free service manual

1. WORKSHOP MANUAL
KUBOTA DUMPER
KC250H/HR
Code No. 97899-61750

2. GB Übersetzung
DANGER DANGER
WARNING WARNING
CAUTION CAUTION
NOTICE NOTICE
Note Note
Important Important

3. Contents
1. Introduction ......................................................... 1
1.1 Purpose of This Manual......................................................................1
1.2 Composition of This Manual ...............................................................1
1.3 Notice to the Technician .....................................................................2
2. Service Data......................................................... 3
2.1 Component Names and Functions .....................................................3
2.2 Product Specifications ........................................................................5
2.2.1 Specifications of this Product ....................................................................... 5
2.2.2 Details of Tool Bag .......................................................................................8
2.2.3 Stroke and Operating Force of Controls.......................................................8
2.2.4 Cylinder Speed ............................................................................................. 8
2.2.5 Falling Rate .................................................................................................. 8
2.3 Serial Number Position.......................................................................9
2.3.1 Product Model and Production Number .......................................................9
2.3.2 Engine Model Number..................................................................................9
2.4 Torque Settings for Fasteners ..........................................................10
2.4.1 Standard Torque Settings for Hex Head Bolts and Nuts............................ 10
2.4.2 Standard Torque Settings for Flange Bolts and Nuts .................................11
2.4.3 Standard Torque Settings for Hydraulic Hose Joints..................................11
2.4.4 Specific Fastening Requirements............................................................... 12

4. 2.5 Fuel, Lubricant, and Cooling Water Chart ........................................12
2.6 Consumables (Replacement Parts) Chart........................................13
3. Safety Covers .................................................... 14
3.1 Removing Safety Covers..................................................................14
4. Engine ................................................................ 16
4.1 Removing Engine .............................................................................16
5. Driveline and Chassis....................................... 17
5.1 Driveline Mechanism ........................................................................17
5.2 Chassis Mechanism .........................................................................18
5.3 Parts Diagrams and Summaries of Assembly and Adjustment ........18
5.3.1 Idler.............................................................................................................18
5.3.2 Roller A (mobile roller)................................................................................19
5.3.3 Roller B (fixed roller)................................................................................... 20
5.3.4 Upper roller (carrier roller) .......................................................................... 21
5.3.5 Track Tension Adjuster............................................................................... 22
5.3.6 Tips for Track Tension Adjustment.............................................................23
5.3.7 Rubber track...............................................................................................23
5.4 Maintenance Standard of the Parts ..................................................24
5.4.1 Idler.............................................................................................................24
5.4.2 Roller A (Mobile Roller)/Roller B (Fixed Roller) .......................................... 24
5.4.3 Upper Roller ...............................................................................................25
5.4.4 Sprocket ..................................................................................................... 25
5.4.5 Rubber Track..............................................................................................25

5. 6. Steering System................................................ 26
6.1 Steering System Diagram.................................................................26
6.2 Adjustment of the Steering System ..................................................27
6.2.1 Neutrality Adjustment .................................................................................27
6.2.2 6.2.2 Linearity Adjustment .......................................................................... 27
7. Vessel................................................................. 29
7.1 Tail Gate Closing Mechanism...........................................................29
8. Electrical Equipment......................................... 30
8.1 Electrical Diagram ............................................................................30
8.2 Tips for Mechanism, Functions, and Maintenance ...........................32
8.2.1 Indicator...................................................................................................... 32
8.2.2 Fuel Level Sensor....................................................................................... 33
8.2.3 Ignition switch............................................................................................. 33
8.2.4 Switch (Parking Brake, High/Low Speed, Light)......................................... 33
8.2.5 Horn Switch ................................................................................................ 34
8.2.6 Relay .......................................................................................................... 34
8.3 Tips for Operational Confirmation.....................................................36
9. Hydraulic Equipment ........................................ 37
9.1 Circuit Diagram.................................................................................37
9.1.1 One-way Dump Model................................................................................37
9.1.2 Turn & Dump Model .................................................................................. 38
9.2 Mechanism, Function, and Specification ..........................................39
9.2.1 HST Pump.................................................................................................. 39
9.2.2 HST Motor (Traveling Motor)...................................................................... 40

