Kubota KX080-3 Workshop Manual
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Kubota KX080-3 Workshop Manual

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Table Of Contents
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Table of Contents

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WORKSHOP MANUAL
KUBOTA EXCAVATOR
Code No.97899-61620

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Summary of Contents for Kubota KX080-3

  • Page 1 WORKSHOP MANUAL KUBOTA EXCAVATOR KX080-3 Code No.97899-61620...
  • Page 2 Record of Revisions Symbol Date Main Revised Points & Corrective Measures Person-in-charge...
  • Page 3 CONTENTS General • Mechanism section • Service section Machine body • Mechanism section • Service section III Engine • Mechanism section • Service section IV Hydraulic System • Mechanism section • Service section V Electrical System • Mechanism section • Service section...
  • Page 4 CONTENTS ir Conditioner • Mechanism section • Service section...
  • Page 5 WSM KX080-3 Service General I General A. Body and engine identification marks ... . I-3 B. Safety precautions for servicing, disassemble and reassembly . I-4 C. Important safety process and critical functional process . I-6 D.
  • Page 6 KX080-3 WSM General...

  • Page 7: A. Body And Engine Identification Marks

    WSM KX080-3 Service General A.Body and engine identification marks (2)Machine and engine serial number If trouble should occur during use, or if servicing is necessary, contact the dealer who handles the machine. At that time please inform the machine model and engine type and serial numbers.
  • Page 8 WSM KX080-3 Service General B.Safety precautions for servicing, disassembly and reassembly Safety precautions for servicing Most accidents during servicing arise from carelessness. Please remember that Safety involves both the welfare of the employees and improved work efficiency. Safety precautions for Disassembly and reassembly Machines must be disassembled and assembled efficiently and safely.
  • Page 9 WSM KX080-3 Service General c. Preparation for disassembly (1) Cleaning Remove mud and dirt from the body before disassembly. (2) Acceptance inspection The machine must be checked before it is disassembled to record existing conditions, such as those listed below.

  • Page 10: C. Important Safety Process And Critical Functional Process

    KX080-3 WSM General C.IMPORTANT SAFETY PROCESS AND CRITICAL FUNCTIONAL PROCESS The following instructions are related to essential adhesives, important safety process and critical functional process .Pay special attention in servicing these process. (Pay also close attention in reconnecting the electrical cables.) a.

