UNIVERSAL SYMBOLS

As a guide to the operation of your machine, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning.

3 Safety Alert Symbol l Engine Oil-Pressure g Battery Charging Condition n Diesel Preheat/Glow Plugs

LST Temperature

Q LST Oil-Pressure k Limited Travel Speed p Parking Brake

0 Hazard Warning Lights

9 Headlight

R Diesel Fuel

E Hydraulic Oil

Bucket Up

Bucket Down

Bucket Tilt

Bucket Dump

Bucket Float

J Travel Forward K Travel Backward Lock

Unlock FOREWORD

You are now the proud owner of a KUBOTA Wheel Loader. This wheel loader is a product of KUBOTA quality engineering and manufacturing. It is made of the fine materials and under rigid quality control systems. It will give you long, satisfactory service. To obtain the best use of your wheel loader, please read this manual carefully. It will help you become familiar with the operation of the wheel loader and contains many helpful hints about wheel loader maintenance. 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 The immediate use of new techniques in the manufacture of products may cause some small parts of this manual to be outdated.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.

3 DANGER : 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.

3 CAUTION: 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 WHEEL LOADER ...... 1 SPECIFICATIONS...... 2 SPECIFICATION TABLE ...... 2 INSTRUMENT PANEL AND CONTROLS...... 5 OPERATING THE ENGINE...... 9 DAILY CHECK ...... 9 STARTING THE ENGINE...... 9 COLD WEATHER STARTING ...... 10 CHECKS IMMEDIATELY AFTER ENGINE START ...... 11 STOPPING THE ENGINE...... 11 JUMP STARTING ...... 12 OPERATING THE MACHINE...... 13 HOW TO USE A NEW MACHINE...... 13 STARTING...... 13 SAFETY LEVERS AND APPLIANCE ...... 14 Safety Key Start System...... 14 Bucket Lever Lock ...... 14 Service Port Lever Lock...... 15 Lift Arm Support...... 15 Roll-Over Protective Structures (ROPS) / Falling Objective Protective Structures (FOPS) ...... 16 Steering Frame Lock ...... 17 Parking Brake Switch...... 18 Hourmeter / Tachometer...... 18 Fuel Gauge...... 19 Coolant Temperature...... 19 Easy Checker ...... 19 Turn Signal Switch...... 20 Headlight Switch...... 20 Hazard Lamp Switch...... 20 Fuse Box...... 20 CONTROL LEVERS AND PEDALS...... 21 Accelerator Pedal ...... 21 Inching and Brake Pedals...... 21 Travel Speed Limiter Switch...... 21 Shuttle Change Lever...... 22 Bucket Lever...... 22 CAB TYPE MACHINES ...... 23 Opening/Closing of CAB Door(CAB type only)...... 23 Interior Lamp(CAB type only) ...... 23 Wiper/Washer Switch(CAB type only) ...... 23 Heater Switch(CAB type only) ...... 24 TRAVELING...... 24 CONTENTS

Starting ...... 24 Turning...... 25 Deceleration on a Slope ...... 25 Traveling on rough roads...... 25 Traveling on Snow...... 25 STOPPING...... 26 HOW TO USE THE INCHING PEDAL...... 26 Inching Pedal Operation ...... 26 Use the Inching Pedal According to the Job...... 27 TYPICAL JOBS USING A WHEEL LOADER ...... 29 Digging and Loading...... 29 Refilling...... 30 Leveling Ground ...... 30 Loading onto a Truck...... 31 MULTI-COUPLER ...... 32 ATTACHING AND DETACHING THE FRONT ATTACHMENTS ...... 32 Attaching the Front Attachments ...... 32 Attaching the Front Attachment ...... 33 Hoses fitting for Hydraulic Multi-Coupler ...... 34 TRANSPORT BY TRUCK ...... 35 HANDLING LOADER IN COLD-WEATHER...... 37 PREPARATIONS FOR COLD WEATHER ...... 37 AFTER-OPERATION DIRECTIONS...... 37 MAINTENANCE...... 38 SERVICE INTERVALS ...... 39 Service Interval Chart (Do all previous checks in addition to New checks.) ...... 39 LUBRICANTS ...... 41 Select the Grade by Referring to the Table...... 41 PERIODIC SERVICE...... 42 HOW TO OPEN THE ENGINE COVER ...... 42 Engine Cover...... 42 DAILY CHECK ...... 42 Checking Coolant Level and Replenishing...... 42 Checking the Engine Oil ...... 43 Checking Hydraulic Oil (LST Oil) Level ...... 44 Checking the Fuel and Replenishing...... 44 Checking and Replenishment of Oil in the Brake Fluid Reservoir...... 45 Grease Fittings ...... 45 Checking Tire Pressure, Wear and Damage and Bolts...... 46 Checking and Cleaning the Radiator and Oil Cooler Fins ...... 46 Checking the Parking Brake ...... 47 Checking the Brake Pedal ...... 47 Checking the Steering Wheel ...... 47 Checking and Tighten Loose Bolts and Nuts...... 47 Checking Electrical Wiring for Short-circuits and Loose Terminals ...... 47 Checking the SMV Emblem for Stains and Damage...... 47 Checking the Lamps and Meters...... 47 Testing the Horn ...... 47 Checking Oil and Water Leak...... 47 CONTENTS

Cleaning and Checking after Operating in Muddy Areas...... 48 EVERY 50 HOURS SERVICE ...... 48 Draining of the Fuel Tank ...... 48 Battery ...... 49 EVERY 200 HOURS SERVICE ...... 51 Checking and Adjusting Fan Belt Tension...... 51 Checking Radiator Hoses (water pipes) ...... 52 Cleaning and Checking Air Cleaner Element ...... 52 Air Filter Maintenance...... 53 Checking Fuel Line and Intake Air Line...... 53 EVERY 250 HOURS SERVICE ...... 53 Changing Engine Oil (change it after first 50 hours of operation.)...... 53 EVERY 500 HOURS SERVICE ...... 54 Replacing Engine Oil Filter Cartridge (change it after first 50 hours of operation.) ...... 54 Checking and Replenishing Oil in the Front / Rear Axle Differential Cases ...... 55 Replacing LST Oil Filter Cartridge...... 55 Replacing Return Filter...... 56 Changing the Fuel Filter ...... 56 EVERY 1000 HOURS SERVICE ...... 57 Changing Oil for the Front and Rear Axle Differential Cases (Change oil the first time after 1st 500 hrs. use.)...... 57 Changing Oil in Hydraulic Oil Tank and the Suction Filter (after 1st 500 hrs. use)...... 57 Replacing Air Cleaner Element...... 58 EVERY 1500 HOURS SERVICE ...... 58 Checking Fuel Injection Nozzle (Injection Pressure) ...... 58 EVERY 2000 HOURS SERVICE ...... 58 Checking Alternator Starter Motor ...... 58 EVERY 3000 HOURS SERVICE ...... 59 Checking Injection Pump...... 59 EVERY TWO YEARS SERVICE...... 59 Checking and Replacing Fuel Pipe and Rubber Hoses...... 59 Replacing Radiator Hoses (water pipes) ...... 59 Replacing Fuel hoses ...... 59 Replacing Intake Air Line...... 59 Changing Coolant...... 60 Periodic Parts Replacement ...... 60 SERVICE AS REQUIRED...... 61 Checking the Electrical System, Handling Fuses ...... 61 Bleeding the Fuel System...... 62 Bleeding Air from the Brake Fluid System...... 62 TIRES...... 63 Handling Tires...... 63 Conservation of Tires...... 64 Changing Tires ...... 64 Mounting the Tires...... 64 STORAGE ...... 65 CAUTION WHEN WASHING THE MACHINE ...... 65 TROUBLESHOOTING...... 66 ENGINE TROUBLES AND REPAIRS...... 66 TROUBLES IN TRAVELING SYSTEM ...... 67 CONTENTS

HYDRAULIC SYSTEM TROUBLES AND REPAIRS...... 68 SAFE OPERATION 1 SAFE OPERATION

Careful operation is your best insurance against an 5. Never modify structural members of ROPS by accident. welding, drilling, bending, grinding or cutting, as this Read and understand this section carefully before may weaken the structure. If any component is operating the Wheel Loader. damaged, replace it. Do not attempt repairs. If ROPS All operators, no matter how much experience they may is loosened or removed for any reason, make certain all parts are reinstalled correctly.Tighten mounting have had, should read this and other related manuals bolts to proper torque. (See "Roll-Over Protective before operating the machine or any attachment. It is the Structures (ROPS) / Falling Objective Protective owner's obligation to instruct all operators in safe Structures (FOPS)".) operation. 6. Do not install any attachments, including water and calcium chloride that is added into the tires, that exceed the weight shown in the "FOR MAXIMUM 1. BEFORE OPERATING THE MACHINE GROSS MACHINE WEIGHT" space on the ROPS / 1. Know your equipment and its limitations. Read this FOPS label. entire manual before attempting to start and operate 7. Do not start or operate an unsafe machine. Before the machine. working the machine, be sure that any unsafe 2. If using an attachment on the machine, read the condition has been satisfactorily remedied. Check attachment operator's manual to ensure safe brakes, steering and attachment controls before operating procedures. moving. Consult with the proper maintenance 3. Pay special attention to the danger, warning and authority if any malfunctioning part of system is caution labels on the machine and the attachments. observed. Be sure all protective guards or panels are 4. For your safety, ROPS/FOPS (Roll-Over Protective in place, and all safety devices provided are in place Structures, Falling Objects Protective Structures.) with and in good operating condition. a seat belt is installed by KUBOTA. Always use seat 8. Wear and use safety items such as non-skid safety belt when the machine is equipped with a ROPS/ shoes or boots, safety glasses and safety hardhats. FOPS. Do not operate or work around the machine, when ROPS is required on Wheel Loaders, Dozertractors, wearing loose, bulky clothing. 9. Never operate the machine or any equipment while Truck type Loaders, Graders and Scrapers by OSHA under the influence of alcohol or other drugs, or while and SAE regulations. (See "SAFETY LEVERS AND fatigued. APPLIANCE" in the OPERATING THE MACHINE 10.Before allowing other people to use your machine, section.) give instruction to the operator on safe and correct use of the machine and make sure the operator reads and understands the Operator's Manual for the machine. 11.Inspect your seat belt daily for signs of fraying, wear or other weakness that could lead to failure. 12.Do not use the loader bucket or attachment to lift or carry a person. 13.Do not use the bucket or any other working attachment of the machine for crane work. Otherwise, the machine may lose its balance and overturn.

2. OPERATING THE MACHINE

1. Mount and dismount safely when entering or leaving the operator's compartment. Face the machine. Maintain a three point contact the steps and handrails. Do not use control levers as handles. Do not jump on or off the machine. Never try to get on or off a moving machine. 2. Do not start engine or operate levers from anywhere other than the seat. 2 SAFE OPERATION

3. Before starting the engine, fasten the seat belt, make 21.Be sure to ease off the accelerator at the end of sure that the shuttle change lever is set at the neutral backfilling grooves, or areas at the edge of cliffs or position, the parking brake switch is set at the parking pond banks, or at the end of an ascent. Upon removal position and the bucket is lowered to the ground. of the external load, the machine speed will 4. Do not start engine by shorting across starter automatically increase, reduce speed to avoid terminals. entering grooves or tipping over. 5. Watch where you are going at all times. Watch for and 22.To avoid machine slip or tipping over, do not operate avoid obstacles. the machine on ungraded or soft terrain, such as land 6. Never permit passengers on the machine. Keep fills. Grade and compact the site beforehand at all bystanders away from the machine during operation. times. 7. When working around other machines, let the other 23.Avoid running the engine for a long time indoors. drivers know what you are doing at all times. When the engine must be run indoors, be sure to open 8. Never allow anyone to get under or near the bucket or the windows and doors. Carbon monoxide gas from attachment when it is raised. exhaust is colorless, odorless and deadly. 9. When raising the bucket or attachment, take extra 24.Check that no one is near the muffler exhaust before caution to prevent it from touching overhead wires or starting the engine. If exposed to exhaust fume, he or other obstacles. Contact with wires may cause death she may get burned or poisoned. Check that there is by electrical shock. no flammable objects, such as dead leaves, sheets of 10.Keep away from the muffler while the engine is running paper, or pieces of cloth, attached to areas around the and immediately after it has stopped. engine before starting the engine. 11.Unreasonable operation such as on dangerous 25.To avoid the danger of exhaust fume poisoning, do not terrain, beyond the load capacity or beyond the operate the engine, in a closed building without proper intended use of the machine must be avoided as it ventilation. Carbon monoxide is odorless, colorless, may cause the machine to tip over. and deadly. 12.Do not drive the machine close edges of ditches or 26.Use extra caution when backing up, look behind and banks which may collapse under the weight of the down-make sure area is clear before moving. machine, especially when the ground is loose or wet. 27.When parking your machine if at all possible park on a 13.Slow down for turns, uneven terrain and slopes to firm, flat and level surface; if not, park across a slope. avoid tip over. Set the parking brake(s), lower the implements to the 14.When transporting a load, keep the loader bucket as ground, remove the key from the ignition and lock the low as possible to avoid tip over. Be extremely careful cab door (if equipped) and chock the crawlers or the when working on inclines. wheels. 15.Operation on slopes can be dangerous. Rain, snow, gravel soft ground, etc. will change the ground C Safety for children conditions. Do not operate the machine in Tragedy can occur if the operator is not alert to the questionable ground conditions. If operating on a presence of children. Children generally are attached to slope or ramp, always slow down, travel straight up machines and the work they do. and down the incline and not across. Keep the bucket as low as possible. If you do not follow these 28.Never assume that children will remain where you last instructions, the machine can go out of control and tip saw them. over. 29.Keep children out of the work area and under the 16. Avoid turning on a slope. watchful eye of another responsible adult. 17. Never perform digging or shoveling with the machine 30.Be alert and shut your machine down if children enter in the articulated condition, or the machine may tip the work area. over. 31.Never carry children on your machine. There is no safe 18.Never dig or shovel at high speed. Such operation can place for them to ride. They may fall off and be run cause the machine to lose stability and its rear wheels over or interfere with your control of the machine. to lift off the ground, which may lead to serious 32.Never allow children to operate the machine even personal injury or death. under adult supervision. 19.Do not go up or down a 30 or steeper hill. Otherwise, 33.Never allow children to play on the machine or on the the machine may skid sideways or turn on its side. If implement. the ground is ungraded or soft, limit the slope below 15 . 20.To avoid possible machine tip over, do not operate the machine in any site whose terrain cannot be ascertained, such as ground covered with seeds or snow and check for hidden projections, dents, road shoulders, etc. beforehand, and take care not to approach them during work. SAFE OPERATION 3

12.If a tire has blown, the machine may slip or turnover. 3. TRAVELING To avoid turnover, do not brake or steer hard, brake slowly to stop the machine gradually. 1. Before traveling on the public road, observe all local and state traffic regulations. Use SMV emblem and C Precaution at Overheating warning flashers as required. Take the following actions in the event the coolant (SMV: Slow Moving Vehicle) temperature reaches nearly or more than the boiling point, what is called "Overheating". 13.Park the machine in a safe place and keep the engine unloaded idling. 14.Don't stop the engine suddenly, but stop it after about 5 minutes of unloaded idling. 15.Keep yourself well away from the machine for further 10 minutes or while the steam blows out. 16.Checking that there is no danger such as burn, get rid of the causes of overheating according to the manual, see "TROUBLESHOOTING" section. And then, start again the engine.