6. 9.2.3 Control Valve ..............................................................................................41
9.2.4 Solenoid Valve............................................................................................ 42
9.3 Tips and Maintenance Standards for HST Circuit ............................43
9.3.1 Pressure Setting Standards........................................................................ 43
9.3.2 Neutrality adjustment.................................................................................. 44
9.4 Towing ..............................................................................................46
10. Troubleshooting ............................................. 47
10.1 The Engine does not Start..............................................................47
10.2 Vehicle does not Move with Lever Engagedand Parking Brake
Unhitched. ..............................................................................................48
10.3 Lever Response is Slow. ...............................................................49
10.4 Unable to Make a Pivot Turn (Unable to Lock One Track).............49
10.5 Unable to Travel Straight. ..............................................................50
10.6 Unable to Turn to Either Side. ........................................................50

7. 1 Introduction
- 1 -
1. Introduction
1.1 Purpose of This Manual
The purpose of this manual is to provide the technician with detailed information so that they will
know the structure and proper method of servicing concerning this machine.
This manual has been prepared for people who are familiar with how to operate and control this
machine.
1.2 Composition of This Manual
This manual gives information by dividing it into the following chapters:
1. Introduction
This Chapter describes the purpose and formation of this manual and information and data
necessary for the maintenance of this vehicle.
2. Service Data
This Chapter describes the names and functions of the parts, specification, and product
number position of this vehicle.
3. Removal and Installation of Covers
This Chapter describes the formation of the safety covers installed in this vehicle.
4. Engine
This Chapter describes the information on the dismounting of the engine.
5. Driveline and Chassis
This Chapter describes the information on the structure and maintenance (disassembly,
reassembly, adjustment) of the driveline and chassis.
6. Steering System
This Chapter describes the information on the maintenance (adjustments) of the steering
system.
7. Vessel
This Chapter describes the information on the structure and maintenance (disassembly,
reassembly, adjustment) of the vessel.
8. Electrical Equipment
This Chapter describes the information on the electrical parts.
9. Hydraulic Equipment
This Chapter describes the information on the structure and maintenance (disassembly,
reassembly, adjustment) of the parts of the hydraulic devices.
10. Troubleshooting
This Chapter describes the causes of troubles and remedial measures for each trouble.

8. - 2 -
Introduction 1
1.3 Notice to the Technician
This manual explains the "structure" of this product and "procedure for assembling" it. Please
read this "service manual" carefully so that you will perform proper servicing, before carrying out
any servicing.
The technician must know that this machine can be potentially
dangerous. Always follow the instructions in this manual when
operating or inspecting the machine.
This manual has been prepared for people who are familiar
with how to operate and use this machine. Before reading this
manual, be sure to read the OPERATOR'S MANUAL
(52345101000) to familiarize yourself with how to operate and
control this machine.
It is illegal to operate this machine on public roads and roads
which are regarded as public roads. Kubota Corporation. will
not assume responsibility for any accidents and violations at-
tributable to operation of this machine on such roads.
Do not modify the machine and do not operate when safety
covers, etc. are removed. Also, do not use this machine for
purposes other than operation.

9. 2 Service Data
- 3 -
2. Service Data
2.1 Component Names and Functions
Seat
Tail gate
Idler
Upper roller
Roller bracket
Head lamp
Track Sprocket
Accelerator lever
Steering lever
Roller
Parking brake switch
High/low speed
selector switch
Lamp switch
Horn button
One-way Dump Model
Turn lever
Lock plate
Dump lever
Lock plate
Ignition switch
Turn lever Turn & Dump Model
Fuel gauge Hour meter
Charge lamp
Cooling water tem-
perature lampEngine oil lamp Parking brake lamp