  • Page 11: E. Servicing Fundamentals

    WSM KX080-3 Service General E.SERVICING FUNDAMENTALS a. Items for Servicing Locking adhesive (1) Tighten bolts, nuts, adapters,and similar parts to their specified torques which are given in the list of tightening torques and adhesive as well as in this manual. Be sure to observe the specified torques for important tightened parts and components.
  • Page 12 WSM KX080-3 Service General (4) Precautions in tightening hoses and pipes. • Flexible hoses have a slight natural bend of their own. Utilize the natural bend. Be also careful not to twist them. • Be careful not to confuse the routes of the hoses.
  • Page 13 WSM KX080-3 Service General b. O-ring, Oil seal, Circlip and Roll (1) General precautions • Make sure the O-ring and the oil seal are free of anything unusual (uneven surface, scratches, chipping, etc.). • Check the O-ring groove for burrs. Correct, if any, using an oil stone or the like.
  • Page 14 WSM KX080-3 Service General (4) Oil seal • Do not confuse the orientation of the oil seal lips. Direct the main lip toward the oil chamber; in other word, toward what is to be sealed. Packing Dustpans lip Metal ring...
  • Page 15 WSM KX080-3 Service General c. Piping (1) General precautions • Tightening the pipe socket to the specified torque. If too tight, the socket itself or a hydraulic component may get damaged. It too loose, an oil leak may result. •...
  • Page 16 KX080-3 WSM General (4) Hose screw Metric Size Hose Tightening torque Torque N·m Thread size N·m kgf·m (piping screw) kgf·m Thread size Wrench size ft·lbf ft·lbf (piping screw) (reference) Taper thread 20 ~ 30 Union nut section × section 2.0 ~ 3.1 14.75 ~ 22.13...
  • Page 17 WSM KX080-3 Service General (6) Hose clamp (screw-in type) tightening torque chart Applicable diameter/Part code Part name. Tightening torque (Ø10 ~ 14) 6C040-5872 Hose clamp (screw-in type 14) 2.5~3.4N.m (25~35kgf.cm )1.8~2.5ft.lbs (Ø12 ~ 16) 09318-81916 Hose clamp (screw-in type) 2.5~3.4N.m (25~35kgf.cm )1.8~2.5ft.lbs (Ø13 ~ 20) RB101-6363...
  • Page 18 KX080-3 WSM General (8) Tightening torque of bolts and nuts Refer to the tightness torque table below. Bolts, Nuts Nomial Dia. SS41 S40C, S45C SCr4 7.8 ~ 9.3 N·m 9.8 ~ 11.3 N·m 12.3 ~ 14.2 N·m 0.80 ~ 0.95 kgf·m 1.00 ~ 1.15 kgf·m...
  • Page 19 WSM KX080-3 Service General (10)Washer-equipped elbow Tightening torque Size N·m kgf·m ft·lbs G1/8 15.0~16.5 1.5~1.7 11.1~12.2 G1/4 24.5~29.4 2.5~3.0 18.1~21.7 G3/8 49.0~53.9 5.0~5.5 36.1~39.8 G1/2 58.8~63.7 6.0~6.5 43.4~47.0 G3/4,G1 117.6~127.4 12.0~13.0 86.7~94.0 G1,1/4 220.5~230.3 22.5~23.5 162.6~169.9 7/8-14UNF 55.9~60.8 5.7~6.2 41.2~44.8 Tightening procedure 1.
  • Page 20 WSM KX080-3 Service General 1.Face sealing (ORS) type Tighten to the specified torque. 9/16UNF size Screw size Part code of O ring 35.2~43.1N.m (3.6~4.4kgf.m) 26.0~30.8ft.lbs 9/6UNF RD809-6184Δ 11/16UNF size 11/16UNF RD809-6161Δ 60.0~73.5N.m (6.1~7.5kgf.m) 44.3~54.2ft.lbs 13/16UNF RD809-6162Δ 1-14UNS RD809-6163Δ 13/16UN size 70.6~86.2N.m (7.2~8.8kgf.m) 52.1~63.6ft.lbs...
  • Page 21 WSM KX080-3 Service General Hose tightening torque chart N.m (kgf.m) ft.lbs Size (ORS) Union nut (metal sealing type) Union nut (ORS type) 7.8~11.8N.m(0.8~1.2kgf.m) 1/8 (-) 5.8~8.7ft.lbs 24.5~29.4N.m(2.5~3.0kgf.m) 35.2~43.1N.m(3.6~4.4kgf.m) 1/4 (9/16-18) 18.1~21.7ft.lbs 26.0~31.8ft.lbs 37.2~42.1N.m(3.8~4.3kgf.m) 60.0~73.5N.m(6.1~7.5kgf.m) 3/8 (11/16-16) 27.4~31.1ft.lbs 44.3~54.2ft.lbs 58.8~63.7N.m(6.0~6.5kgf.m) 70.6~86.2N.m(7.2~8.8kgf.m) 1/2 (13/16-16) 43.4~47.0ft.lbs...