4. AFTER OPERATION

1. When dismounting the machine, stop the engine, set (1) SMV emblem the parking brake switch to the parking position, lower 2. When traveling on a public road, lock the bucket and the bucket and attachment to the ground, release the attachments securely so that they cannot lower, even hydraulic pressure in the hydraulic system by if any control lever is operated. Lift the bucket about 40 operating control levers, lock all control levers in cm (16 in.) above the ground and set it in the proper neutral, and remove the key. position for travel, then completely lock the bucket If the machine has to be parked on a slope, be sure to lever with the lock. block the tires securely. 3. Check area around the machine, then gradually increase the engine rpm and slowly move the machine. Do not move the machine abruptly. To move the machine on a steep slope, press the accelerator pedal gradually while releasing the inching pedal so that the machine does not move backwards. 4. The steering wheel for this machine will not return to the straight ahead position after turning a curve. Be sure to turn the wheel to the straight ahead position by yourself. 5. When operating the machine, obey all safety signals and traffic signs. 6. Use the brake when the machine begins to accelerate. 7. If the engine should stall on a slope, apply the brake to hold the machine in a present position and then set the parking brake switch to the parking position, lower the bucket to the ground to prepare for the next start. (1) Block 8. When crossing over an obstacle such as a rock, cross at a right angle, and slow the machine down. Trying to 2. All equipment left unattended at night adjacent to a cross over it diagonally or at high speed may tip the highway in normal use, or adjacent to construction machine over. areas where work is in progress, shall have 9. If there is the risk of the machine slipping excessively appropriate lights or reflectors, or barricades equipped on frozen ground, install chains on the front wheels; for with appropriate lights or reflectors to identify the operation on snow, install chains on both front and rear location of the equipment. wheels. 3. For storage, be sure to cover machine after all the 10.Do not turn sharply at high speed, or the machine may heated parts have cooled down. tip over. 11.Steering effort will increase if the engine stops. Do not stop the engine during travel. 4 SAFE OPERATION

4. Before storing the machine for long periods of time, do 6. After loading the machine on the truck bed, do the the following. following. A Stop the engine. A Check to see that the machine's center point aligns A Set the parking brake switch to the parking with that of the truck bed. position. A Secure the steering frame lock and attachment. A Lower the bucket and attachment to the ground. A Stop the engine. A Release the hydraulic pressure in the hydraulic A Set the parking brake switch to the parking system by operating control levers. position. A Lock all control levers in neutral. A Lower the bucket and attachment to the truck bed A Remove the key. and lock it. A Release the hydraulic pressure in the hydraulic system by operating control levers. 5. SAFE LOADING AND TRANSPORT A Lock all control levers in neutral. A Remove the key. 1. When loading or un-loading the machine on or from a A Block the machine's wheels. truck or trailer, be sure to use strong planks. Never use A Secure with chains. wet lumber, etc. 2. Keep the planks at an angle such that the machine can be kept stable (10 to 15 ). Never try to change directions while on the planks. 3. When loading or off-loading the machine on or from a truck, keep the bucket about 40cm (1'3 3/4") up from the ground and reverse the machine at the low speed or advance it at the same speed to off-load it. 4. It is dangerous to alter the climbing direction once already on the ramps. If direction of climb needs correction, be sure to first bring the machine down off the ramps and make the directional correction. 5. If a hydraulic lever is operated while the machine is loaded or unloaded, the machine may move at an angle. Be sure to stop the machine before using another control. While loading or un-loading the machine, block the truck tires and apply the truck parking brake. If necessary, place a support under the truck bed behind the rear tires to prevent the truck front from lifting.

7. While traveling with the machine loaded, do not start with a jerk, stop suddenly or make sharp turns on curves so as to prevent the machine from shifting on the truck bed. SAFE OPERATION 5

6. SERVICING THE MACHINE

1. Before checking, adjusting or cleaning the machine parts, or leaving the machine, observe the following items. A Stop the engine. A Set the parking brake switch to the parking position. A Lower the bucket and attachment to the ground. A Release the hydraulic pressure in the hydraulic system by operating control levers. A Lock all control levers in neutral. A Remove the key. 2. Never be under the machine while it is being lifted with only the loader bucket. If servicing or checking underneath, support it firmly with strong jackstands. (1) Key (2) Fuel tank cap 3. Before servicing, secure the front and rear frames with the steering frame lock. 12.A battery, especially when charging, will give off 4. Keep clear of articulation area when servicing. hydrogen and oxygen gases that are very explosive. 5. When checking or servicing the electrical system, Keep away from sparks and open flames at all times. disconnect the battery terminals. To avoid sparks from an accidental short circuit, 6. It is dangerous to drain oil or coolant and to replace the always disconnect the battery ground cable (-) first filter just after stopping the engine. and always reconnect the ground cable (-) last. (See Wait for the machine to cool. "JUMP STARTING" in the OPERATING THE ENGINE 7. Do not allow an unauthorized person to service or section.) maintain the machine. Do not perform any work or equipment that is not authorized. Do not try to do any repairs that you do not understand. Follow the Maintenance and Service procedures. 8. Service or check the machine after it has completely cooled off. Do not touch the muffler and the radiator until they have cooled off. 9. When you drive connecting pins in or out, guard against injury from flying pieces of metal. Use eye or face protection. 10.Keep all safety covers, shields, and guards in place at all times. 11.Always stop the engine before refueling. Keep away from sparks and flames, while refueling. Avoid fuel spills and overfilling the fuel tank. Keep first aid kit and fire extinguisher nearby at all (1) Battery times. 13.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. 14.Never remove the engine/hydraulic oil plug or the radiator cap right after the engine has been stopped, or oil or hot coolant may gush out. Wait for the coolant or oil to cool, loosen the plug or cap just a little to release pressure, and then check the level. This is especially important for the radiator. 6 SAFE OPERATION

A Tow the machine from the towing pin of the counterweight on the rear of the machine. Towing speed shall not exceed 1 km/hr. If towed at a speed in excess of 1 km/hr, the motor could be damaged.

(1) Radiator cap

15.Leaking hydraulic fluid has enough pressure to penetrate the skin and cause serious injuries. Leakages from pin holes can be totally invisible. Do (1) Pump not use the bare hand for checking on possible (2) Brake 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 fluid, contact a doctor immediately. This fluid can cause gangrene or serious allergic reactions.

(1) Towing pin

16.If the machine breaks down and requires towing, please contact your nearest KUBOTA dealer.In case of an emergency, carry out the following procedure. A Remove the caps of the two high pressure relief valves that are located at the top and bottom of the pump. Loosen the M8 nuts and tighten the adjust bolts by 6 turns. (Be careful never to loosen the M8 nuts too much.) A Remove the two M12 bolts of the parking brake case, and remove the two flat washers from each (total of four). A Re-tighten the two M12 bolts. SAFE OPERATION 7

17.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 perform the job. Have it done by your KUBOTA dealer or a qualified tire repair service.

18.Use a face mask or eye protection to protect the eyes and respiratory system against dust and other foreign particles. 8 SAFE OPERATION

7. DANGER, WARNING AND CAUTION LABELS

(1) Part No. R2401-5758-1

(2) Part No. R2401-5759-1 SAFE OPERATION 9

(3) Part No. R2401-5751-1

(6) Part No. R2401-5753-1 1BBABAAAP2290

(4) Part No. R2401-5752-1

1BBABAAAP2300

(5) Part No. R2401-5756-1

1BBABAAAP2320

1BBABAAAP2310 10 SAFE OPERATION

(7) Part No. R2411-5785-1

1BBABACAP0100

(11) Part No. 6C040-5559-1

(8) Part No. R2401-5755-1

1BBABACAP0110

1BBABAAAP2340 (12) Part No. R2401-5736-1 (9) Part No. R2401-5757-1 Diesel fuel only No fire

1BBABAAAP2380

(13) Part No. R2401-5726-1

1BBABAAAP2350

(10) Part No. R2401-5754-1

1BBABAAAP2360 1BBABAAAP2400 SAFE OPERATION 11 12 SAFE OPERATION

8. 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 WHEEL LOADER 1 SERVICING OF WHEEL LOADER

Your dealer is interested in your new wheel loader and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find that you can do some of the regular maintenance yourself. However, when in need of parts or major service, be sure to see your KUBOTA dealer. For service, contact the KUBOTA dealer/Dealership from which you purchased your wheel loader or your local authorized KUBOTA dealer. When in need of parts, be prepared to give your dealer both the machine and engine serial numbers.Locate the serial numbers now and record them in the space provided. Model Serial No. (1) Machine serial No. Wheel Loader Engine Date of Purchase Name of Dealer (To be filled in by purchaser)

(1) Engine serial No.

(1) Engine serial No. 2 SPECIFICATIONS SPECIFICATIONS

SPECIFICATION TABLE

With 1500lbs Counter weight for R420S. Model name R420S Counter weight 1500 lbs Type Canopy CAB

Operating weight (with Rops/Fops Canopy, CAB) kg(lbs.) 3380 (7450) 3600 (7935)

Bucket capacity (cu.yds.) 0.4 (0.5)

Tipping load Straight (SAE Rating) kN(lbf) 20.4 (4585) 23.1 (5200)

Tipping load Full turn (SAE Rating) kN(lbf) 17.1 (3850) 19.3 (4340)

Operating load kN(lbf) 8.6 (1925)

Manufacturer KUBOTA

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

Horsepower (SAE gross) kW(HP)/rpm 32.1 (43) / 2600

Engine Number of cylinders 3

Displacement L (cu.in.) 1.499 (91.4)

Starter V/kW 12/1.4

Battery V/Ah 12/65

Overall length mm(in.) 4210 (165.8)

Overall width (without bucket) mm(in.) 1520 (59.8)

Overall height mm(in.) 2510 (98.8)

Min. ground clearance mm(in.) 285 (11.3)

Wheel base mm(in.) 1775 (69.9) Dimensions Tread mm(in.) 1180 (46.5)

Angle of articulation Deg 40 each

Angle of oscillation Deg 8 each

Loader clearance circle mm(in.) 6170 (242.9) (center of tire)

Hinge pin height mm(in.) 2810 (110.7)

Dump height mm(in.) 2245 (88.4)

Bucket Reach fully raised mm(in.) 780 (30.8)

Lift capacity to max.height kN(lbf) 14.2 (3190)

Breakout force kN(lbf) 29.2 (6570)

Drive system 4 WD

Tire 12.5/70-16-8PR

Traveling Forward km/h(MPH) 0 to 20 (0 to 12.5) Traveling speed Reverse km/h(MPH) 0 to 20 (0 to 12.5)

Traction force kN(lbf) 23.5 (5290)

Fuel tank L(U.S.gal.) 54 (14.3)

Others Hydraulic oil tank L(U.S.gal.) 42 (11.1)

Hydraulic oil system L(U.S.gal.) 60 (15.9) SPECIFICATIONS 3

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

Operating weight (with Rops/Fops Canopy, CAB) kg(lbs.) 4075 (8980) 4295 (9470) 4315 (9510) 4535 (10000)

Bucket capacity (cu.yds.) 0.57 (0.75)

Tipping load Straight (SEA Rating) kN(lbf) 23.1 (5190) 25.5 (5740) 25.4 (5710) 27.8 (6260)

Tipping load Full turn (SEA Rating) kN(lbf) 19.6 (4410) 21.7 (4870) 21.6 (4850) 23.6 (5310)

Operating load kN(lbf) 9.8 (2205) 10.8 (2420)

Manufacturer KUBOTA

Model Water cooled V2203-M-E2RP diesel engine

Horsepower (SAE gross) kW(HP)/rpm 36.6 (49) / 2600

Engine Number of cylinders 4

Displacement L (cu.in.) 2.197 (134.1)

Starter V/kW 12/2.0

Battery V/Ah 12/65

Overall length mm(in.) 4685 (184.5)

Overall width (without bucket) mm(in.) 1760 (69.3)

Overall height mm(in.) 2580 (101.6)

Min. ground clearance mm(in.) 325 (12.8)

Wheel base mm(in.) 1950 (76.8) Dimensions Tread mm(in.) 1360 (53.5)

Angle of articulation Deg 40 each

Angle of oscillation Deg 8 each

Loader clearance circle mm(in.) 6770 (266.5) (center of tire)

Hinge pin height mm(in.) 3310 (130.3)

Dump height mm(in.) 2670 (105.2)

Bucket Reach fully raised mm(in.) 860 (33.9)

Lift capacity to max.height kN(lbf) 17.7 (3960)

Breakout force kN(lbf) 33.1 (7440)

Drive system 4 WD

Tire 15.5/60-18-8PR

Traveling Forward km/h(MPH) 0 to 20 (0 to 12.5) Traveling speed Reverse km/h(MPH) 0 to 20 (0 to 12.5)

Traction force kN(lbf) 31.4 (7055)

Fuel tank L(U.S.gal.) 54 (14.3)

Others Hydraulic oil tank L(U.S.gal.) 42 (11.1)

Hydraulic oil system L(U.S.gal.) 62 (16.4) 4 SPECIFICATIONS

Above dimensions are based on the machine with JPN ROPS/FOPS Canopy and ROPS/FOPS CAB. JPN = made in Japan Mean Value and value for use on concrete roads are given for tipping load and operating load. Specifications Subject to change without Notice. INSTRUMENT PANEL AND CONTROLS 5 INSTRUMENT PANEL AND CONTROLS

B Instrument Panel, Switches and Hand Controls

ILLUSTRATED CONTENTS (1) Hourmeter/Tachometer...... 18 (2) Fuel gauge...... 19 (3) Coolant Temperature...... 19 (4) Key switch...... 9 (5) Turn signal switch...... 20 (6) Horn switch...... - (7) Parking brake switch...... 18 (8) Hazard lamp switch...... 20 (9) Headlight switch...... 20 (10) Travel speed limiter switch...... 21 6 INSTRUMENT PANEL AND CONTROLS

B Foot and Hand Controls

ILLUSTRATED CONTENTS (1) Steering wheel...... - (2) Shuttle change lever...... 22 (3) Shuttle change lever lock knob...... 22 (4) Inching and brake pedal...... 21 (5) Bucket lever...... 22 (6) Bucket lever lock...... 14 (7) Service port lever...... 15 (8) Service port lever lock...... 15 (9) Accelerator pedal...... 21 INSTRUMENT PANEL AND CONTROLS 7

B PART NAMES

(1) Lift arm (2) Tilt arm (3) Bucket (4) Front wheel (5) Tilt cylinder (6) Lift cylinder (7) Fuel tank (8) ROPS/FOPS (9) Seat belt (10) Rear wheel 8 INSTRUMENT PANEL AND CONTROLS

(1) CAB (2) Counter weight (3) Hydraulic oil tank (4) Headlight (5) Turn signal light OPERATING THE ENGINE 9 OPERATING THE ENGINE

STARTING THE ENGINE This machine uses a safety key start system, the engine To avoid personal injury or death: can start only when the parking brake switch is in parking A Read "Safe Operation" in the front of this position and the shuttle change lever in neutral position. manual. A Read the Danger, Warning, Caution labels located on the machine and attachment. 1. Set the Parking Brake Switch to the A To avoid the danger of exhaust fume parking position. 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 Do not start the engine by shorting across starter terminals. A Do not turn off the starter switch while traveling. If turning off the switch, the machine stops abruptly. DAILY CHECK To prevent the trouble, it is important to know the conditions of the machine well. Check it before starting.

(1) Parking brake switch

To avoid personal injury: 2. Set shuttle change lever to the neutral A Be sure to check and service the machine on a position. level surface with the engine shut off and the parking brake "ON".

Check item See "DAILY CHECK" in the MAINTENANCE section.

(1) Shuttle change lever (A) "Forward" (2) Lock knob (B) "Neutral" (C) "Backward" (D) "Lock" (E) "Unlock" 10 OPERATING THE ENGINE

3. Start engine using starter key. A Never turn the key from "ON" to "START" while the engine is running, or the starter motor may be A "OFF ( )" position damaged. With the starter switch in the "OFF ( )" position, all A If the engine fails to start, wait at least 20 seconds the electrical systems are shut off, the key can be before re-starting. Do not keep the starter motor on for inserted. more than 10 seconds, or it may be burnt out or the A "ON ( )" position battery may not be charged. When the key is turned one notch clockwise to "ON A After starting the engine, allow it to warm up for 5 ( )" from "OFF ( )"position, all the circuits are minutes. activated. A "START" position Turn the key another notch clockwise to "START" and A This machine uses the key stop system. To stop the the starter motor starts the engine. Once the engine engine, drop the engine speed and turn the key to the has started, release the key, and it will return to "ON "OFF( )" position. ( )" by itself. A "PREHEAT" position When the key is turned one notch counterclockwise COLD WEATHER STARTING from the "OFF ( )" position, electric current flows 1. Push the accelerator pedal completely down. through the glow lamp circuit for preheating. When the 2. Turn the starter switch counterclockwise to preheat key is released in this position, it will return to the "OFF the engine, and hold it about 10 more seconds after ( )" position by itself. the preheat lamp has gone off. [Super glow plug type] 3. Turn the key to the "START" position. 4. Once the engine has started, release the key, and it will automatically return to the "ON" position. 5. As the engine rpm increases, gradually release the accelerator pedal. Warm up the engine for at least 5 minutes.

A Do not use the starting motor continuously for more than 30 seconds.

(A) "Preheat" (B) "OFF" (C) "ON" (D) "Start"

(1) Insert the key into the starter switch. (2) Press the accelerator pedal slightly. (3) Turn the starter switch to "PREHEAT" and preheat the engine until the preheat lamp goes off, for approx. 5 seconds. [Super glow plug type] (4) Turn the key to the "START" position. (5) Once the engine has started, release the key and it will return to the "ON" position. OPERATING THE ENGINE 11

CHECKS IMMEDIATELY AFTER ENGINE STOPPING THE ENGINE START 1. If the engine or hydraulic oil is cold, the machine will not work at its best. When warming up the engine, do To avoid personal injury or death: not quickly accelerate the engine. A When dismounting the machine, stop the 2. Once the engine has been warmed up, check to see engine, set the shuttle change lever to the A That the engine oil pressure alarm lamp is off. neutral position and set the parking brake A That the battery charge lamp goes off when engine switch to the parking position, lower the bucket speed is increased. and attachment to the ground, release the A That the color of exhaust is normal, and no unusual hydraulic pressure in the hydraulic system by noise or vibrations are observed. operating control levers, lock all control levers A That no lubricant, fuel or water is leaking. in neutral, and remove the key.

