the life of your vehicle. Therefore, to obtain the maximum performance and the longest life of the vehicle, it is very important to properly break-in your vehicle. In handling a new vehicle, the following precautions should be observed. BDo not Operate the Vehicle at Full Speed for the First 50 Hours A Do not start quickly nor apply the brakes suddenly. A In winter, operate the vehicle after fully warming up the engine. A Do not run the engine at speeds faster than necessary. A On rough roads, slow down to suitable speeds. Do not operate the vehicle at fast speed. The above precautions are not limited only to new vehicles, but to all vehicles. But it should be especially observed in the case of new vehicles. BChanging Lubricating Oil for New Vehicles The lubricating oil is especially important in the case of a new vehicle. The various parts are not "broken-in" and are not accustomed to each other. Small pieces of metal grit may develop during the operation of the vehicle; and this may wear out or damage the parts. Therefore, care should be taken to change the lubricating oil a little earlier than would ordinarily be required. For further details of change interval hours, see "MAINTENANCE" section. STARTING 1. Fasten the seat belt. BSeat Belt To avoid personal injury: A Seat belts reduce injury. Always wear your seat belts. The lap-style seat belts may not provide adequate protection for small children. Special care is recommended when carrying a child passenger. A Always use the seat belts when operating and riding in the vehicle. Adjust the seat belts for proper fit and connect the buckle. This seat belt is an auto-locking retractable type. 2. Selecting light switch position. BHead Light Switch The head light switch is operative when the key switch is in the "ON" position. Turn on the key switch and press the top half of the head light switch, the head lights light up. Press the bottom half of the head light switch to turn off the head light. A Pressing the head light switch to the "ON" position causes the following lamps to light simultaneously. (1) Tail lights (lamps at the rear portions of the vehicle) (2) Lamp built in the coolant temperature gauge (3) Lamp built in the fuel gauge (4) Lamp built in the speedometer (if equipped) BHazard Light Switch [if equipped] Press the top half of the hazard light switch, the hazard light flash along with the indicator on the instrument panel. Press the bottom half of the hazard light switch to turn off the hazard light. A The hazard light switch is operative when the key switch is in either the "ON" or "OFF" position. Be careful that leaving the switch "ON" causes the battery to run out. BTurn Signal Light Switch [if equipped] To indicate a right turn, push right side. To indicate a left turn, push left side. When the left or right signal is activated, the indicated turning light will flash and the other will stay on. The indicator lamp at the instrument panel also flashes like the above. A The turn signal light switch is only operative when the key switch is in the "ON" position. A If the hazard light switch is pressed to the "ON" position while the turn signal is activated, the indicated turning light will flash and the other will stay on. A Be sure to return switch to center position after turning. (1) Speedometer (if equipped) (4) Hazard light switch (2) Hazard / Turn signal (if equipped) indicator (if equipped) (5) Coolant temperature gauge (3) Turn signal light switch (6) Fuel gauge (if equipped) BHorn Button The horn switch is operative when the key switch is in either the "ON" or "OFF" position. The horn will sound when the horn button is pressed. BWork Light (Front) [if equipped] BWork Light (Rear) [if equipped] When the key switch is turned to the "ON" position and the slide switch at the rear of each work light is slid to the "ON" position, the work light comes on. When the slide switch is slid to the "OFF" position, the light goes off. After the slide switch for each work light is shifted to the "OFF" position, turn the key switch to the "OFF" position. (1) Work light (if equipped) (A) "ON" (2) Work light switch (if equipped) (B) "OFF" 3. Checking the brake pedal. BBrake Pedal To avoid personal injury: A If the operator suddenly brakes, an accident may occur due to loss of control or the shifting forward of heavy loads. A When driving on icy, wet or loose surface, make sure the vehicle is correctly ballasted to avoid skidding and loss of steering control. Operate at reduced speed. The brake pedal is the left pedal on the foot board. Depress the pedal to slow or stop the vehicle. 4. Selecting the travel speed. BRange Gear Shift Lever To avoid personal injury: A Avoid changing range gear shift lever when ascending or descending a slope. A Before ascending or descending a slope, shift to the "L" range to control the vehicle speed. A If you shift gears while ascending or descending a slope, be prepared to use the brake to maintain control. A Operate in reverse at slow speeds to maintain control. 1. The range gear shift lever can only be shifted when vehicle is completely stopped and the speed control pedal is in the "NEUTRAL" position. 2. To avoid transmission and shift linkage damage, completely stop the vehicle using the brake pedal before shifting gears. 3. Select proper gear and engine speed depending on the type of job. 4. Before dismounting vehicle, shift the range gear shift lever to the "NEUTRAL" position and set parking brake. (1) Range gear shift lever (L) LOW Range (H) HIGH Range (R) "REVERSE" (M) MEDIUM Range (N) "NEUTRAL" POSITION A When range gear shift lever is hard to engage, do not force the lever. Set the parking brake, slightly depress the speed control pedal and release it to neutral position, then shift the lever. When the lever is hard to disengage, do not force the lever. Depress the brake pedal fully, then shift the lever. A An accident may occur with erratic shifting operation. A Improper range gear shift lever position will cause the vehicle to momentarily coast on slopes. B4WD Lever To avoid personal injury: A Do not engage the front wheel drive when traveling at road speed. A When driving on icy, wet or loose surfaces, make sure the vehicle is correctly ballasted to avoid skidding and loss of steering control. Operate at reduced speed and engage front wheel drive. A An accident may occur if the vehicle is suddenly braked, such as by heavy towed loads shifting forward causing loss of control. A The braking characteristics are different between two and four wheel drive. Be aware of the difference and use carefully. A Use the lever to engage the front wheels with the vehicle stopped. Shift the lever to "4WD" to engage the front wheel drive. A Tires will wear quickly if front wheel drive is engaged on paved roads. A If the 4WD lever is difficult to shift to "2WD", stop the vehicle, turn the steering wheel in both directions and then move the lever. C Front wheel drive is effective for the following jobs: 1. When greater pulling force is needed, such as working in a wet field, when pulling a trailer, or when working with a front-end blade. 2. When working in sandy soil. 5. Unlock the parking brake and start slowly. BParking Brake Lever To release the parking brake, depress the brake pedal, push release button and push down parking brake lever. Make sure that indicator in the Easy Checker(TM) goes off. (1) Parking brake lever (A) "RELEASE" (2) Release button BSpeed Control Pedal Use the speed control pedal when traveling. Push down on it for higher speed. STOPPING BStopping 1. Release the speed control pedal. 2. Step on the brake pedal. 3. After the vehicle has stopped, put the range gear shift lever in neutral, and set the parking brake. CHECK DURING DRIVING BImmediately Stop the Engine if: A The engine suddenly slows down or accelerates, A Unusual noises are suddenly heard, A Exhaust fumes suddenly become very dark, While driving, check the following items to see that all the parts are functioning normally. (1) Easy Checker(TM) (2) Coolant temperature gauge (3) Fuel gauge BEasy Checker(TM) If the warning lamps in the Easy Checker(TM) come on during operation, immediately stop the engine, and find the cause as shown below. Never operate the vehicle with an Easy Checker(TM) lamp on. Engine oil pressure If the oil pressure in the engine goes below the prescribed level, the warning lamp in the Easy Checker(TM) will come on. If this should happen during operation, and it does not go off when the engine is accelerated, check level of engine oil. (See "Checking Engine Oil Level" in "DAILY CHECK" in "PERIODIC SERVICE" section.) Electrical charge If the alternator is not charging the battery, the Easy Checker(TM) will come on. If this should happen during operation, check the electrical charging system or consult your local KUBOTA Dealer. ( )Alarm against low brake fluid level or parking brake operation. The warning lamp in the Easy Checker(TM) comes on if the parking brake is applied. If the lamp is on during operation, release the parking brake lever immediately. If the brake fluid goes below the prescribed level, the warning lamp in the Easy Checker(TM) will come on. If this should happen during operation, check to see that there is no oil leak in the brake system, and then add oil. (See "Checking Brake Fluid Level" in "DAILY CHECK" in "PERIODIC SERVICE" section.) BFuel Gauge Park the vehicle on a flat place. When the key switch is "ON", the fuel gauge indicates the fuel level. Be careful not to empty the fuel tank. Otherwise air may enter the fuel system. Should this happen, the system should be bled. (See "Bleeding Fuel System" in "SERVICE AS REQUIRED" in "PERIODIC SERVICE" section.) (1) Fuel gauge BCoolant Temperature Gauge To avoid personal injury: A Do not remove radiator cap until coolant temperature is well below its boiling point. Then loosen cap slightly to the stop to relieve any pressure before removing cap completely. 1. With the key switch "ON" the temperature gauge indicates the temperature of the coolant. White Zone for "cold" and Red zone for "hot". 2. If the indicator reaches the Red zone, engine coolant is overheated. Check the vehicle by referring to "TROUBLESHOOTING" section. BHourmeter The hourmeter indicates in five digits the hours the vehicle has been used; the last digit indicates 1/10 of an hour. (1) Hourmeter BSpeedometer [if equipped] The speedometer indicates the traveling speed. PARKING BParking Brake Lever To avoid personal injury: BEFORE DISMOUNTING VEHICLE A ALWAYS SET PARKING BRAKE AND LOWER ALL IMPLEMENTS TO THE GROUND. Leaving transmission in gear with the engine stopped will not prevent from rolling. A STOP THE ENGINE AND REMOVE THE KEY. 1. Stop the vehicle on a level surface. 2. To set the parking brake, depress the brake pedal and pull the lever to park. 3. To release the parking brake, push release button and push down the parking brake lever. When the parking brake is released, the parking brake warning lamp in the Easy Checker(TM) goes off. (1) Parking brake lever (A) "RELEASE" (2) Release button A If the vehicle is operated with the parking brake applied, the parking brake will be damaged. ACCESSORY B12V Electric Outlet The 12 volt receptacle is located on the front-panel. An auxiliary light or other devices may be connected to this connector. C This outlet is activated when the key switch is in either the "ON" or "OFF" position. When the plug is not used, pull it out. Be careful that leaving the plug inserted causes the battery to run out. C Do not connect a light or other device that draws more than 120 watts to this connector, or the battery may discharge very rapidly or the outlet may fail. A Do not use as a cigarette lighter. A Do not use when wet. BUtility Box OPERATING TECHNIQUES BDifferential Lock To avoid personal injury due to loss of steering control: A Do not operate the vehicle at high speed with differential lock engaged. A Do not attempt to turn with the differential lock engaged. A Be sure to release the differential lock before making a turn in field conditions. If one of the rear wheels should slip, step on the differential lock pedal. Both wheels will then turn together, reducing slippage. Differential lock is maintained while the pedal is depressed or may be held by using differential lock holder. (1) Utility Box C Handling the retaining device for differential lock 1. Pull the differential lock holder while the differential lock pedal is depressed. 2. The differential lock is then maintained even if your foot leaves the pedal. 3. The lock is released when the pedal is depressed again. (1) Differential lock pedal (A) Press to "ENGAGE" (2) Differential lock holder (B) Depress to release again "DISENGAGE" A When using the differential lock, always slow the engine down. A To prevent damage to power train, do not engage differential lock when one wheel is spinning and the other is completely stopped. A If the differential lock cannot be released, stop the vehicle, turn the steering wheel alternately. BDirections for Use of Power Steering 1. Power steering is activated only while the engine is running. While the engine is stopped, the vehicle functions in the same manner as vehicle without power steering. 2. When the steering wheel is turned all the way to the stop, the relief valve is activated. Do not hold the steering wheel in this position for a long period of time. 3. Avoid turning the steering wheel while the vehicle is stopped, or tires may wear out sooner. 4. The power steering mechanism makes the steering easier. Be careful when driving at high speeds. BUnfamiliar Terrain To avoid personal injury: A Be sure to check for hidden obstacles or hazards before driving in a new area. A Keep your speed down until you know the area well. A Use existing trails and stay away from hazardous areas such as steep, rocky slopes or swamps. A Be cautious when visibility is limited, as you may not be able to see obstacles in your path. BDriving in Reverse BDriving in "4WD" To avoid personal injury: A Do not drive in "4WD" on paved surfaces. The maximum traction, shift the range gear shift lever into low range and use "4WD" on steep slopes or when stuck in the mud, with differential locked if necessary. To avoid personal injury: A Turn around, look down and behind you before backing up to be sure there are no obstacles or people in your way. A Depress speed control pedal gradually and back up cautiously. A To stop while driving in reverse take your foot off the speed control pedal and gradually apply the brake. A Do not suddenly engage the brake. BTurning the Vehicle To avoid personal injury: A Reduce vehicle speed before entering the turn and maintain an even speed through the turn. A Do not make sharp turns in order to avoid loss of control or tipping. BHills To avoid personal injury: A Do not turn sideways on a hill, or the vehicle may roll over. A Always go straight up hill or down hill. A Slow down until you can get a clean view of the other side at the crest of a hill. A If the engine stalls on a steep slope, roll slowly straight down, using the brake. A Stop and look for obstacles before descending a hill. BTraversing Hillsides To avoid personal injury: A Reduce vehicles speed to prevent tipping or loss of control. A Do not traverse hillsides that are slippery or covered with rocks or obstacles which may cause you to tip over. BSliding and Skidding To avoid personal injury: A Drive slowly and carefully when you are unsure or unprepared for the surface. A Do not apply heavy braking force or accelerate when skidding to prevent loss of control. A Use 4WD and maintain low speeds on areas covered with clay, mud, ice or snow to prevent uncontrolled skidding. BDriving through Water To avoid personal injury: A Do not drive through water whenever it is possible. A Drive slowly across shallow water and choose a location to enter and exit the water where the banks are not too steep or slippery. A Check before entering for rocks, holes or other obstacles that may cause overturn, stuck or submerged. A Never operate the vehicle in the fast flowing water or in water deeper than the bottom edge of the axle caps. OPERATING HAND THROTTLE [if equipped] A Pull the hand throttle while pushing the button, and the engine speed increases. A Push the hand throttle while pushing the button, and the engine speed decreases. A Fine-tune engine speed by turning the hand throttle. (1) Hand throttle (if equipped) (A) "PUSH" (2) Button "HIGH" "LOW" STATIONARY HYDRAULIC OUTLET [if equipped] To park the Vehicle and use the hydraulic outlet system (for breaker or pump, for example), start the hydraulic outlet system in the following steps. 1. Apply the parking brake and place chocks at the tires. 2. Make sure the shift levers are at "NEUTRAL", and start the engine. 3. Operate the hydraulic outlet lever. (See "HYDRAULIC OUTLET" in "HYDRAULIC OUTLET" section.) 4. Set the engine speed to provide recommended fluid rate. (Refer to the implement operator's manual.) CARGO BED CARGO BED BGeneral Caution A Never carry passengers in the cargo bed. They can be tossed about or even thrown off causing serious injury or death. A Never raise the cargo bed when it is loaded. (if hydraulic dump is not equipped) A Driving with the cargo bed tilted may be hazardous. Always lower the bed and lock the hydraulic lift cylinder lever (if hydraulic dump is equipped) or latch the bed (if hydraulic dump is not equipped) before driving. A Be careful not to put any part of your body, such as hands or arms, between the bed and vehicle. A Drive slowly when it is loaded. BMax. Cargo Load A Maximum Cargo Load (MCL) capacity is 500 kg (1100 lbs). A Never carry loads exceeding the Permissible Cargo Load (PCL). A Max. Cargo load should not exceed "500 kg (1100 lbs.)" or "PCL". PCL = PC - (operator + passenger + opt. + acc. + cabin) weight (PCL: Permissible Cargo Load / PC: Payload Capacity / opt.: option / acc.: accessory) [Payload capacity] Model General purpose Worksite/Orange Worksite/Camo Worksite/Utility Turf Utility Payload capacity kg (lbs.) 775 (1708) 750 (1653) 755 (1664) 720 (1587) 715 (1576) BCargo Bed Tailgate A TO AVOID TAILGATE DAMAGE: Remove the rear trailer hitch when wire loop is removed and cargo bed is raised. To avoid personal injury: A Do not apply a load to the tailgate while the tailgate is open, or the wire loop may break. A Do not place fingers or hands between the tailgate and the arm (latch) when closing, or fingers or hands may be pinched. For loading and unloading, the tailgate of the cargo bed can be opened. The tailgate is held level to the cargo bed floor with wire loops. Do not move the vehicle with the tailgate fully lowered. In a fully lowered position, the tailgate may obstruct the vehicle tail lamps and damage them by swinging motion. 1. Raise the arms (latch) at each end of the tailgate and open the tailgate. 2. Close the tailgate by lifting it and pushing it firmly closed. Push the arms (latch) down to make sure the latches stay securely closed. (1) Tailgate (2) Arm (latch) (3) Wire loop BRaising and Lowering the Cargo Bed [if hydraulic dump is equipped] To avoid personal injury; A Make sure the vehicle is on a firm, level surface and the parking brake is applied before raising the cargo bed. A If the vehicle is facing uphill with cargo bed raised, the weight of the cargo bed may cause the vehicle tip. A When servicing under raised bed with lift cylinder, make sure safety support is properly mounted. C To raise the cargo bed 1. Start engine. 2. Release the restricting plate. 3. Pull up the hydraulic lift cylinder lever to raise the cargo bed. 4. Return the hydraulic lift cylinder lever to the "NEUTRAL" position immediately after raising the cargo bed. C To lower the cargo bed 1. Shift the hydraulic lift cylinder lever to the "DOWN" position and then lower the cargo bed. 2. After making sure that the bed has been lowered to the lowest position, return the lever to the "NEUTRAL" position and then lock the lever with the restricting plate. C Using the "FLOAT" position 1. If the cargo bed cannot be raised or lowered due to trouble with the engine or hydraulic system, shift the lever to the "FLOAT" position. The cargo bed can be raised or lowered manually. (1) Hydraulic lift cylinder lever (A) "UP" (if equipped) (N) "NEUTRAL" (2) Restricting plate (if equipped) (B) "DOWN" (3) Knob bolt (if equipped) (C) "FLOAT with Detent" (1) Safety support HYDRAULIC OUTLET HYDRAULIC OUTLET [if equipped] BHydraulic Outlet Lever To avoid personal injury: A Leaving the vehicle while the engine runs requires shifting the range gear shift lever to the "NEUTRAL" position, and locking the parking brake lever firmly. C Steps for operation 1. Check the outlet and return directions of the hydraulic coupler and then connect the hydraulic hose. 2. Make sure that the hydraulic lever at the side of the working vehicle is in the "NEUTRAL" position. 3. Shift the hydraulic outlet lever to the "ON" position (detended). 4. Operate the hand throttle, to adjust oil volume for implements. 5. Return the hydraulic outlet lever to the "OFF" position after use, and lock it with the restricting plate. (1) Hydraulic outlet lever (if equipped) (A) "ON" (Detent position) (2) Restricting plate (if equipped) (B) "OFF" (3) Knob bolt (if equipped) Lever Push (ON) Pull (OFF) Port A In In B Out In A Do not hold the lever in the "PULL" or "PUSH" position once the remote cylinder has reached the end of its stroke, as this will cause oil to flow through the relief valve. Forcing oil through the relief valve for extended periods will overheat the oil. A Continuing to use the lever may cause oil temperature to rise excessively. The use of oil at a high temperature causes the seals to become damaged and fail. A Shift the hydraulic outlet lever to the "OFF" position and then stop the engine. A Because of the safety devices, the engine will not start except when the hydraulic outlet lever is placed in the "OFF" position and range gear shift lever is placed in the "NEUTRAL" position. BHydraulic Outlet Valve Coupler Connecting and Disconnecting To avoid personal injury: A Stop the engine and relieve pressure before connecting or disconnecting lines. A Do not use your hand to check for leaks. A Make sure couplers are locked securely after connecting them. A Always wear protective gloves when handling hydraulic tools, hoses and couplers. C Connecting 1. Remove dust plugs. 2. Clean both couplers. 3. Insert the implement coupler to the vehicle hydraulic coupler. 4. Pull the implement coupler slightly to make sure couplers are firmly connected. 5. Turn the ring of the female coupler to the "LOCK" position as shown in the following figure. (1) Ring of female coupler (A) "UNLOCK" position (2) Male coupler (B) "LOCK" position C Disconnecting 1. Lower the implement first to the ground to relieve hydraulic pressure in the hoses. 2. Clean the couplers. 3. Relieve pressure by moving hydraulic control levers with engine shut off. 4. Turn the ring of the female coupler to the "UNLOCK" position as shown in the following figure. 5. Pull the hose straight from the hydraulic coupler while pulling the ring to release it. 6. Clean oil and dust from the coupler, then replace the dust plugs. (1) Ring of female coupler (A) "UNLOCK" position (2) Male coupler A Your local KUBOTA Dealer can supply parts to adapt couplers to hydraulic hoses. TIRES AND WHEELS TIRES BTire Type and Use C Heavy duty work site tire To avoid personal injury: A Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. A Always maintain the correct tire pressure. Do not inflate tires above the recommended pressure shown in the operator's manual. A Do not use tires other than those approved by KUBOTA. BInflation Pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it everyday and inflate as necessary. Tire sizes Inflation Pressure 25 x 10 - 12 HDWS, Front & Rear 25 x 12 - 12 Turf, Front & Rear 140 kPa (1.4 kgf/cm , 20 psi) 25 x 10 - 12 ATV, Front 25 x 11 - 12 ATV, Rear WHEELS To avoid personal injury: A Support vehicle securely on stands before removing a wheel. A Never operate vehicle with loose wheel bolts. A When re-fitting a wheel, tighten the bolts to the following torques then recheck after driving the vehicle 200 m (200 yards) and thereafter according to service interval. (1) Torque wheel bolts to 75 to 90 N-m (7.6 to 9.2 kgf-m) (55.3 to 66.4 ft-lbs.) TOWING AND TRANSPORTING TOWING AND TRANSPORTING BRear Trailer Hitch [if equipped] A Always tow a load slowly enough to maintain control and avoid tipping. A To provide adequate braking ability and traction, do not tow a load unless vehicle cargo bed is loaded or attachment is installed. A Attach a trailer to the trailer hitch only. The rear trailer hitch load is referred to "VEHICLE LIMITATIONS" section. When towing other equipment, use a safety chain. BFront Trailer Hitch [if equipped] A Do not tow this vehicle unless all the functions of the vehicle are properly working, since the malfunction of steering operation or braking may cause an accident. Use the front trailer hitch for greater maneuverability in confined areas such as a barn. The front trailer hitch load is referred to "VEHICLE LIMITATIONS" section. BWinch Mount Bracket Mounting the optional winch always requires reading the instruction manual attached to the winch thoroughly before using it. BTransporting Vehicle Pay attention to the points below when transporting the vehicle. 