  • Page 22: F. Maintenance Intervals

    KX080-3 WSM General F. Maintenance intervals a. Maintenance intervals chart : EU-version I-18...
  • Page 23 WSM KX080-3 Service General I-19...
  • Page 24 KX080-3 WSM General b. Maintenance interval chart : PP-version To be announced soon. I-20...
  • Page 25 Control levers and links Du-bushing Assemble after applying grease Inspection of hydraulic oil The hydraulic tank of KX080-3 is pressurized type. When checking the hydraulic oil level, satisfy the following conditions and make sure the oil level is above the center the oil gauge.
  • Page 26 KX080-3 WSM General d. Recommended oil IMPORTANT: 1. Before delivery the hydraulic oil used was an ISO 46 viscosity grade. 2. Use engine oil API service classification CD, CE or CF. 3. Use SAE 90 (API, CLA/GL5) as drive unit oil for all seasons.
  • Page 27 Hydraulic hose (Bucket cylinder) Hydraulic hose (Swing cylinder) Hydraulic hose (Dozer cylinder) Hydraulic hose (Service port) *2+2 Hydraulic hose (Swivel motor) Note: The *-marked hydraulic hoses are Kubota’s genuine ultra wear-resistant hoses. Be sure to use these parts. I-23...
  • Page 29 WSM KX080-3 Mechanism II Machine Body II. Machine Body Mechanism Section A. New Product Feature ..........II-M-3 a.
  • Page 30 WSM KX080-3 Mechanism II Machine Body II-M-2...
  • Page 31 WSM KX080-3 Mechanism I Machine Body A.New Product Feature a. Feature, quick chart Protected front hoses routed through the swing bracket Anti-theft system New control lever with finger control aux. circuit Device for locking all hydraulic control Digital meter Safety (anti-drop) boom valve...
  • Page 32 WSM KX080-3 Mechanism I Machine Body b. Feature points 1. Performance 1-1. Kubota original engine Kubota original new DI engine contributes for stronger digging force, lower noise level, and lower fuel consumption. Kubota Kubota Takeuchi KX080-3 KX251 TB175 Model V3800DI...