C If one of the following should be found, 1. Idle the engine for about five minutes to allow it to cool. immediately stop the engine. 2. By turning the key to the "OFF ( )" position, the A Engine speed suddenly decreases or increases. engine stops. A Sudden, abnormal noise is heard. 3. Slowly operate the bucket control levers to place the A Color of exhaust is dark. bucket on the ground. A The engine oil pressure alarm lamp lights up during operation. A LST filter warning lamp lights up during operation. A Do not stop the engine before it cools sufficiently, or the service life of the engine parts may be shortened. A If the engine overheats, do not stop it immediately but A Check and maintain the machine, following the cool it gradually by running it at medium speed before directions from your KUBOTA dealer. stopping. 12 OPERATING THE ENGINE

JUMP STARTING C Starting the engine of the troubled vehicle. 1. After confirming the connection, start the engine. 2. If the engine fails to start, wait 2 or 3 minutes before trying again. To avoid personal injury: A To avoid accidental short circuit, be sure to C Disconnecting the booster cables. attach the positive cable to the positive 1. Disconnect the clip of booster cable (B) from the body terminal before the ground cable is attached to of the troubled vehicle and the other end from the the negative terminal. negative terminal of the normal vehicle. 2. Disconnect the clip of booster cable (A) from the 1. Since the battery generates flammable gas, fire or positive terminal of the normal vehicle and the other sparks around the battery may cause an explosion. end from the positive terminal of the troubled vehicle. Therefore, it is best not to start the engine with booster cable. 2. When the battery nears the end of its service life, replace it quickly to prevent any problems from developing. If booster cable must be used to start the engine, handle the battery as follows.

C Before connection 1. The booster cables and clips should be identical to the battery in capacity. 2. Make sure that the terminals of the cables, clips and battery are properly connected and are not corroded. 3. Make sure that the start switch is off. 4. The battery of the two vehicles should have the same capacity.

(1) Frame of troubled vehicle C Connecting the booster cables (2) Battery of normal vehicle 1. Connect the clip of booster cable (A) to the positive (3) Battery of troubled vehicle terminal of the troubled vehicle and the other end to the positive terminal of the normal vehicle. 2. Connect the clip of booster cable (B) to the negative terminal of the normal vehicle and the other end to the body of troubled vehicle. The clip should be connected to the body away from the battery. 3. Before starting the engine, make sure that booster cables are properly connected.

(1) Battery of troubled vehicle (2) Battery of normal vehicle (3) Frame of troubled vehicle OPERATING THE MACHINE 13 OPERATING THE MACHINE

HOW TO USE A NEW MACHINE A new machine has been carefully tested and inspected, 2. Operator's Seat and various adjustments have been made in the factory. However, you can say that the machine is the same as a newly born baby as the machine should be handled with the greatest care during the first 100 hours. To avoid personal injury: The life of the machine is greatly affected by how the A Make sure that the seat is completely secured machine has been used during the initial 100 hours. after each adjustment. A Do not allow any person other than the driver to STARTING ride on the machine. 1. To adjust the seat to the longitudinal direction, lift the 1. Engine Cover adjusting lever up and unlock the stopper, then slide the driver's seat to the desired position. 2. To adjust the cushion of the seat, turn the knob to operator's weight position. To avoid personal injury: A Make sure that the engine cover is completely latched.

(1) Seat (2) Adjusting lever (3) Adjusting knob (A) "Look" 14 OPERATING THE MACHINE

SAFETY LEVERS AND APPLIANCE 3. Operator's Seat Belt BSafety Key Start System This is the safety system to prevent the machine from moving suddenly. To avoid personal injury: The parking brake switch is to be set to the parking A Never operate the machine without ROPS/ position and the shuttle change lever is to be set to the FOPS and Seat Belt. neutral position before stopping the engine. A Always use the seat belt before you start the The safety key start system does not allow the engine to engine. start when the parking switch is out of the parking position, and the shuttle change lever is out of the neutral position.

BBucket Lever Lock

To avoid personal injury or death: A When dismounting the machine or when servicing the machine, be sure to stop the engine, set the shuttle change lever to the neutral position and set the parking brake switch to the parking position, lower the bucket and the attachment to the ground, release the hydraulic pressure in the hydraulic system by operating control levers. Lock all control levers (1) Seat belt in neutral, and remove the key.

This lock is used to lock the bucket lever. With the bucket 4. Where to keep the Tools and Operator's lever in neutral, press the lock. Manual

(1) Bucket lever (A) "UNLOCK" (2) Bucket lever lock (B) "LOCK" (1) Box for storage (A) "open" (3) Service port lever (4) Service port lever lock OPERATING THE MACHINE 15

BService Port Lever Lock BLift Arm Support

To avoid personal injury or death: To avoid personal injury or death: A When dismounting the machine or when A Before installing the lift arm support, remove servicing the machine, be sure to stop the the front attachment set the shuttle change engine, set the shuttle change lever to the lever to the neutral position and the parking neutral position and set the parking brake brake switch to the parking position, lock all switch to the parking position, lower the bucket control levers in neutral, and remove the key. and the attachment to the ground, release the hydraulic pressure in the hydraulic system by The lift arm support is used to prevent the loader lift arms operating control levers. Lock all control levers from falling when servicing the machine. in neutral, and remove the key. Install as follows. A In case of the service port lever is used for the 1. Remove the front attachment. hydraulic quick coupler, always lock the 2. Raise the loader lift arms completely. service port lever after installing front 3. Stop the engine and remove the key. attachment (bucket etc.) to the hydraulic quick 4. Insert the lift arm support onto the lift cylinder rod. coupler. If the machine is operated without the 5. Install the pin and snap pin in the lift arm support. lock, it causes sever injury or death. 6. Slowly lower the loader lift arms onto the lift arm support. This lock is used to lock the service port lever. With the service port lever in neutral, press the lock.

(1) Lift arm support device (Storage position)

(1) Lift arm support device (Installed position) 16 OPERATING THE MACHINE

BRoll-Over Protective Structures (ROPS) / Falling Objective Protective Structures (FOPS) For your safety, ROPS/FOPS with a seat belt is installed with your machine. A ROPS/FOPS label is fastened to the ROPS/FOPS. This label shows the serial No. of ROPS/ FOPS, gross weight, approval and regulation No. and model No. of the machine.

(1) Nut (2) Bolt

(1) ROPS/FOPS (2) Bolt (3) Spring washer (4) Plain washer (5) Bolt OPERATING THE MACHINE 17

BSteering Frame Lock To avoid personal injury or death: A Always use a ROPS/FOPS with seat belt, when driving or operating the machine. Do not To avoid personal injury or death: modify a ROPS/FOPS in any way. Welding, A Secure steering frame lock before servicing, bending, drilling or cutting any portion of the hauling or transporting the machine. ROPS/FOPS may weaken the structure. Do not repair a damaged ROPS/FOPS. A damaged This is used to lock the front and rear frames together to ROPS/FOPS structure must be replaced, not repaired or revised. If any structural member of prevent the frames from articulating unexpectedly during the ROPS/FOPS is damaged, replace the entire servicing or hauling or transporting. structure at your local KUBOTA dealer. Check To attach the steering frame lock: the seat belt daily and replace it if damaged or 1. Align front and rear frames. frayed. 2. Shut off the engine and remove the key. A Do not remove the ROPS/FOPS except for 3. Attach steering frame lock with snap pins. service. Install the ROPS/FOPS correctly 4. If holes are not aligned, move the steering wheel before you operate the machine again. slightly with the engine off. Bolt QTY. Grade Tightening Torque 260 to 304(N-m) M16x2.0x35 8 9T 192 to 224(ft-lbf) 103 to 118(N-m) M12x1.25x30 10 9T 76 to 86(ft-lbf)

A Do not install any attachments that will cause the total gross weight of the machine to exceed the weight shown in the "FOR MAXIMUM GROSS MACHINE WEIGHT" space on the ROPS/FOPS label.

CAB

Nut QTY. Grade Tightening Torque (1) Snap pin (2) Steering frame lock [Steering frame lock in lock position] 196 to 226(N-m) M16 4 7T 145 to 167(ft-lbf) 48 to 56(N-m) M10x1.25 2 7T 35 to 41(ft-lbf) Bolt QTY. Grade Tightening Torque 48 to 56(N-m) M10x1.25x40 2 7T 35 to 41(ft-lbf) 48 to 56(N-m) M10x1.25x45 2 7T 35 to 41(ft-lbf)

(1) Snap pin (2) Steering frame lock [Steering frame lock in lock position]

A Store the steering frame lock securely after use. 18 OPERATING THE MACHINE

BHourmeter / Tachometer BParking Brake Switch

To avoid personal injury or death: A When dismounting the machine or when servicing or hauling, be sure to apply the parking brake. A Make sure that the shuttle change lever is in the neutral position and the parking brake switch is at the parking position before starting the engine. To prevent the machine from starting suddenly and unexpectedly, the safety key start system is provided. The engine can start only when the shuttle change lever is in the neutral position and the (1) Engine tachometer parking brake switch is at the parking position. (2) Coolant temperature (3) Fuel gauge (4) Hourmeter The parking brake is to be used when parking the machine. C Hourmeter This counter indicates the time the engine has run at the 1. The lamp on the parking brake switch lights up rated rpm. The white-framed figure should be multiplied and parking brake is applied when the parking by 6 to obtain the running time in minutes. brake switch is pressed. e.g. 0170 (1)...170 hours. 6 minutes. 2. The lamp comes off and the parking brake is released by pressing the parking brake switch. C Engine tachometer Indicates engine speeds.

(1) Parking brake switch (A) "ON" (B) "OFF" OPERATING THE MACHINE 19

BFuel Gauge BEasy Checker With the starter switch in the "ON( )" position. Fuel level meter indicates the remaining fuel.

A Refuel before the meter points to the E mark. If the fuel system is allowed to go empty, air-bleeding will be necessary.

BCoolant Temperature With the starter switch in the "ON ( )" position, it indicates engine coolant temperature. The symbol C stands for cool and the symbol H, hot.

A When the pointer deflects across the bold line on the side of the H range, immediately stop the engine and Travel speed limiter lamp check the following: This lamp lights up when the travel speed 1) lack or leaking of coolant. limiter switch is pressed. 2) fan belt tension. Engine oil pressure alarm lamp 3) mud and dirt deposits between the radiator fins. This lamp lights up if the engine oil is A When the engine overheats. circulating abnormally. 1) Stop the operation. This lamp lights up with the starter switch in 2) Idle the engine for about 5 minutes. the "ON ( )" position and it is put out as soon 3) Stop the engine and check. as the engine starts. If the lamp stays on after the engine has started, check the engine lubricant level.

Battery charge lamp This lamp lights up if the battery charge system is abnormal. This lamp lights up when turning the starter switch to the "ON ( )" position and goes off when the engine has started. Glow lamp This lamp lights for five seconds when the starter switch is turned to the "PREHEAT" position, or from "ON ( )" to "START".

LST oil temperature alarm lamp This lamp lights up when the oil temperature becomes out of the range. Once the lamp lights up, stop working and wait while idling the engine until it goes off. LST oil pressure lamp This lamp lights up when turning the starter switch to the "ON ( )" position and goes off when the engine has started.

A Carry out routine checks sufficiently. It is not safe to perform checks with easy checker only. 20 OPERATING THE MACHINE

BTurn Signal Switch BHazard Lamp Switch Operate the turn signal switch to the right or left according Press the hazard lamp switch for the hazard lamps to to the direction in which the machine is to be turned. The blink. corresponding turn signal will blink. Be sure to return the switch to the center position after the turn.

(1) Hazard lamp switch (A) To blink the hazard lamp (B) "OFF"

(1) Turn signal switch (A) To blink left turn signal BFuse Box (B) To blink light turn signal The fuse box houses fuse for protection of the electrical circuit. There are six 5 ampere fuses and six 10 ampere BHeadlight Switch fuses in the fuse box. There are also extra fuses provided.

To avoid personal injury: A For night operation, keep all machine mounted lights operating. Check for burned out lights and replace immediately. With the starter switch in the "ON" position, press the headlight switch for the headlights.

(1) Fuse box

(1) Headlight switch (A) "ON" (B) "OFF" OPERATING THE MACHINE 21

CONTROL LEVERS AND PEDALS BInching and Brake Pedals BAccelerator Pedal The inching and brake pedal are interlocked with each This pedal controls engine rpm. The more the pedal is other. pressed, the greater the engine rpm. The brake functions in the same way when either is pressed down. Press either pedal down slightly, then the LST pump comes in neutral and cuts off the engine power on the way of the transmission, that is so-called dynamic brake, unique to LST (Load Sensing Transmission). When pressing it further, the disc brake acts together to obtain strong braking effect. For the details of inching and brake pedal, refer to the section "How to use the inching pedal".

(1) Accelerator pedal

A When the pedal is released, the engine speed will drop. A The engine rpm suitable for starting the machine on a plain ground is about 1,000 to 1,200 rpm, though depending on the situations; i.e. ground condition, weather, etc. Press the accelerator pedal gradually when starting the machine. (1) Inching and brake pedal

BTravel Speed Limiter Switch

To avoid personal injury or death: A While descending a slope in the high speed, be extremely careful when applying the travel speed limiter range from the high speed, there is the risk of the machine rear lifting which could be dangerous. A When descending a slope, use the engine brake to slow the machine.

1. The lamp on the easy checker lights up and speed is limited to 0 to 5 km/h (0 to 3.1 MPH) when the switch is pressed. 2. The lamp comes off and gets maximum speed when the switch is pressed one more time. 22 OPERATING THE MACHINE

BShuttle Change Lever BBucket Lever

To avoid personal injury or death: To avoid personal injury: A To prevent the machine from moving suddenly A Do not use float position to lower the bucket or unexpectedly, be sure and push the lock and attachment. The bucket and attachment knob to lock the shuttle change lever whenever will lower in response to control lever getting on or off. movement even when the engine is off.

This lever is used for changing the machine's running A single lever controls all bucket and lift arm operations. direction, forward or back. (1) Lift arm up Pull the lock knob to unlock the shuttle change lever lock (N) Hold (neutral) and push the shuttle change lever forward for forward (2) Lift arm down direction and pull it back for reverse direction. (3) Floating (A) Bucket dump (B) Bucket tilt

(1) Shuttle change lever (A) "Forward" (2) Lock knob (B) "Neutral" (C) "Backward" (1) Bucket lever (D) "Lock" (E) "Unlock"

(A) "Tilt" (B) "Dump" (C) "Up" (D) "Down" OPERATING THE MACHINE 23

CAB TYPE MACHINES 3. To close the CAB door, pull the release lever and undo the lock. BOpening/Closing of CAB Door(CAB type only) 1. To open the CAB door from outside, unlock the CAB door with the CAB key and pull the knob. Open the CAB door fully, push on its end, and the CAB door will be locked.

(1)Release lever (A) "Release"

4. When leaving the wheel loader, always lock the door.

BInterior Lamp(CAB type only) To turn on the interior lamp, set the starter switch to the (1) Door knob "RUN" and then the interior lamp switch to the "ON" positions, respectively. 2. To open the CAB door from inside, raise the lock and pull the release lever.

(1) Interior lamp (A) "ON" (B) "OFF"

(1) Lock (A) "Release" (2) Release lever BWiper/Washer Switch(CAB type only) Turn the starter switch to position "RUN" and push the switch for the wiper and washer system; the wiper will begin to move. A further push on the switch will activate the washer system. A Do not activate the switch if the tank for the cleaning fluid is empty; the pump can be damaged. A This can also be the case if the wiper is moved on a dry window. In this case, make sure that cleaning fluid is applied to the pane before activating the wiper. A In frosty conditions, make sure that the wiper blade is not frozen to the glass before switching-on. The motor can be damaged if the wiper system is used under such conditions. 24 OPERATING THE MACHINE

(1) Working light (3) Wiper switch (front) (1) Heater valve (A) "Close" (2) Wiper switch(rear) (B) "Open" TRAVELING BHeater Switch(CAB type only) BStarting Turn the starter switch to position "RUN", turn the heater switch clockwise, and the heater fan will be activated to warm up the CAB. The heater switch has 3 positions - "Low" , "Medium" and "High" -. To avoid personal injury or death: A Fasten seat belt before operating the machine A When transporting a load, keep the loader bucket as low as possible to avoid tip over. Be extra careful when working on inclines. A Before operating, check operating area. Make sure no bystanders are near the machine. Sound the horn before moving.