1. Use a suitable truck or trailer. 2. Apply the parking brake and place chocks against the front and rear tires. 3. Secure the portions of the vehicle, which are shown in the figure below, by using strong straps or chains. (1) Pipe frame (2) Heavy-duty strap MAINTENANCE A Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. A If you don't have the knowledge and equipment which are necessary to perform the maintenance task, consult your local KUBOTA Dealer. A Have your local KUBOTA Dealer perform inspection items which are marked *4 in the chart below. SERVICE INTERVALS A The jobs indicated by must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 Every year or every 6 times of cleaning. *3 Replace only if necessary. *4 Consult your local KUBOTA Dealer for this service. *5 When the battery is used for less than 100 hours per year, check the battery condition by reading the indicator annually. A The items listed below (@marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA non road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the below instruction. Please see Warranty Statement in detail. No. Items Indication of Hour Meter After 700 hrs Ref. Page 50 100 150 200 250 300 350 400 450 500 550 600 650 700 1 Engine start system Check every 50 hrs 56 2 Greasing Apply every 50 hrs 55 3 Engine oil Change every 200 hrs 66 4 Muffler [Spark arrester] Clean every 100 hrs 63 5 Wheel bolt torque Check every 100 hrs 58 6 Battery condition Check every 100 hrs 61 *5 7 Alternator belt Adjust every 100 hrs 59 8 VHT neutral spring Check every 100 hrs 57 9 VHT pressure release Check every 100 hrs 57 *4 10 Toe-in Adjust every 100 hrs 62 11 Fuel filter element Check every 100 hrs 60 @ Replace every 500 hrs 79 *4 No. Items Indication of Hour Meter After 700 hrs Ref. Page 50 100 150 200 250 300 350 400 450 500 550 600 650 700 12 Fuel line Check every 100 hrs 60 @ Replace every 2 years 81 *3 13 Air cleaner element Clean every 100 hrs 59 *1 @ Replace every 1 year 79 *2 14 Air cleaner element [Hydraulic utility valve equipped model] Clean every 150 hrs 64 *1 @ Replace every 1 year 79 *2 15 Engine oil filter Replace every 200 hrs 65 16 Transmission oil filter (HST) (Yellow color) Replace every 200 hrs 67 17 Transmission oil filter (Suction) (Orange color) Replace every 200 hrs 68 18 Brake pedal Check every 200 hrs 71 *4 19 Parking brake lever Adjust every 200 hrs 65 20 Brake light switch Check every 200 hrs 72 21 Front brake case Check every 200 hrs 72 22 Power steering oil Change every 200 hrs 74 23 Hydraulic lift oil Change every 200 hrs 69 24 Hydraulic auxiliary tank oil [Hydraulic utility valve equipped model] Change every 200 hrs 70 25 Hydraulic auxiliary oil line [Hydraulic utility valve equipped model] Check every 200 hrs 75 26 Hydraulic auxiliary tank oil filter [Hydraulic utility valve equipped model] Replace every 400 hrs 77 27 Radiator hose and clamp Check every 200 hrs 72 Replace every 2 years 81 28 Power steering oil line Check every 200 hrs 73 Replace every 2 years 81 *4 No. Items Indication of Hour Meter After 700 hrs Ref. Page 50 100 150 200 250 300 350 400 450 500 550 600 650 700 29 Intake air line Check every 200 hrs 75 @ Replace every 2 years 81 *3 30 Engine breather hose Replace every 2 years 81 *4 31 Brake hose & pipe Check every 200 hrs 71 Replace every 4 years 81 *4 32 Tire wear Check every 300 hrs 76 33 Transmission fluid Change every 400 hrs 76 34 Front axle case oil Change every 400 hrs 78 35 Knuckle case oil Change every 400 hrs 76 36 Engine valve clearance Adjust every 800 hrs 79 *4 37 Fuel injection nozzle Injection pressure Check every 1500 hrs 79 *4 @ 38 Injection pump Check every 3000 hrs 79 *4 @ 39 Brake Master cylinder (inner parts) Replace every 2 years 81 *4 40 Brake fluid Change every 2 years 79 *4 41 Remote hydraulic hose Replace every 2 years 81 *4 42 Rear brake cylinder seal Replace every 2 years 81 *4 43 Front brake seal Replace every 2 years 81 *4 44 Cooling system Flash every 2 years 79 45 Coolant Change every 2 years 79 46 Fuel system Bleed Service as required 81 47 Fuse Replace 81 48 Light bulb Replace 83 49 Oil cooler net [Hydraulic utility valve equipped model] Clean 83 LUBRICANTS, FUEL AND COOLANT No. Locations Capacities Lubricants 1 Fuel 28 L (7.4 U.S.gals.) No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below -10 (14 ) 2 Coolant (with reserve tank) 4.0 L (4.2 U.S.qts.) Fresh clean water with anti-freeze 3 Engine crankcase [Filter exchanged] 3.1 L (3.3 U.S.qts.) [Filter non-exchanged] 2.7 L (2.9 U.S.qts.) Engine oil: API Service Classification CD, CE or CF Above 25 (77 ) SAE30, SAE10W-30 or 15W-40 0 to 25 (32 to 77 ) SAE20, SAE10W-30 or 15W-40 Below 0 (32 ) SAE10W, SAE10W-30 4 Transmission case 10 L (2.6 U.S.gals.) KUBOTA UDT or SUPER UDT fluid* 5 Front axle case 0.6 L (0.6 U.S.qts.) KUBOTA UDT or SUPER UDT fluid* 6 Knuckle case Ref. 0.15 L (0.16 U.S.qts.) KUBOTA UDT or SUPER UDT fluid* 7 Brake fluid (reservoir and lines) 0.4 L (0.4 U.S.qts.) KUBOTA DOT3 GENUINE BRAKE FLUID 8 Hydraulic lift oil [Hydraulic dumping equipped model) 8.0 L (8.5 U.S.qts.) KUBOTA UDT or SUPER UDT fluid* Hydraulic auxiliary tank oil [Hydraulic utility valve equipped model] 17.0 L (18.0 U.S.qts.) 9 Power steering oil 5.9 L (6.2 U.S.qts.) Greasing No. of greasing points Capacity Type of grease Parking brake linkage 4 moderate amount Multipurpose EP2 Grease (NLGI Grade No. 2) Battery terminal 2 Cargo lift cylinder pivot 2 Cargo bed pivot 2 VHT link 2 Until grease overflows Range gear shift lever pivot 1 moderate amount 4WD lever pivot 2 Rear drive shaft 2 VHT pressure release 2 Throttle cable 1 Antirust silicone grease Hand throttle cable [Hydraulic utility valve equipped model] --­ *KUBOTA UDT or SUPER UDT fluid --- KUBOTA original transmission hydraulic fluid For North American market A Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above: A Refer to the following table for the suitable API classification engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the fuel. Fuel used Engine oil classification (API classification) Oil class of engines except external EGR Oil class of engines with external EGR Ultra Low Sulfur Fuel [<0.0015% (15 ppm)] CF, CF-4, CG-4, CH-4 or CI-4 CF or CI-4 (Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR type engines) EGR: Exhaust Gas Re-circulation A The CJ-4 engine oil is intended for DPF (Diesel Particulate Filter) type engines, and cannot be used on this vehicle. except external EGR with external EGR Model RTV900 --­ C Fuel: A Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20 (-4 ) or elevations above 1500 m (5000 ft). A Diesel fuels specified to EN 590 or ASTM D975 are recommended. A No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87) C Transmission Oil: The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and to complete lubrication of the transmission, it is important that a multi-grade transmission fluid is used in this system. We recommend the use of KUBOTA UDT or SUPER UDT fluid for optimum protection and performance. (Consult your local KUBOTA Dealer for further detail.) Do not mix different brands together. C Brake fluid: Always use KUBOTA DOT3 GENUINE BRAKE FLUID from a sealed container. If it is not available, you should use only DOT3 fluid as a temporary replacement from a sealed container. However, the use of any non-KUBOTA brake fluid can cause corrosion and decrease the life of the system. Have the brake system flushed and refilled with KUBOTA DOT3 GENUINE BRAKE FLUID as soon as possible. A Indicated capacities of water and oil are manufacturer's estimate. For other than North American market A Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above: A With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-sulfur fuel on on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the "CF or better" lubricating oil with a high Total Base Number (TBN of 10 minimum). A Refer to the following table for the suitable API classification engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the fuel (low-sulfur or high-sulfur fuel). Fuel used Engine oil classification (API classification) Oil class of engines except external EGR Oil class of engines with external EGR High Sulfur Fuel [ 0.05% (500 ppm)] CF (If the "CF-4, CG-4, CH-4 or CI-4" lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals. (approximately half)) --­ Low Sulfur Fuel [<0.05% (500 ppm)] or Ultra Low Sulfur Fuel [<0.0015% (15 ppm)] CF, CF-4, CG-4, CH-4 or CI-4 CF or CI-4 (Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR type engines) EGR: Exhaust Gas Re-circulation A The CJ-4 engine oil is intended for DPF (Diesel Particulate Filter) type engines, and cannot be used on this vehicle. except external EGR with external EGR Model RTV900 --­ C Fuel: A Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20 or elevations above 1500 m. A If diesel fuel with sulfur content greater than 0.5% (5000 ppm) sulfur content is used, reduce the service interval for engine oil and filter by 50%. A NEVER use diesel fuel with sulfur content greater than 0.05% (500 ppm) for EXTERNAL EGR type engine. A DO NOT use diesel fuel with sulfur content greater than 1.0% (10000 ppm). A Diesel fuels specified to EN 590 or ASTM D975 are recommended. A No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87) C Transmission Oil: The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and to complete lubrication of the transmission, it is important that a multi-grade transmission fluid is used in this system. We recommend the use of KUBOTA UDT or SUPER UDT fluid for optimum protection and performance. (Consult your local KUBOTA Dealer for further detail.) Do not mix different brands together. C Brake fluid: Always use KUBOTA DOT3 GENUINE BRAKE FLUID from a sealed container. If it is not available, you should use only DOT3 fluid as a temporary replacement from a sealed container. However, the use of any non-KUBOTA brake fluid can cause corrosion and decrease the life of the system. Have the brake system flushed and refilled with KUBOTA DOT3 GENUINE BRAKE FLUID as soon as possible. A Indicated capacities of water and oil are manufacturer's estimate. PERIODIC SERVICE To avoid personal injury: A Do not work under any hydraulically supported devices. They can settle, suddenly leak down, or be accidentally lowered. If necessary to work under vehicle or any vehicle elements for servicing or adjustment, securely support them with stands or suitable blocking beforehand. HOW TO OPEN THE HOOD AND TILT THE SEAT To avoid personal injury from contact with moving parts; A Never open the operator's seat while the engine is running. BOperator's Seat A Support hood with other hand while unlocking support link. To open the seat, raise the seat to the forward position. BHood To open the hood, pull up the latch lever to release the latch and open the hood. (1) Latch lever (A) "RELEASE" (2) Hood A To close the hood, hold the hood and release the support link and press-fit the hood into position with both hands. HOW TO RAISE THE CARGO BED To avoid personal injury: A When servicing under raised bed, make sure safety support is properly mounted. A Do not touch muffler or exhaust pipes while they are hot; Severe burns could result. BRaising and Lowering the Cargo Bed [if equipped with hydraulic dump] C To raise the cargo bed 1. Apply the parking brake and start the engine. 2. Release the restricting plate. 3. Pull up the hydraulic lift cylinder lever to raise the cargo bed. 4. When the cargo bed has been raised, return the lever to the "NEUTRAL" position. 5. Stop the engine. 6. Mount the safety support. C To lower the cargo bed 1. Start the engine and then lift the bed slightly by operating the lever. 2. Remove the safety support and store it in the given location. 3. Lower the lever to the "DOWN" position to lower the bed. 4. After making sure that the bed has lowered to the lowest position, return the lever to the "NEUTRAL" position and lock it by the restricting plate. A To raise or lower the cargo bed when the engine does not start or the hydraulics are not operating, shift the lever to the "FLOAT" position and raise or lower the bed manually. (1) Hydraulic lift cylinder lever (A) "UP" (if equipped) (N) "NEUTRAL" (2) Restricting plate (if equipped) (B) "DOWN" (3) Knob bolt (if equipped) (C) "FLOAT with Detent" (1) Safety support BRaising and Lowering the Cargo Bed [without hydraulic dump] To avoid personal injury: A Always lower and latch the bed before driving. A Be careful not to catch any part of your body, such as hands or arms, between the bed and cab frame or vehicle frame when lifting and lowering the bed. To prevent injury, use only the handgrips provided. The cargo bed may be tilted by releasing the latches on each side, and then lifting the bed with the handgrips. Support the bed in the raised position with the propping rod. (1) Latch (A) "LOCK" (2) Handgrip (B) "RELEASE" (1) Propping rod JACK-UP POINT To avoid personal injury, death or vehicle damage: A Do not work under the vehicle unless it is secured by safe stands or suitable blocking. BFront End Jack up at the front bumper only. BRear End Jack up the rear side after placing a wooden block under the right and left pipe frames for securing the engine and then supporting it. Do not jack it up supporting the steel plate portion under the engine directly. DAILY CHECK For your own safety and maximum service life of the vehicle, make a thorough daily inspection before operating the vehicle to start the engine. To avoid personal injury: A Be sure to check and service the vehicle on a flat surface with the engine shut off and the parking brake "ON". BWalk Around Inspection Look around and under the vehicle for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts. BChecking and Refueling To avoid personal injury: A Do not smoke while refueling. A Be sure to stop the engine before refueling. 1. Turn the key switch to "ON", check the amount of fuel by fuel gauge. 2. Fill fuel tank when fuel gauge shows 1/4 or less fuel in tank. 3. Use grade No.2-Diesel fuel at temperatures above -10 (14 ). Use grade No.1-Diesel fuel at temperatures below -10 (14 ). (1) Fuel tank cap A Do not permit dirt or trash to get into the fuel system. A Be careful not to let the fuel tank become empty, otherwise air will enter the fuel system, necessitating bleeding before next engine start. A Be careful not to spill during refueling. If should spill, wipe it off at once, or it may cause a fire. A To prevent water condensation from accumulating in the fuel tank, fill the tank before parking overnight. BChecking Engine Oil Level To avoid personal injury: A Be sure to stop the engine before checking the oil level. 1. Park the vehicle on a flat surface and raise the cargo bed. 2. Check engine oil before starting the engine or 5 minutes or more after the engine has stopped. 3. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level lies between the two notches. If the level is too low, add new oil to the prescribed level at the oil inlet. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) (1) Oil inlet (A) Oil level is acceptable within this range. (2) Dipstick A When using an oil of different maker or viscosity from the previous one, remove all of the old oil. Never mix two different types of oil. A If oil level is low, do not run engine. BChecking Transmission Fluid Level 1. Park the vehicle on a flat surface, raise the cargo bed and shut off engine. 2. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level lies between the two notches. If the level is too low, add new oil to the prescribed level at the oil inlet. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) (1) Oil inlet (A) Oil level is acceptable within this range. (2) Dipstick A If oil level is low, do not run engine. BChecking Power Steering Oil Tank Level 1. Park the vehicle on a flat surface. 2. Check to see that the oil level is between the "H" and "L" marks on the oil tank. If the level is too low, add new oil to the "H" mark. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) A If oil level is low, do not run engine. BChecking Hydraulic Lift Oil Tank Level [Hydraulic dumping system model] 1. Park the vehicle on a flat surface. 2. Raise the cargo bed and mount the safety support. (See "HOW TO RAISE THE CARGO BED" in "PERIODIC SERVICE" section.) 3. To check the oil level, remove the dipstick, wipe it clean, screw it into filling hole and remove dipstick again. If the level is too low, add new oil to the prescribed level at the oil inlet. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) A If oil level is low, do not run engine. BChecking Hydraulic Auxiliary Tank Oil Level [Hydraulic utility valve equipped model] 1. Park the vehicle on a firm, flat and level surface. 2. Raise the cargo bed and mount the safety support. (See "HOW TO RAISE THE CARGO BED" in "PERIODIC SERVICE" section.) 3. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level lies between the range. If the level is too low, add new oil to the prescribed level at the filling plug. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) (1) Filling plug (2) Dipstick BCleaning Oil Cooler Net [Hydraulic utility valve equipped model] To avoid personal injury: A Allow oil cooler or oil line parts to cool down sufficiently, they can be hot and can cause injury. 1. Park the vehicle on a flat surface, lower the cargo bed, shut off the engine and turn the key to the "OFF" position. If the key switch is "ON", the oil cooler fan may start to rotate suddenly. 2. Take off the oil cooler net from the lower side and remove all trash. (1) Oil cooler net BChecking Coolant Level BCleaning Radiator Screen To avoid personal injury: A Be sure to stop the engine before removing the screen. 1. Park the vehicle on a flat surface and raise the seat. 2. Detach the screen and remove all foreign materials. (1) Radiator screen (A) "DETACH" (2) Cover A Radiator screen must be clean from debris to prevent engine from overheating. To avoid personal injury: A Do not remove radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. 1. Park the vehicle on a flat surface and raise the seat. 2. Check to see that the coolant level is between the "FULL" and "LOW" marks of recovery tank. 3. When the coolant level drops due to evaporation, add water only up to the full level. In case of leakage, add anti-freeze and water in the specified mixing ratio up to the full level. (See "Flush Cooling System and Changing Coolant" in "EVERY 2 YEARS" in "PERIODIC SERVICE" section.) A If the radiator cap has to be removed, follow the caution above and securely retighten the cap. A Use clean, fresh water and anti-freeze to fill the recovery tank. A If water should leak, consult your local KUBOTA Dealer. BChecking Brake Fluid Level BChecking Brake Pedal To avoid personal injury: A Stop the engine and chock the wheels before checking brake pedal. 1. Inspect the brake pedals for free travel, and smooth operation. 2. Adjust if incorrect measurement is found: (See "Checking Brake Pedal" in "EVERY 200 HOURS" in "PERIODIC SERVICE" section.) To avoid personal injury: A Never operate the vehicle, if the brake fluid is below the "MIN" mark. A Use only KUBOTA DOT3 GENUINE BRAKE FLUID from a sealed container. Using other type of oil ruins synthetic resin or rubber installed in brake system components, and may cause brake failure. A Avoid contamination of the brake fluid. Thoroughly clean area around the filler cap before removing. Do not open the brake fluid reservoir cap unless absolutely necessary. A Use extreme care when filling the reservoir. If brake fluid is spilled on power steering hose, wash off with water immediately. Brake fluid quickly ruins synthetic resin or rubber hoses. 1. Park the vehicle on a level ground and open the hood. 2. Check to see that the brake fluid level is between the "MAX" and "MIN" marks. 3. If it is below the "MIN" mark, add brake fluid to the "MAX" mark. BChecking Parking Brake Pull the parking brake lever to apply the brakes. With the key switch at "ON" position, the parking brake indicator on the instrument panel lights up. To release the brakes, push in the button at the tip of the parking brake lever and tilt down the lever. A Make sure the parking brake warning lamp on the Easy Checker(TM) goes off when parking brake lever is down. (1) Parking brake lever (A) "PULL" (2) Release button (B) "RELEASE" BChecking Gauges, Meter and Easy Checker(TM) 1. Inspect the instrument panel for broken gauge(s), meter(s) and Easy Checker(TM) lamps. 2. Replace if broken. BChecking Head Light, Turn Signal Light etc. 1. Inspect the lights for broken bulbs and lenses. 2. Replace if broken. BChecking Seat Belt and ROPS 1. Always check condition of seat belt and ROPS attaching hardware before operating vehicle. 2. Replace if damaged. BChecking Joint Boot 1. Check to see if the joint boots are not damaged. 2. If the boots are cuts, cracked or shows signs of deterioration, consult your local KUBOTA Dealer. BChecking Tire Inflation Pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it everyday and inflate as necessary. Tire sizes Inflation Pressure 25 x 10 - 12 HDWS, Front & Rear 25 x 12 - 12 Turf, Front & Rear 140 kPa (1.4 kgf/cm , 20 psi) 25 x 10 - 12 ATV, Front 25 x 11 - 12 ATV, Rear BChecking Backup Beeper [if equipped] 1. Sit on the operator's seat. 2. Set the parking brake and stop the engine. 3. Shift the range gear shift lever to the "NEUTRAL" position. 4. Turn the key to "ON" position. 5. Shift the range gear shift lever to the "REVERSE" position. 6. If the backup beeper does not beep, consult your local KUBOTA Dealer. (1) Range gear shift lever (R) "REVERSE" (2) Backup beeper (if equipped) EVERY 50 HOURS BGreasing Apply a small amount of multi-purpose grease to the following points every 50 hours: If you operated the vehicle in extremely wet and muddy conditions, lubricate grease fittings more often. (1) Cargo lift cylinder pivot (if equipped)(spray type grease) (2) Cargo bed pivot (spray type grease) (1) Rear drive shaft (Grease fitting) (1) Rear drive shaft (Grease fitting) BOiling BChecking Engine Start System To avoid personal injury: A Do not allow anyone near the vehicle while testing. A If the vehicle does not pass the test do not operate the vehicle. C Preparation before testing. 1. Place all control levers in the "NEUTRAL" position. 2. Set the parking brake and stop the engine. (1) VHT pressure release (Grease fitting) C Test: Range gear shift lever safety switch 1. Sit on the operator's seat. 2. Shift the range gear shift lever to H, M, L or reverse position. 3. Return the Speed control pedal to the "NEUTRAL" position. 4. Shift the hydraulic lift cylinder lever to the "NEUTRAL" position (if equipped). 5. Turn the key to "START" position. 6. The engine must not crank. 7. If it cranks, consult your local KUBOTA Dealer for this service. C Test: Hydraulic outlet lever safety switch (if equipped) 1. Sit on the operator's seat. 2. Shift the hydraulic outlet lever to "ON" position. 3. Return the Speed control pedal to the "NEUTRAL" position. 4. Shift the range gear shift lever to the "NEUTRAL" position. 5. Shift the hydraulic lift cylinder lever to the "NEUTRAL" position (if equipped). 6. Turn the key to "START" position. 7. The engine must not crank. 8. If it cranks, consult your local KUBOTA Dealer for service. (1) Range gear shift lever (2) Hydraulic outlet lever (if equipped) (3) Hydraulic lift cylinder lever (if equipped) (4) Speed control pedal EVERY 100 HOURS BChecking VHT Neutral Spring 1. Park the vehicle on a flat place. 2. Set the parking brake. 3. Shift the range gear shift lever to the neutral position. 4. Lock the hydraulic lift cylinder lever to "NEUTRAL" position with restricting plate (if equipped). 5. Start the engine. 6. Make sure that the rotation speed of the engine returns to the idling rotation immediately when taking the foot off the pedal, after depressing the speed control pedal several times. If the above does not occur immediately, consult your local KUBOTA dealer for this service. BChecking VHT Pressure Release To avoid personal injury: A Do not touch muffler or exhaust pipes while they are hot; severe burns could result. 1. Park the vehicle on a level ground and set the parking brake. 2. Start the engine and shut off it soon. 3. Check the points as shown in the figures below. 4. If the result corresponds to either of the following (a) or (b), consult your local KUBOTA Dealer. (a) The clearance (x) is more than 1 mm. (b) Spring needs adjusting. (1) VHT pressure release arm (2) VHT pressure release valve (1) Spring BChecking Wheel Bolt Torque To avoid personal injury: A Never operate vehicle with a loose wheel bolts. A Any time bolts are loosened, retighten to the specified torque. A Check all bolts frequently and keep them tight. Check wheel bolts regularly especially when new. If they are loose, tighten them as follows. (1) Torque wheel bolts to 75 to 90 N-m (7.6to 9.2 kgf-m) (55.3 to 66.4 ft-lbs.) BCleaning Air Cleaner Primary Element 1. Remove the air cleaner cover and primary element. 