  • Page 33: Lifting Capacity

    51.5 +27% 52.7 +24% 38.1 37.2 36.7 1-4. Lifting capacity Keeping better lifting capacity than TB175 Comparison with 1470kg load. Kubota KX080-3 machine (EU-version) Takeuchi TB175 Kubota Takeuchi Difference KX080-3 TB175 with TB175 condition of measurement long arm long arm...
  • Page 34 Less possibility to use ?? Kubota KX080-3 machine Takeuchi TB175 It contributes saving cost for fuel Fuel consumption of KX080-3 machine 9.73 liter (comes from average data of durability test) Fuel consumption in idling time ( 1000 rpm) 6.00 liter/hour We calculate how AI contributes fuel consumption.
  • Page 35 WSM KX080-3 Mechanism I Machine Body 1-7. Max. Hydraulic flow adjustor auxiliary circuit (SP1) Combined with Kubota Intelligent Control System, operator can adjust the maximum oil flow of SP1 according to the attachment you use. Function : You can adjust the Maximum oil flow of SP1.
  • Page 36 I Machine Body 2. Durability and service ability 2-1. Rubber crawler Kubota newly adopts reinforced rubber crawler, against by cutting edge. We made a comparison test with TB175 of rubber crawler’s durability at our supplier. Test condition... 100h traveling test ( 10 times load = condition of after 1000h) Comparison test results ;...
  • Page 37 8 ton machine is designed with triplebonnet. Kubota KX080-3 machine Takeuchi TB175 3. Safety 3-1. ROPS / FOPS cabin For the maximum safety for operator, Kubota adopted ROPS/FOPS certified cabin. ROPS certified cabin FOPS certified cabin Kubota KX080-3 machine...
  • Page 38 3-2. Anti-fall valve (Holding valve) Boom anti-fall valve will be adopted as standard. 3-3. Anti-theft system Same as -3 series introduced in Europe, Kubota original anti-theft system will be equipped as standard. Easy operation No special procedures needed. Just turn the key and the engine can be started.
  • Page 39 WSM KX080-3 Mechanism II Machine Body B.Maintenence components layout (16) (12) (15) (17) (14) (18) (13) (19) (22) (20) (11) (10) (22) (10) (11) (13) (15) Idler Grease tension cylinder Upper roller Track roller Rubber track Travel motor Pilot filter...
  • Page 40 WSM KX080-3 Mechanism II Machine Body II-M-12...
  • Page 41 WSM KX080-3 Mechanism II Machine Body C.Rubber track vs Iron track Rubber track type Part name Idler assembly Cylinder assembly Spring assembly (rubber) 319mm(12.6inch) Iron track type Part name Idler assembly Cylinder assembly Spring assembly (rubber) (1) Set the cotter pin into the hole inside.
  • Page 42 WSM KX080-3 Mechanism II Machine Body D.Greasing intervals Greasing intervals are extended. Bushing material has been changed from metal (carbon steel) to copper alloy castings (high strength brass). High-strength brass is excellent in abrasion resistance. 1. Swivel gear : Every 50 hrs 2.
  • Page 43 WSM KX080-3 Mechanism II Machine Body RD809-6662-0 BUSH RD809-6665-0 BUSH RD809-6665-0 BUSH RD809-6677-0 BUSH RD809-7442-0 BUSH II-M-15...
  • Page 44 WSM KX080-3 Mechanism II Machine Body FYI (For Your Information) What is the material of bushing? Answer : High strength brass According to JIS, this is high strength brass continuous casting class 4. CAC304C Continuous castings Class 4 High strength brass...
  • Page 45 WSM KX080-3 Service Machine body II Machine Body Service Section A. Specifications ....... II-S-3 B.
  • Page 46 WSM KX080-3 Service Machine body II-S-2...
  • Page 47 WSM KX080-3 Service Machine body A.Specifications a. Machine weight Truck Unit KX080-3 7960 STD. (lbs) (17549) Rubber 8020 Long (lbs) (17681) Cabin 8060 STD. (lbs) (17769) Steel 8080 Long (lbs) (17813) II-S-3...
  • Page 48 WSM KX080-3 Service Machine body b. Major specifications Unit KX080-3 Engine Vertical, water-cooled Type 4 cycle, 4 cylinders diesel Model V3800DI-E2-BH kW/rpm 49.7/2000 ISO 3046 Net PS/rpm 67.6/2000 Rated engine output SAE J1349 Net HP/rpm SAE J1995 Gross HP/rpm Displacement 3769 230.0...