To avoid personal injury: A Before traveling on the public road, observe all local and state traffic regulations. Use SMV emblem and warning flashers as required. A To start the machine on a slope, press the (1) Heater switch accelerator pedal gradually while releasing the inching pedal so that the machine does not A During the summer, turn the heater valve clockwise to move backwards. close the valve. A Immediately after starting, check that the brake and the steering wheel work normally. A If a tire has blown, the machine may slip or turnover. To avoid turnover, do not brake or steer hard, brake slowly to stop the machine gradually.

1. Release the lock for the bucket lever. 2. Slightly press the accelerator pedal to increase the engine rpm. 3. Move the bucket lever to lift the bucket about 40 cm (16 in.) above the ground and set it in the proper position for travel. 4. Press the parking switch for releasing the parking brake. When the parking brake is released, the light on the parking switch comes off. OPERATING THE MACHINE 25

5. Set the shuttle change lever to the desired position, gradually increase the engine rpm by pressing the BDeceleration on a Slope accelerator pedal and the machine will move.

To avoid personal injury or death: A Going up or down a slope diagonally is dangerous as the machine may skid. Always drive or operate straight up or down a slope, or the machine may slip side ways and tip over. A Use foot brake together with engine brake if the machine tends to over-run when descending a slope.

To avoid personal injury: A If the engine should stall on a slope, set the parking brake switch to the parking position (1) SMV emblem immediately for safety purpose, although the disc brake is automatically applied. BTurning Then set the shuttle change lever to the neutral position to prepare for the next start. A When descending down along slope, use engine brake. Using the foot brake alone To avoid personal injury or death: accelerates brake pad wear and cause heat A Do not turn sharply at high speeds. It is buildup and will result in poor brake dangerous. In the worst possible case, the performance. machine may turn over. A The steering wheel for this machine will not B return of itself to the straight ahead position Traveling on rough roads after turning. Be sure to return the wheel to the straight ahead position. A Steering lose will result if the engine is stopped To avoid personal injury or death: during travel. A Slow down when turning on rough uneven Do not stop the engine during travel. terrain and slopes to avoid tip over.

To steer the machine to either side, turn the steering BTraveling on Snow wheel in the intended direction. 1. The front and rear frames of this machine bend at the center pin (the pin connecting the two frames) so that when the machine turns, the rear wheels follow the To avoid personal injury or death: tracks of the front wheels. A There is the risk of the machine slipping 2. Rotate the steering wheel to follow the turn of the excessively on frozen ground, install chains on machine. When turning fully, never attempt to rotate the front wheels, for operation on snow install the steering wheel once it reaches its full stroke. chains on both front and rear wheels.

When traveling on snow, it is important to keep the wheels and their related parts in good condition. After traveling, be sure to remove all snow and ice from those parts. 26 OPERATING THE MACHINE

STOPPING HOW TO USE THE INCHING PEDAL BInching Pedal Operation Operate the inching pedal as follows according to the To avoid personal injury or death: application. A Choose flat and level ground for parking the machine. It is important to lower the bucket to C To stop the machine the ground. 1. The inching pedal controls LST pump and brake. If the machine must be parked on a slope, be 2. To stop the machine completely during work, first sure to block the tires securely. press the pedal slightly. Oil flow from LST pump A When dismounting the machine, stop the comes to zero and cuts the driving power to slow down engine, set the parking brake switch to the or stop the machine. parking position lower the bucket and 3. Press the pedal completely. attachment to the ground release the hydraulic The disc brake will be applied to stop the machine pressure in the hydraulic system by operating completely. control levers, and lock all control levers in neutral, and remove the key.

1. Remove foot from the accelerator pedal. 2. Depress the brake pedal and stop the machine. 3. Stop the engine. 4. Set the parking brake switch to the parking position. 5. Lower the bucket and attachment to the ground. 6. Release the hydraulic pressure in the hydraulic system by operating control levers. 7. Lock all control levers in neutral. 8. Remove the key.

(A) Press the pedal with force

C To approach slowly 1. Press the inching pedal slightly while pressing the accelerator pedal. The machine approaches slowly. 2. The machine can slowly approaches an object by accelerator pedal regulation only, without inching pedal operation.

(1) Block the tires

(A) Press the pedal slightly OPERATING THE MACHINE 27

C To scoop during digging BUse the Inching Pedal According to the In case of the bucket does not raise up during digging, Job. press the inching pedal. Traction force is reduced and lifting force is increased, if the inching pedal is pressed. To avoid personal injury or death: A When traveling with a fully-loaded bucket, do not press the inching pedal all the way. The machine will brake abruptly and cause dangerous loss of balance that may cause an accident.

C Loading 1. Press the inching pedal slightly while pressing the accelerator pedal to approach an object slowly. Slow approach can be done also by regulating accelerator pedal operation. 2. The bucket can be operated at the maximum engine rpm when the inching pedal is used to approach slowly. Bucket operation speed is thus maintained. 3. Press the inching pedal slightly to allow the machine to (A) Press the pedal fully approach to the desired stop position. (B) Release the pedal Then press the pedal all the way to stop the machine completely.

(A) Press the pedal slightly 28 OPERATING THE MACHINE

C Refilling 1. Press the inching pedal slightly to approach the desired stop position, then press the pedal all the way to stop the machine at the exact position. 2. The traveling speed automatically decreases to prevent engine stalling as the external load increases. 3. During traveling with bucket operation, the traveling speed abruptly increases at the time of dumping operation since the external load changes at that time. 4. Use inching pedal and concentrate the power to the attachment operation near holes or slopes.

(A) Press the pedal slightly (B) Press the pedal all the way

(A) Leave one pile (B) Press the pedal slightly (C) Press the pedal all the way OPERATING THE MACHINE 29

TYPICAL JOBS USING A WHEEL LOADER Below are some typical jobs performed using a wheel BDigging and Loading loader. The machine can also be used to perform other jobs by connection with various attachments. C Loading a sand pile 1. Direct the bucket blade parallel to the ground and advance the machine to drive the bucket into the sand pile. To avoid personal injury or death: A When transporting a load, keep the loader bucket as low as possible to avoid tipping over. Be extremely careful when working on inclines. A Unreasonable operation such as on dangerous terrain, beyond the load capacity or beyond the intended use of the machine must be avoided as it may cause the machine to tip over. A Slow down before entering ungraded terrain. A Do not drive the machine close to the edges of ditches or banks which may collapse under the weight of the machine especially when the ground is loose or wet. A Operating on slopes can be dangerous, rain, snow, loose gravel, soft ground, etc., will change the ground conditions. Do not operate this machine in questionable 2. When the bucket is sufficiently driven into the sand, lift ground conditions. the bucket while advancing the machine. A Never perform digging or shoveling with the machine in the articulated condition. A Never dig or shovel at high speed. Such operation can cause the machine to lose balance and its rear wheels to lift off the ground, which may in turn cause a serious accident. A To avoid possible machine tip over, do not operate the machine in any site whose terrain cannot be ascertained, such as ground covered with seeds or snow and check for hidden projections, dents, road shoulders, etc., beforehand, and take care not to approach them during work. A Be sure to ease up on the accelerator at the end of backfilling grooves, or areas at the edge of 3. If the bucket is insufficiently driven into the sand, move cliffs or pond banks, or at the end of an ascent: the bucket blade up and down while moving forward. Upon removal of the external load, the machine speed will automatically increase, reduce speed to avoid entering grooves or tipping over. A To avoid machine slip or tipping over, do not operate the machine on ungraded or soft terrain, such as landfills. Grade and compact the site beforehand at all times. 30 OPERATING THE MACHINE

C Digging and loading from flat ground 1. Direct the bucket blade slightly downward and lower BRefilling the bucket as you advance the machine. The recommended digging depth per pass is between 1. Direct the bucket horizontally and push the piled sand 10 and 15cm (4-6"). toward the ditch. 2. When the bucket reaches the ditch, dump the bucket to discharge the sand into the ditch.

2. While adjusting the vertical movement of the bucket, lift the bucket so that sand can be removed by layers. Continue in this manner as you advance the machine.

BLeveling Ground

1. Dump and tilt the bucket alternately to distribute the soil from the bucket over the ground as you move the machine backward. 2. Then, dump the bucket, lower the bucket and move the machine backward so that the blade scratches the ground surface. 3. Direct the bucket horizontally, set the lift arms in the "floating" position using the bucket lever and level the ground while backing the machine. OPERATING THE MACHINE 31

BLoading onto a Truck Examine the job site situation and choose the efficient loading method that minimizes the swivel angle and moving distance.

C Cross loading method 1. Position a truck perpendicular (90 ) to the shoveling direction of the machine. 2. After digging and shoveling with the bucket, move the machine backward. Then drive the truck to a point between the machine and the piled sand. Then, load the sand onto the truck. 3. This method is the fastest and leads to the shortest cycle time.

C V-shift loading method 1. Position a truck at an angle of about 60 from the shoveling direction of the machine. 2. After digging and shoveling with the bucket, move the machine backward and turn the steering wheel to position the machine perpendicular (90 ) to the truck. Then move the machine forward to load sand onto the truck. 3. A smaller angle between the machine and truck will provide a shorter cycle time and more efficient operation. 32 MULTI-COUPLER MULTI-COUPLER

ATTACHING AND DETACHING THE FRONT ATTACHMENTS

[Mechanical Multi-Coupler] This machine utilizes a multi-coupler for easy connection and disconnection of various attachments. By replacing the front attachments, this machine can be used in agriculture, raising stock, landscaping, gardening and snow removal as well as general civil engineering and construction work.

BAttaching the Front Attachments

(1) Holes of the attachment To avoid personal injury or death: (2) Attachment to be attached A After doing these procedures, make sure the attachment is securely attached to the multi- coupler, or the attachment may be detached. A When handling the control lever, you should do it after setting the shuttle change lever to the neutral position and the parking brake switch to the parking position, lowering the bucket, locking all control levers in neutral position.

Attach the front attachments as follows. 1. Choose the flat ground before attaching the front attachments. 2. Pull the lock lever in the direction of the arrow and put in at the hook on the multi-coupler. 3. Slowly move the machine until the edge of the multi- coupler adapts to the attachment. (1) Edge of the multi-coupler 4. Slowly raise the bucket and tilt it back so that the edge (2) Attaching and detaching lever (lock lever) of the multi-coupler can be fully adapted and both the (3) Hook center of the connecting pins and holes of the (4) Multi-coupler attachment can be aligned. (5) Connecting pins 5. The connecting pins are automatically pushed out, and then the attachment is securely connected to the multi-coupler only by releasing the lock lever off the A It is important to apply grease periodically around the hook. sliding part of the connecting pin so that the front attachment can be easily attached or detached. MULTI-COUPLER 33

[Hydraulic Multi-Coupler] (Does not apply to all machines.)

To avoid serious personal injury or death: A Make sure the attachment is securely latched to multi-coupler and service port lever lock is engaged. A Failure to follow this procedure may result in separation of attachment from multi-coupler.

This machine utilizes a multi-coupler for easy connection and disconnection of various attachments. By replacing the front attachments, this machine can be used in agriculture, raising stock, landscaping, gardening (1) Edge of the multi-coupler and snow removal as well as general civil engineering and (2) Indicator construction work. (3) Latched position (4) Unlatched position (5) Multi-coupler (6) Connecting pins

(1) Holes of the attachment (2) Attachment to be attached

(1) Service port lever (A) "Unlatch" BAttaching the Front Attachment (2) Hydraulic Multi-Coupler (B) "Latch"

1. Place machine on flat ground before attaching the front attachments. 2. Pull the service port lever in the direction of the arrow (A), and make sure the indicator and the connecting pins are in the unlatched position. 3. Slowly move the machine until the edge of the multi- coupler adapts to the attachment. 4. Slowly raise the bucket and tilt it back so that the edge of the multi-coupler can be fully adapted and both the center of the connecting pins and holes of the attachment become aligned. 5. Push the service port lever in the direction of the arrow (B), and make sure the indicator and the connecting pins are in the latched position. 6. Lock the service port lever lock for Hydraulic Multi- Coupler (2). 34 MULTI-COUPLER

BHoses fitting for Hydraulic Multi-Coupler Connect the Male Coupler of hose to the Female Coupler on the Hydraulic Multi-Coupler, fit the other side solid (marked green) on the bottom piping (marked green) on the shovel frame with swivel joint. Connect the Female Coupler of hose to the Male Coupler on the Hydraulic Multi-Coupler, fit the other side solid (marked yellow) on the upper piping (marked yellow) on the shovel frame with swivel joint.

(1) Male coupler (2) Female coupler (3) Male coupler (4) Shovel frame (5) Yellow (6) Green (7) Female coupler (8) Hydraulic multi-coupler

A It is important to apply grease periodically around the sliding part of the connecting pin so that the front attachment can be easily attached or detached. TRANSPORT BY TRUCK 35 TRANSPORT BY TRUCK

B Loading on a Truck, off-Loading 3. Support the rear end of the bed to prevent the truck front from rising. To avoid personal injury or death: A When loading or off-loading the machine on or from a truck, be sure to use strong planks. Never use wet lumber, etc. A Keep the planks at an angle such that the machine can be kept stable (10 to 15degrees). Never try to change directions while on the planks. A Do not alter the climbing direction once already on the ramps. If direction of climb needs correcting, first bring the machine down off the ramps and make the directional correction.

1. To load the machine onto a truck, apply the parking brake of the truck, block the front and rear wheels. 4. When loading or off-loading the machine on or from a truck, keep the bucket about 40cm (16in.) up from the ground and reverse the machine at the low speed or advance it at the same speed to off-load it.

A When advancing, reversing or turning the machine on the truck bed, be careful not to hit the cabin and the gates.

2. Install the ramps with lock plates securely.

(1) Lock plate (A) 500 to 600mm (B) 650mm (C) H x 4 or more 36 TRANSPORT BY TRUCK

B Transportation

To avoid personal injury or death: A Before transportion, do the following to prevent the machine from moving during transportation. (1) Check to see that the machine's center point aligns with that of the truck bed. (2) Stop the engine. (3) Set the parking brake switch to the parking position. (4) Lower the bucket and attachment to the truck bed. (5) Release the hydraulic pressure in the hydraulic system by operating control levers. (6) Lock all control levers in neutral. (7) Secure the steering frame lock and remove the key. (8) Block the machine's wheels. (9) Securely fasten the machine to the truck.

After loading the machine, lower the bucket, outriggers on the truck bed. Set the shuttle change lever to the neutral position and the parking brake switch to the parking position. Securely fasten the machine to the truck or trailer. HANDLING LOADER IN COLD-WEATHER 37 HANDLING LOADER IN COLD-WEATHER

PREPARATIONS FOR COLD WEATHER AFTER-OPERATION DIRECTIONS After operation, be sure to remove mud or water from the 1. Change engine oil to one of low-viscosities suitable for machine's body. use in cold weather. Then park the machine on concrete or where ground is 2. In cold weather, battery power drops, and electrolyte dry. Lay planks or mats on the ground and park the may freeze if the battery is not sufficiently charged. To machine on them. If the machine should be parked on the prevent electrolyte from freezing, be sure to keep the ground and the tires freeze during the night, driving will be battery charged at 75% or more of capacity after an impossible. operation is over. It is also important to wipe the piston rod surface of the Also keep the battery indoors to facilitate next starting. If the battery electrolyte level is low, do not add distilled hydraulic cylinders completely. If mud should enter the water after operating, do it before starting the next seal with frozen water, it may be damaged. operation while the engine is running. Water in the fuel system should be drained to prevent 3. Add anti-freeze to cooling water in the radiator and freezing at night. reserve tank, if ambient temperature might drop below 0 C(32 F) while the machine is out of use. Mixing ratio between water and anti-freeze is determined by how low the ambient temperature will be.

A Mixing ratio between water and anti-freeze Ambient -5 -10 -15 -20 -25 -30 -35 -40 temperature (+23) (+14) (+5) (-4) (-13) (-22) (-31) (-40) ( F)

Anti-freeze 30 30 30 35 40 45 50 55 %

Water %7070706560555045

A Use a permanent-type anti-freeze or long-life coolant. A Be sure to drain cooling water completely and deposits from the radiator interior before adding solution, that is mixture of water and anti-freeze. A Anti-freeze contains anticorrosive, it is not necessary to add radiator cleaner to the mixture of water and anti- freeze. A Engine coolant capacity Type Capacity R420S 6.5L (1.7U.S.gals.) R520S 6.5L (1.7U.S.gals.) 38 MAINTENANCE MAINTENANCE

Whether the machine is properly lubricated and A Never get under the machine while it is being lifted maintained directly determines the trouble frequency and with only the bucket. If servicing or checking service life of the machine. Periodically check and underneath, support it firmly with strong blocks, maintain your machine, and you will find in the long run etc. If you do not follow this, serious injury or that the jobs can be finished earlier and more death can result. A Keep clear of articulation area when servicing. economically. A Keep all sparks and flames away from the fuel and Shown in the Service Interval Chart below are the hours the oil. indicated on the hourmeter, practically, it will be A To avoid the danger of exhaust fume poisoning, convenient to schedule the time of inspection and do not operate the engine in a closed building maintenance according to the calendar (day, week, without proper ventilation. month) on the basis of the chart. If the machine is used in harder-than-usual working conditions, it must be checked and maintained at shorter intervals. To avoid personal injury: B Maintenance A When servicing or checking the electrical system, disconnect the battery terminals. A Wear safety wear such as a helmet, glasses and safety shoes. A Never touch the relief valves because all of them have been adjusted to proper setting pressure at the factory.