2. Clean the primary element: (1) When dry dust adheres to the element, blow compressed air from the inside, turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm , 30 psi). (2) When carbon or oil adheres to the element, soak the element in detergent for 15 minutes then wash it several times in water, rinse with clean water and dry it naturally. After element is fully dried, inspect inside of the element with a light and check if it is damaged or not. 3. Replace the primary element: Once yearly or after every sixth cleaning, whichever comes first. A Check to see if the evacuator valve is blocked with dust. A Check the rubber seal. Replace if damaged. A The air cleaner uses a dry element, never apply oil. A Do not run the engine with filter element removed. A Be sure to refit the cover with the arrow (on the rear of cover) upright. If the cover is improperly fitted, evacuator valve will not function and dust will adhere to the element. A Do not touch the secondary element except in cases where replacing is required. (See "Replacing Air Cleaner Secondary Element" in "EVERY 1 YEAR" in "PERIODIC SERVICE" section.) C Evacuator Valve Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place - to get rid of large particles of dust and dirt. BAdjusting Alternator Belt Tension To avoid personal injury: A Be sure to stop the engine before checking belt tension. 1. Park the vehicle on a flat surface and raise the cargo bed. 2. Stop the engine and remove the key. 3. Apply moderate thumb pressure to belt between pulleys. 4. 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. 5. Replace alternator belt if it is damaged. BChecking Fuel Line and Fuel Filter To avoid personal injury: A Be sure to stop the engine and remove the key when attempting to make the following checks and changes. A Never fail to check the fuel lines periodically. The fuel lines are subject to wear and aging. Fuel may leak out onto the running engine, causing a fire. The fuel line connections should be checked annually or every 100 service hours, whichever comes first. 1. Park the vehicle on a flat surface and raise the cargo bed. 2. The fuel line is made of rubber and ages regardless of service period. 3. If the fuel line and clamps are found to be damaged or deteriorated, replace them. 4. Check fuel filter, if it is clogged by debris or contaminated with water, replace it. A When the fuel line is disconnected for maintenance or repair, close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering. In addition, particular care must be taken not to admit dust and dirt into the fuel pump. Entrance of even a small amount of dust or dirt cause premature wear and malfunction of the fuel pump and injector components. BChecking Battery Condition For the refillable type battery, follow the instructions below. A Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion. Check the fluid level regularly and add distilled water as required so that the fluid level is between the UPPER and LOWER levels. A Never remove the vent caps while the engine is running. A Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention. A Wear eye protection and rubber gloves when working around the battery. The factory-installed battery is non-refillable type. If the battery is weak, charge the battery or replace it with new one. 1. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the standard fashion. 2. A boost charge is only for emergencies. It will partially charge the battery at a high rate and in a short time. When using a boost-charged battery, it is necessary to recharge the battery as early as possible. Failure to do this will shorten the battery's service life. 3. When exchanging an old battery for a new one, use battery of equal specification shown in table 1. C Battery Charging A When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery. A When charging the battery, ensure the vent caps are securely in place. (if equipped) A When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first. A Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Reserve Cold Cranking Normal Charging Capacity (min) Amps Rate (A) 80 535 6.5 C Direction for Storage 1. When storing the vehicle for a long period, remove the battery from vehicle, adjust the electrolyte to the proper level (refillable type only) and store in a dry place out of direct sunlight. 2. The battery self-discharges while it is stored. Recharge it once every three months in hot seasons and once every six months in cold seasons. C Adjusting procedures BAdjusting Toe-in 1. Loosen the lock nut and turn the tie rod to adjust the rod length until the proper toe-in measurement is obtained. 2. Retighten the lock nut. 1. Park vehicle on a flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lock the park brake and stop the engine. 4. Measure distance between tire beads at front of tire, at hub height. 5. Measure distance between tire beads at rear of tire, at hub height. 6. Front distance should be shorter than rear distance. If not, adjust tie rod length. A Keep the length of the left and right tie-rod equal. (A) Wheel - to - wheel distance at rear (B) Wheel - to - wheel distance at front (C) "FRONT" BCleaning Muffler To avoid personal injury: A Before touching any part of an exhaust system, be absolutely sure that it has sufficient time to cool ! A Always wear safety goggles and a (face) mask. A The particulate matter contained in the muffler contains chemicals that are harmful to people, animals and marine life. A If you are unable to do this work, have it done by your KUBOTA Dealer. C Cleaning spark arrester of muffler This screen type spark arrester was examined, tested, and qualified in accordance with the USDA Forest Service Standard 5100-1c, "Spark Arresters for Internal Combustion Engines" for the RTV900. Maintenance & cleanout procedure: The screen type spark arrester should be removed, cleaned, and inspected after every 100 hours of use. 1. The spark arrester is located inside of the exhaust pipe, and is fastened with two bolts. 2. Unfasten the bolts and remove the spark arrester. 3. Shake loosened particles out of the screen assembly and lightly clean the screen with wire brush. Soak in solvent and again clean with wire brush if necessary. 4. If any breaks in the screen or weldments are discovered, the assembly must be replaced. 5. Return the spark arrester to the muffler body and refasten the bolts. A Visually check the muffler for cracks or holes in the body, weldment or pipes at regular intervals. A USDA approval requires clearance between spark arrester sleeve and exhaust pipe to be no larger than 0.023" (0.584 mm). A Replace the entire muffler if it is damaged. A Do not operate the vehicle with a damaged muffler. EVERY 150 HOURS BCleaning Air Cleaner Primary Element [Hydraulic utility valve equipped model] 1. Loosen the knob bolt and remove the intake air guard from the air cleaner. 2. Unlock the air cleaner fixing band and remove the air cleaner. 3. Remove the air cleaner cover and primary element. 4. Clean the primary element: (1) When dry dust adheres to the element, blow compressed air from the inside, turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm , 30 psi). (2) When carbon or oil adheres to the element, soak the element in detergent for 15 minutes then wash it several times in water, rinse with clean water and dry it naturally. After element is fully dried, inspect inside of the element with a light and check if it is damaged or not. 5. Replace the primary element: Once yearly or after every sixth cleaning, whichever comes first. A Check to see if the evacuator valve is blocked with dust. A Check the rubber seal. Replace if damaged. A The air cleaner uses a dry element, never apply oil. A Do not run the engine with filter element removed. A Be sure to refit the cover with the arrow (on the rear of cover) upright. If the cover is improperly fitted, evacuator valve will not function and dust will adhere to the element. A Do not touch the secondary element except in cases where replacing is required. (See "Replacing Air Cleaner Secondary Element" in "EVERY 1 YEAR" in "PERIODIC SERVICE" section.) C Evacuator Valve Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place - to get rid of large particles of dust and dirt. EVERY 200 HOURS BAdjusting Parking Brake C Adjusting procedure 1. Release the parking brake. 2. Loosen the lock nut, and adjust the cable wire length. 3. Tighten the lock nut, and check the free play. BReplacing Engine Oil Filter To avoid personal injury: A Be sure to stop the engine before changing the oil filter. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface, raise the cargo bed, and mount the safety support. 2. Remove the oil filter. 3. Put a film of clean engine oil on the rubber seal of the new filter. 4. Tighten the filter quickly until it contacts the mounting surface. Tighten filter by hand an additional 1/2 turn only. 5. After the new filter has been replaced, the engine oil normally decreases a little. Make sure that the engine oil does not leak through the seal and be sure to check the oil level on the dipstick. Then, replenish the engine oil up to the prescribed level. A To prevent serious damage to the engine, use only a KUBOTA genuine filter. BChanging Engine Oil To avoid personal injury: A Be sure to stop the engine before changing the oil. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface and raise the cargo bed. 2. To drain the used oil, remove the drain plug at the bottom of the engine and completely drain the oil into an oil pan. All the used oil can be drained out easily when the engine is still warm. 3. After draining, reinstall the drain plug. 4. Fill with the new oil up to the upper notch on the dipstick. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) [Filter exchanged] 3.1 L (3.3 U.S.qts.) Oil capacity [Filter non-exchanged] 2.7 L (2.9 U.S.qts.) (1) Oil inlet (A) Oil level is acceptable within this range (2) Dipstick BReplacing Transmission Oil Filter [HST] To avoid personal injury: A Be sure to stop the engine before changing the oil filter. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface, raise the cargo bed and mount the safety support. 2. Remove the oil filters. 3. Put a film of clean transmission oil on the rubber seal of the new filter. 4. Quickly tighten the filter until it contacts the mounting surface, then, with a filter wrench, tighten it an additional 1 turn only. 5. After the new filter has been replaced, fill the transmission oil up to the upper notch on the dipstick. 6. After running the engine for a few minutes, stop the engine and check the oil level again, add oil to the prescribed level. 7. Make sure that the transmission fluid doesn't leak past the seal on the filters. (1) Transmission oil filter (HST) (Yellow color) (1) Oil inlet (A) Oil level is acceptable within this range (2) Dipstick A To prevent serious damage to the transmission, use only a KUBOTA genuine filter. BReplacing Transmission Oil Filter [SUCTION] To avoid personal injury: A Be sure to stop the engine before changing the oil filter. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface, raise the cargo bed and mount the safety support. 2. Remove the rear guard and the hose guard. 3. Remove the oil filter. 4. Put a film of clean transmission oil on the rubber seal of the new filter. 5. Quickly tighten the filter until it contacts the mounting surface, then, with a filter wrench, tighten it an additional 1 turn only. 6. After the new filter has been replaced, fill the transmission oil up to the upper notch on the dipstick. 7. After running the engine for a few minutes, stop the engine and check the oil level again, add oil to the prescribed level. 8. Make sure that the transmission fluid doesn't leak past the seal on the filters. 9. Install the rear guard and the hose guard. (1) Transmission oil filter (Suction) (Orange color) (2) Rear guard (3) Hose guard (1) Oil inlet (A) Oil level is acceptable within this range (2) Dipstick A To prevent serious damage to the transmission, use only a KUBOTA genuine filter. BChanging Hydraulic Lift Oil [Hydraulic dumping system model] To avoid personal injury: A Be sure to stop the engine before changing the oil. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a firm, flat and level surface. 2. Raise the cargo bed and mount the safety support. 3. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan. (1) Drain plug (A) Oil level is acceptable within 4. After draining, reinstall the drain plug. (2) Filling plug with dipstick this range 5. Fill with new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) How to check: Wipe dipstick clean with a rag and screw it into filling hole. Remove dipstick again to see if the oil level is between the upper and lower notch. 6. After filling, reinstall the filling plug. BChanging Hydraulic Auxiliary Tank Oil [Hydraulic utility valve equipped model] To avoid personal injury: A Be sure to stop the engine before changing the oil. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a firm, flat and level surface. 2. Raise the cargo bed and mount the safety support. 3. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan. (1) Drain plug (A) Oil level is acceptable within 4. After draining, reinstall the drain plug. (2) Filling plug this range 5. Fill with the new KUBOTA SUPER UDT fluid up to (3) Dipstick upper notch on the dipstick. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) 6. After filling, reinstall the filling plug. BChecking Brake Pedal To avoid personal injury: A Stop the engine and chock the wheels before checking brake pedal. A If movement is outside of the specifications, contact your local KUBOTA Dealer for adjusting the brake. C Checking the brake pedal free travel 1. Release the parking brake. 2. Slightly depress the brake pedal and measure free travel at the top of the pedal stroke. 3. If brake pedal free travel is outside of the specifications, contact your local KUBOTA Dealer for adjusting the brake. C Checking the brake pedal stroke 1. Release the parking brake. 2. Step on the pedal and measure the pedal stroke. 3. If brake pedal stroke is outside of the specifications, contact your local KUBOTA Dealer for adjusting the brake. BChecking Brake Hose and Pipe 1. Check to see that brake hose and pipe are not swollen, hardened or cracked. 2. Check the brake hose and pipe joints for oil leaks. 3. If there is any abnormality, consult your local KUBOTA Dealer for this service. BChecking Front Brake Case 1. Remove the drain plug. 2. Check the brake case for brake fluid leak. 3. If there is brake fluid leak, consult your local KUBOTA Dealer for this service. BChecking Brake Light Switch 1. Park the vehicle on a flat surface and raise the cargo bed. 2. Turn the key switch to the "ON" position. 3. Step on the brake pedal to check if the brake light comes on. 4. If it does not, check the bulb or brake light switch. BChecking Radiator Hose and Clamp Park the vehicle on a flat surface and raise the cargo bed. Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first. 1. If hose clamps are loose or water leaks, tighten bands securely. 2. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen, hardened or cracked. Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked. C Precaution at Overheating Take the following actions in the event the coolant temperature is close to or more than the boiling point, which is called "Overheating". 1. Stop the vehicle operation in a safe place and keep the engine unloaded idling. 2. Don't stop the engine suddenly, but stop it after about 5 minutes of unloaded idling. 3. Keep yourself well away from the vehicle for at least 10 minutes or while the steam is blowing out. 4. Check to see if there is no danger such as burning, get rid of the causes of overheating according to the "TROUBLESHOOTING" section of this manual, and then start the engine again. BChecking Power Steering Line 1. Check to see that all lines and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once. BChanging Power Steering Oil To avoid personal injury: A Be sure to stop the engine before changing the oil. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface and raise the cargo bed. 2. To drain the used oil, remove the suction hose on the gear pump. 3. Drain the oil completely into the oil pan. 4. After draining, reinstall suction hose. 5. Fill with the new oil up to the "H" mark of the oil tank. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) 6. Start the engine and then turn the steering wheel toward the right and left several times (this motion causes air in the hose to discharge). 7. Check to see if the oil level is between the "H" and "L" marks on the oil tank. (1) Suction hose (2) Gear pump BChecking Intake Air Line 1. Check to see if the hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found to be worn or damaged, replace or repair them at once. [Hydraulic utility valve equipped model] (1) Hose (2) Hose clamps BChecking Hydraulic Auxiliary Oil Line [Hydraulic utility valve equipped model] 1. Check to see if the hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found worn or damaged, replace or repair them at once. EVERY 300 HOURS BChecking Tire 1. Check to see if tires are not damaged. 2. If the tires are cracked, bulged, or cut, or they are worn out, replace or repair them at once. C Tire Tread Depth Always replace the tires when the tread depth is worn to minimum allowable. EVERY 400 HOURS BChanging Knuckle Case Oil 1. Remove the tire. 2. Park the vehicle on a firm, flat and level surface. 3. To drain the used oil, remove the drain and filling plugs at the LH knuckle case and drain the oil completely into the oil pan. 4. After draining, reinstall the drain plug. 5. Fill with the new oil up to the filling port level. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) 6. After filling, reinstall the filling plug. 7. Use the same procedure to change the RH knuckle case oil. BChanging Transmission Fluid To avoid personal injury: A Be sure to stop the engine before changing the oil. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface, raise the cargo bed, and mount the safety support. 2. To drain the used oil, remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan. 3. Clean off metal filings with clean rags at the drain plug with magnet. 4. After draining, reinstall the drain plug. 5. Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) 6. After running the engine for a few minutes, stop the engine and check the oil level again; add oil to prescribed level. (1) Oil inlet (A) Oil level is acceptable within this range (2) Dipstick (1) Drain plug with magnet C Cleaning magnetic plug Remove the magnetic plug and clean off metal filings. A Do not operate the vehicle immediately after changing the transmission fluid. Run the engine at medium speed for a few minutes to prevent damage to the transmission. BReplacing Hydraulic Auxiliary Tank Oil Filter [Hydraulic utility valve equipped model] To avoid personal injury: A Be sure to stop the engine before changing the oil filter. A Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a firm, flat and level surface, raise the cargo bed and mount the safety support. 2. Remove the oil filter. (Take care of the oil that spills from filter.) 3. Put a film of clean transmission oil on the rubber seal of the new filter. 4. Quickly tighten the filter until it contacts the mounting surface, then, with a filter wrench, tighten it an additional 1 turn only. 5. After the new filter has been replaced, fill the auxiliary tank oil up to the upper notch on the dipstick. 6. After running the engine for a few minutes, stop the engine and check the oil level again, add oil to the prescribed level. 7. Make sure that the hydraulic auxiliary tank oil doesn't leak past the seal on the filter. (A) Oil level is acceptable within this range (3) Dipstick A To prevent serious damage to the hydraulic line, use only a KUBOTA genuine filter. BChanging Front Axle Case Oil 1. Park the vehicle on a firm, flat and level surface. 2. To drain the used oil, remove the drain and filling plugs at the front axle case and drain the oil completely into the oil pan. 3. After draining, reinstall the drain plug. 4. Fill with the new oil up to the upper notch on the dipstick. (See "LUBRICANTS, FUEL AND COOLANT" in "MAINTENANCE" section.) 5. After filling, reinstall the filling plug. (1) Drain plug (A) Oil level is acceptable (2) Filling plug with dipstick within this range EVERY 500 HOURS BReplacing Fuel Filter Consult your local KUBOTA Dealer for this service. EVERY 800 HOURS BAdjusting Engine Valve Clearance Consult your local KUBOTA Dealer for this service. EVERY 1500 HOURS BChecking Fuel Injection Nozzle Injection Pressure Consult your local KUBOTA Dealer for this service. EVERY 3000 HOURS BChecking Injection Pump Consult your local KUBOTA Dealer for this service. EVERY 1 YEAR BReplacing Air Cleaner Primary Element and Secondary Element (See "Cleaning Air Cleaner Primary Element" in "EVERY 100 HOURS" or "EVERY 150 HOURS" in "PERIODIC SERVICE" section.) EVERY 2 YEARS BChanging Brake Fluid Consult your local KUBOTA Dealer for this service. (See "Checking Brake Fluid Level" in "DAILY CHECK" in "PERIODIC SERVICE" section.) BFlushing Cooling System and Changing Coolant To avoid personal injury: A Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely. 1. Stop the engine and let cool down. 2. Remove the protective cover. 3. To drain the coolant, open the radiator drain plug and remove radiator cap. The radiator cap must be removed to completely drain the coolant. 4. After all coolant is drained, close the drain plug. 5. Fill with clean water and cooling system cleaner. 6. Follow directions of the cleaner instruction. 7. After flushing, fill with clean water and anti-freeze until the coolant level is just below the radiator cap. Install the radiator cap securely. 8. Fill with fresh water up to the "FULL" mark on the recovery tank. 9. Start and operate the engine for few minutes. 10.Stop the engine and let cool. 11.Check coolant level of recovery tank and add coolant if necessary. (1) Drain plug (2) Protective cover (1) Radiator cap (A) "FULL" (2) Recovery tank (B) "LOW" A Do not start engine without coolant. A Use clean, fresh water and anti-freeze to fill the radiator and recovery tank. A When the anti-freeze is mixed with water, the antifreeze mixing ratio must be less than 50%. A Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat. BAnti-Freeze To avoid personal injury: A When using antifreeze, put on some protection such as rubber gloves. (Antifreeze contains poison.) A If should drink antifreeze, throw up at once and take medical attention. A When antifreeze comes in contact with the skin or clothing, wash it off immediately. A Do not mix different types of Antifreeze. The mixture can produce chemical reaction causing harmful substances. A Antifreeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze. A When draining fluids from the engine, place some container underneath the engine body. A Do not pour waste onto the grounds, down a drain, or into any water source. A Also, observe the relevant environmental protection regulations when disposing of antifreeze. If it freezes, coolant can damage the cylinders and radiator. If the ambient temperature falls below 0 (32 )or before a long-term storage, let out cooling water completely, or mix fresh water with long-life coolant and fill the radiator and recovery tank with the mixture. 1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol (EG) type for this engine. 2. Before employing LLC-mixed cooling water, fill the radiator with fresh water and empty it again. Repeat this procedure 2 or 3 times to clean up the inside. 3. Mixing the LLC Put the LLC in cooling water in the percentage (%) for a target temperature. When mixing, stir it up well, and then fill into the radiator. 4. The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature. Refer to SAE J1034 standard, more specifically also to SAE J814c. A When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50%. Vol % Anti-freeze Freezing Point Boiling Point* 40 -24 -12 106 222 50 -37 -34 108 226 * At 1.013 x 10 Pa (760 mmHg) pressure (atmospheric). A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system. 5. Adding the LLC (1) Add only water if the mixture reduces in amount by evaporation. (2) If there is a mixture leak, add the LLC of the same manufacturer and type in the same mixture percentage. * Never add any long-life coolant of different manufacturer. (Different brands may have different additive components, and the engine may fail to perform as specified.) 6. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts. 7. Kubota's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years. A The above data represent industry standards that necessitate a minimum glycol content in the concentrated antifreeze. A When the coolant level drops due to evaporation, add water only to keep the antifreeze mixing ratio less than 50%. In case of leakage, add antifreeze and water in the specified mixing ratio before filling into the radiator. BReplacing Radiator Hose (Water pipes) Replace the hoses and clamps. (See "Checking Radiator Hose and Clamp" in "EVERY 200 HOURS" in "PERIODIC SERVICE" section.) BReplacing Power Steering Hose Consult your local KUBOTA Dealer for this service. BReplacing Fuel Hose Consult your local KUBOTA Dealer for this service. BReplacing Engine Breather Hose Consult your local KUBOTA Dealer for this service. BReplacing Brake Master Cylinder (Inner Parts) Consult your local KUBOTA Dealer for this service. BReplacing Front Brake Seal Consult your local KUBOTA Dealer for this service. BReplacing Rear Brake Cylinder Seal Consult your local KUBOTA Dealer for this service. BReplacing Intake Air Line Consult your local KUBOTA Dealer for this service. BReplacing Remote Hydraulic Hose Consult your local KUBOTA Dealer for this service. EVERY 4 YEARS BReplacing Brake Hose Consult your local KUBOTA Dealer for this service. SERVICE AS REQUIRED BBleeding Fuel System Air must be removed: 1. When the fuel filter or lines are removed. 2. When tank is completely empty. 3. After the vehicle has not been used for a long period of time. C Bleeding procedure is as follows: 1. Fill the fuel tank with fuel. 2. Start the engine and run for about 30 seconds, and then stop the engine. BReplacing Fuse The vehicle electrical system is protected from potential damage by fuses. A blown fuse indicates that there is an overload or short somewhere in the electrical system. If any of the fuses should blow, replace with a new one of the same capacity. A Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the vehicle electrical system. Consult your local KUBOTA Dealer for specific information dealing with electrical problems. C Replacement procedure 1. Disconnect the negative cable of the battery. 2. Remove the cover and the fuse box cover. 3. Pull out the blown fuse using FUSE PULLER in the fuse box. 4. Insert a new fuse into the fuse box. 5. Install the fuse box cover and the cover. 6. Connect the negative battery cable. C Protected circuit Fuse No. Capacity (A) Protected circuit 1 Slow-blow fuse (50) Key switch 2 Slow-blow fuse (60) Alternator 3 15 Head lamp, Tail lamp, Panel 4 5 Glow lamp 5 10 (Hazard) 6 20 Fan motor 7 15 Eng. Stop 8 15 Alternator, Brake lamp, Fan motor relay 9 5 Panel, Eng. Stop control 10 10 12V DC output 11 10 Horn 12 15 (Work light) 13 --­ Fuse puller 14 5, 10, 15, 20 Spare 15 * 20 Oil cooler fan motor * Hydraulic utility valve equipped model BReplacing Slow-Blow Fuses The slow-blow fuses are intended to protect the electrical cabling. If any of them have blown out, be sure to pinpoint the cause. Never use any substitute, use only a KUBOTA genuine part. C Replacement procedure 1. Disconnect the negative cable of the battery. 2. Remove the cover and the slow-blow fuse box cover. 3. Pull out the slow-blow fuse. 4. Insert a new slow-blow fuse into the slow-blow fuse box. 5. Install the slow-blow fuse box cover and the cover. 6. Connect the negative battery cable. (1) Cover (2) Slow-blow fuse box cover BReplacing Light Bulb 1. Head lights Take the bulb out of the light body and replace it with a new one. 2. Other lights Detach the lens and replace the bulb. Light Capacity Head lights 37.5 W Tail light 5 W Brake light 21 W Easy Checker(TM) 3.8 W (14V, 0.27A) Turn signal light (front) 20 W (if equipped) Turn signal light (rear) 21 W (if equipped) Work light 27 W (if equipped) Instrument panel light 3.8 W (14V, 0.27A) BCleaning Oil Cooler Net (See "Cleaning Oil Cooler Net" in "DAILY CHECK" in "PERIODIC SERVICE" section.) STORAGE A Do not clean the vehicle with engine running. A To avoid the danger of exhaust fume poisoning, do not operate the engine in a closed building without proper ventilation. A When storing, remove the key from the key switch to avoid unauthorized persons from operating the vehicle and getting injured. VEHICLE STORAGE If you intend to store your vehicle for an extended period of time, follow the procedures outlined below. These procedures will insure that the vehicle is ready to operate with minimum preparation when it is removed from storage. 1. Check the bolts and nuts for looseness, and tighten if necessary. 2. Apply grease to vehicle areas where bare metal will rust also to pivot areas. 3. Unload from cargo bed. 4. Inflate the tires to a pressure a little higher than usual. 5. Change the engine oil and run the engine to circulate oil throughout the engine block and internal moving parts for about 5 minutes. 6. With all implements lowered to the ground, coat any exposed hydraulic cylinder piston rods with grease (if equipped). 7. Remove the battery from the vehicle. Store the battery following the battery storage procedures. (See "Checking Battery Condition" in "EVERY 100 HOURS" in "PERIODIC SERVICE" section.) 8. Keep the vehicle in a dry place where the vehicle is sheltered from the elements. Cover the vehicle. 9. Store the vehicle indoors in a dry area that is protected from sunlight and excessive heat. If the vehicle must be stored outdoors, cover it with a waterproof tarpaulin. Put boards under the tires to keep dampness away from tire. Keep the tires out of direct sunlight and extreme heat. A When washing the vehicle, be sure to stop the engine. Allow sufficient time for the engine to cool before washing. A Do not wash with a high-pressure car-washing machine. A Cover the vehicle after the muffler and the engine have cooled down. REMOVING THE VEHICLE FROM STORAGE 1. Check the tire air pressure and inflate the tires if they are low. 2. Install the battery. Before installing the battery, be sure it is fully charged. 3. Check the alternator belt tension. 4. Check all fluid levels (engine oil, transmission oil, engine coolant and any attached implements). 5. Start the engine. Observe all gauges. If all gauges are functioning properly and reading normal, move the vehicle outside. Once outside, park the vehicle and let the engine idle for at least five minutes. Shut the engine off and walk around vehicle and make a visual inspection looking for evidence of oil or water leaks. 6. With the engine fully warmed up, release the parking brake and test the brakes for proper adjustment as you move forward. Adjust the brakes as necessary. TROUBLESHOOTING ENGINE TROUBLESHOOTING If something is wrong with the engine, refer to the table below for the cause and its corrective measure. Trouble Cause Countermeasure Engine is difficult to start or won't start. A No fuel flow. A Check the fuel tank and the fuel filter. Replace filter if necessary. A Air or water is in the fuel system. A Check to see if the fuel line coupler bolt and nut are tight. A Bleed the fuel system. (See "Bleeding Fuel System" in "SERVICE AS REQUIRED" in "PERIODIC SERVICE" section.) A In winter, oil viscosity increases, and engine revolution is slow. A Use oils of different viscosities, depending on ambient temperatures. A Battery becomes weak and the engine does not turn over quick enough. A Clean battery cables and terminals. A Charge the battery. A In cold weather, always remove the battery from the engine, charge and store it indoors. Install it on the vehicle only when the vehicle is going to be used. Insufficient engine power. A Insufficient or dirty fuel. A The air cleaner is clogged. A Check the fuel system. A Clean or replace the element. Engine stops suddenly. A Insufficient fuel. A Refuel. A Bleed the fuel system if necessary. Exhaust fumes are colored. Black A Fuel quality is poor. A Too much oil. A The air cleaner is clogged. A Change the fuel and fuel filter. A Check the proper amount of oil. A Clean or replace the element. Blue white A The inside of exhaust muffler is dumped with fuel. A Injection nozzle trouble. A Fuel quality is poor. A Heat the muffler by applying load to the engine. A Check the injection nozzle. A Change the fuel and fuel filter. Engine overheats A Engine overloaded. A Shift to lower gear or reduce load. A Low coolant level. A Fill cooling system to the correct level; check radiator and hoses for loose connections or leaks. A The motor driven fan does not turn. A Check to see if the fuse is not blown. A Check the electric system. A Dirty radiator core or grille screens. A Remove all trash. A Coolant flow route corroded. A Flush cooling system. If you have any questions, contact your local KUBOTA Dealer. BATTERY TROUBLESHOOTING Trouble Cause Countermeasure Preventive measure Starter does not function. A Battery overused until lights are dim. A Charge battery sufficiently. A Charge the battery properly. A Battery has not been recharged. A Poor terminal connection. A Clean the terminal and tighten securely. A Keep the terminal clean and tight. Apply grease and treat with anti-corrosives. A Battery life expired. A Renew battery. From beginning starter does not function, and lights soon become dim. A Insufficient charging. A Charge battery sufficiently. A Battery must be serviced properly before initial use. When viewed from top, the top of plates look whitish. * Refillable type battery only A Battery was used with an insufficient amount of electrolyte. A Add distilled water and charge the battery. A Regularly check the electrolyte level. A Battery was used too much without recharging. A Charge battery sufficiently. A Charge the battery properly. Recharging is impossible. A Battery life expired. A Replace battery. Terminals are severely corroded and heat up. A Poor terminal connection. A Clean the terminal and tighten securely. A Keep the terminal clean and tight. Apply grease and treat with anti-corrosives. Battery electrolyte level drops rapidly. * Refillable type battery only A There is a crack or pin holes in the electrolytic cells. A Replace battery. A Charging system trouble. A Consult your local KUBOTA Dealer. A If you have any questions, consult your local KUBOTA Dealer. A The factory-installed battery is non-refillable type. MACHINE TROUBLESHOOTING Trouble Cause Countermeasure Machine operation is not smooth. A Hydrostatic transmission fluid is insufficient. A Replenish oil. A Filter is clogged. A Replace the filter. Machine does not move while engine is running. A Parking brake is on. A Release the parking brake. A Transmission fluid level is insufficient. A Replenish oil. Brakes not working correctly A Brake fluid level is low. A Check fluid level. A Air is in brake system. A Consult your KUBOTA Dealer. A Brake pads are worn. A Consult your KUBOTA Dealer. Brake noise --­ A Consult your KUBOTA Dealer. If you have any questions, consult your local KUBOTA Dealer. OPTIONS Consult your local KUBOTA Dealer for further details. A Backup Beeper A Bed Liner A Cab Heater (cab only) A Camo Steel Cab A Console Kit (for cab, with FM / AM / CD unit / blower / dome light) A Engine Hand Throttle Kit A Fabric Cover A Front Accessory Box A Front Heavy Load Springs (required for cab or enclosure or front blade) A Front Heavy Load Strut A Front Mud Guard A Front Trailer Hitch & Pin A Front Work Light (for plastic canopy or no canopy, one or two) A Glove Box A Golf Cage A Headrest A Hydraulic Bed Lift Kit A Hydraulic Bed Lift Kit with One Remote A Hydraulic Upgrade Kit (to put remote feature on the unit with Bed Lift) A Large Front Guard (Silver) A Metal Canopy (FOPS) A Plastic Canopy A Rear Trailer Hitch & Pin A Rear Work Light (for plastic canopy or no canopy, one or two) A Safety Glass Windshield (for canopy) A Snow Blade (72") require Heavy Duty Spring Kit A Soft Cab (W/ soft doors and Safety Glass Wind Shield) A Speedometer A Steel Cab (W/ steel doors) A Strobe Light A Superwinch ATV 2000 A Tail Lamp Guards A Turn Signal / Hazard Light Kit A Warn 2.5CI A Winch Mounting Kit A Windshield Single Wiper Kit (for cab or wind shield) (one or two for one unit) A Work Lights Kit (for metal canopy or cab, include two lights for front or rear) #Kubota #RTV #RTV900 #UtilityVehicle #OperatorsManual #OwnersManual

    • Kubota U17 Excavator Operator's Manual

      (click image to view PDF) The U17 Operators Manual has been converted to plain text for your convenience. MODEL U17 English (U.S.A.) U 1BAABBKAP0850 Code No. RA238-8150-8 17 PRINTED IN JAPAN © KUBOTA Corporation 2008 LIST OF ABBREVIATION Abbreviations Description API American Petroleum Institute ASTM American Society for Testing and Materials, USA CECE Commitee for European Construction Machinery DIN German Institute for Standards, Federal Republic of Germany EN European Standard Front “Front” means the front view towards the boom and dozer Hi High speed ISO International Organization for Standardization JIS Japanese Industrial Standard L Volume (Liter) Lo Low speed L/min Liter per minute MIL Military Standards OPG Operator Protective Guards of Top Guard Level I (Top Guard Level I) ROPS Roll-over Protective Structures rpm Revolutions Per minute SAE Society of Automotive Engineering TPSS Two Pattern Selection System U17 English (U.S.A.) AU . L . 13 - 23 . 3 . AK GENERAL SYMBOLS The instruments and operation elements have been marked with a series of symbols in order to simplify the operation of your excavator. These symbols are listed below with the respective descriptions. 3 Safety alert Symbol T Warning lamp “Fuel level too low” System lamp lWarning lamp “Engine Oil pressure” g Warning lamp “Battery charge” Warning lamp “Auto Idle (AI) Lamp” Indicator lamp “Glow” 7 Working light switch 5 Horn Z Wiper/Washer switch R Diesel E Hydraulic . uid W Gear oil Grease j Fast k Slow Excavator - Overhead movement toward the front Excavator - Overhead movement toward the rear æ Boom up … Boom down = Arm up = Arm crowd ‘ Bucket crowd ’ ” “ Bucket dump Boom swing (left) Boom swing (Right) Dozer raise Dozer lower Operation direction of control lever Operation direction of control lever V Read operator’s manual Engine stop control lamp c Lock Unlock Reducing / Increasing track width FOREWORD You are now the proud owner of a KUBOTA excavator. This excavator is a product of KUBOTA quality engineering and manufacturing. It is made of the .ne materials and under rigid quality control systems. It will give you long, satisfactory service. To obtain the best use of your excavator, please read this manual carefully. It will help you become familiar with the operation of the excavator and contains many helpful hints about excavator maintenance. It is KUBOTA’s policy to utilize as quick as possible every advance in our research. The immediate use of new techniques in the manufacture of products may cause some small parts of this manual to be outdated. KUBOTA distributors and dealers will have the most up-to-date information. Please do not hesitate to consult with them. 3 SAFETY FIRST This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use this unit. 3DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. 3WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. 3CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. IMPORTANT : Indicates that equipment or property damage could result if instructions are not followed. NOTE : Gives helpful information. CONTENTS 3 SAFE OPERATION ..................... 1 DEALER SERVICE ...........................13 TECHNICAL DATA ...........................14 Operating Instructions DESCRIPTION OF MACHINE PARTS .........................15 INSTRUMENT PANEL AND CONTROL ELEMENTS ...................16 BEFORE START ...............................19 DAILY CHECKS ............................19 Tilting The Seat ...........................19 OPENING AND CLOSING OF PARTS ..............19 HANDLING THE SAFETY DEVICES .................................22 OPERATION OF THE ENGINE .........23 STARTING THE ENGINE .............23 STARTING THE ENGINE UNDER COLD CONDITIONS ...31 STOPPING THE ENGINE .............31 STARTING WITH AN AUXILIARY BATTERY ......32 EXCAVATOR OPERATION ...............33 CONTROL OBSERVATIONS DURING OPERATION .............33 RUNNING-IN OF THE NEW EXCAVATOR ........33 STARTING ..................................33 TWO PATTERN SELECTION SYSTEM (TPSS) ......................35 OPERATION OF THE BOOM .......36 OPERATION OF THE ARM ..........36 OPERATION OF BUCKET ...........37 SWIVEL (UNIT SWING) OPERATION ............................37 BOOM SWING OPERATION ......38 BOOM SWING PEDAL ................38 OPERATION OF TRACK WIDTH CHANGE AND DOZER ...........................39 SERVICE PORT OPERATION ......41 DRIVING ......................................41 TURNS .......................................43 UP AND DOWNHILL TRAVELLING ..........................45 PARKING ON A SLOPE ...............45 IMPORTANT INFORMATION ON EXCAVATOR OPERATION .....46 TRANSPORTING THE EXCAVATOR ON A TRUCK ................................47 LIFTING OF THE EXCAVATOR .........49 Care and Maintenance MAINTENANCE ...............................51 MAINTENANCE INTERVALS ......51 DAILY CHECKS ............................53 REGULAR CHECKS AND MAINTENANCE WORK ...............58 EVERY 50 SERVICE HOURS ......58 EVERY 200 SERVICE HOURS ....60 EVERY 250 SERVICE HOURS .....60 EVERY 500 SERVICE HOURS .....61 EVERY 1000 SERVICE HOURS ...66 EVERY 1000 SERVICE HOURS OR ONCE A YEAR .........................67 EVERY 2000 SERVICE HOURS ....67 ANNUAL SERVICING ................68 BIENNIAL SERVICING ...............68 OTHER SERVICING .....................69 OTHER ADJUSTMENTS AND REPLACEMENTS ........................70 PURGING OF THE FUEL SYSTEM .................................70 ADJUSTMENT OF TRACKS ........70 EXCHANGE OF BUCKET TEETH AND SIDE CUTTERS [JPN BUCKET VERSION] ........72 FUSES .........................................74 TROUBLESHOOTING ......................75 OPERATION UNDER COLD WEATHER CONDITIONS ................81 PREPARATION FOR OPERATION IN COLD WEATHER ................81 PROCEDURE AFTER DONE WORK ...........................81 LONG STORAGE .............................82 RECOMMENDED OILS ...................84 BIODIESEL FUEL (BDF) ..............86 MAIN DIMENSIONS .......................88 LIFTING CAPACITY .........................89 The best insurance against accidents is to abide by the safety regulations. Read and understand this section carefully, before operating the excavator. Every user, however experienced, should carefully read and understand this section and those of the attachments and accessories before taking the excavator into operation. The owner is obliged to inform the operators of these instruction in detail. Keep this manual in the storage place. (See "Keeping the Operator's Manual" in the BEFORE START section.) 1. BEFORE OPERATION 1. Make yourself acquainted with the excavator and be aware of its limits. Read this operator’s manual carefully before starting the excavator. 2. Obey the danger, warning and caution labels on the machine. 3. For your safety, a ROPS/OPG (Top Guard Level I) with a seat belt is installed by KUBOTA. A ROPS: Roll-Over Protective Structure A OPG (Top Guard Level I): Operator Protective Guards of Top Guard Level I OPG (Top Guard Level I) in accordance with ISO10262 is equivalent in de. nition to FOPS (Falling Object Protective Structure). Always use the seat belt when the machine is equipped with a ROPS/OPG (Top Guard Level I) as this combination will reduce the risk of serious injury or death, should the excavator be upset or falling objects occur. Do not modify any structural members of the ROPS/OPG (Top Guard Level I) by welding, drilling, bending, grinding or cutting, as this may weaken the structure. If any component is damaged, replace it. Do not attempt repairs. If the ROPS/ OPG (Top Guard Level I) is loosened or removed for any reason, make sure all parts are reinstalled correctly. Tighten mounting bolts to proper torque. 4. ROPS meets requirements of ISO 3471. OPG (Top Guard Level I) meets requirements of OSHA 1926·1003/ISO 10262. 5. The seat belt must be inspected regularly and replaced if frayed or damaged. 6. Track can be set at the narrow width 39in. (990mm) and the standard width 49in. (1240mm). (for details see “OPERATION OF TRACK WIDTH CHANGE AND DOZER”) Do not operate in narrow track width 39in. (990mm), it makes risk of the excavator tipping over, operate always in standard track width 49in. (1240mm), except to pass through narrow space on a even ground. 7. Do not use the excavator under the in.uence of alcohol, medication as well as other substances. Fatigue is also dangerous. 8. Check the surroundings carefully before using the excavator or when attachments are being attached. • Pay attention to the overhead clearance with electric wires. • During excavator use do not allow any persons within the working range. 9. Do not allow other persons to use the machine before having informed him on the exact operation and work instructions, and be assured that the operator’s manual has been read and understood. 10. Do not wear baggy, torn or too large clothing when working with the excavator. Clothing can get caught in rotating parts or control elements which can cause accidents or injuries. Wear adequate safety clothing, e.g. safety helmet, safety shoes, eye protection, ear protection, working gloves, etc., as necessary and as prescribed by law or statutes. (1) Helmet (2) Clothing .t for work (3) Tight seams (4) Good grip shoewear (5) Well . tting cuffs (6) Working gloves (7) Straw hat (8) Towel (9) Baggy trousers (10) Loose cuffs of the shirt (11) Baggy shirt (12) Rubber sandals 11. Do not allow passengers to get on any part of the excavator seat throughout operation. 12. Check mechanical parts for correct adjustments and wear. Exchange worn or damaged parts immediately. 13. Keep your excavator clean. Heavy soiling, grease, dust and grass can in.ame and cause accidents or injuries. 14. Use only KUBOTA authorized attachments. 15. Before starting the excavator, be absolutely sure that the excavator has been . lled with fuel, lubricated, greased and undergone other maintenance work. 16. Do not modify the excavator, otherwise it could lead to unforeseen safety problems. 17. Make sure attachments, particulary those utilizing quick attach systems, are securely mounted. 2. STARTING OF THE EXCAVATOR 1. Get into and out of the machine safely. Always face the machine. Always use handrails and available steps and keep yourself well balanced. Do not hold any of the control Ievers and switches. Do not jump on or off the machine, whether stationary or in motion. 2. Start and control the excavator only from the operator’s seat. The driver should not lean out of his seat when the engine is running. 3. Before starting the engine, make sure that all control levers (including auxiliary control levers) are in their neutral positions. Before starting the engine, make sure that the control levers, travel lever, pedals and other control elements are not stuck and can be moved smoothly. If stuck, for example, a lever may fail to return, possibly putting you in danger. If anything wrong is found, immediately pinpoint the cause and correct it. 4. Do not start the engine by jumping the starter connections. Do not try to circumvent using the starter switch, otherwise the engine could start suddenly and the excavator could move. 5. Make sure that the dozer is on the front side. (The dozer must be raised.) If the levers are activated with the dozer on the rear end, the driving direction is in the opposite direction of the drive levers. 6. Do not run the engine in closed or badly ventilated rooms. Carbon monoxide is colourless, odourless and deadly. 7. Keep all safety equipment and covers in place. Replace damaged or missing safety device. 8. Precautions against tipping over. In order to secure safe operation, keep away from steep slopes and embankments. Do not swing the bucket downwards. Lower the dozer during digging. Keep the bucket as low as possible while driving upwards. Turn slowly on slopes (do not fast). Do not keep the excavator near the edges of trenches and banks, as the earth can give away due to the weight of the excavator. 9. Watch out at all times where the excavator is being moved to. Keep an eye out for hindrances. 10. Keep enough distance from trench and bank edges. • Safety for children Tragedy can occur if the operator is not alert to the presence of children. Children generally are attached to machines and the work they do. 1. Never assume that children will remain where you last saw them. 2. Keep children out of the work area and under the watchful eye of another responsible adult. 3. Be alert and shut your machine down if children enter the work area. 4. Never carry children on your machine. There is no safe place for them to ride. They may fall off and be run over or interfere with your control of the machine. 5. Never allow children to operate the machine even under adult supervision. 6. Never allow children to play on the machine or on the attachments. 7. Use extra caution when backing up. Look behind and down to make sure the area clear before moving. 