  • Page 49 WSM KX080-3 Service Machine body c. Lever stroke and operating force KX080-3 Remarks Unit Stroke Boom 14.7 14.7 Up/Down Force Stroke 15.7 16.7 Crowd/Dump Force Stroke Bucket 12.7 12.7 Crowd/Dump Force Stroke Swivel 12.7 12.7 Left/Right Force Stroke Travel(Left/Right) 18.6 18.6...
  • Page 50 WSM KX080-3 Service Machine body d. Dimensions of parts : (1) Front pins KX080-3 Position Unit 70 x 200 Swing bracket Pin diameter x length -Boom cylinder 2.76 x 7.87 80 x 437 Pin diameter x length Swing bracket - Boom 3.15 x 17.20...
  • Page 51 WSM KX080-3 Service Machine body (2) Bucket 1) Bucket dimensions Unit KX080-3 26.61 27.56 130 x t10 5.12 x t0.39 11.42 7.87 0.75 1.77 3.94 4.13 4.72 +0.10 +0.05 +0.004 2.36 +0.002 +0.10 +0.05 +0.004 2.36 +0.002 890.5 35.06 30.83 5.31...
  • Page 52 2) Bucket installation relevant dimensions Unit KX080-3 Standard arm KX080-3 Lomg arm M20 x 1.5 3.54 3.54 0.00 30.0 1.18 1490 1840 58.66 72.44 0.51 14.57 17.76 10.98 1745 68.70 16.85 15.87 10.24 NOTE : KUBOTA JAPAN BUCKET, STANDARD ARM II-S-8...
  • Page 53 WSM KX080-3 Service Machine body (3) Rubber crawler Unit KX080-3 Crawler ass'y code No. RD809-2231-0 Identification mark (Core metal rapping position) A : Lug height 1.18 B : Link height 2.05 C : Crawler width 17.72 25 to 40 D : Crawler sag distance 0.98 to 1.57...
  • Page 54 WSM KX080-3 Service Machine body (5) Track roller, idler, sprocket KX080-3 Unit Remark 104 / 99 A : Guide width (A)/(B) 4.09 / 3.89 132 / 128 B : Outer diameter (A)/(B) 5.20 / 5.04 228.5 / 220.5 C : Roller width 9.00 / 8.68...
  • Page 55 WSM KX080-3 Service Machine body (6) Blade KX080-3 STD Unit Remark Blade ass'y code No. RD809-7441-0 60 x 167 Blade am A : Pin diameter x length -Track frame 2.36 x 6.57 70 x 147 Blade cylinder B : Pin diameter x length -Track frame 2.76 x 5.79...
  • Page 56 WSM KX080-3 Service Machine body (7) Parts weight Unit KX080-3 Remarks Truck frame (lbs) (1911.4) Swivel frame (lbs) (2137.4) Swing bracket (lbs) (388.0) Boom (lbs) (798.1) STD. (lbs) (354.9) Long (lbs) (401.2) For STD. (lbs) Japan Bucket STD.Bucket For Long...
  • Page 57 WSM KX080-3 Service Machine body Unit KX080-3 Remarks 22.0 Sprocket (lbs) (48.5) Idler ass'y (lbs) (147.7) Control valve Without adaptors (lbs) (207.2) Boom cylinder Canopy / Cabin (lbs) Arm cylinder (lbs) Bucket cylinder (lbs) Swing cylinder (lbs) (168.4) Blade cylinder (lbs) (122.6)
  • Page 58 WSM KX080-3 Service Machine body e. Quality specification KX080-3: KE, KUK, KBM Version Machine specification : Auxiliary port,Wrist rest,STD-arm,japan-cab,KBM-bucket Specificatios Items Unit KX080-3 Remarks Main Speed JIS A8404 Machine size 6410 ± 128 Total length (Transport) inch 252.4 ± 5.0 2200 ±...
  • Page 59 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks Front attachment ± CECE ± Bucket heaped capacity 0.162 ± 0.009 SAE, JIS Slope angle: 1x1 0.212 ± 0.012 0.162 ± 0.006 Bucket struck capacity 0.212 ± 0.008 ± 14...
  • Page 60 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks Main Specs JIS A8404 Without shockless Bucket tooth slaggish F=30 kgf (66 lbf) inch Front boom lateral declination inch 0.39 Blade's lateral declination inch 0.39 ± 19 From swivel center...
  • Page 61 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks Work performance Boom lifting capacity 1529.6 Front end, Arm extend bucket crowd, at tooth 15.0 3372.1 Arm digging force 3885.1 Bucket tooth root 38.1 8565.2 Bucket digging force 6648.6 Machine stance to JIS bucket tooth root 65.2...
  • Page 62 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks Swivel block performance deg. Bucket loaded at heaped. Slope angle at 20° for 1 min. deg. Engine idling, lever lock deg. released. deg. Swivel start-up speed sec. 2.9 ± 0.3 0~90 deg.
  • Page 63 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks Boom lever operating force -0.5,+0.5 Measuring point : 20 mm lower from the lever 14.7 -4.7,+5.3 top. Pilot lever with engine -1.1,+1.2 Max. speed. down -0.5,+0.5 14.7 -4.7,+5.3 -1.1,+1.2 Arm lever crowd -1.1,+2.1 Dump &...