10. - 4 -
Service Data 2
Accelerator lever. . . . . . . . . . . . Increases and decreases the engine revolutions.
Ignition switch . . . . . . . . . . . . . . Starts and stops the engine and used for glow. Turning the key to
the “ | ” position breaks the electrical circuit of the truck.
Parking brake switch . . . . . . . . Parks the truck. When the switch is at “P” position, the truck does
not move if you move the steering lever. The switch should be
placed at “P” position when you start the engine.
High/low speed selector switch. Switches the speed (high or low).
Light switch . . . . . . . . . . . . . . . . Turns on the head lamp.
Horn button . . . . . . . . . . . . . . . . Sounds the horn.
Dump lever . . . . . . . . . . . . . . . . Lifts or lowers the vessel.
Turn lever . . . . . . . . . . . . . . . . . Rotates the vessel (for the turn & dump model).
Lock plate . . . . . . . . . . . . . . . . . Locks the dump and turn levers.
Steering lever . . . . . . . . . . . . . . Switches the traveling direction (forward or backward) and rotates
the truck.
Fuel gauge . . . . . . . . . . . . . . . . Indicates how much the fuel is left.
Hour meter . . . . . . . . . . . . . . . . Indicates the accumulated operation hours of the machine by
0.1 hour units.
Engine oil lamp . . . . . . . . . . . . . Turns on during ignition and when engine oil pressure is too low.
Coolant temperature lamp . . . . Turns on when the engine coolant temperature is too high.
Charge lamp . . . . . . . . . . . . . . . Turns on when battery is sufficiently charged.
Parking brake lamp. . . . . . . . . . Turns on when the parking brake switch is at “P” position.

11. 2 Service Data
- 5 -
2.2 Product Specifications
2.2.1 Specifications of this Product
Machine model, type
KC250H KC250HR
One-way Dump Turn & Dump
Weight
Mass in working order kg 2,230 2,430
Max. Payload kgf 2,500
Payload
Struck payload*1 m³ 0.89 1.03
Heaped payload*1 m³ 1.26 1.40
Performance
Velocity
Low km/h 0 - 6.0
High km/h 0 - 11.0
Gradability
Empty degree 30
Loaded degree 15
Stability
Front degree 30
Rear degree 30
Left degree 25
Right degree 25
Ground
Pressure
Empty kPa (kgf/cm²) 24.7 (0.25) 26.9 (0.26)
Loaded kPa (kgf/cm²) 51.6 (0.52) 53.8 (0.54)
Vessel dump degree degree 60 85
Size
Lenght mm 3280 3650
Width mm 1775
Height mm 2370
Ground clearance mm 295
Ground contact length mm 1960
Track length mm 1230
Track width mm 3456
Vessel
Length (inner) mm 1315 1340
Width (inner) mm 890
Depth - 495
Engine
Model - Kubota V2203
Type -
In-line water-cooled vertical four-cycle swirl-chamber
diesel engine
Cylinder - bore × stroke mm 4 - 87 × 92.4
Total displacement L(cc) 2.197(2,197)
Max. output kW(PS)/rpm 34.1(46.4)/2,800
Max. torque Nm(kgfm)/rpm 139.6(14.2)/1,600 to 1,800
Max. engine speed rpm 3,000
Idling engine speed rpm 950±50
Starter - 12V, 1.4 kW
Alternator - 12V, 35A
Battery - 100E41R, 12V, 80Ah×1

12. - 6 -
Service Data 2
Chassis
Carrier roller (upper roller) piece/side 1
Track roller piece/side 6
Track
Type - Built-in rubber track
Pitch mm 90
Width mm 320
Hydraulicequipment
Hydraulic
pump
Type × unit - Triple pump (piston × 2 + gear) × 1
Discharge rate L/min
Piston:64.4 × 2
Gear:31
Set pressure MPa (kgf/cm²)l
Traveling:34.3(350)
DUMP:15.7(160) DUMP:11.8(120)
Hydraulic motor (type × unit) Piston, integral reducer in the parking brake × 2
Operating valve
Type × unit - Spooled × 1
Operating method - Spooled direct pulling
Dumpcylinder
Type - Double-acting piston
Size
Cylinder bore mm 80
Rod diameter mm 40
Stroke mm 407
Max. pin
distance
mm 1,072
Min. pin mm 665
Turncylinder
Type - - Double-acting piston
Size
Cylinder bore mm - 60
Rod diameter mm - 30
Stroke mm - 250
Max. pin
distance
mm - 685
Min. pin mm - 435
Hydraulic oil tank - Box sealed
Hydraulic oil filter - Pump suction side
Hydraulic oil cooler - Air-cooled
*1 Payloads are measured as per ISO 6483.
Machine model, type
KC250H KC250HR
One-way Dump Turn & Dump