8. When parking your machine, if at all possible, park on a . rm, .at and level surface; if not, park across a slope. Lower the bucket and dozer to the ground, remove the key place the control lock levers in the locked position from the ignition before you leave. 3.AFTER OPERATION Before leaving the machine, • Bring the excavater on a . rm, . at and level surface. • Lower the attachments and the dozer blade on the ground. • Stop the engine. • Lock all control levers. • Remove the key. 4. SAFE LOADING AND TRANSPORT OF THE EXCAVATOR 1. Observe all regulations concerning the transport of excavators on public roads. 2. Use adequately long and robust ramps when loading on a truck. (for details see “TRANSPORTING THE EXCAVATOR ON A TRUCK”) 3. Do not change the running direction and to avoid a tipping over, do not try to swing the attachment crosswise to the loading ramps. 4. After loading of the excavator on a truck, engage the swing lock pin. Lower the attachment on the loading plane and release the pressure from the hydraulic system. Block the tracks with blocks and wire down the excavator. After loading the excavator on a truck, tie down the undercarriage of the excavator with a strong steel wire on the truck. 5. Do not brake abruptly with the excavator loaded. Mortal accidents could happen. 6. If the excavator is used to tow another machine, the load must be smaller than the strength of the hook. 7. Do not use hooks on the roof of canopy for lifting the excavator. Max. drawbar pull at 32.3 kNcoupling hook Max. vertical load at 2.7 kNcoupling hook 5.MAINTENANCE Before doing maintenance work on the excavator, place the machine on a . rm, . at and level surface, Iower the attachments on the ground, stop the engine then remove the key and release the cylinder pressure by actuating the levers. When dismantling hydraulic parts, make sure that the hydraulic oil has cooled down suf.ciently to avoid burns. Start maintenance work carefully, e.g. loosen screws slowly so that oil will not squirt out. 1. Before doing work on the engine, the exhaust system, the radiator and the hydraulics, let the excavator cool down suf. ciently. 2. Turn off the engine at all times when .lling with fuel. Avoid spilling and over­.lling of fuel. 3. Smoking is prohibited while tanking and handling the battery! Keep sparks and .re away from the fuel tank and battery. Flammable gases escape from the battery, especially during charging. 4. Do not use or charge the re. llable type battery if the .uid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion. Check the . uid level regularly and add distilled water as required so that the .uid level is between the UPPER and LOWER levels. 5. Read and follow “STARTING WITH AN AUXILIARY BATTERY” in “OPERATION OF THE ENGINE”, when starting with an auxiliary battery. 6. To avoid short-circuiting the battery, always remove the earth cable . rst and attach the plus cable . rst. 7. Keep a .rst-aid box and a . re extinguisher at hand at all times. 8. Do not open the radiator cap before the radiator has cooled down suf. ciently. First loosen the cap to the . rst stop and allow the system enough time to release the remaining pressure. Then loosen the cap completely. 9. Leaking hydraulic .uid has enough pressure to penetrate the skin and cause serious injuries. Leakages from pin holes can be totally invisible. Do not use the bare hand for checking on possible leakages. Always use a piece of wood or cardboard. It is strongly recommended to use a face mask or eye protection. Should injuries occur with leaking hydraulic .uid, contact a doctor immediately. This .uid can cause gangrene or serious allergic reactions. 10. To avoid leakage of battery acid which contains heavy metals, do not throw the battery away. 11. Observe all laws and regulations concerning the disposal of used oil, coolants, solvents, hydraulic . uids, battery acids and batteries. 12. To avoid .re, do not heat the hydraulic components (tanks, pipes, hoses, cylinders) before they are drained and washed. 13. Use a face mask or eye protection to protect the eyes and respiratory system against dust and other foreign particles. 14. Securely support excavator with stands or suitable blocking before working underneath. For your safety, do not work under any hydraulically supported devices. They can settle, suddenly leak down, or be accidentally lowered. 15. Do not crawl under the excavator if the excavator is only supported by the boom and arm or the dozer. The excavator can tip over or lower itself due to hydraulic pressure loss. Always use safety struts or other appropriate supports. 16. KUBOTA uses no parts which are lined with asbestos. Do not use these kind of parts even if they can be installed. 17. Fire prevention Excavator and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcing or sparks. The following .re prevention guidelines will help to keep your equipment up and running ef.ciently and keep the risk of .re to a minimum. • Blow off all accumulated debris near hot engine exhaust components such as turbocharger and exhaust manifold as well as exhaust pipes and muf. er more frequently when working in severe conditions. • Clean out all accumulated . ammable debris such as leaves, straw, pine needles, branches, bark, small wood chips and any other combustible materials from inside the machine belly pans or lower unit structures as well as from area in proximity to the engine. • Inspect all fuel lines and hydraulic hoses for wear or for deterioration. Replace them immediately if they begin to leak. • Examine electrical wiring and connectors frequently for damage. Repair any wires that are loose or frayed before operating the machine. Clean all electrical connections and tighten all electrical connections as necessary. • Inspect the exhaust system daily for any signs of leakage. Check for broken pipes and muf.er and also for loose or missing bolts, nuts and clamps. If any exhaust leaks or fractured parts are found, repairs must be completed prior to operation. • Always keep a multipurpose . re extinguisher on or near the machine. Be familiar with the operation of the . re extinguisher. 6.DANGER, WARNING AND CAUTION LABELS (1) Code No. RA238-5747-1 (2) Code No. RA228-5733-1 (1) Code No. RC418-5753-1 (2) Code No. RA228-5762-1 (3) Code No. RD517-5795-2 [Both sides] (1) Code No. RC418-5728-4 (2) Code No. RC418-5727-4 (3) Code No. RC418-5733-5 (4) Code No. RD809-5738-2 (6) Code No. 6C300-4744-1 (1) Code No. RC108-5718-1 (2) Code No. RA228-5728-2 [Both sides] (3) Code No. RD358-5736-1 (4) Code No. RA228-5776-1 (6) Code No. RC108-5796-1Diesel fuel only No . re [Both sides] (5) Code No. 68328-5735-1 [Both sides] (7) Code No. RB419-5796-2 [Both sides] (1) Code No. RB238-5737-1 (2) Code No. RC418-5737-2 7.CARE OF DANGER,WARNING AND CAUTION LABELS (1) Keep danger, warning and caution labels, clean and free from obstructing material. (2) Clean danger, warning and caution labels with soap and water, dry with a soft cloth. (3) Replace damaged or missing danger, warning and caution labels with new labels from your KUBOTA dealer. (4) If a component with danger, warning and caution label (s) af.xed is replaced with new part, make sure new label (s) is (are) attached in the same location (s) as the replaced component. (5) Mount new danger, warning and caution labels by applying on a clean dry surface and pressing any bubbles to outside edge. Your KUBOTA dealer is always ready to help so that your excavator offers the best performance. After having carefully read this manual, you will realize that much of the routine maintenance can be done by yourself. Your KUBOTA dealer is responsible for servicing and the delivery of spare parts. When ordering spare parts from your KUBOTA dealer, always mention the serial number of the excavator and the engine. Note these numbers right away in the supplied lines. Model Serial No. Excavator Engine Dealer's name (To be .lled in through the owner) (1) Serial No. (1) Engine serial No. TECHNICAL DATA KUBOTA EXCAVATOR Model name U17 Type Canopy Operating weight lbs.(kg)(including operator's) 3704 (1680) Engine Type Water cooled 4 cycle diesel engine with 3 cylinder Model name KUBOTA D902 Total displacement cc (cu.in) 898 (54.8) Engine power SAE gross kW(HP) 12.0 (16.1) SAE NET kW(HP) 11.3 (15.1) Rated speed rpm 2300 Low idle speed rpm 1300 ~ 1400 Performance Unit swing speed rpm 9.1 Travel speed Fast mph (km/h) 2.6 (4.1) Slow mph (km/h) 1.4 (2.1) Ground psi pressure (kPa) (With operator) [kgf/cm2] 3.7 26 [0.26] Climbing angle %(deg) 58 (30) Dozer Width X Height in.(mm) 39.0/48.8 X 10.2 (990/1240 X 260) Boom swing angle Left deg (rad) 65 (1.13) Right deg (rad) 58 (1.01) Pressure connection for attachments Max. displacement (Theoretical) US gal (L)/min 7.32 (27.7) Max. pressure psi (MPa) [kgf/cm2] 2702 (18.6) [190] Fuel tank capacity US gal (L) 5.0 (19) NOTE: • Above dimensions are based on the machine with rubber trucks and JPN bucket. JPN = made in Japan • Speci.cations subject to change without notice. * With unloaded digging bucket. * Firm compacted soil. * Operators must exercise extra caution and follow instructions in the operator's manual. * Worse condition or heavier attachment to the above will decrease climbing angle. DESCRIPTION OF MACHINE PARTS DEPICTED CONTENTS (1) Arm (2) Bucket cylinder (3) Bucket link (4) Bucket (5) Swing bracket (6) Dozer cylinder (7) Dozer (8) Arm cylinder (9) Boom (10) Canopy (Rops / OPG (Top Guard Level I)) (11) Operator’s seat (12) Boom cylinder (13) Drive sprocket (14) Track roller (15) Front idler INSTRUMENT PANEL AND CONTROL ELEMENTS • Instrument Panel, Switches DEPICTED CONTENTS (1) Horn switch (2) LCD display (3) Starter switch (4) Working light switch (5) Working light (6) Working light (Option) Instrument Panel DEPICTED CONTENTS (1) Speed indicator lamp (2) AUX operation lamp (3) Periodic check lamp (4) Clock setting request lamp (5) Glow lamp (6) Remaining fuel warning lamp (7) Engine oil pressure warning lamp (8) Battery charge lamp (9) Coolant temperature warning lamp (10) Warning lamp (11) Fuel gauge (12) Coolant temperature gauge (13) LCD display (14) User setting switch (switch 2) (15) Display selector switch (switch 3) • Control Pedals and Levers DEPICTED CONTENTS (1) Drive lever (left) (2) Control lever for front attachments (left) (3) Lock lever for attachment control (4) Service port pedal (5) Drive lever (right) (6) Control lever for front attachments (right) (7) Two travel speed switch (8) Control lever for dozer or track width (9) Throttle lever (10) Boom swing pedal (11) Track width change / dozer select lever DAILY CHECKS In order to avoid damage, it is important to check the condition of the excavator before starting. 3 CAUTION To avoid personal injury: • Do maintenance work on the excavator only on even ground with the engine off and the safety devices in the “Lock” position. Checks Walk around the excavator and check for visual damage and wear. Check coolant level. (See regular checkpoints in “MAINTENANCE”.) Check fuel level. Check engine oil level. Check hydraulic . uid level. Check air . lter for clogging. Check all control lamps, indicators, engine rpm's counter and hour meter. Check the light system. Check the seat belt and the Rops/OPG (Top Guard Level I) safety device. Check the condition of the danger, warning and caution labels. (See "DANGER, WARNING AND CAUTION LABELS" in "SAFE OPERATION" .) TILTING THE SEAT 3 CAUTION To avoid personal injury: • Lock the lever for attachment control when tilting the seat. To tilt the seat forward, pull the seat tilting lock lever and tilt the seat forward. (1) Seat tilting lock lever (A) “Tilting forward” (2) Lock lever for (B) “Lock” attachment control OPENING AND CLOSING OF PARTS • Opening / Closing the Rear Bonnet 3 CAUTION To avoid personal injury: • Do not touch the exhaust muf.er or the exhaust pipe; serious burns can occur. 1. Put the starter key in the key slot and turn it clockwise to the vertical position. The rear bonnet will be unlocked. Press the button, and the rear bonnet can be opened sideways. When the rear bonnet is opened, the rear bonnet will be locked with the lock lever. 2. To close the rear bonnet, make sure the left bonnet is locked, unlock the lock lever and push the rear bonnet until it clicks into position. To lock the bonnet, turn the starter key counterclockwise to the horizontal position. (1) Lock lever (A) “Lock” (B) “Unlock” IMPORTANT: • Do not run the machine with the bonnet open. The bonnet may get damaged. Opening/closing the left bonnet 1. Remove the rubber mat off the left bonnet side. Then undo the step . xture. (1) Left bonnet (2) Rear bonnet (3) Wing nut 3. To close the left bonnet, do this: push it back into position, apply the lock . xture in place and hand-tighten the wing nut. 4. Spread the rubber mat back in its original place. • Opening and Closing of the Fuel • Keeping the Tools Tank Cover To open the tank cover, .rst insert the key into the key slot and turn it counterclockwise to unlock, then open the tank cover upward. For closing, return the tank cover to original position and turn the key clockwise to lock, then remove the key. HANDLING THE SAFETY DEVICES Control lever lock 3 CAUTION When the excavator is not used or left unattended, be sure to place the lock lever in "Lock" position . The attachment control lever lock is located on the left side. (1) Lock lever for attachment (A) “Lock” control (B) “Unlock” • Swing lock pin This pin is used to lock the swing frame. Set the lock pin to the “Lock” position and the swing frame gets locked to the track frame. IMPORTANT: • Before locking the lock pin, be sure to place the swing frame and the track frame in parallel with each other. 3 CAUTION To avoid personal injury: OPERATION” Read “SAFE at the beginning of this operator's manual. Obey the danger, warning and caution labels on the excavator. Exhaust gases are poisonous. Do not let the engine run in closed quarters without suf. cient and adequate ventilation. Always start the engine from the operator's seat. Do not start the engine while standing next to the excavator. Before starting the engine, sound the horn to get the attention of persons standing nearby. IMPORTANT: • Do not use start help spray or similar . uids. • In order not to overload the battery and starter, avoid start-ups of more than 10 sec. • When the engine does not start in 10 sec., please set the interval of 20 sec. or more, and restart. • Horn Switch When the key in "RUN" position, the horn sounds by pushing the switch. STARTING THE ENGINE 3 CAUTION To avoid personal injury: The operator should not depend solely on the alarm lamps, but should always conduct the routine checks (see “MAINTENANCE”). Start the engine in the following manner: 1. Make sure that the fuel shutoff-valve is in the “Open” position. 3. Pull the lock lever all the way back. (lock position). 4. Insert the key into the starter switch and turn it to the "RUN" position. (1) Starter Switch (A) “STOP” (B) “RUN” (C) “START” 5. Turn the key to "START" position and release after the engine has started; it will automatically return to the "RUN" position. 6. Check if all warning lamps have gone out. Should a warning lamp still be lit up, stop the engine then remove the key and check for the cause. NOTE: • When the lock levers are in "UNLOCK" position, the engine dose not start. • Display Selector Switch Press the display selector switch while the engine is running. The electronic meter’s LCD display will change from one indication mode to the other. Change the three-mode display according to your jobs. (1) Display selector switch (2) LCD display NOTE: • With the starter key at the ”STOP” position, press the electronic meter’s display selector switch, and the LCD display shows the hour meter for 10 seconds. • Setting the clock [Selecting the clock setting mode] 1. Insert the key into the starter switch and turn it to the "RUN" position. (1) Starter Switch (A) “STOP” (B) “RUN” (C) “START” 2. Press the user setting switch (switch 2 (1)). 3. Select the clock setting mode by pressing the display selector switch (switch 3 (2)) and the clock setting request lamp “ ” on the instrument panel lights up. (1) User setting switch (switch 2) (2) Display selector switch (switch 3) (3) Clock setting request lamp NOTE: • Press switch 3 (2) for a long time and the year, month, day, hour and minute will be selected in this order. [Setting the year] Press switch 2 (1) and the numeric setting will be smaller. Press switch 3 (2) and the numeric setting will be larger. Switch 2 Switch 3 2015 2017 2014 2016 2013 2015 NOTE: • While setting the clock, the clock setting request lamp on the instrument panel is blinking. [Setting the month] Press switch 2 and the numeric setting will be smaller. Press switch 3 and the numeric setting will be larger. Switch 2 Switch 3 10 12 9 11 8 10 [Setting the day] Press switch 2 and the numeric setting will be smaller. Press switch 3 and the numeric setting will be larger. Switch 2 Switch 3 09 11 08 10 07 09 [Changing the AM/PM system to the 24-hour system] Select the AM/PM system or 24-hour system by pressing switch 3. [Setting the hour] Press switch 2 and the numeric setting will be smaller. Press switch 3 and the numeric setting will be larger. Switch 2 Switch 3 11 13 (or 01) 10 12 9 11 [Setting the minute] Press switch 2 and the numeric setting will be smaller. Press switch 3 and the numeric setting will be larger. Switch 2 Switch 3 50 52 49 51 48 50 If switch 3 is pressed for a long time, the new settings will be made. NOTE: • If the battery is disconnected, the clock setting request lamp ” ” (yellow) will blink for requesting the setting the clock. • LCD Display for Normal Operation Fuel gauge 3 CAUTION To avoid personal injury: Before adding fuel, be sure to stop the engine. Be sure to keep open . ame away from the machine. Otherwise a .re may result. If the fuel in the tank goes below the prescribed level, the warning lamp will . ash. If this should happen during operation, refuel as soon as possible. (1) Fuel gauge (A) ”FULL” (2) Remaining fuel warning lamp (B) ”EMPTY” IMPORTANT: • If the fuel gauge indicator is near the ” ”, add fuel as soon as possible. If the indicator is near ” ” and the machine operates on a slope, the engine may run out of fuel. NOTE: • To open the fuel cap, keep the starter key inserted. Coolant Temperature Gauge 3 CAUTION To avoid personal injury: Do not open the radiator cap during or just after operation. Hot coolant may gush out and scald you. Wait for the coolant to cool down before opening the cap. With the starter key at the ”RUN” position, the cooling water temperature is indicated. (1) Coolant temperature gauge (A) ”HOT” (B) ”COOL” Hour-meter Indicates the total operating hours of the machine. How the indicator works • The meter advances one hour after an hour of operation regardless of the engine rpm. Engine tachometer Indicates the current rpm of the engine. NOTE: • The LCD display may be illegible when viewed from a certain angle. This is not a display failure. • LCD Display for Warning • Engine oil pressure warning lamp The engine oil pressure warning lamp lights up due to failure of the lubricating system with the engine running. When the starter key is turned to ”RUN” position with the engine off, this engine oil pressure lamp lights up, warning lamp blinks and when the engine starts, the lamps go out. If the lamp stays on with the engine running, stop the engine and check the engine oil level. (1) Engine oil pressure lamp (2) Warning lamp (red) (3) Error code • Battery charge lamp This battery charge lamp lights up if the charging system fails with the engine running. When the starter key is turned to ”RUN” position with the engine off, the battery charge lamp lights up, warning lamp blinks and when the engine starts, the lamps go out. If the lamp stays on with the engine running, stop the engine and check the V-belt. • Warning Lamp The warning lamp is used to indicate broken wire, short-circuit, fuel shortage and other problems. IMPORTANT: • Do not just look at the meter, but also carry out the inspection and correction accordingly. NOTE: • The warning lamp starts .ashing in red if a serious problem occurs. If the system gets in warning signal, the warning lamp starts .ashing in yellow. • Warnings and errors are displayed and an alarm buzzer beeps. • Let your KUBOTA dealer inform you of details concerning care and maintenance. (1) Warning lamp (2) Error code Overheat warning If the water temperature has risen too high, the water temperature warning lamp lights up and the following error code (E:015) gets displayed. With the error code displayed, take the procedure below. 1. Bring the machine to a stop on a safe place. (Get the engine unloaded.) 2. Do not yet stop the engine, but allow it to run idle unloaded for 5 minutes or so. Then stop the engine. 3. Keep yourself away enough from the machine for another 10 minutes or while the engine is emitting steam. 4. Make sure there is no risk of getting burned. Then remove the cause of overheat, referring to “TROUBLESHOOTING”. Finally get the engine restarted. • Checkpoints after Starting the Engine After starting the engine, but before starting operation, check the following points: 1. Put the throttle lever down and let the engine idle for approx. . ve minutes. This allows the engine lubricant to warm up and penetrate every part of the engine. 2. Once the engine has warmed up, check: • the warning lamp ”Engine oil pressure” has gone out. • the warning lamp ”Battery charge” goes out when engine speed is increased. • the color of the exhaust is normal and no abnormal noises or vibrations are heard or felt. • no .uid is leaking from pipes or hoses. • Should any following conditions occur, stop the engine immediately. • The engine rpm’s increases or decreases suddenly. • Sudden abnormal noises are heard. • Exhaust is black. • Warning lamp for engine oil lights up during operation. IMPORTANT: • In these cases, the excavator must be checked and serviced by your local the KUBOTA dealer. • Glow Lamp With the starter key at the ”RUN” position, the engine’s preheat status is indicated. NOTE: • When the starter switch is turned to the ”RUN” position, the engine will be preheated for a given period of time and the indicator will turn on. • The above indication appears momentarily when the engine is started, but it does not indicate trouble. (This is because the oil charge sensor output . uctuates when the engine is started.) • The following symbol appears momentarily as the engine starts. This is not an error. (1) Glow lamp • Battery Charge Lamp This warning lamp lights up if the charging system fails while the engine is running. When the starter switch is turned ”ON” with the engine off, the lamp lights up, and when the engine gets started, the lamp goes out. NOTE: • If there is disconnection or failure in the charging system when the key is turned to ”RUN”, the following symbol will appear. • Engine Oil Pressure Warning Lamp The engine oil pressure warning lamp lights up due to failure of the lubricating system with the engine running. When the starter switch is turned ”ON” with the engine off, this lamp lights up, and when the engine starts, the lamp goes out. If the lamp stays on with the engine running, stop the engine and check the engine oil level. NOTE: • If there is disconnection, failure or breakdown in the lubricating system when the key is turned to ”RUN”, the following symbol will appear. (1) Engine oil pressure warning lamp • Checkpoints after Starting the Engine After starting the engine, but before starting operation, check two following points: 1. Put the throttle lever in "LOW" position and let the engine idle for approx. 5 minutes. This allows the engine lubricant to warm up and penetrate every part of the engine. Note: • This idling is usually called "Warm­up". 2. Once the engine has warmed up, check: • the warning lamp "Engine oil pressure" has gone out. • the warning lamp "Battery charge" goes out when engine speed is increased. • the colour of the exhaust is normal and no abnormal noises or vibrations are heard or felt. • no .uid is leaking from pipes or hoses. • Should any following conditions occur, stop the engine immediately. • The engine rpm's increases or decreases suddenly. • Sudden abnormal noises are heard. • Exhaust is black. • Alarm lamp for engine oil lights up during operation. IMPORTANT: • In these cases, the excavator must be checked and serviced by your local KUBOTA dealer. • Precautions in case of overheat 3 CAUTION Do not open the radiator cap during and just after operation. Hot water may gush out and get you burned. Wait long enough until the radiator cools down. If by any chance cooling water gets heated up to the boiling point or over (overheated), the whistle at the reserve tank drain hose end blows. In such case, take the following steps. 