To safely use the machine and prevent any trouble from occurring, be sure to conduct daily inspections and periodic servicing.

A If machine cannot be operated and must be towed, please contact your local KUBOTA dealer for correct towing procedures. A For parts that are difficult to service or inspect and for details regarding construction and functions, contact your KUBOTA dealer. A Clean the machine so that it is easy to find what is To avoid personal injury or death: wrong. A Place the machine on the flat ground. Clean the oil replenishment parts and the oil level A Before servicing or checking the machine, do gauge in particular to keep them free of dust and other the following procedures. foreign matter. (1) Stop the engine. When washing, be careful not to get the electrical parts (2) Set the parking brake switch to the parking wet. position. A Check or replenish the oil in a place where there is little (3) Lower the bucket and attachment to the dust and use a clean oil container to prevent dust from ground. permeating the oil. (4) Release the hydraulic pressure in the A Check or replenish oil when the machine is level. Use hydraulic system by operating control levers. the same brand when replenishing oil. (5) Lock all control levers in neutral. A After greasing the machine, wipe off all old grease, (6) Remove the key. especially from those parts where sand and dust can (7) Secure the front and rear frames with the accelerate wear. steering frame lock. A When changing the oil or replacing the filter, check whether the old oil or filter is abnormally permeated with metal fillings or foreign matter. A Use a light oil or noncombustible washing agent to wash the parts. MAINTENANCE 39

SERVICE INTERVALS BService Interval Chart (Do all previous checks in addition to New checks.)

First (hrs) Maintenance (hrs) One Two Maintenance hours year years Ref. (Hourmeter) every every every every every every every every from from Page Item of Maintenance 50 100 500 50 200 250 500 1000 1500 2000 3000 buying buying

Check battery liquid level. 49

Drain of the fuel tank 48

Change engine oil * 53

Replace engine oil filter * 54 cartridge

Check for fan belt tension 51 and adjust as necessary.

Clean and check Outer * *1 air cleaner element element, and 52 @ Inner change if *1 necessary. element

Change, check and replenish 55 oil in front/rear axle differential * 57 case.

Change hydraulic oil. * 57

Change LST oil filter cartridge 55

Change return filter cartridge 56

Change suction filter * 57

Change fuel filter cartridge and discharging water from the 56 @ sediment filter.

Check alternator starter motor. 58

Change coolant Twice a year (Spring and Autumn) 60

Check and change radiator 52 hose and band. 59

Change fuel line and intake air 53 *2 @ line. 59

Change rubber hose 59

Check and retighten the wheel bolts in the first 50 hrs, and * 64 after exchanging tires.

Check the damage of electrical circuit and the looseness of the - coupler.

Check fuel injection nozzle 58 *3 @ injection pressure.

Check injection pump 59 *3 @

: Check and replenish * : Replace for the first time : Replace * : Check and clean for the first time : Consult your local KUBOTA Dealer for this service

*1 Clean and replace the air filter more frequently if used under dusty conditions. By heavy soiling, replace the filter. *2 Replace only if necessary. *3 Consult your local KUBOTA Dealer for this service. 40 MAINTENANCE

A 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. MAINTENANCE 41

LUBRICANTS BSelect the Grade by Referring to the Table.

A In areas where the temperature drops to -10 or lower, drain all oil in hydraulic oil tank and replace with all season type engine oil SAE5W-30(CD) for the winter. A Use engine oil API service classification CD,CE or CF.

A It cannot be guaranteed against any problem caused by use of the fuel and lubricating oil and grease that are not specified.

D Always use the specified gear oil, M80B or equivalent, which is permitted by KUBOTA. When engine oil is used to the LSD specification differential, paki-paki sounds are generated from differential gears during turning (especially when the steering wheel is maintained at a turned position). (This occurs due to wrong combination of LSD clutch plate and oil, causing change in the friction characteristics, which has no adverse effects including durability.) Specified differential oil type M80B Chevron Mobiland Multipurpose Multi gear Shell Universal Gear super Tcuban EP Lubricant EP Donax TD Lubricant SAE Universal SAE 80W SAE 80W-90 80W-90 42 PERIODIC SERVICE PERIODIC SERVICE

HOW TO OPEN THE ENGINE COVER DAILY CHECK

It is of Extremely importance to maintain your machine To avoid personal injury from contact with moving properly to prevent trouble. parts: 1. Check to see that there is no trace of water or oil leak A Never open the engine cover while the engine by walking around the machine carefully check is running. connections of high-pressure hoses, oil pressure A Do not touch muffler or exhaust pipes while cylinder and fuel piping. If there are any leaks, take they are hot; Severe burns could result. proper measures to stop them. If repair is impossible, contact your KUBOTA dealer. BEngine Cover 2. Check for loose bolts, nuts and tighten if necessary, especially wheel nuts. Use the engine starter key for releasing the lock of the 3. Check the electrical circuit for any disconnections, Engine Cover. shorts or loose terminals. Insert the key into the lock and turn the key to counter clockwise, then the lock is released. Pull up the lever and lift the back-rest of the seat, then top BChecking Coolant Level and Replenishing cover will open. When the engine cover is opened completely, it will be automatically held by gas cylinder. To avoid personal injury or death: A Do not remove radiator cap while coolant is hot. When cool, rotate the cap to the first stop to allow excessive pressure to escape. Then remove the cap completely.

The radiator is equipped with a reserve tank. When the cooling water level drops in the radiator, water is added automatically from the reserve tank. It is necessary to check the water level in the reserve tank and refill water if necessary. Do not disconnect the hose but remove the cap. If the water level is between "FULL" and "LOW", the condition is normal. If it drops quickly, water may be leaking somewhere, be sure to find the cause of leakage.

(1) Lever (A) "PULL" (2) Key A Do not fill the reserve tank above the "FULL" mark. A Add only clean water or coolant. PERIODIC SERVICE 43

(1) Oil port (A) Proper oil level (1) Radiator cap (2) Oil dipstick BChecking the Engine Oil A Use engine oil of appropriate viscosity according to outside temperature. To avoid personal injury: A Immediately after the engine stops, it is difficult to A Be sure to stop the engine before checking the check the oil level exactly as the oil remains in each oil level. part. Check the oil level with the machine on flat ground at least five minutes after engine is shut off. Insert the oil dipstick all the way into the oil port, take it out, check the oil level, and add oil if necessary. When checking engine oil level, make sure that the machine body is level.

(1) Oil port (A) Proper oil level (2) Oil dipstick 44 PERIODIC SERVICE

BChecking Hydraulic Oil (LST Oil) Level BChecking the Fuel and Replenishing

To avoid personal injury or death: To avoid personal injury or death: A Never open the oil port immediately after the A Before refueling, always stop the engine, set engine has stopped or hydraulic oil may rush the parking brake switch to the parking out, causing scalding. position, lower the bucket and attachment to the ground, release the hydraulic pressure in 1. Stop the machine on flat ground and lower the bucket the hydraulic system by operating control to the ground. levers. Lock all control levers in neutral, and 2. Check the hydraulic oil. remove the key. 3. If the oil level is between the upper and lower marks, Keep sparks and flames away from the fuel the amount of the oil is appropriate. while refueling, or serious personal injury 4. If the hydraulic oil level is below the proper range, add result. oil through the oil port. Use diesel engine oil in the oil tank. 1. Check the fuel level at the fuel gauge. 2. Open the cover with the key, remove the cap and add the fuel if necessary.

(1) Oil port (2) Oil level gauge (1) Fuel gauge

A When refilling the hydraulic oil, wipe sand and dust off the area around the oil port, and use the same brand of the same hydraulic fluid manufacturer. A Never mix hydraulic oils of different manufacturer.

(1) Key (2) Cap (3) Cover PERIODIC SERVICE 45

A Avoid fuel spills and overfilling the fuel tank. BGrease Fittings A Every time after operation is over, fill the fuel tank fully and be sure to replace the cap and lock the cover.

BChecking and Replenishment of Oil in the To avoid serious personal injury or death: Brake Fluid Reservoir A Keep clear of articulation joint in area of service.

To avoid personal injury or death: A Only use hydraulic oil that meets ISO VG 32. To avoid personal injury or death: Use of incorrect oil will cause damage of brake A Before greasing, always stop the engine, set parts and potential brake failure. the parking brake switch to the parking position, lower the bucket and attachment to Check the brake oil level. The level must be between the the ground, release the hydraulic pressure in upper and lower marks on the brake fluid reservoir. the hydraulic system by operating control levers. Lock all control levers in neutral, and remove the key. A Always remove the bucket and attachment and use the lift arm support when servicing the machine with the loader lift arms raised.

C Greasing bucket section Apply grease to the nipples indicated by the arrows in the illustration.

(1) Brake fluid reservoir

A If oil is used up sooner than expected, check the brake lines for oil leaks.

(1) Lift arm attachment pin (2 places) (2) Quick coupler attachment pin (2 places) (3) Tilt link pin (1 place) (4) Tilt arm pin (3 places) (5) Tilt cylinder bottom pin (1 place) (6) Lift cylinder rod pin (2 places) (7) Lift cylinder bottom pin (2 places) 46 PERIODIC SERVICE

C Greasing the universal joint C Greasing the steering cylinder pin Apply grease to the universal joint at three grease nipples. Apply grease to the steering cylinder pin at two grease nipples, one on the rod side and the other on the bottom side.

(1) Grease nipples

C Greasing the oscillation pin (1) Grease nipples Apply grease to the oscillation pin at one grease nipple.

BChecking Tire Pressure, Wear and Damage and Bolts Refer to the section on "Tire" for checking.

BChecking and Cleaning the Radiator and Oil Cooler Fins

1. Open the engine cover. 2. Check the fins for clogging. If clogged, they should be cleaned out with a jet of compressed air or steam. 3. Check the rubber hose for damage. If broken or cracked, change it. Also, check to see that the hose clamp are tight. (1) Grease nipple

C Greasing the articulate shaft Apply grease to the articulate shaft at one grease nipple.

(1) Radiator grill

(1) Grease nipple PERIODIC SERVICE 47

BChecking and Tighten Loose Bolts and BChecking the Parking Brake Nuts Check the bolts and nuts and tighten them if necessary. 1. Set the parking brake switch to the parking position to test its performance. BChecking Electrical Wiring for Short- 2. If it fails to work effectively, it must be adjusted by your circuits and Loose Terminals KUBOTA dealer.

To avoid personal injury: A Never wear metal rings or metal watch bands. You can make a ground for the electric circuit and get a burn on your hand or arm. A Know the electrical circuit before you connect or disconnect an electrical component. A wrong connection can cause injury or damage.

Check them carefully, since any defects will cause electric problems.

BChecking the SMV Emblem for Stains and Damage (1) Parking brake switch Check the SMV emblem for damage and stains, and replace if necessary. BChecking the Brake Pedal BChecking the Lamps and Meters 1. Check the brake pedal. 2. If it fails to work effectively, it must be adjusted by your 1. Check that the lamps flicker normally. KUBOTA dealer. 2. Check that the meters work normally.

BTesting the Horn Check the horn's sound and operation.

BChecking Oil and Water Leak Visually check the machine's body.

(1) Brake pedal

BChecking the Steering Wheel

1. Start the engine, turn the steering wheel left and right and check the operation. 2. If any abnormality is found, have it inspected further by your KUBOTA dealer. 48 PERIODIC SERVICE

EVERY 50 HOURS SERVICE BCleaning and Checking after Operating in Muddy Areas BDraining of the Fuel Tank

1. If the machine is used in muddy areas, immediately wash it with water to remove the mud and dirt. To avoid personal injury or death: 2. After washing it, check and lubricate the universal A Always stop the engine before draining. joint. A Keep sparks and flames away from the fuel while draining, or serious personal injury results.

1. Slightly open the drain plug on the tank bottom to discharge water that has accumulated in the bottom. 2. After draining, be sure to shut the plug completely.

(1) Grease nipples

(1) Drain plug PERIODIC SERVICE 49

BBattery

C Checking Battery Electrolyte Level

To avoid the possibility of battery explosion: 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 2. Clean the battery ventilation port and the battery. level is between the UPPER and LOWER levels.

To avoid personal injury: A Before inspecting or removing the battery, be sure to stop the engine and turn off the starter switch. Never remove the battery cap while the engine is running. A Do not allow the battery liquid to contact your skin or clothes. Wash away any spilled battery liquid with water as soon as possible. If you do not wash off the battery fluid, diluted sulfuric acid may burn your skin or clothes. A Protect your eyes with glasses when working close to the battery. (1) Battery electrolyte level (A) Low (B) Proper 1. Remove the cap and check the battery electrolyte (C) High level, if it does not reach the required level, add distilled water. A When refilling dilute sulfuric acid solution, do not use a metal funnel. Handle sulfuric acid with extreme caution and do not get any on your skin or clothing.

(1) Battery 50 PERIODIC SERVICE

C Charging Battery C Maintenance of battery How the battery is handled greatly affects the life of the battery. To avoid personal injury or death: When the batteries are mishandled and not properly A The charging generates gas, creating the cared for, the life will be considerably shortened. danger of ignition or explosion. Be sure to keep Handle the battery correctly so as to obtain the most from all fire away and allow no sparks in the area. the battery. Remove all stoppers from all the cells. 1. The battery of the engine is absolutely necessary for starting the engine, the electric source for the lights, etc. A Avoid rapid charging as much as possible. This may 2. When the battery becomes discharged, it would shorten the battery's service life. become difficult to start the engine and the lights would A When disconnecting cables from the battery, become dim. disconnect the negative (-) terminal first; when The battery should be charged before it becomes connecting, connect the positive (+) terminal first. If completely discharged. done in the opposite order, a short will occur when the 3. In a battery, water in the electrolyte will evaporate terminal is touched by the disconnecting/connecting during the charging procedure. When there is tool. shortage of electrolyte, the battery would be damaged. A When charging the battery, connect the (+) of the If the electrolyte is excessive, it will spill and damage battery to the (+) of the charger, and the (-) of the the machine. battery to the (-) of the charger. And charge in the 4. Check to see if the battery plate separators are above ordinary way (long time charging). Slow charge is the electrolyte. If electrolyte is insufficient, add distilled best. water. A Rapid charging method is the way of recharging the 5. When the engine is to be stored for a long period of battery in a very short time with a large current. This time, remove the battery from the machine, charge method should be used only in emergencies. fully, adjust the electrolyte to the correct level, and A Disconnect the battery cable before handling the keep stored in a cool, dry place. battery except when checking the liquid level and 6. Even during storage the battery will discharge, charge specific gravity. the battery once a month. A Clean the battery case with a solution of baking soda and water and waste rags. Discard rags after use.

A When replenishing dilute sulfuric acid solution, do not use a metal funnel. Handle sulfuric acid with extreme caution and do not get any on your skin or clothing. PERIODIC SERVICE 51

C Charging a battery still mounted beside the engine EVERY 200 HOURS SERVICE (only in emergency conditions) Normally, remove the battery from the machine. When performing inspection and servicing for every 200 1. Before charging, disconnect the cable from the hours of operation, perform inspection and servicing for negative terminal of the battery. Otherwise the alternator may be applied with every 50 hours at the same time. abnormal voltage and be damaged. 2. When charging, remove all vent caps. BChecking and Adjusting Fan Belt Tension 3. If the battery becomes overheated [The liquid temperature exceeding 45 (113 F)], temporarily stop charging. 4. When the charge is completed, stop operation To avoid personal injury or death: A immediately. Do not place head, body, limbs, feet, fingers or If charging is performed too long, the following hands near a rotating fan or belts. problems may develop. A Overheating of the battery. 1. Press the fan belt in the middle with a fingertip by a A Reduction in the battery liquid level. force of about 10 kg (22.0 lbs.). The belt tension is A Damage to the battery. proper if the belt deflects about 7 mm (0.3 in.). If the 5. When connecting the battery, be careful of its polarity. tension is improper, adjust the tension by loosening Otherwise the alternator and other parts may be bolts and shifting alternator in the direction of the damaged. arrow. 6. It should be added here that if the engine is started in 2. Check the pulleys and the V-belts for damage and this way, after work is finished and as soon as possible wear. the battery should be correctly and fully charged using Carefully check to see if the V-belts fit snugly into the a slow charging method. V-belt grooves. 3. If the V-belt has been stretched too much, nicked or cracked, replace it.