13. 2 Service Data
- 7 -
1300
320
295
1230
1550
(1410)
2370
1775
1960
3650
495
2155
768
2945
1560
1420
1685
295
1550
1230
770370
1960
3280
2370
1775
440
One-way Dump Model
Turn & Dump Model
85
55
32
320
60
54
One-way Dump Model
Turn & Dump Model

14. - 8 -
Service Data 2
2.2.2 Details of Tool Bag
2.2.3 Stroke and Operating Force of Controls
*Figures herein are standard values on a new machine.
2.2.4 Cylinder Speed
* These figures are obtained with the engine at maximum speed, oil temperature is at 50°C,and with no
load in the loading deck or bucket.
2.2.5 Falling Rate
* These figures are obtained with the engine at maximum speed, oil temperature is at 50°C,and with no
load in the loading deck or bucket.
No. Part Name Q’ty Remarks
1 Operation and Maintenance Manual 1
2 Instruction manual for engine 1
Item Unit Value Note
Steering Lever Stroke (forward) mm 110±5 mm
Stroke (backward) mm 110±5 mm
Force N (kgf) 49 (5)
Throttle Lever Stroke mm 30 at the base of the lever.
Force N (kgf) 24.5 (2.5)
Dump Lever
(One-way)
Stroke (up) mm 48 at the tip of the lever.
Stroke (down) mm 48 at the tip of the lever.
Dump Lever
(Turn & Dump)
Stroke mm 55 at the stopper pin.
Dump Lever
(Turn & Dump)
Stroke mm 59 at the stopper pin.
Item Unit Value
Dump Cylinder (One-way) Extend sec 3 - 6
Contract sec 3 - 4
Dump Cylinder (Turn & Dump) Extend sec 6 - 8
Contract sec 6 - 8
Turn Cylinder 180° sec 8 - 9
Item Unit Use Limit Note
Dump Cylinder (One-way) mm/min. 1 Unloaded
Dump Cylinder (Turn & Dump) mm/min. 1 Unloaded

15. 2 Service Data
- 9 -
2.3 Serial Number Position
When inquiring of our company about this machine, confirm in advance the relevant items, such
as product model, production number for this machine, engine model, transmission production
number, and front differential production number.
2.3.1 Product Model and Production Number
2.3.2 Engine Model Number
Location of
product label
Location of
production label
View from left side front
2-47, Shikitsuhigashi 1-Chome,
Naniwa-ku, Osaka Japan, 556-8601
MODEL:
MODELE:
MODELL:
MASS:
MASSE:
GEWICHT:
POWER:
PUISSANCE
LEISTUNG:
SERIAL No.
NO DE SERIE
SERIEN-NR.
MADE IN JAPAN:
FABRIQUE AU JAPON
HERGESTELLT IN JAPAN
CONSTRUCTION YEAR:
ANNEE DE FABRICATION:
BAUJAHR:
KC250H/KC250HR
2100kg/2350kg
33.8kw
2 0 0 7
1 0 0 0 1KC250-KC250-
< Product label >
View from right side
Location of engine
model number