1. Stop operation in a safe condition. (Disconnect the engine’s load.) 2. Do not stop the engine suddenly. Keep the engine idling under no load for about 5 minutes and turn it off. 3. Keep yourself enough away from the machine for another 10 minutes or while steam is given off. 4. Make sure there is no hazard of getting burned. Pinpoint and remove the cause of overheat, referring to “TROUBLESHOOTING”. Then get the engine restarted. STARTING THE ENGINE UNDER COLD CONDITIONS 3 CAUTION To avoid personal injury: Make sure that the lock lever is in the lock position during warm up. Start the engine in the following manner; 1. Pull the lock levers all the way back (lock position). 2. Turn the starter switch to the "RUN" position (glow position) and keep until the indicator lamp has gone out. 3. Move the starter switch to the "START" position; to crank and start the engine. 4. Release the starter switch after the engine has started; it will automatically return to the "RUN" position. IMPORTANT: • Let the engine warm up after start­up for approx. 10 minutes under no load conditions. If the hydraulic . uid temperature is too low, the operations will be affected. Do not operate the excavator under full load before the engine has warmed up enough. STOPPING THE ENGINE 3 WARNING To avoid personal injury or death: Do not keep the bucket or dozer in the lifted position, as a person could accidently touch the levers and cause serious accidents. 1. After slowing the engine to idle, turn the key to "STOP". 2. Remove the key. • Emergency Engine Stop Fuse 3 CAUTION To avoid personal injury: Do not open engine hood before stopping engine. Only when engine does not stop by key, open engine hood and pull out the fuse. The engine will stop when the cap is removed and the fuse inside is pulled out. The engine can be restarted when the fuse is pushed back into its original position. (1) Emergency engine stop fuse (A) “OPEN” (B) “PULL OUT” NOTE: • If the engine does not stop with the key, contact your KUBOTA dealer. STARTING WITH AN AUXILIARY BATTERY 3 CAUTION To avoid personal injury: Battery gases can explode. Do not smoke and keep sparks and . ames away. Do not start the engine with an auxiliary battery if excavator battery is frozen. Do not connect the black jumper cable to the negative (—) terminal of the excavator battery. Observe Following Guidelines when Starting with an Auxiliary Battery 1. Bring the helping machine with the same battery voltage as near as possible to the machine. THE MACHINES MUST NOT COME IN CONTACT WITH EACH OTHER. 2. Bring the levers and pedal of both machines in the neutral position. 3. Wear eye protection and rubber gloves. 4. Remove the battery caps from both batteries. (If present) 5. Connect the terminal of the red jumper cable with the plus (+) terminal of the low battery and connect the other end of the cable to the plus (+) terminal of the auxiliary battery. 6. Connect the black negative cable to the minus (—) terminal of the auxiliary battery. 7. Connect the other end of the black cable (coming from the auxiliary battery) to the machine frame as far away as possible from the low battery. 8. Start the engine of the helping machine and let it run for a while. Start the machine with the low battery. 9. Disconnect the jumper cables in the reverse sequence. (1) Low battery (2) Auxiliary battery (3) Jumper cables IMPORTANT: • This excavator has a negative (—) earthed 12 Volt starting system. • Only use the same voltage when using an auxiliary battery. • Using a higher voltage will cause serious damage to the electrical system. When using an auxiliary battery, only the compatible (same) voltage is permissible. CONTROL OBSERVATIONS DURING OPERATION • Stop the Engine immediately if: • Sudden increase or decrease in engine rpm's occurs. • Sudden abnormal noises occur. • Exhaust gases turn suddenly very dark. Make following control observations during operation to be sure that everything functions normally. RUNNING-IN OF THE NEW EXCAVATOR The operation and care of the new excavator in.uences its life span. Your new excavator has been carefully checked and tested before leaving the factory. In spite of this, all movable components must run-in during the .rst 50 work hours. Do not work with full engine rpm's and full loads during this period. It is most important to run-in your excavator properly in order to achieve its full performance and longevity. During the running-in, the following points should be adhered to in all cases. • Do not Work with Full Engine Rpm's or Full Loads during the First 50 Working Hours • Let the engine warm up suf. ciently in the cold season. • Do not let the engine rev-up more than necessary. • Oil Change in the Run-in Stage The lubrication oil plays a speci. c and important role during the run-in phase of the excavator. The numerous movable parts are not yet run-in, so many . ne metal particles are generated and cause damage and shorten the lifetime of many components. Pay attention to the oil-change intervals and complete them sooner than later. See the subject "REGULAR CHECKS AND MAINTENANCE WORK" for more details on the oil-change intervals. Seat Belt 3 WARNING To avoid personal injury or death: Always use the seat belt with a ROPS/OPG (Top Guard Level I) protection structure. Adjust the seat to the optimal position and buckle up. (1) Seat belt STARTING 3 CAUTION To avoid personal injury: No persons, other than those familiar with the excavator, are allowed to use the excavator. Do not allow any person other than the operator to ride on the excavator. 1. Adjusting the Operator’s Seat • Operator's Seat 3 CAUTION To avoid personal injury: Make sure that the seat is completely secured after each adjustment. Do not allow any person other than the driver to ride on the excavator. (1) Knob for tilt (A) "FORWARD" (2) Suspension adjustment (B) "BACK" lever (C) "UNLOCK" (3)Travel adjust lever • Backrest angle adjust knob : (1) Pull up and unlock the backrest angle adjust knob (1). Reposition the backrest in Direction A or B to an optimum angle. • Driver's weight adjustment : (2) Sit on the seat and swing the weight adjust lever (2) 90º in Direction (c). Move up or down the lever (2) several times until the arrow mark comes to the center of the weight indicator (3). Move up the lever (2) toward G from the center (free state), and the spring force gets stronger. Move it down toward F, and the spring force gets weaker. • Travel adjustment (Horizontal) : (4) Pull up and unlock the travel adjust lever (horizontal) (4). Slide the seat back and forth to an optimum position. Make sure the seat has got locked in the desired position. • Armrest angle adjustment : (5) Turn up or down the armrest angle adjust knob (5) to position the armrests to an appropriate angle. Turn up the knob (5) toward (d) to tilt up the armrests toward E. Turn it down toward (e) to tilt them down toward D. 2. Bring the lock lever into the "Unlock" position. 3 CAUTION To avoid personal injury: Check safety features all around the excavator. • Working Light Switch If the key in “RUN” position, the lights can be switched on by pressing the switch. (1) Working light switch Night operation 3 CAUTION To avoid personal injury: Visibility is reduced in darkness, so that the working light alone is not enough. Prepare additional lighting, observe safety rules as well as special regulations for night work. • Travel Buzzer (OPTION) When you handle the drive levers, the buzzer sounds at the same time or before the excavator starts to run. TWO PATTERN SELECTION SYSTEM (TPSS) 3 CAUTION To avoid personal injury: Study control lever pattern A and pattern B. Then choose the one which is most familiar Position the pattern selector lever in either the left side position of the machine (pattern A) or the right side position (pattern B). Familiarize yourself with the pattern selected by operating slowly. Pattern Change Position the pattern selector lever to the desired position. (1) Pattern selector lever (A) Pattern A (Two Pattern Selection (B) Pattern B System: TPSS) Lever Position Pattern A Pattern B Attachment Control Lever (Left) A B C D Boom down Boom up Swing left Swing right Arm up Arm crowd Swing left Swing right Attachment Control Lever (Right) 1 2 3 4 Arm up Arm crowd Bucket crowd Bucket dump Boom down Boom up Bucket crowd Bucket dump OPERATION OF THE BOOM To raise the boom, pull the attachment control lever back. The boom is equipped with a cushion cylinder which helps prevents excavated material in the bucket from falling out. Low hydraulic oil temperature, (e.g. after starting the engine in cold weather) the cushioning function will be effected for a short period of time (approx. 3 to 5 seconds). This condition results from the viscosity of the hydraulic oil and is not a sign of malfunction. The cushion cylinder will operate normally as the oil warms up. IMPORTANT: • When lowering the boom, make sure that it does not hit the dozer and that the bucket teeth do not touch the dozer. OPERATION OF THE ARM Pull back the attachment control lever and the arm will be pulled in. To move the arm out, push the control lever towards the front. NOTE: • When pulling in the arm, the movement may stop for a short moment when the arm is in its vertical position. This is caused by the combined load of the arm and bucket moving the cylinder piston away from the hydraulic .ow causing a short delay in the cylinder action, until the .ow catches up with cylinder piston. This is a characteristic of the hydraulic system and is no sign of a malfunction. OPERATION OF BUCKET To dig using the bucket, move the right attachment control lever from the neutral position left. Moving the control lever right, moves the bucket outwards and dumps its contents. SWIVEL (UNIT SWING) OPERATION 3 CAUTION To avoid personal injury: When working in groups, always let the others know what you are going to do before you do it. Keep away from the working area. IMPORTANT: • Do not operate the left attachment control lever abruptly from right to left (or vice versa). Because of the law of inertia, this causes an impact load on the swing gear and the swing motor. Additionally, the life of the excavator will be shortened. • Unlock the swing lock pin before doing swivel operations. 1. Move the control lever to the left and the upper structure will turn to the left. 2. Move the control lever to the right and the upper structure will turn to the right. BOOM SWING OPERATION 1. Step on the left side of the pedal to swing the boom to the left. 2. Step on the right side of the pedal to swing the boom to the right. BOOM SWING PEDAL 3 WARNING To avoid personal injury or death: • Always keep your toes within the edge of foot step; otherwise there is a possibility that your toes will be caught between swing frame and boom or boom cylinder. 3 CAUTION To avoid personal injury: • When boom swing operation is not in use, fold the boom swing pedal forward to .x the pedal from unexpected move. OPERATION OF TRACK WIDTH CHANGE AND DOZER 3 CAUTION To avoid personal injury: • Do not operate in narrow track width [39in. (990mm)], it makes risk of the excavator tipping over, operate always in standard track width [49in. (1240mm)], except to pass through narrow space on a even ground. • For changing the track width or using the dozer, set the track width change/ dozer select lever fully. If not, the excavator may unintentionaly move. • Operation of the Track Width 1. Set the track width change/dozer select lever to the “Track width change” position (B). 2. Push the control lever forward. ... The track width increases [from 39in. to 49in. (990 mm to 1240 mm)]. Pull the control lever backward. ... The track width reduces [from 49in. to 39in. (1240 mm to 990 mm)]. • Adjustment of the Dozer Width For changing from standard width to narrow width: 1. Pull out the .xing pin (2) and remove the extension dozer (1). 2. Set as under illustration the extension dozer (1), insert .xing pin (2). 3. It is the same operations for opposite side (left or right), and also for changing from standard width to wide width. • Operation of the Dozer NOTE: • While operating the dozer, the track width change / dozer select lever must be set position (A). SERVICE PORT OPERATION This pedal is used to operate attachments such as breakers. Max. Flow Volume Theoretical US gal (L)/min. 7.32 (27.7) Max. Pressure psi 2697 [MPa (kgf/cm2)] [18.6 (190)] IMPORTANT: • When the service port is not used for a long period, dirt particles can settle in the lower part of the service port lines. When the plugs on the service port lines are removed to connect attachments, drain approx. 100 cc of oil per side. For breaker choices, contact your dealer. NOTE: • When the service port is not in use, fold the service port pedal forward. The pedal gets .xed and can be used as footrest. (1) Service port pedal (A) “Fix” DRIVING 3 WARNING To avoid personal injury or death: Before starting the engine, make sure that no one is near the excavator. • Before operating the excavator, check the track direction. (Idler and dozer to the front of the excavator). (A) ”Front” Avoid travelling across a slope or working sideways on a slope. 1. To lock the swing frame with the track frame, engage the swing lock pin. 2. Adjust the engine speed from idling to an intermediate speed. 3. Unlock the lock lever for attachment control. 4. Raise the dozer and hold the bucket about 8 to 16 in. (20 to 40 cm) over the ground. (A) 8 to 16 in. (20 to 40 cm) • Throttle Lever At the operator’s seat, 1. Move the throttle lever to the “FAST” position, and the engine speed increases. 2. To stop the engine, push the throttle lever fully to the “SLOW” position and turn the starter switch to the “STOP” position. • Drive Levers (Right, Left) 3 WARNING To avoid personal injury or death: • If the swing frame has been turned 180º, i.e. the dozer is, seen from the operator, “behind”, then the travel direction is opposite to the drive direction of the levers (when activating the drive lever forwards, the excavator, seen from the operator, will move backwards). Pushing the drive lever forward, moves the excavator forward, and vice-versa. The front of the excavator is the direction where the dozer is present. (1) Drive lever (left) (A) “Forward” (2) Drive lever (right) (B) “Backward” IMPORTANT: • If the track are clogged with sand or gravel while working on soft ground, lift up one track with the help of the boom, arm and bucket and let the track rotate to shake off the sand and gravel. • Travel Speed Switch 3 CAUTION To avoid personal injury: When activating the travel speed switch, it must be pushed down completely. Travel speed will increase when the switch is pushed down. 1. Press the travel speed switch. The travel speed changes from . rst speed to second. The jsymbol lights up. 2. Press the travel speed switch again, and the travel speed changes from second to . rst. The jsymbol light goes out. (1)Travel speed switch (2) j symbol NOTE: • Each time the travel speed switch is pressed, the travel speed is switched between .rst and second. IMPORTANT: • Do not activate the travel speed switch when there is increased drive resistance (e. g. driving on inclines or on uneven grounds). TURNS 3 CAUTION To avoid personal injury: Do not change direction on steep slopes, or the excavator could tip over. Before changing direction, beware of people in the working area. Pivot Turn NOTE: • Movement as illustrated shows the turning directions with the dozer in the front. When the dozer is in the back, the steering direction is reversed. (For example, push the left drive lever forward and the excavator turns right; the left track, seen from the operator, will move backward from the operator.) • Change of Direction while Stationary 1. Push the left drive lever forward; the excavator will turn to the right. 2. Pull the left drive lever backward; the excavator will turn to the left. • Change of Direction while Travelling 1. While travelling forwards, bring the left (right) drive lever in the neutral position; the excavator will turn to the left (right). Spin Turn When both drive levers are activated in the opposite directions, both track will rotate with the same speed but in opposite directions. Center of rotation is the center of the excavator. UP AND DOWNHILL TRAVELLING 3 CAUTION To avoid personal injury: Before travelling up and downhill, be sure to be in standard track width [49in. (1240mm)]. When travelling up or down a slope for long periods of time, be sure to engage the swing lock pin. Also engage the swing lock pin when standing on a slope for a long time or the excavator is being transported. While travelling uphill, keep the lower edge of the bucket approx. 8 to 16in. (20 to 40cm) above the ground. Although the KUBOTA excavator will not slip easily because of the tracks, it is safer to let the bucket slide over the ground while travelling downhill. Always choose slow speed for uphill and downhill travelling. [UPHILL TRAVELLING] PARKING ON A SLOPE 3 WARNING To avoid personal injury or death: When the excavator is parked or left unattended on a slope, be sure to put the bucket on the ground and place all control levers in neutral position, then brace the tracks with drags. IMPORTANT INFORMATION ON EXCAVATOR OPERATION • Do not try to crush concrete or boulders using side swings with the bucket. Also avoid using side sweeps of the bucket to move earth piles. • Under all circumstances avoid the following operations: • Excavation using the gravitational impact of the machine. • Compacting of gravel or soil using the dropping action of the bucket. • Excavation using the travelling power of the machine. • Do not try to drop or shake off soil adhering to the bucket in the manner given in the points below. This can cause damage to the machine. Adhered soil can be shaken off when the bucket is being emptied by moving the bucket out to the maximum stroke of the cylinder. Should this not suf. ce, swing out the arm as far as possible and operate the bucket back and forth. • Do not hit the dozer with the boom cylinder! Make sure that the boom cylinder does not hit the dozer when doing deep excavation. If necessary swing around so that the dozer is in the back of the machine. • Pay attention when pulling in the bucket! When pulling in the bucket (for driving or transportation) avoid hitting the dozer. • Avoid collisions! When moving the excavator, pay attention that the dozer does not collide with obstructions such as boulders etc.. Such collisions shorten the life of the dozer and the cylinder substantially. • Support the machine correctly! When stabilizing the machine with the dozer, Iower the dozer to engage the full width on the ground. • If the water or mud level reaches higher than the top of the tracks, the swivel bearing, swivel motor gear and ring gear may be exposed to mud, water and other foreign objects. The excavator must be properly pressure washed after each use. • Thoroughly clean the area around the swivel bearing, swivel motor gear and ring gear to remove foreign objects. • Inspect the swivel motor oil sump (if equipped) for water contamination. If water is present, refer to operator's manual for lubricant replacement procedure. • Refer to operator's manual for proper swivel bearing, swivel motor gear and ring gear lubrication procedures. • Reinstall any protective covering if removed earier. 3 DANGER To avoid personal injury or death: • No directional changes should be made when the excavator is on the ramp. Should a change of direction be necessary, drive off the ramp completely and make the turn. • When driving forwards or backwards onto the truck, or when swinging the upper body, make sure that neither the cabin or the gates of the truck will be damaged. • When the excavator reaches the point between the ramps and the truck bed, halt and then move very slowly until the excavator reaches the horizontal position. • Move the excavator onto the truck only with the arm completely pulled in. Otherwise the truck cabin could be damaged when swinging around the upper body. • Do not jack up the machine using its boom to load or unload the excavator from the truck. Dangerous situation could arise. • Transporting on a Truck 3 WARNING To avoid personal injury or death: • After loading the machine on the truck, lower the bucket and dozer onto the truck bed. Lock the swing frame with the swing lock pin. Prepare a platform to load or unload the excavator. Take following steps when using ramps. 1. Apply the parking brakes of the truck, and block the drive wheels from both sides. 2. Use mounting brackets to secure the ramp properly. Connect the ramps directly to the truck bed. 3. For additional safety, use blocks or supports under the ramps and the truck bed. 4. Align the ramps and the tracks and then drive the excavator slowly up the ramps. After ensuring that the tracks are completely on the truck bed, swivel the upper body around to the back of the truck. 5. Block the tracks and wire down the excavator. 6. Before unloading, remove the swing lock pin and then raise the dozer and bucket from the truck bed. 3 DANGER To avoid personal injury or death: • The correct instructions for safe handling are described here. Read these instructions carefully before moving the machine. Make sure that the operating personnel read the operator's manual carefully. • Basics when Lifting with Cables or Straps 1. The lifting and crane operation is to be undertaken according to the guidelines described. 2. The equipment for lifting mentioned in these instructions are only given as reference, the standards concerning strength, control and other details are based on the respective applicable guidelines. • Safety Aspects when Lifting with Cables or Straps Abide by following steps when lifting: 1. Do not lift loads that exceed the maximum load capacity of the crane. 2. Choose correct equipment suitable to the weight, size and form of the load. 3. First assess the center of gravity of the load, position the hook directly over the load and lift the load so that the center of gravity of the load is as low as possible. 4. The steel cables or straps must be . xed in the middle of the hook. 5. The load must be lifted vertically from the ground. 6. Do not enter the working area under suspended loads and do not move the load over people. The load must only be moved in an area where the balance can be easily maintained. • Lifting Procedure for the Excavator 3 WARNING To avoid personal injury or death. • Do not use the hooks on the roof of canopy and cabin for lifting the excavator. • General guidelines for lifting 1. Lifting position. (see illustration) 1) Pull in the boom towards rear. 2) Pull in the arm completely. 3) Pull in the bucket completely. 4) Adjust the swing angle to the right end. 5) Swing frame so that dozer blade is to the rear and frame is parallel with tracks. 6) Raise the dozer blade fully. 7) Insert the swing lock pin. 2. Attaching the steel wires. 1) Always hook the excavator at three points. (one on the boom and right and left of the dozer) 2) Always use a shackle on each lifting hole when attaching the cables or straps. 3) Using protective material at all places where the cables or straps contact the machine. 4) Keep the angle between the front and rear cables or straps within. 30° (0.52 rad.). 3. Tackle Choose components having enough strength. 4. Lifting 1) Lift slowly and safely 2) Do not enter the excavator area when lifting. 