(1) Fan belt (2) Bolt 52 PERIODIC SERVICE

(1) Fan belt (1) Radiator hoses (2) Bolts (2) Clamps

A If the engine is running with a loose fan belt, the belt BCleaning and Checking Air Cleaner may slip, causing engine overheat or insufficient Element battery recharging. Always keep the fan belt properly tightened. Open the engine cover and remove the dust-cover. A If the fan belt should break, the battery charge lamp Remove the wing nut and take out only outer element, lights up. clean the element, case interior and reassemble. During Immediately stop the engine. reassembly, take care to install the dust cup so that its TOP mark (arrow) faces upwards. Do not remove the BChecking Radiator Hoses (water pipes) inner element. Check to see if radiator hoses are properly fixed every 200 hours of operation or six months, whichever comes first. A Should the machine be used in extreme dusty areas, 1. If clamp bands are loose or water leaks, tighten bands the air filter element must be inspected and cleaned securely. more frequently than in the specified maintenance 2. Replace hoses and tighten clamp bands securely, if periods. radiator hoses are swollen, hardened or cracked. A The air filter has a dry element, keep free from oil. A Do not run the engine without the air filter.

(1) Radiator hoses (2) Clamps (1) Outer element (2) Inner element (3) Case (4) Dust cover PERIODIC SERVICE 53

EVERY 250 HOURS SERVICE BAir Filter Maintenance When performing inspection and servicing for every 250 hours of operation, perform inspection and servicing for To avoid personal injury: every 50 hours at the same time. A Wear eye protection. BChanging Engine Oil (change it after first 50 hours of operation.)

To avoid personal injury or death: A Always stop the engine before changing the engine oil. A Never open the drain plug immediately after the engine has stopped, or hot engine oil may rush out, causing scalding.

1. Remove the drain plug on the bottom of the engine, and drain all the old oil. [The hexagon bolt: 22 mm] 2. Then retighten the plug completely. The quickest and safest method of maintenance is the exchange of the paper cartridge. Furthermore there are different methods of cleaning the cartridge.

C Cleaning with compressed air Pressure of compressed air must be under 205kPa (2.1kgf/ ,30psi), and the cartridge should be blown clean from the inside to the outside until the dust deposits are remarkably reduced.

(1) Drain plug

3. Apply engine oil from the oil port to the correct level. 4. Idle the engine. About 5 minutes after stopping the engine, check with the oil level gauge to make sure the proper amount of engine oil has been supplied.

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

BChecking Fuel Line and Intake Air 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. 54 PERIODIC SERVICE

EVERY 500 HOURS SERVICE

When performing inspection and servicing for every 500 hours of operation, perform inspection and servicing for every 50 and 250 hours at the same time.

BReplacing Engine Oil Filter Cartridge (change it after first 50 hours of operation.)

To avoid personal injury or death: A Always stop the engine before replacing the oil (1) Oil port (A) Proper oil level filter. (2) Oil dipstick A Never remove the oil filter immediately after the engine has stopped, or hot engine oil may rush out, causing scalding.

1. Replace the engine oil filter cartridge at the same time engine oil is changed. MODEL PART No. R420S 16414-3243-1 R520S 15831-3243-0

2. Use the supplied filter wrench to remove the engine oil filter cartridge.

(1) Oil port (A) Proper oil level (2) Oil dipstick

A Use engine oil of appropriate viscosity according to ambient temperature. A Drain the engine oil once every 6 months regardless of the running time on the machine.

(1) Oil filter cartridge

3. Apply a thin layer of oil over the O-ring of the new filter cartridge and firmly tighten it in place by hand. 4. Add the engine oil to the specified level. 5. Run the engine for about 5 minutes and stop the engine after confirming that the oil level indicator lights normally. 6. Check the oil level again. If the oil level is low, add an additional amount of oil. PERIODIC SERVICE 55

BChecking and Replenishing Oil in the BReplacing LST Oil Filter Cartridge Front / Rear Axle Differential Cases

To avoid personal injury or death: To avoid personal injury or death: A Never remove the filter immediately after the A Before changing oil in the front and rear axle engine has stopped, or hot hydraulic oil may differential case, always stop the engine, lock rush out, causing scalding. the shuttle change lever in neutral, and set the parking brake switch to the parking position. 1. Loosen the nut located on the bottom of the filter and A Always remove the bucket and attachment, and remove the filter. use the lift arm support device when servicing [The hexagon nut: 27 mm] the machine with the loader lift arms raised to 2. Change to an new filter cartridge and reinstall the filter. avoid serious personal injury. Tightening Torque : 73.6 to 83.4 N-m (54.5 to 61.5 ft-lb) 1. Remove the plug for checking oil level and refilling oil and check that the oil level is equal to the lower rim of the plug hole. [The plug is a hex bolt whose across- the-flats is 27 mm ]. 2. Add oil if necessary. 3. After inspection or replenishment, be sure to retighten the plug completely.

(1) LST oil filter Part No. of filter element R1411-64930

A After changing the filter cartridge, be sure to check the oil level. (1) Oil feed plug

(1) Oil feed plug 56 PERIODIC SERVICE

BReplacing Return Filter BChanging the Fuel Filter

To avoid personal injury or death: To avoid personal injury: A Never remove the filter immediately after the A Keep fire away. engine has stopped, or hot hydraulic oil may rush out, causing scalding. 1. Close the cock of the fuel filter. Remove the filter with the supplied filter wrench. 1. Loosen the filter with a filter wrench and remove the 2. Apply a light film of fuel to the seal of the new filter and filter. turn in tightly by hand. 2. When installing the new filter, apply a light coat of 3. Open the cock of the fuel filter again. hydraulic oil to the gasket. 3. Tighten the filter about 2/3 turn by hand after its sealing face touches the gasket.

(1) Cock of the fuel filter (A) "Close" (2) Retainer ring (3) Fuel filter (1) Return filter A After exchange of the filter, the fuel system must Part No. of filter R1411-63860 purged of air.

A After changing the filter, be sure to check the oil level. A Do not use a wrench to tighten the new filter since it can distort the filter. Be sure to tighten it by hand. PERIODIC SERVICE 57

EVERY 1000 HOURS SERVICE 2. After draining, be sure to tighten the plug completely. 3. Supply oil up to the oil port level through the oil port. When performing inspection and servicing for every 1000 hours of operation, perform inspection and servicing for Oil capacity every 50, 200, 250 and 500 hours at the same time. Front, Rear 3.0L (0.8U.S.gal.)

BChanging Oil for the Front and Rear Axle BChanging Oil in Hydraulic Oil Tank and the Differential Cases (Change oil the first Suction Filter (after 1st 500 hrs. use) time after 1st 500 hrs. use.)

To avoid personal injury or death: To avoid personal injury or death: A Always stop the engine before changing oil. A Before changing oil in the front and rear axle A Never open the drain plug immediately after the differential case, always stop the engine, lock engine has stopped, hot hydraulic oil may rush the shuttle change lever in neutral, and set the out, causing scalding. parking brake switch to the parking position. A Always remove the bucket and attachment, and 1. Drain the oil by removing the drain plug from the use the lift arm support device when servicing bottom of the tank. Then retighten the plug completely. the machine with the loader lift arms raised to [The hexagon plug:22 mm] avoid serious personal injury. 2. Remove the bolt from the tank bottom cover. Then remove the cover. 1. Remove the drain plug to discharge the oil. 3. Replace the suction filter. [The drain plug has a hex hole : 10 mm] [The hexagon nut:50mm].

(1) Drain plug (1) Suction filter (2) Drain plug Part No. of suction filter 68773-6221-0

4. After replacing the filter, check the gasket for scratches or damage, and replace gasket if necessary. 5. Remove the oil port cap, refill the hydraulic fluid to the specified quantity and replace the cap.

(1) Drain plug 58 PERIODIC SERVICE

6. Make sure that the oil port cap is securely fitted. Run the engine at low speed, set the shuttle change lever to the neutral position and repeatedly press the parking brake switch (ON to OFF and OFF to ON) for two minutes. Then operate the bucket lever and the steering wheel for about five minutes. Stop the engine and make sure that the oil quantity is sufficient through the oil level gauge.

(1) Outer element (3) Case (2) Inner element (4) Dust cover 5 inch R1411-4228-0 Part No. of inner element 6 inch R2401-4228-0 5 inch R1411-4227-0 Part No. of outer element 6 inch R1401-4227-0

(1) Oil port (2) Oil level gauge A Shorten the cleaning period if using in a place exposed to lots of dust or sandy areas. Specified oil quantity 42L (11.1 U.S.gals.) EVERY 1500 HOURS SERVICE

A If there are deposits in the tank, wipe them all with a BChecking Fuel Injection Nozzle (Injection clean rag and light oil. Pressure) A Use great caution not to admit any foreign particles Consult your local KUBOTA Dealer for this service. into the tank.

BReplacing Air Cleaner Element EVERY 2000 HOURS SERVICE When performing inspection and servicing for every 2000 Open the engine cover and remove the dust-cover. hours of operation, perform inspection and servicing for Remove the wing nut and take out outer element. every 50, 200, 250, 500 and 1000 hours at the same time. Remove the wing nut and take out inner element. Replace inner and outer element. When install the dust cup so that its TOP mark (arrow) B faces up-wards. Checking Alternator Starter Motor After every 2000 hours of use, check and maintain the alternator. It is just about the time the brushes would become worn, ask the KUBOTA dealer for repairs. The motor has been made drip-proof so moisture will not penetrate into the motor. It would be best to ask the dealer to make repairs. If the headlights are often used for work in the evening, inspect the alternator and starter motor every 1000 hours. PERIODIC SERVICE 59

EVERY 3000 HOURS SERVICE BReplacing Radiator Hoses (water pipes) BChecking Injection Pump Replace hoses and clamp bands every 2 years or earlier Consult your local KUBOTA Dealer for this service. if checked and found that hoses are swollen, hardened or cracked. EVERY TWO YEARS SERVICE

When performing inspection and servicing for every two service years of operation, perform inspection for every 200 hours at the same time.

BChecking and Replacing Fuel Pipe and Rubber Hoses

To avoid personal injury or death: A A broken fuel line will cause fuel to leak. Be sure to check the line. Fire or injuries may result if a fuel line is leaking. (1) Radiator hoses A Make sure the engine is cool before (2) Clamps disconnecting fuel lines.

Inspection and replacement of lines. Rubber parts like the fuel lines are likely to age even if the engine is not used regularly. Therefore, it is necessary to replace these parts with new ones once every two years or sooner if they are damaged. 1. Occasionally check that the lines and clamps are not loose or damaged. 2. When the fuel line has been replaced, be sure to bleed air from the line.

A When replacing the fuel pipe, take special care to prevent dirt and other foreign matters from entering the pipe or the injection pump. Entry of foreign matter (1) Radiator hoses in these parts will likely cause the injection pump to (2) Clamps malfunction. BReplacing Fuel hoses Replace the hoses and clamps. (See "Checking Fuel and Intake Air Line" every 200 hours maintenance.)

BReplacing Intake Air Line Replace the hoses and clamps, if necessary. (See "Checking Fuel and Intake Air Line" every 200 hours maintenance.) 60 PERIODIC SERVICE

BChanging Coolant BPeriodic Parts Replacement To ensure safety at all times, it is important to inspect and maintain the engine on a regular basis. For further safety, To avoid personal injury or death: it is strongly recommended to periodically replace the A Never open the plug immediately after the following parts which are most essential to safe operation. engine has stopped, or hot coolant may rush These parts tend to wear out or deteriorate with time and out, causing scalding. it is often difficult to determine their condition by periodic inspection. Therefore, even if no defect is found, they 1. Open the plug under the radiator to drain the coolant. should be replaced at certain intervals to maintain their safe operation. If any defect is found before the specified time, immediately replace or repair the part. Please understand that such periodic replacement is not covered by the maker's warranty. Replacement Periodic parts of replacement intervals 1 Brake rubber hose every year Rubber parts (piston packing 2 every two years of brake master cylinder etc.) Brake fluid (Hydraulic oil ISO 3 every two years VG 32) 4 Fuel lines every two years (1) Plug Oil pressure hose for steering 5 every two years 2. To drain the reserve tank, disconnect the pipe at the cylinder bottom of the reserve tank. Packing of steering cylinder, 6 every four years 3. Clean the radiator interior by pouring water at the seal O ring supply port and keeping the plug open until clean water flows out of it. 4. Close the plug and fill the radiator and reserve tank with coolant. After filling, idle the engine for about five minutes, stop the engine and make sure that the coolant level is above the radiator core tubes.

(1) Radiator cap PERIODIC SERVICE 61

SERVICE AS REQUIRED BChecking the Electrical System, Handling Fuses

The damage of electrical wiring and looseness of the coupler cause the electrical components to malfunction and also lead a short circuit, leakage and burn- out.Replace and repair as quickly as possible.

C Replacing the fuses

To avoid personal injury: A Before replacing a fuse, be sure to turn off the Capacity Applied circuit starter switch. 1 10A Working Lamp 1. Open the engine cover. 2 10A Head Lamp 2. Remove the cover of the fuse box. 3 5A Tail Lamp 3. Replace the blown fuse using a new one of the same capacity. 4 20A Auxiliary 5 10A Work Light (Cab) C Fuse capacities and their circuits 6 20A Wiper / Washer 7 5A Room Light 8 10A Hazard 9 10A Spare 10 10A Parking / F-R 11 10A Indicator / Panel 12 5A Alternator/ Flasher / Low 13 10A Stop Lamp / Work Light (BH) 14 5A Fuel Pump 15 5A Horn 16 20A (1) Fuse box 17 10 18 5A

Spare fuses are provided on the new machine. (1-piece for each capacity (20A 10A 5A)) 62 PERIODIC SERVICE

BBleeding the Fuel System

To avoid personal injury or death: A Keep sparks and flames away from the fuel, or personal injury may result.

After the engine has been run until no fuel is left in the fuel tank, the engine cannot be started again after refueling. This is because air has entered the fuel pump, making fuel injection impossible. It is thus necessary to bleed the fuel system in the following manner (do the same after replacing the fuel filter): (1) Fusible link 1. Fill the fuel tank with fuel. 2. Turn the starter switch one notch clockwise. Thus the fuel pump starts working to supply fuel into A Fusible link also protects the electrical circuit. If the the line. fuse or fusible link has blown, determine why it blew 3. About 10 seconds later, the air will be bled out from the and make any necessary repairs. line. Then the engine is ready for starting. In replacing, never use any substitutes for it but a new one of the same capacity. Part No. of fusible link RC411-53980 50A A The engine may sometimes stall after starting if air bleeding was not complete. If this should occur, repeat steps 2 and 3.

BBleeding Air from the Brake Fluid System

To avoid personal injury or death: A For above procedure, stop the engine, set the parking brake switch to the parking position, lower the bucket and attachment to the ground, release the hydraulic pressure in the hydraulic system by operating control levers, lock all control levers in neutral, and remove the key. A Only use hydraulic oil that meets ISO VG 32. Use of incorrect oil will cause damage of brake parts and potential brake failure.

Bleed the air from the brake circuit after disassembling and repairing the brake or when the brake fluid falls too low, allowing air inside the brake system. (This operation requires two workers.) 1. Fill the brake fluid reservoir with only hydraulic oil ISO VG32. Make sure that the brake fluid reservoir is always half full or more during air-bleeding. 2. Remove the cap from the air-bleeding plug located on the speed reducer brake housing, connect a vinyl tube about one meter long to the plug, and place the other end of the tube in an oil catcher. 3. Loosen the plug with a wrench and press the brake pedal gradually to bleed the air. Repeat this procedure until bubbles no longer emerge from the tube, then slowly release the brake pedal. PERIODIC SERVICE 63

4. If air is not fully bled by one operation, repeat step 3. TIRES 5. After the bubbles are completely removed, retighten the plug and replace the cap. BHandling Tires 6. Refill the brake fluid reservoir with the ISO VG32 hydraulic oil to the specified level. The brake fluid properties are different from manufacturer to manufacturer. Use the same brand of To avoid personal injury or death: hydraulic oil. A Before handling tires, stop the engine, set the parking brake switch to the parking position, lower the bucket and attachment to the ground, release the hydraulic pressure in the hydraulic system by operating control levers. Lock all control levers in neutral, and remove the key. A When raising the tire, block up the chassis for safety. A Before adding air, have the tire correctly installed on the machine or put the tire in a retaining device (tire inflation cage). Explosive separation of the tire can cause serious injury.

(1) Brake fluid reservoir

(1) Air bleeder plug 64 PERIODIC SERVICE

BConservation of Tires BChanging Tires If the air pressure in the tire is too high or too low, the life of the tire will be shortened. Make routine checks of the air pressure in tires, and adjust so the pressure is correct. Always measure the tire pressure, and check for damage to the tires or rims before starting operation.