16. - 10 -
Service Data 2
2.4 Torque Settings for Fasteners
When fastening a threaded fastener, torque it to an appropriate torque setting. Some fasteners
are provided with specific torque settings; fasten them to these settings. For the fasteners with
no settings specified, follow the standard torque settings shown below and in the next page.
2.4.1 Standard Torque Settings for Hex Head Bolts and Nuts
Units in N•m (kgf•m)
property class
nominal size
4T 7T 8T 9T 11T
M3
0.3~0.5
0.03~0.05)
-
(-)
-
(-)
-
(-)
-
(-)
M4
0.8~1
(0.08~0.1)
-
(-)
-
(-)
-
(-)
-
(-)
M5
2.5~3.4
(0.25~0.35)
5.4~6.4
(0.55~0.65)
6.4~7.4
(0.65~0.75)
6.4~7.4
(0.65~0.75)
8.8~9.8
(0.9~1)
M6
4.9~6.9
(0.5~0.7)
9.8~11.8
(1~1.2)
11.8~13.7
(1.2~1.4)
11.8~13.7
(1.2~1.4)
14.7~16.7
(1.5~1.7)
M8
11.8~16.7
(1.2~1.7)
24.5~29.4
(2.5~3)
29.4~34.3
(3~3.5)
29.4~34.3
(3~3.5)
36.3~41.2
(3.7~4.2)
M10
20.6~29.4
(2.1~3)
39.2~44.1
(4~4.5)
49~53.9
(5~5.5)
49~53.9
(5~5.5)
72.6~82.4
(7.4~8.4)
M12
44.1~53.9
(4.5~5.5)
83.4~93.2
(8.5~9.5)
93.2~107.9
(9.5~11)
93.2~107.9
(9.5~11)
122.6~137.3
(12.5~14)
M14
63.7~78.5
(6.5~8)
117.7~132.4
(12~13.5)
132.4~147.1
(13.5~15)
147.1~166.7
(15~17)
205.9~225.6
(21~23)
M16
88.3~107.9
(9~11)
152~171.6
(15.5~17.5)
176.5~196.1
(18~20)
215.7~245.2
(22~25)
313.8~343.2
(32~35)
M18
117.7~137.3
(12~14)
205.9~235.4
(21~24)
245.2~274.6
(25~28)
313.8~343.2
(32~35)
441.3~470.7
(45~48)
M20
147.1~166.7
(15~17)
235.4~274.6
(24~28)
313.8~353
(32~36)
441.3~480.5
(45~49)
617.8~657
(63~67)
M22
176.5~205.9
(18~21)
421.7~451.1
(43~46)
539.4~578.6
(55~59)
608~647.2
(62~66)
843.4~882.6
(86~90)
M24
235~264.8
(24~27)
539.4~568.8
(55~58)
706.1~745.3
(72~76)
784.5~823.8
(80~84)
1098.3~1137.6
(112~116)

17. 2 Service Data
- 11 -
2.4.2 Standard Torque Settings for Flange Bolts and Nuts
Units in N•m (kgf•m)
2.4.3 Standard Torque Settings for Hydraulic Hose Joints
property class
nominal size,
Type
4T 7T
M4
without serration 1.5~2
(0.15~0.2)
-
(-)
M5
without serration 3.9~4.4
(0.4~0.45)
6.9~7.8
(0.7~0.8)
with serration 2.9~3.4
(0.3~0.35)
5.4~6.4
(0.55~0.65)
M6
without serration 6.4~8.3
(0.65~0.85)
13.7~15.7
(1.4~1.6)
with serration 4.9~6.9
(0.5~0.7)
10.8~12.7
(1.1~1.3)
M8
without serration 16.7~21.6
(1.7~2.2)
26.5~31.4
(2.7~3.2)
with serration 12.3~17.2
(1.25~1.75)
20.6~25.5
(2.1~2.6)
M10
without serration 34.3~39.2
(3.5~4)
50~54.9
(5.1~5.6)
with serration 33.3~38.2
(3.4~3.9)
48~52.9
(4.9~5.4)
mm 6 8 9 12 15 19 25
- -04 -05 -06 -08 -10 -12 -16
Nominal size PT 1/4 3/8 3/8 1/2 3/4 1
Torque N•m (kgf•m) 25 (2.5) 34 (3.5) 34 (3.5) 59 (6) 118 (12) 118 (12) 137 (14)
Nominal size UNF 7/16 - 20 1/2 - 20 9/16 - 16 3/4 - 16 7/8 - 14
Torque N•m (kgf•m) 25 (2.5) 29 (3) 39 (4) 49 (5) 69 (7)