3) Lift the excavator horizontally. (Modify wire connections according to needs) MAINTENANCE MAINTENANCE INTERVALS No. Checkpoints Measures Hour meter indicator Interval Ref. page 50 100 150 200 250 300 350 400 450 500 550 600 1000 2000 1 Fuel check Daily check 49 2 Engine oil check Daily check 50 change every 500 hrs 57 3 Hydraulic oil** check Daily check 51 change every 1000 hrs 63 4 Coolant check Daily check 49 change every 2 years 64 5 Lubrication points check Daily check 52 6 Radiator check Daily check 53 7 Battery condition check every 50 hrs 54 8 Electrical lines check Daily check, Annual servicing 53 9 Greasing of swing bearing teeth every 50 hrs 54 10 Drive unit oil change every 500 hrs 59 11 Fan belt tension adjust every 200 hrs 56 12 Radiator hoses and clamps check every 200 hrs 57 change every 2 years 64 13 Air filter element* clean every 200 hrs 55 @ change every 1000 hrs 63 14 Greasing of swing ball bearings every 200 hrs 56 15 Fuel pipes and hoses check every 200 hrs change every 2 years 59 16 Engine oil filter change every 500 hrs 58 17 Fuel filter check every 50 hrs change every 500 hrs 59 @ 18 Hydraulic return filter element change every 1000 hrs 60 19 Hydraulic suction filter element change every 1000 hrs 62 20 Front idler and track roller oil change every 2000 hrs 63 21 Dynamo and starter motor check every 2000 hrs 63 22 Radiator system rinse every 2 years 64 23 Fuel injection nozzle (Injection pressure) check every 1500 hrs 59 @ 24 Injection pump check every 3000 hrs 60 @ IMPORTANT: • First operation • * Clean the air .lter more frequently if used in dusty conditions. With heavy soiling, replace the . lter. ** When using a hydraulic breaker, change hydraulic oil and return . lter according to the table on “Hydraulic Oil Change(Including Exchange of the Suction Filter in the Hydraulic Tank)” under “EVERY 1000 SERVICE HOURS” in “REGULAR CHECKS AND MAINTENANCE WORK”. • The items listed above (@ marked) are registered as emission related critical parts by KUBOTA in the U.S.EPA nonroad emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction. Please see the Warranty Statement in detail. DAILY CHECKS For your own safety and to assure the long life of your machine, a careful check should be made before each operation. • Coolant Check 3 CAUTION To avoid personal injury: Move the excavator to even ground. Make sure that the engine is turned off. Do not open the radiator cap right after the engine has been stopped; Serious burns can occur from contact with escaping hot coolant . uid. Check the coolant level in the reserve tank only after the engine has cooled down. Remove the radiator cap only if absolutely necessary. The radiator has a reserve tank. Should the coolant level in the radiator sink, the water will be automatically be transfered to the radiator. Check the coolant level in the reserve tank and .ll up if necessary. The coolant level should be between the marks “FULL” and “LOW”. (1) Reserve tank (A) “FULL” (B) “LOW” IMPORTANT: Do not .ll the reserve tank over the “FULL” marking. Do not .ll with dirty or salty water. NOTE: Before delivery coolant were . lled with 50 % water and 50 % antifreeze. • Check Fuel Level 3 CAUTION To avoid personal injury: Stop the engine and remove the key before fuelling. Do not smoke while fuelling. IMPORTANT: • Temperatures over –5ºC, use No.2-D diesel fuel, temperatures are under –5ºC, use No.1-D diesel fuel. • Make sure that the fuel tank is not empty. Air will enter into the fuel system, and must be purged before restarting. • Always .ll up fuel after a day's work. • See “PURGING OF THE FUEL SYSTEM” in “OTHER ADJUSTMENTS AND REPLACEMENTS”. If the fuel in the tank goes below the prescribed level, the warning lamp will . ash. If this should happen during operation, refuel as soon as possible. If necessary, open the tank cap with the starter key, and add fuel. NOTE: • The gauge is located next to the oil . lling port. When the fuel tank gets nearly full (about 2 liters more to full), the gauge needle starts moving up to "F" (Full). Use this gauge to avoid an over. ow. IMPORTANT: • Fuel tank cap has an air breather. Make sure to clean the air breather when . lling up fuel. If the air breather is clogged with mud, the fuel tank gets under-pressurized. • Check Engine Oil Level 3 CAUTION To avoid personal injury: Stop the engine and remove the key before checking the oil level. Insert the engine oil dipstick fully into the prepared opening, remove again and check the oil level; if necessary . ll with oil. The machine must be on level ground when checking the oil level. (1) Oil . lling port IMPORTANT: • Use engine oil with the correct viscosity. (according the outside temperature) • After stopping the engine and removing the key, wait .ve minutes, then check oil level. (Excavator must be on level ground.) • Check Hydraulic Oil Level 3 CAUTION To avoid personal injury: First lower all attachments on the ground then stop the engine and remove the key. IMPORTANT: • Before .lling oil, wipe away all sand and dust from around the oil port. Make sure you use an identical type of hydraulic . uid. • The excavator has been . lled with hydraulic .uid before delivery. See “RECOMMENDED OILS”. (Do not mix different oils!) 1. Park the excavator on a . rm, . at and level surface. Adjust the swing angle to the center. Pull in the arm completely. Pull in the bucket completely. Lower the attachments and dozer blade to the ground and stop the engine. Track width increases [16 in. (1240 mm)]. 2. Check the oil level as to whether it lies on the center of the gauge at normal temperature (10 to 30ºC). 3. Enough oil is present if the oil level lies between the markings. 4. Should the oil level be too low, . ll oil through the oil port before starting the engine. This step is important for the protection of the hydraulic system. (1) Speci.ed oil level (2) Tank cap • Checking water separator 1. Open the engine bonnet. 2. When the separated water is being drained, the red .oat moves upward. When the red .oat has reached the indication line, close the shutoff-valve so that no fuel can run out. Now loosen the ring nut, remove the cup, empty the cup and clean the cup. 3. Place the cup back into position. Bleed the fuel system. 4. Finally, do not forget to open the shutoff-valve. (1) Ring nut (A) “Open” (2) Float (B) “Closed” (3) Cup (4) shutoff-valve (5) Indication line • Lubrication Points 3 CAUTION To avoid personal injury: • First lower all attachments on the ground then stop the engine and remove the key. • While greasing, take care not to step on the bucket teeth. • When doing excavation work in water, generously grease the following points. After ending work, grease again. Grease the marked grease . ttings shown by arrows in the illustration below. 1. Boom bottom linkage ................ 1 place 2. Arm bottom linkage ................... 1 place 3. Boom cylinder boss ................... 2 places 4. Arm cylinder boss ...................... 2 places 5. Bucket cylinder boss .................. 1 place 6. Bucket link pin ............................ 3 places 7. Arm cylinder pin ......................... 1 place 8. Boom swing fulcrum ................. 2 places 9. Swing cylinder boss ................... 2 places 10. Dozer cylinder boss ....................2 places 11. Dozer linkage boss ..................... 2 places • Check Radiator and Oil Cooler 3 CAUTION To avoid personal injury: • Always stop the engine and remove the key before checking the radiator and the oil cooler. • Wear eye protection when cleaning with compressed air. 1. Check if the .ns and ribs are clogged. If so clean with compressed air or steam. 2. Check the rubber hoses for damage and replace if cracked or old. Check if the hose clamps are tight enough. (1) Rubber hoses (2) Clamps IMPORTANT: • Radiator and oil cooler .ns and ribs must be clean in order not to overheat the engine and allow free .ow of air through the cooling elements. • Cleaning of Engine and Electrical Wiring 3 CAUTION To avoid personal injury: • Always stop the engine and remove the key before cleaning the wiring, cables and engine. Before starting, check whether . ammable substances have gathered on the battery, the cables and wiring, the muf.er or on the engine. If so, remove thoroughly. • Checking the Electrical Circuit Check the electrical circuitry for disconnections, shorts or loose terminals. • Washing the Whole Machine IMPORTANT: • Do not wash the excavator with the engine running. Water could enter the air .lter and damage the engine. Make sure that the air .lter is kept dry. EVERY 50 SERVICE HOURS Battery Charging 3 CAUTION To avoid personal injury: When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and . ames away from the battery at all times, especially when charging the battery. When charging battery, remove battery vent plugs. When disconnecting the cable from the battery, start with the negative terminal . rst. When connecting the cable to the battery, start with the positive terminal . rst. Do not check battery charge by placing a metal object across the terminals. Use a voltmeter or hydrometer. 1. Make sure each electrolyte level is to the bottom of vent wells, if necessary add distilled water in a well-ventilated area. 2. The water in the electrolyte evaporates during recharging. Liquid shortage damages the battery. Excessive liquid spills over and damages the excavator body. 3. To slow charge the battery, connect the battery positive terminal to the charge positive terminal and the negative to the negative, then recharge in the standard fashion. 4. A boost charge is only for emergencies. It will partially charge the battery at a high rate and in a short time. When using a boost-charged battery, it is necessary to recharge the battery as early as possible. Failure to do this will shorten the battery’s service life. 5. When the speci.c gravity of electrolyte falls between 1.27 and 1.29 charge has completed. 6. When exchanging an old battery for a new one, use a battery of equal speci. cation. • Greasing of Swing Bearing Teeth 1. Pump greace with the grease gun through the grease . tting. 2. Grease at each 90º (1.58 rad.) position of the swing frame. 3. Fill with approx. 50g of grease (approx. 20 pumps with the grease gun). Distribute the grease over the teeth. • Inspection and Cleaning of the Air Filter Element Open the engine bonnet and remove the dust-cover. Take out only outer element, clean the element, case interior and reassemble. During reassembly, take care to install the dust-cover so that its TOP mark (arrow) faces up-wards. Do not remove the inner element. IMPORTANT : Should the machine be used in extremely dusty areas, the air .lter element must be inspected and cleaned more frequently than in the speci. ed maintenance periods. The air .lter has a dry element, keep free from oil. Do not run the engine without the air . lter. 3 • Air Filter Maintenance CAUTION To avoid personal injury: Wear eye protection. • Cleaning with compressed air Pressure of compressed air must be under 30 psi (205 kPa, 2.1 kgf/cm2) and the cartridge should be blown clean from the inside to the outside until the dust deposits are remarkably reduced. IMPORTANT: • If the air suction is still inadequate, or the colour of the exhaust gases is abnormal even after the cleaning, the air . lter element must be replaced. EVERY 200 SERVICE HOURS Do all 50 and 100 hour servicing at the same time. • Greasing of the Swing Bearing 1. Grease through the respective grease . tting. 2. Grease at each 90º (1.58 rad.) position of the swing frame. Using the grease gun, apply 5 shots at every position. EVERY 250 SERVICE HOURS Do all 50 hour servicing at the same time. • Checking the Fan Belt Tension • Check and adjustment of the fan belt tension 3 CAUTION To avoid personal injury: First stop the engine and remove the key. After servicing, make sure to replace the belt cover in its original position. 1. Press the fan belt down in the middle, with a force of approx. 98N (10kgf). The belt tension is correct if it de. ects about 0.3in. (8mm). If otherwise, loosen bolt (1) and (2) and shift the dynamo in the direction shown by the arrow. 2. Replace the fan belt if worn out, cracked or torn. IMPORTANT: • If the engine is run with a loose fan belt, the belt could slip and cause overheating of the engine or insuf. cient battery charging. Check fan belt tension regularly. • Should the fan belt break or jump out, the indicator light for battery charge will light up. Stop the engine and remove the key immediately. • Checking the Radiator Hoses 3 CAUTION To avoid personal injury: • Wait long enough for the radiator coolant to cool down. Check the water hoses for proper . xation. This check should be carried out every 250 hours or every 6 months, whichever comes . rst. 1. Should the hose clamps become loose or water leaks, tighten the hose clamps properly. 2. Should the radiator hoses become swollen, aged or cracked, they must be replaced and the hose clamps tightened again properly. EVERY 500 SERVICE HOURS Do all 50, 100 and 250 hour servicing at the same time. • Engine Oil Change 3 CAUTION To avoid personal injury: First stop the engine then remove the key and wait long enough for the oil to cool down. 1. Remove the drain plug on the underside of the engine and drain all oil. 2. Re-tighten the drain plug. (1) Engine oil dipstick (A) Required level 4. Let the engine idle for approx. 5 min. Check the engine oil level. To check the engine oil level, insert the engine oil dipstick completely into the respective port opening and pull out again. If the oil level lies between both markings, no oil must be added. IMPORTANT: • Regardless of the service hours, an engine oil change is due every six months. • Replacing Engine Oil Filter 1. Replace the oil .lter cartridge at the same time as doing engine oil change. 2. Remove the cartridge with the supplied . lter wrench. (1) Oil . lter cartridge 3. Oil the O-ring of the new oil . lter cartridge lightly. Then tighten the oil . lter cartridge by hand. 4. Fill engine oil to the speci. ed level. 5. Let the engine run for approx. 5 min. and make sure that the engine oil indicator light does not light up. Then stop the engine and remove the key. 6. The engine oil level will sink parallel to the oil .lter capacity after the engine is started. It is necessary to add oil. IMPORTANT: • Always check the oil level when replacing the . lter. • Drive unit Oil Change (First Oil Change at 100 hours) 3 CAUTION To avoid personal injury: Lower attachments to the ground, stop the engine and remove the key before undertaking the oil change. 1. Rotate the track so that the drain plug of the drive unit is in the bottom position. 2. Remove the drain plug to let the oil run out. Screw in and tighten the drain plug again and .ll with gear oil through the oil check port. 3. Fill oil until it over.ows out of the oil check port. Oil change - .rst oil change after 100 hrs - then every 500 hrs - or at least once a year 4. Use prescribed gear oil SAE 90. • Replacing of Fuel Filter 3 CAUTION To avoid personal injury: Keep . re away. 1. Close the shutoff-valve of the water separator. Remove the .lter with the supplied . fter wrench. 2. Add fuel to the new . lter before installing. 3. Apply a light .lm of fuel to the seal of the new .lter and turn in tightly by hand. • Replacing Hydraulic Return Filter Element (.rst replacement after 250 service hours) 3 CAUTION To avoid personal injury: Remove the oil . lter only after the oil in the hydraulic tank has cooled down. Contact your KUBOTA dealer for details. • Battery Service 3 DANGER To avoid the possibility of a battery explosion: For re. llable type battery, follow the instructions below. Do not use or charge the re.llable type battery if the . uid level is below the LOWER (lower limit level) mark. Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion. Check the . uid level regularly and add distilled water as required so that the .uid level is between the UPPER and LOWER levels. 3 CAUTION To avoid personal injury: Batteries contain sulphuric acid which can cause severe burns. Avoid all contact with skin, eyes or clothing. Antidote - External: Rinse with plenty of water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call a physician immediately. Eyes: Rinse with plenty of water for 15 minutes and get prompt medical attention. Keep batteries out of the reach of children. Before inspection or dismounting the battery, be sure to turn of the engine and turn the starter switch to the "OFF" position. When removing the battery, always disconnect the negative ground cable . rst. The reverse when installing a battery, always connect the ground cable last. This prevents a possible explosion caused by sparks. Always wear eye protection when working with the battery. 1. Check the battery .uid level and add distilled water if necessary. 2. Clean the battery caps (ventilation holes). • Draining water of the Fuel Tank 3 CAUTION To avoid personal injury: Before draining water of the fuel tank, be sure to stop the engine and remove the key. Do not smoke during inspection. 1. Remove the drain plug on the underside of the body and drain water. 2. Re-tighten the dran plug. EVERY 1000 SERVICE HOURS Do all 50, 100, 200, 250 and 500 hour servicing at the same time. • Cleaning of the Pipe . lter of the Hydraulic Pilot System Dust and dirt collect on the concave side of the . lter. Clean the .lter by letting hydraulic oil . ow through from the convex side. (A) Oil • Hydraulic Oil Change (Including Replacing of the Suction Filter in the Hydraulic Tank) 3 CAUTION To avoid personal injury: Wait long enough for the hydraulic .uid to cool down. Then begin with the change of the hydraulic . uid. 1. Move the excavator to a level ground and stop the engine. Extend the piston rods of the cylinders halfway out and lower the bucket on the ground. 2. Remove the drain plug on the underside of the hydraulic tank and drain the oil. (1) Cover (2) Suction . lter (3) Drain plug 5. Retighten the drain plug. 6. Fill oil through the oil .lling opening on the top side of the tank. 7. Let the engine run for approx. 5 min. and check the oil level again. Hydraulic 3.44 US gal (13 L) tankHydraulic oil volumes Whole oil 5.55 US gal (21 L) volumes • Hydraulic Oil Check with Hydraulic Breakers The hydraulic oil change after 1000 operating hours in the operator's manual is based on normal excavator work. Following inspection measures are valid when hydraulic breakers are used: 1. Changing and .lling up of hydraulic oil 1) The hydraulic oil must be changed more often when breakers are used because the machine is subject to harder conditions than at normal excavating work. 2) Use only the recommended oils mentioned in the operator's manual when changing or . ll oil. 3) When .lling up oil, do not mix oils of different makes. 2. Changing the return .lter and oil 1) The .lter must be changed more often because of contamination resulting from the frequent assembly and disassembly of the hoses. 2) Use the correct replacement . lter. 3) Oil change according to operating hours. Hydraulic oil Return Filter Normal excavator work every 1000 Hrs. every 500 Hrs. (250Hrs. after first operation) Breaker work portion 20% every 800 Hrs. every 200 Hrs. 40% every 400 Hrs. 60% every 300 Hrs. every 100 Hrs. more every 200 Hrs. EVERY 1000 SERVICE HOURS OR ONCE A YEAR • Replacing Air Filter Element Open the engine bonnet and remove the dust-cover. Remove and replace the outer element and inner element with new elements. When reassembling, install the dust-cover so that its TOP mark (arrow) faces up-wards. (1) Outer element (2) Inner element (3) Dust-cover (4) Clamps IMPORTANT: • Shorten the replacement period if the machine is used in dusty or sandy areas. EVERY 2000 SERVICE HOURS Do all 50, 200, 250, 500 and 1000 hour servicing at the same time. • Chang Front Idler and Track Roller Oil NOTE: Contact your KUBOTA dealer for details. • Check the Dynamo and Starter Motor NOTE: Contact your KUBOTA dealer for details. ANNUAL SERVICING • Electrical Wiring and Fuses Check the terminals periodically for proper connections. Loose wiring or damaged cables can cause improper functioning or short circuiting of the electrical system. Check wiring and replace damaged components immediately. If a fuse blows out soon after having been replaced, contact your nearest KUBOTA dealer. Never use a fuse other than speci. ed. BIENNIAL SERVICING 3 CAUTION To avoid personal injury: Do not loosen the radiator cap before the radiator has cooled down suf. ciently. Then only loosen the cap and allow enough time for the pressure in the system to be released. Now remove the cap completely. • Replacement of Radiator Hoses Replace radiator hoses and hose clamps ever two years. If the hoses are swollen, hard or cracked, they must be replaced earlier. • Changing Radiator Coolant (In case of long-life coolant . uid) Stop the engine then remove the key and wait until it has cooled down completely. 1. Open the drain plug on the bottom of the radiator and drain coolant completely. 2. To clean, rinse the radiator with water. 3. Close the drain plug and . ll the radiator and the reserve tank with coolant . uid. Let the engine idle for about 5 min., stop the engine and remove the key then check the coolant level. 4. The machine has been shipped . lled with 50% anti-freeze solution. IMPORTANT: • Do not operate the engine without coolant. • To .ll the radiator system use fresh water and anti-freeze . uid. • When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50%. • Tighten the radiator cap properly. If the cap is loosely or not properly . tted, overheating of the engine can result due to coolant . uid loss. OTHER SERVICING • Cleaning the Track Frame Slide Pipes When the slide pipes of the track frame are clogged or adhered with soil or sand, clean the slide pipes in the following manner according to need. 3 WARNING To avoid the personal injury or death: Place the machine on even ground when cleaning the track frame slide pipes. 1. First lift the machine off the ground using the dozer blade and boom functions. 2. Switch the track width change / dozer select lever to the “Track width change” position. 3. Push the control lever forward, and expand the track width to 49 in. (1240 mm). 4. Remove soil and sand adhered to the slide pipes, then put grease evenly around the pipes. Make sure all 4 slide pipes are greased. 5. Retract and expand the track width repeatedly for a few times by moving the control lever, so that the grease is spread adequately. 6. Switch the track width change / dozer select lever to the “Dozer” position. 7. Place the machine down on the ground carefully by moving the dozer blade and the boom. (1)Track frame slide pipes PURGING OF THE FUEL SYSTEM 1. Fill up the excavator with fuel. 2. Turn the starter key to the “RUN” position. 3. The air in the fuel system will automatically be purged within one minute. (1) Starter key (A) “STOP” (B) “RUN” (C) “START” IMPORTANT: • If the purging was insuf.cient, the engine dies right after starting. In this case repeat steps 2 to 3 again. ADJUSTMENT OF TRACKS • To loosen the tracks, follow the following procedure: 3 CAUTION To avoid personal injury: Do not loosen the grease . tting completely or too quickly. Otherwise grease under high pressure in the tension cylinder could squirt out. Do not crawl under the excavator. 1. Using a socket wrench, loosen the grease .tting a few turns. 2. When grease oozes out from the thread, rotate the track and loosen the track in the lifted position (see illustration). After adjustment is completed: Using the socket wrench, tighten the grease . tting. Tightening torque must be between 72 to 80 ft·lbs (98 to 108 N·m, 10 to 11 kgf·m). IMPORTANT: • If the tracks are too tight, wear is increased. • If the tracks are too loose, the track pads may collide with the sprocket, wear is increased. The track may dislocate or come off. • Clean the track after every use. • Should the track tension be high due to sticking mud, lift the track with the help of the boom, arm and bucket, idle the engine and remove mud from the track by rotating it. Tension the tracks as speci. ed: 1. Apply grease to the grease . tting (1). (1) Grease . tting (2) Grease gun 2. Tension the track in the lifted position, so that the distance "A" (clearance between the track roller and the inside surface of the track) is 0.4 to 0.6in. (10 to 15mm) (see illustration). In this case, the track seam is positioned on the top center between the idler and the sprocket. 3 DANGER To avoid serious injury or death: Do not work under the machine in this condition. For your safety do not rely on hydraulically supported devices, they may leak down and suddenly drop or be accidentally lowered. (1) Seam (Mark “oo”) (A) 0.4 to 0.6 in. (10 to 15 mm) IMPORTANT: • Make sure that no obstacles, such as stones are caught in the track. Remove such obstacles before adjusting the track tension. • Track seam The ends of the rubber track are joined with a seam. When adjusting the tracks, the seam must be positioned on the top center between the idler and the sprocket. If the seam is positioned incorrectly, the tracks will be tensioned to loosely, and a further readjustment will be necessary. • Rotate the track after adjustment one to two times to check the tension. • Additionally following points are to be observed when adjusting rubber tracks. 1) If the track slackens more than 0.98 in. (25mm), readjust them. 2) Check track tension 30 hours after initial use and readjust if necessary. Check and adjust thereafter every 50 service hours. • Special Information when Using Rubber Tracks 1. When turning, make a slow swing turn. Avoid spin turns to lessen lug wear and entry of dirt. 2. The relief valve may be activated if too much dirt and sand clog the tracks. In this case move the machine for a short distance straight backwards to let the earth and sand fall off, then a turn can be made. 3. Avoid using rubber track on riverbeds, stony underground, ferro-concrete and on iron plates. The rubber can damage as well as increase wear on the tracks. EXCHANGE OF BUCKET TEETH AND SIDE CUTTERS [JPN BUCKET VERSION] Bucket Tooth Replacement 3 CAUTION To avoid personal injury: Wear eye protection when changing the tooth points. 