C Tire pressure

C Removal 1. Loosen the hub bolts each by one turn on the wheel to be removed. 2. Raise the wheel off the ground, then loosen and remove the hub bolts and change the tire to a new one.

C Fitting (1) Deficient 1. Mount wheel to axle and lightly tighten the hub bolts. (2) Correct 2. Lower the wheel to the ground, and tighten the hub (3) Excessive bolts to the recommended torque in the order shown (4) Ground level above. Type R420S R520S Tightening torque 275 to 314N-m (203 to 231ft-lb) Tire 12.5/70-16-8PR 15.5/60-18-8PR size BMounting the Tires Front 0.26 0.01MPa 0.22 0.01MPa Lug tires are used to provide strong traction and buoyancy tire (36.9 1.4psi) (31.2 1.4psi) on soft ground. When mounting them, take care to Rear 0.26 0.01MPa 0.22 0.01MPa position their tread pattern in the proper direction. tire (36.9 1.4psi) (31.2 1.4psi)

Make sure the tire size marked on the R420 tire. Then follow above chart.

1. Insufficient tire pressure Too small an amount of air in the tire can cause it to have excessive slack, which makes for faster wearing down of the tread. 2. Correct tire pressure 3. Excessively high tire pressure Too high a tire pressure causes the tractive force of the machine to decrease, or the tire to slip. There is also the risk of a blow out. (1) Correct (2) Incorrect (3) Forward STORAGE 65 STORAGE

CAUTION WHEN WASHING THE MACHINE

To avoid personal injury or death: Wash the machine after stopping the engine. If you wash A While storing, do the following. the machine while running the engine, splashing water will Stop the engine, set the parking brake switch to get into the air cleaner through its intake and cause the parking position, lower the bucket and engine trouble. Carefully, wash and do not splash water attachment to the ground, release the hydraulic over the air cleaner. pressure in the hydraulic system by operating control levers, lock all control levers in neutral, and remove the key.

C Before storing the machine for long periods of time, do the following: 1. Wash and clean each part of the machine, and store the machine indoors: never leave it outdoors. If it must be stored outdoors, choose a flat place, lay planks, park the machine, and cover it completely. 2. Add oil and grease, and change oil. 3. Apply grease sufficiently to the piston rods of the oil pressure cylinders where they are exposed. 4. Remove and store the battery separately. 5. If there is possibility that temperature may drop below 0 (32 F) during storage, add anti-freeze to the cooling water. See "Mixing ratio between water and anti-freeze" in the HANDLING LOADER IN COLD- WEATHER section. 6. Run the engine, drive the machine for a short distance, and operate the lift arm and bucket. 7. At the same time, recharge battery.

C When using equipment that has not been used for a long time, follow the procedure below. 1. Remove the grease applied to the hydraulic cylinder rod. 2. Run the engine with no load until the attachment drive system and the travel system have been thoroughly lubricated. 66 TROUBLESHOOTING TROUBLESHOOTING

ENGINE TROUBLES AND REPAIRS

Trouble Cause Countermeasure * Check fuel tank and filter Fuel is too viscous * Remove impurities and water * If necessary, replace filter * Remove water from the fuel tank. * Check fuel pipe joint bolts and nuts for looseness Air or water in the fuel system. * Purging of the fuel system (for fuel filter and injection pump Starting difficulties see "PURGING OF THE FUEL SYSTEM" in the chapter "OTHER ADJUSTMENTS AND REPLACEMENTS".) *Pour hot water over the radiator Oil viscosity is too high that the *Use oils of different viscosities depending on the ambient engine runs sluggishly in winter temperature. (Use SAE10W, SAE10W-30 or SAE10W-40) Battery is almost dead; insufficient * Recharge battery compression

Insufficient Low fuel level * Check fuel and add if necessary engine power Clogged air cleaner * Clean the air filter element Engine suddenly * Check fuel and add if necessary Low fuel level stops * Purge the fuel system

Abnormal exhaust Poor fuel * Use high quality fuel gas colour Too much engine oil * Drain engine oil to prescribed oil level 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 * Replace coolant fluid and add anti-rust from the cylinder head or crank case Water temperature in red zone Defective radiator cap (Evaporation) * Replace (Overheating) Corroded coolant pipes * Clean Continuous operation under full load * Reduce load Cylinder head gasket is damaged * Replace (Coolant loss) Engine oil level too low * Fill to prescribed level Maladjustment of fuel injection * Readjust ignition timing Use of poor fuel * Use prescribed fuel

If there is any question, contact your KUBOTA dealer TROUBLESHOOTING 67

TROUBLES IN TRAVELING SYSTEM

Trouble Cause Countermeasure Malfunction in LST control valve. Defect electrical switch for shuttle Wheel loader does not change lever. Contact KUBOTA dealer. travel properly. Malfunction in LST pump servo- It does not start cylinder. when speed change Add hydraulic oil to specified level, while checking lever is operated. Short of hydraulic oil. the oil gauge. Not pressing accelerator pedal. Press accelerator pedal. Loose bolt on universal joint or flange. Retighten. Improper meshing of differential gears. Readjust tooth bearing and backlash. Worm damaged differential gear tooth Noise during traveling. Disassemble, check and replace if necessary. surface. Cavitation inside the pump. (at cold Drive after warm-Up the machine. temperature) Air in brake system. Bleed. Oil leaks from master cylinder piston Inefficient travel brake. cup. Contact KUBOTA dealer. Damaged brake seal. Brake pedal does not Damaged in brake pedal return spring. Disassemble, check and replace if necessary. return properly after being pressed. Master cylinder oil port is clogged. Contact KUBOTA dealer. Unresponsive brake Leaking brake fluid. Check and change fluid. Then bleed. pedal. Parking brake Brake disc worn down. Check and replace if necessary. insufficient. oil leak inside steering control valve. Contact KUBOTA dealer.

Steering wheel is heavy Misaligned steering shaft. to turn. Too much play in steering shaft spline. Check and replace if necessary. Too much play in steering cylinder pin.

If there is any question, contact your KUBOTA dealer 68 TROUBLESHOOTING

HYDRAULIC SYSTEM TROUBLES AND REPAIRS

Trouble Cause Countermeasure Pump coupling damaged. Check and replace, if necessary. Hydraulic oil low. Add oil. Bucket-lift malfunctioning Air enters oil pressure system through inlet pipe Check inlet pipe, and tighten joint bolt joint. where air enters, or replace joint. Efficiency decreased because of worn oil pressure Check, and replace pump, if necessary. pump. Preset pressure of relief valve lowered, or valve Check, adjust or replace valve. open. Bucket-lift and tilt lacks Add or replace oil. Be sure to use Hydraulic oil low or oil viscosity is improper. drive power and/or speed. recommended oil. Check inlet pipe, and tighten joint bolt Air enters inlet pipe joint. where air enters, or replace joint. Oil leaks because of worn or damaged control valve Check, and replace assembly in trouble. spool. Internal oil leakage because of worn or damaged Check piston packing, and replace if piston packing. necessary. Bucket-lift and tilt lacks power or does not maintain Oil leakage because of worn or damaged control Check spool, and replace if necessary. strong holding power. valve spool. Present pressure of port relief valve dropped. Check, valve and adjust or replace. Oil leakage through rubber hose or piping joint. Replace hose or joint. Corresponding section in control valve not Check steering system, and repair. Only one hydraulic action is functioning because foreign matter caught. Check control valve, and repair. unobtainable. Disassemble and check valve and Control valve spool broken. replace corresponding part if necessary. Hose, piping or joint broken. Replace. Operation of control lever causes wrong function to Piping or rubber hose connected improperly. Connect properly. be effected. Hydraulic oil low. Add oil to correct. Air enters inlet piping or joint. Check piping or joint, and repair.

Abnormal noise is heard Pipe, hose or joint deformed. Repair or replace. Disassemble and check gear, and repair Cavitation inside the pump (at cold temperature) or replace. Drive after warm-up the machine. Oil viscosity too high. Use correct oil. Relief valve pressure miss-adjusted. Adjust it correctly. Engine overloaded continuously. Stop operation. Hydraulic oil temperature increases. Check and clean pump or valve, and Pump or valve clearance too narrow. change oil. Control lever not returned to hold position when Return lever to hold position. piston reaches end.

If there is any question, contact your KUBOTA dealer

UNIVERSAL SYMBOLS

As a guide to the operation of your machine, various universal symbols have been utilized on the instruments and controls. The symbols are shown below with an indication of their meaning.

3 Safety Alert Symbol Boom Down p Parking Brake Boom Up

0 Hazard Warning Lights Left Swing

7 Working Light Right Swing

E Hydraulic Oil Dipperstick Up

Lock Dipperstick Crowd

, Unlock Bucket Crowd

Bucket Dump

Left Outrigger Down

Left Outrigger Up

Right Outrigger Down

Right Outrigger Up

Slide Lock Lever Lock

Slide Lock Lever Unlock FOREWORD

You are now the proud owner of a KUBOTA Backhoe for Wheel Loader. This backhoe is a product of KUBOTA quality engineering and manufacturing. It is made of the fine materials and under rigid quality control systems. It will give you long, satisfactory service. To obtain the best use of your backhoe, please read this manual carefully. It will help you become familiar with the operation of the backhoe and contains many helpful hints about backhoe maintenance. 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 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.

3 DANGER : 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.

3 CAUTION: 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 SPECIFICATIONS...... 1 SPECIFICATION TABLE ...... 1 PARTS NAMES...... 2 OPERATING THE BACKHOE...... 3 STARTING...... 3 Operator's Seat...... 3 SAFETY LEVERS AND APPLIANCE ...... 4 Backhoe Lock Lever ...... 4 Slide Lock Lever ...... 4 CONTROL LEVERS AND SWITCH...... 4 Backhoe Levers...... 4 Outrigger Levers...... 5 Backhoe Hand Throttle...... 5 Working Light Switch ...... 6 BACKHOE OPERATION ...... 6 Sliding the Backhoe...... 7 Backhoe operation...... 8 ATTACHING AND DETACHING THE BACKHOE...... 9 Detaching the Backhoe...... 10 Attaching the Backhoe...... 11 TRAVELING...... 13 TRANSPORT BY TRUCK ...... 14 MAINTENANCE...... 15 PERIODIC SERVICE...... 16 DAILY CHECK ...... 16 Grease Fittings ...... 16 LIFTING CAPACITY...... 17

SAFE OPERATION 1 SAFE OPERATION

This section contains an explanation of how to operate the backhoe safely. Be sure to read the manual for this machine (wheel loader) before reading the manual for the backhoe. Read and understand this section carefully before operating the backhoe on the wheel loader. All operators, no matter how much experience they may have had, should read this and other related manuals before operating the machine or any attachment. It is the owner's obligation to instruct all operators in safe operation.

1. BEFORE OPERATING THE BACKHOE 3. The machine's balance changes greatly when the backhoe is slid. This means that sliding the backhoe on a slope or on irregular terrain increases the chance 1. Know your equipment and its limitations. Read this that the machine will tip over. Be sure to slide the entire manual before attempting to start and operate backhoe on flat and firm ground to facilitate work and the backhoe. to prevent it from tipping over. 2. Pay special attention to the danger, warning and 4. When working with a backhoe, lower the outriggers caution labels on the backhoe. and the loader bucket to stabilize the machine. Lock the shuttle change lever in neutral, set the parking 2. OPERATING THE BACKHOE brake switch to the parking position and lock the loader bucket lever with the loader bucket lever lock on the 1. Before operating the backhoe, be sure to adjust the ground. seat to the backhoe operating position. Any other Working with a backhoe without lowering the method could result in serious injury. outriggers will cause the machine to incline or move For your safety, ROPS/FOPS (Roll-Over Protective back and forth. This is extremely dangerous. Structures, Falling Objects Protective Structures.) with 5. Before moving the machine, always be in the seat a seat belt is installed by KUBOTA. Always use seat (seat in loader position). Raise the loader bucket and belt when the machine is equipped with a ROPS/ outriggers sufficiently to clear the ground, and then FOPS. drive the machine forward. After the machine has been positioned, do the same things in item 4. 6. Do not dig around the outriggers or tires. If the ground collapses, the machine may fall into the area excavated and result in serious personal injury or death.

2. Before starting work, look around the machine to check that there are no bystanders or obstacles near by. 2 SAFE OPERATION

3. TRAVELING

1. Before traveling on the public road, ovserve all local and state traffic regulations. Use SMV emblem and warning flashers as required. (SMV:Slow Moving Vehicle)

(1) Backhoe locking hook (A) "LONG SIDE" (B) "SHORT SIDE"

3. When turning corners, slow the machine, and be careful not to allow the front end of the backhoe to hit anything.

(1) SMV emblem 4. AFTER OPERATION

2. When traveling the machine with backhoe on public 1. When leaving the machine, road, raise the outriggers, put the backhoe at the right A Stop the engine. side, and retract the bucket and fixed dipperstick fully A Set the shuttle change lever to the neutral position as shown in the drawing. Secure with the backhoe and set the parking brake switch to the parking locking hook and lock all control levers. position. A Lower the loader bucket, attachment, backhoe bucket and outriggers to the ground. A Release the hydraulic pressure in the hydraulic system by operating control levers. A Lock all control levers in neutral. A Remove the key.

5. ATTACH AND DETACH A BACKHOE

1. The machine must be moved back and forth to attach or detach the backhoe. To ensure safety, the operator should be helped by an assistant and they should work closely with each other. 2. When the backhoe is removed, the machine's balance is changed. Mount counterweights in place of the backhoe to ensure the stability of the machine and to avoid the danger of tipping over while shoveling. SAFE OPERATION 3

6. SAFE LOADING AND TRANSPORT 7. SERVICING THE MACHINE

1. Before loading the machine on a truck or trailer, make 1. If servicing or checking underneath, support it firmly sure the backhoe is securely looked by backhoe with strong blocks etc. Never get under the machine locking hook and outriggers are fully raised. while it is being lifted with only the loader bucket, backhoe or outriggers. If you do not follow this, serious injury or death can result.

Avoid the "bridge posture"

(1) Backhoe locking hook (A) "LONG SIDE" (B) "SHORT SIDE" 4 SAFE OPERATION

8. DANGER, WARNING AND CAUTION LABELS

(1) Part No. R2401-5767-1 (3) Part No. 2401-5766-1

(2) Part No. R2401-5765-1 (4) Part No. R2401-5777-1 SAFE OPERATION 5

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.

SPECIFICATIONS 1 SPECIFICATIONS

SPECIFICATION TABLE

Model name R420S R520S Type Canopy CAB Canopy CAB Operating weight kg(lbs.) 3410(7520) 3660(8070) 3750(8270) 4000(8820) (with ROPS/FOPS Canopy, CAB) Tipping Load (Full Turn) kN(lbf) 20.6(4630) 22.8(5130) 22.1(4960) 24.1(5420) Operating load kN(lbf) 10.3(2315) 11.0(2480) Overall length mm(in.) 4695(184.8) 5135(202.2) Max. digging depth mm(in.) 2750(108.3) 2750(108.3) Max. digging height mm(in.) 3220(126.8) 3220(126.8) Max. dumping height mm(in.) 2040(80.3) 2040(80.3) Max. digging radius mm(in.) 3700(145.7) 3700(145.7) Swing angle Deg 180 180 Backhoe Width of boom slide mm(in.) 1000(39.4) 1000(39.4) Bucket capacity (cu.ft) 0.07(2.4) 0.07(2.4) Bucket width mm(in.) 450(17.7) 450(17.7) Digging force bucket kN(lbf) 18.2(4100) 18.2(4100) Digging force dipperstick kN(lbf) 12.3(2755) 12.3(2755)

Above dimensions are based on the machine with JPN Quick Coupler, Standard Loader, ROPS/FOPS Canopy, Backhoe and Standard Backhoe Bucket. JPN = made in Japan Mean Value and value for use on concrete roads are given for tipping load and operating load. Specifications Subject to change without Notice. 2PARTS NAMES PARTS NAMES

(1) Backhoe lever (2) Outrigger lever (3) Backhoe lever (4) Slide lock lever (5) Swing cylinder (6) Locking hook (7) Outrigger (8) Slide frame (9) Slide bracket (10) Boom cylinder (11) Dipperstick cylinder (12) Fixed dipperstick (13) Bucket cylinder (14) Bucket (15) Boom (16) Swing bracket (17) Slide lock cylinder OPERATING THE BACKHOE 3 OPERATING THE BACKHOE

STARTING BOperator's Seat

To avoid personal injury or death: A Locate the seat to the backhoe operating position. Never operate the backhoe in the loader operating position. A Make sure that the seat is completely secured after each adjustment. A Do not allow any person other than the driver to ride on the machine. A Never operate the machine without ROPS/ FOPS and Seat Belt. Loader operating position When working with a backhoe, change the seat position accordingly. 1. Pull the lock knob up to release the lock. 2. Turn the seat counterclockwise by 180 . (Push and release it on the way, it will stop at the fixed position and lock by itself.) 3. When restoring the seat for traveling, cancel the lock in the same way and turn the seat clockwise.