18. - 12 -
Service Data 2
2.4.4 Specific Fastening Requirements
2.5 Fuel, Lubricant, and Cooling Water Chart
Thread Locking
Adhesive
Tightening Torque Note
Sprocket Axle Nut Three-Bond 1324
or Equivalent
Standard Align slot on the nut with hole on
the axle at the specified torque.
Steering Lever
Ball-joint (upper)
Three-Bond 1324
or Equivalent
Standard Apply a small amount of adhesive
on the thread of the ball-joint stud
and secure with a nut.
Item Interval Recommended product Capacity
Fuel Whenever needed Diesel fuel 45.0 liters
Engine oil Filling: Check every day, add
when level is low.
Change:
1st time: 50 hours.
2nd time on: every 200 hours.
API category: CD class or higher
SAE category: 10W-30
9.7 liters
HST fluid
(used also as hydraulic
fluid)
Change:
1st time: 500 hours.
2nd time on: every 200 hours.
High viscosity index hydraulic fluid
VG46 or engine oil
API category : CD class or above
SAE category : 10W-30
* When using in cold areas (below
-15°C), use wear resistant hydrau-
lic fluid VG32.
36 liters
Traveling motor lubri-
cating fluid
Change:
1st time: 200 hours.
2nd time on: every 1000 hours.
Gear oil
API category: GL4
SAE category: # 90
0.6 liters
Cylinder pin, roller sup-
port shaft
Every 100 hours Lithium all-round grease (NLG
No.2 or equivalent)
–
Engine cooling water Adding: Check every day, add
when level is low.
Change: Every 2 years.
Long Life Coolant (LLC) and pure
water mixture 7.2 liters
Battery electrolyte Check every 50 hours, add when
level is low.
Distilled water
–

19. 2 Service Data
- 13 -
2.6 Consumables (Replacement Parts) Chart
NOTICE
Rubber parts such as hydraulic hoses will deteriorate even when not used. Replace
them every 2 years, or whenever damaged.
Item Part number Replacement interval Quantity
Air cleaner element (outer) R1401-4227-0
Every 1000 hours or more often,
when you are working in dusty
areas.
1
Air cleaner element (inner) R2401-4228-0 Every 1000 hours 1
Fuel filter element 36640221500 Every 500 hours 1
Engine oil filter cartridge 36610001300
Every 200 hours
(first time: 50 hours)
1
HST filter element 36616036300 Every 500 hours 1
Suction filter element 36636029000 Every 1000 hours 1
Battery 36610502000
Replace if there is any problem
1
Track 36632111999 2
Push-pull wire (for engine control) 37073321000 1
Wire (for engine control) 36550105100 1
Sprocket 15T 366321060X0 2
Track roller A assembly 52322201000 8
Track roller B assembly 52322211000 4
Carrier roller assembly 364022180X0 2
Idler assembly 364023310X0 2
Hydraulichose
Piping conncetion port
HST pump front
right A1
HST motor top left
P1
52296101000
Replace every 2 years (or replace if
there is any problem)
1
HST pump front
left B1
HST motor bottom
left P2
52296102000 1
HST pump front
left B2
HST motor bottom
right P2
36646101200 1
HST pump front
right A2
HST motor top
right P1
52296104000 1
HST motor left
drain bottom T1
Oil tank 52296111000 1
HST motor right
drain bottom T1
Oil tank 52296112000 1
Pump top front
drain
Oil cooler top 52296115000 1

20. - 14 -
Safety Covers 3
3. Safety Covers
3.1 Removing Safety Covers
1. Start the engine and raise the vessel. Hold the
vessel with the safety prop (dump body support
rod) securey. Stop the engine.
2. Unfasten bolts on the hinges to remove the en-
gine hood.
3. Undo elecrtical couplers from the control panel.
Remove the throttle wire from the lever. Remove
the hydraulic control valve from the control pan-
el. Unfasten mount bolts to remove the Control
panel. Then, unfasten mount bolts on the lower
side to remove the side panels.
4. Undo hose clamp to remove the air hose from
the front panel.
5. Remove the front panel.
6. Remove the side panel.
7. Remove the back panel.
Engine Hood
Control Panel
Side Panels
Air Hose
Front panel
Back Panel
Side Panel
Front Panel

21. 3 Safety Covers
- 15 -
8. Undo radiator drain bolt to drain engine cooling
water. Remove the radiator.
9. Remove the pump cover.
Radiator
Pump Cover

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for your reading.
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