4. Mount a new point on the adapter. (1) Rubber plug (2) Lock pin (3) Point (4) Tooth adapter 5. Align the holes of the point and adapter and knock in the rubber plug together with the lock pin until the top surface of the pin is .ush with the top surface of the adapter. (It is recommended to replace the rubber plug and lock pin when replacing the point.) • Replacing the Bucket 3 CAUTION To avoid personal injury: The bucket can tilt over and cause accidents if in an unstable position. Therefore: 1) Only change the bucket if no other persons are in the area. 2) Lower the bucket on an even ground and make sure that it will not tilt when touched. FUSES Replacing Fuses 1. Remove the cover of the fuse box. 2. Replace the burnt out fuse with a fuse having the same capacity. • Fuse Capacities and Circuits • Slow Blow Fuse No. Capacity Circuit (1) 5A HORN SW (2) 30A ENGINE STOP (3) 5A METER (+B) (4) 15A WORK LAMP (5) 10A HORN (6) 5A AUXILIARY (+B) (7) 5A ECU (+B) (8) 5A STARTER (9) 5A RELAY (10) 10A ECU (AC) (11) 5A FUEL PUMP (12) 5A LEVER LOCK (13) 10A ALTERNATOR (14) 15A P. SOURCE/BEACON (15) 15A AUXILIARY 2 (16) 15A AUXILIARY 1 Slow blow fuse is provided to protect the electrical circuits. If the fusible link is blown, check the electrical circuits for trouble and then replace with a new compatible slow blow fuse. TROUBLESHOOTING If the excavator does not show the desired performance, or when trouble arises, refer to the table below and undertake appropriate measures. Trouble Cause Countermeasure Engine Starting difficulties Fuel is too viscous * Check fuel tank and filter * Remove impurities and water * If necessary, replace filter Air or water in the fuel system * Remove water from the fuel tank * Check fuel pipe joint bolts and nuts for looseness * Purging of the fuel system (for fuel filter and injection pump, see "PURGING OF THE FUEL SYSTEM" in "OTHER ADJUSTMENTS AND REPLACEMENTS".) Oil viscosity is too high the engine runs sluggishly in winter * Pour hot water over the radiator * Use oils of different viscosities depending on the ambient temprature. (Use SAE10W, SAE10W-30 or SAE10W-40) Battery is almost dead; insufficient compression * Recharge battery Insufficient engine power Low fuel level * Check fuel and add if necessary Clogged air cleaner * Clean the air filter element Engine suddenly stops Low fuel level * Check fuel and add if necessary * Purge the fuel system Abnormal exhaust gascolour Poor fuel * Use high quality fuel Too much engine oil * Drain engine oil to prescribed oil level Water temperature in red zone (Overheating) Defective seal of the water pump * Replace Worn or torn fan belt * Adjust or replace Thermostat is defect * Replace Coolant level too low * Fill to prescribed level Radiator grill or fins are clogged * Clean Coolant is contaminated with rust from the cylinder head or crank case * Replace coolant fluid and add anti-rust Defective radiator cap (Evaporation) * Replace Corroded coolant pipes * Clean Continuous operation under full load * Reduce load Cylinder head gasket is damaged (Coolant loss) * Replace Engine oil level too low * Fill to prescribed level Maladjustment of fuel injection * Readjust ignition timing Use of poor fuel * Use prescribed fuel Trouble Cause Countermeasure HydraulicSystem Boom, arm, bucket, drive, swing and dozer power is too low Hydraulic oil level too low * Add oil Leakages of hoses and / or joints * Replace hose or joint Non-function of swing motor Swing lock pin is in lock position * Remove swing lock pin in unlock position DriveSystem Deviation of drive direction Blocked through stones * Remove Track too loose or too tight * Adjust accordingly KUBOTA I.C.S. NAVIGATION LIST OF ERROR CODE If an error occurs with the machine, one of the following error codes appears in the LCD display. In case of a trouble, immediately contact your local dealer for inspection and repair. LCD display LED Problem / Error Solution #1 Solution #2 1 CAN system error The Controller Area Network (CAN) has developed a fault. Measured values may be incorrect and switches may not function. The machine can be started and driven. Do not perform any work with the machine. Inform your KUBOTA dealer immediately. 2 Feed fuel This message appears when the fuel level is low and prompts the operator to refuel. - Refuel the excavator. This message 3 Periodic check soon (notice) appears 10 hours before the periodic check interval. This message means that the regular service is Operate the machine as usual. Ask your KUBOTA dealer about the relevant parts. Run the maintenance procedure. due shortly. 4 Periodic check passed (warning) This message means that the regular service is due. The machine can be operated but service must be carried out urgently. Ask your KUBOTA dealer about the relevant parts. Run the maintenance procedure. 5 Warning temperature rising The temperature of the coolant is higher than normal. Operate the machine only with reduced loads until the temperature is normal again. - 6 - - - - - 7 - - - - - 8 - - - - - LED Display LED Problem / Error Solution #1 Solution #2 9 Clock setting request Power was interrupted and the clock now has to be set again. In order to set the clock, press the user setting switch. - 10 - - - - - 11 Raise the control lever lock (yellow) This message indicates a step in a procedure. Raise the lock lever (unload lever); the indicator goes out. - 12 Lower the control lever lock (yellow) This message indicates a step in a procedure. Lower the lock lever (unload lever); the indicator goes out. - 13 Oil pressure too low (red) + The engine oil pressure is too low. Stop the engine immediately. The engine may have developed a fault. Inform your KUBOTA dealer immediately. 14 Overheat The machine is overheated and must cool off by idling. Allow the machine to cool off by idling. Do not switch the engine off as the coolant could then boil over. Clean the radiator and check the coolant. Re.ll the radiator with coolant by its boiled-over amount. Unclog the radiator and other components before use again. Check also the hydraulic system for oil leak and other troubles. If an oil leak is found, immediately contact your local dealer for repair. 15 Charging system error (red) + The charging system has developed a fault. Check the V-belt. When the V-belt is OK, let the engine run until the indicator goes out. If the indicator does not go out, inform your KUBOTA dealer immediately. 16 Fuel sensor error (red) The fuel sensor has developed a fault; the fuel gauge does not appear in the display. Press the display selector switch to return to the default display. Inform your KUBOTA dealer immediately. LCD Display LED Problem / Error Solution #1 Solution #2 17 Water temperature sensor error (red) The coolant temperature sensor has developed a fault; the coolant temperature gauge does not appear in the display. Press the display selector switch to return to the default display. The functions of the machine are stable but overheating cannot be excluded. Inform your KUBOTA dealer immediately. 18 - - - - - 19 Lever lock system error (red) The electrical system in the lock lever (unload lever) has developed a fault. The engine can be started but the machine cannot be set in motion. Inform your KUBOTA dealer immediately. 20 Travel 2 speed system error (red) The electrical system in the travel speed has developed a fault. The machine can only be set in motion at low speed. Inform your KUBOTA dealer immediately. 21 - - - - - 22 - - - - - 23 - - - - - 24 Overvoltage (red) This is a warning that a higher volt­age (from a 24-V battery, for exam­ple) is being ap­plied to the electric circuit, or that there is a problem with the alternator. Switch the engine off immediately and check the battery and the alternator. Restart the engine. If the indicator lights up again after restarting, inform your KUBOTA dealer immediately. 25 - - - - - 26 External 5-V system error (red) The 5-V sensor supply line has de­veloped a system fault. The main functions are not available. The machine can be started and driven. Do not per­form any work with the machine. Inform your KUBOTA dealer immediately. 27 External 12-V system error (red) The 12-V sensor supply line has de­veloped a system fault. The main functions are not available. The machine can be started and driven. Do not per­form any work with the machine. Inform your KUBOTA dealer immediately. 28 Starting the engine (yellow) This error code indicates a step in a procedure. Start the engine; the indicator goes out. - • Service hour meter When the hour meter has counted up to the hours circled in the maintenance list below, the message appears. The message shows up as follows. No. Check points Intervals Hour meter indicator Consequently 50 100 250 300 500 550 600 750 800 1000 1 Engine oil change every 500 hrs or every 1 year 2 Hydraulic oil every 1000 hrs 3 Air filter element Outer element replace every 1000 hrs Inner element every 1000 hrs 4 Drive unit oil change every 500 hrs 5 Engine oil filter replace every 500 hrs or every 1 year 6 Hydraulic return filter element every 500 hrs 7 Hydraulic breather filter element every 1000 hrs 8 Hydraulic suction filter element every 1000 hrs The message appears. The message shows up as follows. (The message reappears on the hour meter designated next.) NOTE: • The maintenance message disappears automatically in about 10 seconds. • When the key is turned from OFF to RUN, the maintenance message reappears and disappears again automatically in about 10 seconds. • When the key is turned from OFF to RUN repeatedly 10 times, the message disappears. • In case the service hour meter replaced due to any trouble with it, the meter is set to ”0”. Contact your KUBOTA dealer for details. PREPARATION FOR OPERATION IN COLD WEATHER 1. Replace engine oil and hydraulic oil with those of viscosities suitable for cold weather. 2. In cold weather, battery power drops, and the battery .uid may freeze if the battery is not suf.ciently charged. To prevent the battery .uid from freezing, be sure to keep the battery charged at least 75% or more of its capacity after operation. To ease next starting, it is recommended to keep the battery stored in closed or heated rooms. If the battery .uid level is too low, do not add after operation, but add with the engine running before the next operation. 3. Add anti-freeze to coolant in the radiator and reserve tank, if the ambient temperature is expected to drop below 0ºC. Mixing ratio of water and anti­freeze depends on the expected ambient temperature. • Mixing ratio between water and anti­freeze Ambient Temperature°C –5 –10 –15 –20 –25 –30 –35 Antifreeze % 30 30 30 35 40 45 50 Water % 70 70 70 65 60 55 50 IMPORTANT: • Use permanent anti-freeze or longlife coolant. • Drain the coolant completely and clean inside of the radiator then . ll with the water and anti-freeze mixture. • The anti-freeze acts as an anti-corrosive, it is not necessary to add an additive to the water and anti-freeze mixture. • See “Coolant check” under “DAILY CHECKS” in “MAINTENANCE” for radiator . ll volumes. PROCEDURE AFTER DONE WORK Clean the excavator thoroughly after work and wipe dry. Otherwise mud and earth on the tracks could freeze if the temperature drops below the 0ºC mark. Operation of the excavator is then not possible. Store the excavator in a dry place; if not possible, store on wooden planks or on mats. If the excavator is kept on damp or muddy ground, the tracks could freeze overnight. Operation of the excavator is then not possible. Furthermore the reduction gear may be damaged. Additionally, the piston rods of the hydraulic cylinders must be rubbed dry. Otherwise severe damage could occur if dirty water seeps through the seals. LONG STORAGE 3 CAUTION To avoid personal injury: Do not clean the excavator with the engine running. To avoid the danger of exhaust fume poisoning, do not operate the engine in a closed building without proper ventilation. When storing, remove the key from the starter switch to avoid unauthorized persons from operating the excavator and getting injured. • Should the Excavator be Stored for a Longer Period of Time, Observe Following Procedures: 1. The whole excavator should be cleaned thoroughly and in all cases stored indoors. If the excavator has to be kept outdoors, Iay out wooden planks on even ground, place the excavator on the planks and cover completely. 2. Do an oil change and grease the excavator. 3. Heavily grease the visible sections of the cylinder rods. 4. Remove the battery and store indoors. 5. If it is expected that the temperature will sink below the 0ºC mark, add anti-freeze or drain coolant completely. IMPORTANT : Wash the excavator after stopping the engine. If you wash the excavator while running the engine, splashing water get into the air cleaner through its intake and cause engine trouble. Carefully, wash and do not splash water over the air cleaner. • Observe Following Procedures when the Machine is to be Operated after Long Storage 1. Wipe off the grease from the hydraulic cylinder rods. 2. Turn on the engine and operate the attachments and the drive mechanisms under no load in order to circulate the hydraulic oil . (If the machine is stored for longer than one month, Do steps (1) and (2) once every month) Periodic replacement of important component parts To ensure safety in operation, you are strongly requested to inspect and service the machine at regular intervals. For added safety, ask your KUBOTA dealer to replace the following important component parts. These parts are prone to degradation in material or subject to wear and tear with time. It is dif. cult to judge how much they have been affected at regular inspection. It is therefore necessary to replace them with new ones, whether wear is visible or not after a speci.ed time of use. If any of them is found to be worn before the speci. ed use. They must be repaired or replaced the same as other parts. If any of the hose clamps are found deformed or cracked, the hose slamps must also be replaced. For the hydraulic hoses other than the ones to be replaced periodically, inspect them for the following points. If found loose or very worn, tighten and/or replace the hose. When replacing the hydraulic hoses, change their O rings and sealing components with new ones. For replacement of the important parts, contact your KUBOTA dealer. At the following periodic inspections, check the fuel hoses and hydraulic hoses as well. Inspection Interval Check points Daily Checks Oil leak at fuel and hydraulic hose connections and points Every month Oil leak at fuel and hydraulic hose connections and points Damages at fuel and hydraulic hose (cracks, chafing) Every year Oil leak at fuel and hydraulic hose connections and points Interference, deformation, degradation, twist and other damages (cracks, chafing) of fuel and hydraulic hoses List of important component parts No. Component parts Q'ty Period 1 Fuel hose (Fuel tank-Fuel filter) 2 Every 2 years or 4000 hours 2 Fuel hose (Fuel filter-Fuel pump) 2 3 Fuel hose (Fuel pump-Fuel nozzle) 2 4 Fuel hose (Fuel nozzle-Fuel tank) 1 5 Fuel hose (Fuel tank-Fuel drain) 1 6 Hydraulic hose (Main pump suction) 1 7 Hydraulic hose (Main pump delivery) 4 8 Hydraulic hose (Boom cylinder) 2 9 Hydraulic hose (Arm cylinder) 2 10 Hydraulic hose (Bucket cylinder) 2 11 Hydraulic hose (Swing cylinder) 2 12 Hydraulic hose (Dozer cylinder) 2 13 Hydraulic hose (Service port) 4 To prevent serious damage to the hydraulic system, use only a KUBOTA genuine hydraulic hose. RECOMMENDED OILS IMPORTANT 1. Before delivery, the hydraulic oil used was Shell Tellus S2M46. 2. Use engine oil API service classi.cation CF/CF-4 or better and SAE 10W-30. 3. Use SAE 90 (API, GL-4/GL-5) as drive unit oil for all seasons. For north american market NOTE: Engine Oil: • Oil used in the engine should have an American Petroleum Institute (API) service classi.cation and Proper SAE Engine Oil according to the ambient temperatures. • Refer to the following table for the suitable API classi.cation engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the fuel. Above 25°C (77°F) SAE30 or SAE 10W-30 SAE 15W-40 0°C to 25°C (32°F to 77°F) SAE20 or SAE 10W-30 SAE 15W-40 Below 0°C (32°F) SAE10W or SAE 10W-30 SAE 15W-40 Fuel used Engine oil classi.cation (API classi. cation) Oil class of engines except external EGR Oil class of engines with external EGR Ultra Low Sulfur Fuel [<0.0015% (15 ppm)] CF, CF-4, CG-4, CH-4 or CI-4 CF or CI-4 (Class CF-4, CG-4 and CH-4 engine oils cannot be used on EGR type engines) EGR: Exhaust Gas Re-circulation • The CJ-4 engine oil is intended for DPF (Diesel Particulate Filter) type engines, and cannot be used on this machine. except external EGR with external EGR Model U17 --­ Fuel: • Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below -20°C (-4°F) or elevations above 1500 m (5000 ft). • Diesel fuels speci.ed 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) BIODIESEL FUEL (BDF) B0-B20 Biodiesel fuels (BDF): mixed diesel fuels containing 20% or less biodiesel can be utilized under the following conditions. IMPORTANT : Concentrations greater than B5 (5%) are NOT approved for common rail engines and engines with aftertreatment device. Such fuel use can cause damage and reduce engine life. A Refueling and handling fuel should be done with caution in order to avoid contact with the fuel and spillage that could create a potential environmental or .re hazard. Wear appropriate protective equipment when refueling. Applicable BDF: 1. Blended diesel fuels containing 6% thru 20% BDF (B6 - B20) which comply with American Society for Testing and Materials (ASTM) D7467 Standard, as revised, can be used without adversely affecting the performance and durability of the engine and fuel system components. 2. Any mineral oil diesel fuel, if used, must conform to ASTM D975 (or the European EN590) Standard, as revised. B100 fuel used to make Biodiesel blended fuels must meet ASTM D6751 (or EN14214) Standard, as revised. The .nal blended fuel B20 must conform to ASTM D7467 Standard, as revised. Straight vegetable oil is NOT allowed in any blended fuel. 3. Allowable blended fuel is mineral oil diesel fuel blended with B100 (i.e. 100% BDF). The blended fuel ratio shall be less than 20% B100 and 80% or more diesel fuel. The B100 source used for Biodiesel blends must be purchased from an accredited BQ-9000 marketer or producer. More information about quali.ed marketer(s) and producer(s) can be found at http://www. bq-9000.org. Preparation: 1. Before using BDF concentrations greater than B5, you are advised to replace the engine oil, engine oil .lter and fuel .lter with new oil and .lters. For replacement procedures, refer to the “PERIODIC SERVICE” section. Product Warranty, Emission and Other Precautions: 1. The engine emission control system was certi.ed according to current regulations based on the use of non-BDF. When using BDF, the owner is advised to check applicable local and federal emission regulations and comply with all of them. 2. BDF may cause restricted or clogged fuel .lters during cold weather conditions, resulting in the engine not operating properly. 3. BDF encourages the growth of microorganisms which may cause degradation of the fuel. This in turn may cause fuel line corrosion or reduce fuel . lter .ow earlier than expected. 4. BDF inherently absorbs moisture which may cause degradation of the fuel earlier than expected. To avoid this, drain the water separator and fuel . lter port often. 5. Do not use Biodiesel concentrations higher than 20% (i.e. greater than B20). Engine performance and fuel consumption will be affected, and degradation of the fuel system components may occur. 6. Do not readjust the engine fuel control system as this will violate emission control levels for which the equipment was approved. 7. Compared with soybean-based and rapeseed-based feedstock, palm oil-based feedstock has a thicker consistency (i.e. higher viscosity) at lower temperatures. Consequently, fuel .lter performance may be reduced, particularly during cold weather conditions. 8. The KUBOTA Warranty, as speci.ed in the Owner’s Warranty Information Guide, only covers defects in product materials and workmanship. Accordingly, any problems that may arise due to the use of poor quality fuels that fail to meet the above requirements, whether biodiesel or mineral oil based, are not covered by the KUBOTA Warranty. Routine handling: 1. Avoid spilling BDF onto painted surfaces as this may damage the . nish. If fuel is spilled immediately wipe clean and .ush with soapy water to avoid permanent damage. 2. When using BDF, you are advised to maintain a full tank of fuel, especially overnight and during short term storage, to reduce condensation within the tank. Be sure to tighten the fuel cap after refueling to prevent moisture build up within the tank. Water in the Biodiesel mixture will damage fuel .lters and may damage engine components. Maintenance Requirements when using BDF B0 thru B5: Follow the oil change intervals recommended by referring to the “MAINTENANCE” section. Extended oil change intervals may result in premature wear or engine damage. Maintenance Requirements when using BDF B6 thru B20: The maintenance interval for fuel related parts changes. See the table below for the new maintenance interval. Items Interval Remarks Fuel . lter Replace every 250 hrs Fuel hose Check every 100 hrs Replace if any deterioration (crack, hardening, scar or deformation) or damage occurred. Replace every 1 year Consult your local KUBOTA Dealer for this service. Long Term Storage: 1. BDF easily deteriorates due to oxygen, water, heat and foreign substances. Do not store B6 thru B20 longer than 1 month and B5 longer than 3 months. 2. When using B6 thru B20 and storing the machine longer than 1 month, drain the fuel from the tanks and replace with light mineral oil diesel fuel. Subsequently, run the engine at least 30 minutes to remove all of the Biodiesel from the fuel lines. 3. When using B5 fuel and storing machine longer than 3 months, drain the fuel from the tanks and replace with light mineral oil diesel fuel. Subsequently, run the engine at least 30 minutes to remove all of the Biodiesel from the fuel lines. MAIN DIMENSIONS in. (mm) A B C D E F G H I J K L M N O P Q R S 20.08 (510) 15.2 (385) 39/ 48.8 990/ 1240( ) 24.4 (620) 39.0 (990) 39/ 48.8 990/ 1240( ) 139.0 (3540) 96.1 (2440) 90.9 (2310) 75.2 (1910) 56.7 (1440) 92.1 (2340) 11.0 (280) 7.5 (190) 108.3 (2750) 31.3 (795) 139.6 (3545) 151.2 (3840) 153.5 (3900) LIFTING CAPACITY 1. The lifting capacities are based on ISO 10567 and do not exceed 75% of the static tilt load of the machine or 87% of the hydraulic lifting capacity of the machine. 2. The strokes are as follows. 1) The load point corresponds to the front bolt part of the arm. 2) The machine positions are (i) over – front (Blade up), (ii) over – front (Blade down), and (iii) over – side. 3) The operating cylinder is the boom cylinder. 3. The bucket of the excavator, the hook, the sling and other lifting accessories are taken into consideration for the loads. Machine conditions: No bucket, all others according to the standard regulations. 3 WARNING To avoid personal injury or death: It is forbidden to lift loads greater than those values mentioned in the lifting capacity tables. The values mentioned in the table are valid only on even, hard grounds. When lifting on soft ground, the machine 'can tilt over due to the fact that the load is concentrated only on one side of the machine. The table values are calculated at the end of the arm without the bucket. In order to .nd the allowable loads for machines with bucket, the bucket weight must be subtracted from the values in the table. 3 WARNING To avoid personal injury or death: In this manual, the machine's lifting capacity is discussed, but it does not mean that it is recommended to use the machine for lifting jobs. It is speci. ed in item 3.4 of ISO 10567:1992 that the following devices must be additionally installed if a hydraulic excavator with the rated lift load of over 2,205 lbs (1,000 kg) at its minimum lifting radius or the tilting moment of over 29,504 ft-lbs (40,000 N-m) is used for lifting loads. (1)Lifting hook (2)Acoustic alarm or warning lamp for the operator when the rated load or the corresponding tilting moment has been exceeded. (3)Boom decending control device comforming to ISO 8643:1997 U17 ROPS CANOPY RUBBER TRACK LIFTING CAPACITY OVER-FRONT BLADE DOWN Unit=1000 lbs. LIFT POINT HEIGHT (ft) LIFT POINT RADIUS (ft) 4 6 8 10 GL 8 0.67 6 0.62 0.70 4 1.17 0.85 0.69 2 1.50 0.96 0.70 0 1.40 0.94 0.67 -2 1.64 1.19 0.82 -4 1.58 0.94 0.63 LIFTING CAPACITY OVER-FRONT BLADE UP Unit=1000 lbs. LIFT POINT HEIGHT (ft) LIFT POINT RADIUS (ft) 4 6 8 10 GL 8 0.57 6 0.62 0.57 4 0.85 0.55 0.39 2 0.78 0.52 0.38 0 0.76 0.50 0.37 -2 1.53 0.76 0.50 -4 1.55 0.77 0.50 LIFTING CAPACITY OVER-SIDE TRACK WIDTH 49.0 in Unit=1000 lbs. LIFT POINT HEIGHT (ft) LIFT POINT RADIUS (ft) 4 6 8 10 GL 8 0.54 6 0.62 0.53 4 0.78 0.51 0.36 2 0.72 0.49 0.35 0 0.70 0.47 0.34 -2 1.37 0.70 0.46 -4 1.38 0.71 0.47 3 WARNING To avoid personal injury or death: Operate always in standard track width 49.0 in(1240mm), except to pass through narrow space. Do not operate in narrow track width 39.0 in(990mm), it makes risk of the excavator tipping over. LIFTING CAPACITY OVER-SIDE TRACK WIDTH 39.0 in ONLY REFERENCE Unit=1000 lbs. LIFT POINT HEIGHT (ft) LIFT POINT RADIUS (ft) 4 6 8 10 GL 8 0.36 6 0.56 0.36 4 0.52 0.34 0.24 2 0.46 0.32 0.23 0 0.44 0.30 0.22 -2 0.81 0.44 0.29 -4 0.83 0.45 0.30 #Kubota #Excavator #U #OperatorsManual

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