Backhoe operating position 4 OPERATING THE BACKHOE

SAFETY LEVERS AND APPLIANCE CONTROL LEVERS AND SWITCH BBackhoe Lock Lever BBackhoe Levers

C Position of lever A To avoid personal injury or death: Dipperstick, bucket lever A When dismounting the machine, lower the (A) Dipperstick up backhoe to the ground. Lock the backhoe (B) Dipperstick crowd levers by the backhoe lever lock. (C) Bucket crowd (D) Bucket dump A Boom, swing lever (E) Boom down (F) Boom up (G) Left swing (H) Right swing

(1) Backhoe lock lever (A) PUSH "LOCK" (B) PULL "UNLOCK"

BSlide Lock Lever The slide lock is used to slide the backhoe to the right or left. Pushing the lever forward activates the hydraulic pressure (1) Boom, swing lever to lock the slide frame and the slide bracket. Pulling the (2) Dipperstick, bucket lever lever rearward releases the hydraulic lock. For correct backhoe operating procedure, refer to "Sliding the Backhoe" in this section.

(A) Dipperstick up (E) Boom down (B) Dipperstick crowd (F) Boom up (C) Bucket crowd (G) Left swing (D) Bucket dump (H) Right swing (1) Slide lock lever (A) "LOCK" (B) "UNLOCK" OPERATING THE BACKHOE 5

BOutrigger Levers BBackhoe Hand Throttle

To avoid personal injury: To avoid personal injury or death: A When working with a backhoe, lower the A When not digging always keep the Hand outrigger and the loader bucket to stabilize the throttle fully pushed position. (" " position) machine. Working with a backhoe without A Always do the following before using the lowering the outrigger will cause the machine backhoe. to incline or move back and forth. This can be (1) Set and lock the shuttle change lever in the dangerous. neutral position. To move the machine when working with a (2) Set the parking brake switch to the parking backhoe, lift the outrigger and the loader position. bucket above the ground so that they will not (3) Lay the loader bucket on the ground and lock be hit by the ground or other obstacles. its lever. (4) Locate the seat to the backhoe operating C Position of lever position. (A) Left outrigger down (B) Left outrigger up 1. Set the Hand throttle so that maximum revolutions are (C) Right outrigger down between 1500 and 2000 rpm. Do not set this over 2000 (D) Right outrigger up rpm for any reason whatsoever, or else you will shorten machine working life. 2. Always keep the Hand throttle fully pushed position after Backhoe operation.

(1) Left outrigger lever (2) Right outrigger lever

(1) Hand throttle (A) " " (B) " "

(A) Left outrigger down (B) Left outrigger up (C) Right outrigger down (D) Right outrigger up 6 OPERATING THE BACKHOE

BACKHOE OPERATION BWorking Light Switch To turn the working light on, set the starter switch to the "ON" position and push the working light switch. To avoid personal injury or death: A Operate backhoe from backhoe operator's seat position only. Any other method could result in serious injury or death. For your safety, ROPS/FOPS (Roll-Over Protective Structures, Falling Objects Protective Structures.) with a seat belt is installed by KUBOTA. Always use seat belt when the machine is equipped with a ROPS/ FOPS.

(1) Working light switch (A) "ON" (B) "OFF"

A Before starting work, look around the machine to check that there are no bystanders or obstacles. Never allow anyone to stand in the work area.

(1) Working light OPERATING THE BACKHOE 7

A When leaving the machine, (1) Stop the engine. BSliding the Backhoe (2) Set the shuttle change lever to the neutral This backhoe is provided with a digging section that can position and set the parking brake switch to slide to the right and left to allow side-digging. the parking position. 1. Place the machine on flat ground, extend the (3) Lower the loader bucket, attachment, the outriggers so that slide frame is level and the wheels backhoe bucket and outriggers to the ground. are slightly lifted off the ground. (4) Release the hydraulic pressure in the 2. Swing the boom in the direction opposite to the hydraulic system by operating control levers. direction you wish to slide until it touches the rubber (5) Lock all control levers in neutral. cushion. (6) Remove the key. 3. Set the slide lock lever in the RELEASE position to A When working with a backhoe, lower the release hydraulic lock between the slide frame and the outriggers and the loader bucket to stabilize slide bracket. the machine. Lock the shuttle change lever in 4. Lower the bucket, and move the boom, dipperstick neutral set the parking brake switch to the and bucket operating levers so that the bucket pushes parking position and lock the loader bucket the ground away. Repeat this operation to slide the lever with the loader bucket lever lock on the backhoe to the desired position. ground. Working with a backhoe without Depending on the work situation the backhoe can be lowering the outriggers will cause the machine slid in such a way that the bucket digs into the ground to incline or move back and forth. This is and pulls in the soil. extremely dangerous. A Never get under the machine while it is being lifted with only the bucket, backhoe, or outriggers when servicing or checking underneath. Support it firmly with strong blocks, etc. If you do not follow this, serious injury or death can result.

A Before moving the machine, always be in the seat (seat in loader position). Raise the loader bucket and stabilizers sufficiently to clear the ground, and then drive the machine forward. After the machine has been position, lower the outriggers and the loader bucket, lock the shuttle change lever in neutral, set the parking 5. When the backhoe has been slid to the desired brake switch to the parking position and lock position, set the slide lock lever to the LOCK position. the loader bucket lever with the loader bucket Shift the bucket lever left side until relief valve works, lever lock. hold the bucket lever for a couple of seconds while relief valve is working. Repeat this action a couple of times, then hydraulic slide lock will be set. 8 OPERATING THE BACKHOE

6. Finally, move the dipperstick and bucket to make sure C Ditch digging that the hydraulic lock is activated. 1. Position the machine so that it aligns with the center line of the ditch to be digged. 2. Lower the outriggers and the loader bucket. A Always lock the slide lock lever. Otherwise, the 3. Dig the ditch by operating the backhoe levers. backhoe will be unstable during work resulting in 4. Move the machine step by step taking into possible damage. consideration the bucket's dumping reach and proceed in digging.

BBackhoe operation

C Standard Digging Posture 1. Lower the outriggers and loader bucket to stable the machine.

To avoid personal injury or death: A Do not dig around the outriggers or tires. If the ground collapses, the machine may fall into the 2. Lock the shuttle change lever in neutral set the parking area excavated and result in serious personal brake switch to the parking position and lock the loader injury or death. bucket lever with the loader bucket lever lock on the ground. 3. Slide the backhoe so that it aligns with the center line of the machine, then firmly secure it using the slide lock lever. 4. Operate the outrigger levers so that the outriggers support some of the machine weight. 5. Run the engine at the proper speed that matches the work, and start digging.

A Never use the bucket in such a way that its side strikes an object by swinging the bucket boom. Also, do not use the bucket to drive pipes. Such action can damage the digging section.

A When moving the machine to proceed with digging, always lift the outriggers above the ground. OPERATING THE BACKHOE 9

C Digging on a slope ATTACHING AND DETACHING THE When digging a ditch along a slope, start digging from the top of the ditch and proceed downhill. BACKHOE When digging a ditch along a contour line, first scrape off the shoulder of the slope so as to keep the machine level. Dig only after a safe, level place is secured for the machine. To avoid personal injury or death: A When the backhoe is removed, the machine's balance is changed. Mount counterweights in place of the backhoe to ensure the stability of the machine and to avoid the danger of tipping over while shoveling. A The machine's balance changes greatly when the backhoe is slid. This means that sliding the backhoe on a slope or on irregular terrain increases the chance that the machine will tip over. Be sure to slide the backhoe on flat and firm ground to facilitate work and to prevent it from tipping over. A To prevent the machine from tipping over, position the backhoe in the center of the slide frame. A If the backhoe is detached from the machine and left unused, retract the outriggers as shown in the Fig. to ensure a safe posture and lock the backhoe operating lever. A When the backhoe is detached from the machine, immediately mount counterweights in its place. This ensures safety when shoveling.

C When digging a long ditch When digging a long continuous ditch, keep a constant depth and use the longest dumping reach so that the number of stops-and-goes is minimized as much as possible.

C When side-digging When digging a ditch along an obstacle such as a wall, move the digging section of the backhoe to that direction. 10 OPERATING THE BACKHOE

7. Extend the outriggers so that the pin on the slide frame BDetaching the Backhoe is 1 to 3 cm (0.4 to 1.2 in.) from the rear frame bracket. 1. Run the engine at low speeds. 2. Position the backhoe in the center of the slide frame. 3. Locate the machine on flat ground. 4. Extend the outriggers so that their floats approach the ground, but do not touch it. 5. Operate the dipperstick, boom and bucket so that the bucket just slightly touches the ground. Do not press the bucket against the ground, too strongly or the wheels will lift off the ground.

(1) Rear frame (A) 1 to 3 cm (2) Slide frame (0.4 to 1.2 in.)

8. Slowly move the machine forward by gradually pressing accelerator pedal so that its backhoe mounting hook is separated 1 to 10 cm (0.4 to 3.9 in.) from the backhoe.

(1) Float

6. Pull out the backhoe locking snap pins and lock pins on both sides.

(1) Rear frame (A) 1 to 10 cm (2) Slide frame (0.4 to 3.9 in.)

A Since the hydraulic oil piping is still connected, the machine should be moved very little when moving forwards so as not to pull the hose tight. (1) Lock pin (2) Snap pin 9. Slowly retract the outriggers fully to settle the backhoe.

A Temporarily store these pins by fitting them in the A Should the slide frame tilt forward or backward at this holes on the backhoe. time, operate the boom and dipperstick levers to maintain a proper, safe posture. Then retract the outriggers. OPERATING THE BACKHOE 11

10.Stop the engine and move the backhoe operating levers to relieve pressure inside the hydraulic circuit. Repeat this operation until the backhoe components A Never leave the quick coupler disconnected. no longer move. Reconnect it as quickly as possible to prevent the entry of dirt or other foreign matter. A Always stop the engine before disconnecting or A If pressure inside the hydraulic circuit remains, the reconnecting the quick coupler. quick coupler will be difficult to attach or detach. The quick coupler is provided with lock pins for safety. After connecting it, make sure that it is locked by 11.Disconnect the two hydraulic hoses connecting the turning the sleeve. machine and the backhoe.

A To disconnect the hose, push in the sleeve (1) of the quick coupler, and at the same time, pull the hydraulic hose (2) in the opposite direction.

(1) Lock pin (A) "UNLOCK" (2) Turn the sleeve (B) "LOCK"

BAttaching the Backhoe 1. Position the machine so that its center line aligns with (1) Sleeve (A) "REMOVE" the center line of the backhoe. (2) Hydraulic hose 2. Slowly move the machine by operating the inching A To connect the hose, push in the sleeve (1) of the pedal until it almost touches the backhoe. quick coupler and, at the same time, push in the hydraulic hose (2) in the same direction.

(1) Sleeve A When bringing the machine near the backhoe, run the (2) Hydraulic hose engine at low speed. 12 OPERATING THE BACKHOE

3. Stop the engine and reverse the hydraulic hose connections at the quick couplers, that is, reconnect A Make sure that the center line of the rear frame aligns the hose on the machine side to the backhoe, and with that of the slide frame bracket when viewed from reconnect the hose on the backhoe side to the above. machine.

(1) Rear frame (2) Slide frame 4. Start the engine and release the backhoe lever lock. Extend the right and left outriggers so that the pin on 5. Slowly back the machine further to fit the rear frame the slide frame is 1 to 3 cm (0.4 to 1.2 in.) above the bracket into the slide frame bracket. rear frame bracket.

(1) Rear frame (2) Slide frame (1) Rear frame (A) 1 to 3 cm (2) Slide frame (0.4 to 1.2 in.) OPERATING THE BACKHOE 13

6. Gradually retract the right and left outriggers evenly so that the two pins on the slide frame properly fit into the two rear frame bracket grooves.

(1) SMV emblem

1. Bring the slide bracket to the far right position, lock the slide bracket, fold the backhoe and retract the bucket (1) Rear frame fully. (2) Slide frame 2. When traveling in the work site, especially on roads, (3) Pin do not forget to attach the backhoe locking hook. 1) Crowd the bucket fully. 7. Insert the lock pins and secure them with the snap 2) Crowd the dipperstick fully. pins. 3) Raise the boom fully. 4) Swing the boom to left side fully. 5) Attach the backhoe locking hook. 6) Stop the engine and then operate the boom lever to relieve hydraulic pressure and secure the locking hook.

(1) Lock pin (2) Snap pin

A After attaching the backhoe, gradually increase the engine speed and make sure that the backhoe moves (1) Backhoe locking hook (A) "LONG SIDE" as intended. (B) "SHORT SIDE" TRAVELING A Do not pull the locking hook with hydraulic power. Lock the locking hook with gravity after stopping the engine.

To avoid personal injury or death: A Before traveling on the road, observe all local and state traffic regulations. Use SMV emblem and warning flashers as required. 14 TRANSPORT BY TRUCK TRANSPORT BY TRUCK

B TRANSPORTATION

To avoid personal injury or death: A Before transportation, do the following to prevent the machine from moving during transportation. (1) Make sure the backhoe locking hook is attached. (2) Check to see that the machine's center point aligns with that of the truck bed. (3) Stop the engine. (4) Set the parking brake switch to the parking position. (5) Lower the bucket and attachment to the truck bed. (6) Release the hydraulic pressure in the hydraulic system by operating control levers. (7) Lock all control levers in neutral. (8) Secure the steering frame lock and remove the key. (9) Block the machine's wheels. (10) Securely fasten the machine to the truck.

After loading the machine, lower the bucket, outriggers on the truck bed. Set the shuttle change lever to the neutral position and the parking brake switch to the parking position. Securely fasten the machine to the truck or trailer. MAINTENANCE 15 MAINTENANCE

B Checking Hydraulic Oil Level Make sure that the oil port cap is securely fitted. To avoid personal injury or death: Run the engine at low speed, set the shuttle change lever A Never get under the machine while it is being to the neutral position and repeatedly press the parking lifted with only the loader bucket, backhoe, or brake switch (ON to OFF and OFF to ON) for two minutes. outriggers. If servicing or checking Then operate the bucket lever and the steering wheel for underneath, support it firmly with strong about five minutes. blocks, etc. Stop the engine and make sure that the oil quantity is If you do not follow this, serious injury or death sufficient through the oil level gauge. can result.

(1) Oil port A Before servicing or checking the machine, do (2) Oil level gauge the following things. (1) Stop the engine. (2) Set the shuttle change lever to the neutral position and set the parking brake switch to the parking position. (3) Lower the loader bucket, attachment, backhoe bucket outriggers to the ground. (4) Release the hydraulic pressure in the hydraulic system by operating control levers. (5) Lock all control levers in neutral. (6) Remove the key. (7) Secure the front and rear frames with the steering frame lock. 16 PERIODIC SERVICE PERIODIC SERVICE

DAILY CHECK BGrease Fittings

To avoid personal injury or death. A When servicing or checking the machine, do the following things. (1) Stop the engine. (2) Set the shuttle change lever to the neutral position and set the parking brake switch to the parking position. (3) Lower the loader bucket, attachment, backhoe bucket outriggers to the ground. (4) Release the hydraulic pressure in the hydraulic system by operating control levers. (5) Lock all control levers in neutral. C Greasing the sliding section of the slide frame (6) Remove the key. Check that the guide rail is sufficiently greased. If (7) Secure the front and rear frames with the insufficient, apply extreme pressure lubricant (EP2 steering frame lock. grease). C Greasing backhoe section

(1) Swivel case (1 place) (2) Swing bracket (2 places) (3) Swing bracket (1 place) (4) Boom mounting pin (1 place) (5) Boom cylinder bottom pin (1 place) (6) Arm cylinder bottom pin (1 place) (7) Boom cylinder rod pin (1 place) (8) Dipperstick cylinder rod pin (1 place) (9) Dipperstick mounting pin (1 place) (10) Bucket cylinder bottom pin (1 place) (11) Bucket cylinder rod pin (1 place) (12) Bucket mounting pin (1 place) (13) Bucket link pin (1 place) (14) Bucket link pin (1 place) (1) Grease LIFTING CAPACITY 17 LIFTING CAPACITY

1. Lift capacity figures on this chart are 87% of the maximum lift force per SAE Definition J31 and J49 at 2700 psi (18.6 MPa) system relief pressure and does not exceed 75% of the machine tipping load. 2. Top numbers - lift capacity within 45 either side of prime mover. 3. Bottom numbers - lift capacity anywhere within full swing arc. 4. Figures stated are determined by static tests and do not include dynamic factor. Machine conditions : Standard bucket, all else according to standard specifications. B R420, R520