  • Page 64 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks 15 Accelerator lever This machine has accel dial not a lever. down 17 Swing pedal 5.8 ± -1.0,+1.0 Pedal edge. 45 degree inward 56.9 ± 9.9,+10.1 12.8 ± -2.2,+2.3 5.8 ± -1.0,+1.1 ±...
  • Page 65 WSM KX080-3 Service Machine body Specificatios Items Unit KX080-3 Remarks Boom lever stroke ± 10 inch 3.94 ± 0.39 down ± 10 inch 3.94 ± 0.39 Arm lever stroke crowd ± 10 inch 3.94 ± 0.39 dump ± 10 inch 3.94...
  • Page 66 WSM KX080-3 Service Machine body B: Removing and reassembling a. Front attachment removing 1. Dismount bracket and bracket link. 2. Disconnect bracket cylinder hose. Lifting the arm assy, tap out the pins and dismount arm assy. 3. Remove the pipe and hose connections.
  • Page 67 WSM KX080-3 Service Machine body 4. While lifting the boom assy, remove the boom pin. 5. While lifting the swing bracket assy, remove the pin. II-S-23...
  • Page 68 WSM KX080-3 Service Machine body Shims Bushings II-S-24...
  • Page 69 WSM KX080-3 Service Machine body b. Grease nipple set up 1.Grease nipple setup direction Type A: Straight (06611-15010) Type B: 67 degree (06616-25010) Type C: 90 degree (06616-35010) Mount the fittings as shown at left. 2.Greasing quantity Apply grease until it comes out of the other end of the moving section.
  • Page 70 WSM KX080-3 Service Machine body 3.Grease nipple setup direction Type A: Straight (06611-15010) Type B: 67°(06616-25010) Mount the fittings as shown at left. 4.Greasing quantity Apply grease until it comes out of the other end of the moving section. (1)Type A...
  • Page 71 WSM KX080-3 Service Machine body C. Pin and bushing installation 1.Fitting the bushings Using a block or the like, fit the bushings into position. * Do not hit directly against the bushings. 2.Bushing setup dimensions 1) Without the dust seals Make sure the bushings do not stretch out of both sides.
  • Page 72 WSM KX080-3 Service Machine body 1.Arm assembly - Bucket cylinder 2.Boom assembly - Arm assembly 3.Arm assembly - Arm cylinder 4.Boom assembly - Arm cylinder 5.Swing bracket - Swing cylinder 6.Swivel frame ~Swing cylinder 7.Boom assembly - Swing bracket 8.Swing bracket -Swivel frame 9.Swing bracket - Boom...
  • Page 73 WSM KX080-3 Service Machine body d.Shim installation 1.Clearance at the front Boom assembly - Boom cylinder Shim (1.0, 140-71) * Gap in thrust direction at each support pin Less Shim (0.5, 140-71) than 0.6 mm(0.02inch) To be selected *If over 0.6 mm(0.02inch), add a shim to readjust the gap.
  • Page 74 WSM KX080-3 Service Machine body Bucket link (1) Cylinder (blade) - Blade Bucket link support 1 (at the bucket) (16) (15) (5)(6)(7) Shim (1.0, 120-71) (17) (18) Shim (0.5, 120-71) To be selected (1)Connect the bucket links 2 and 3 with their...
  • Page 75 WSM KX080-3 Service Machine body e.Fitting the control lever With the control levers in place, make sure the distance between them is as specified at left. Reference: 530 mm(20.9inch) 530 (20.9) II-S-31...
  • Page 76 WSM KX080-3 Service Machine body 1.Fitting the grommets (RD809-4143 ) (RD809-4144 ) (RD809-4145 ) Fit the grommets in position as shown at left. Apply an instant adhesive. (1)Guide (hose, swing) Bolt (2)View of A (3)Grommet (2, swivel) (4)View of B...
  • Page 77 WSM KX080-3 Service Machine body f.Travel levers 1.Adjusting the lever neutral position Fit the levers in position as shown at left. 2.Adjusting the travel levers Keep them at the neutral position. (1)Dimension from the step end 265mm (10.4inch) (reference) (2)To-and-fro difference between left and right...
  • Page 78 WSM KX080-3 Service Machine body g.Dozer lever 1.Adjusting the dozer lever neutral position Fit the lever in position as shown at left. 2.Checking the setup condition Make sure the valve spool moves over its full stroke. Make sure the valve spool moves smoothly.
  • Page 79 WSM KX080-3 Service Machine body h.Cab 1.Anti-vibration rubber (Cab) Tightening torque of mounting bolt To be installed Tightening torque 103.0~117.7N.m (10.5~12.0kgf.m) 75.9~86.8ft.lbs 2.Nut (M16-6T, cab) Rear rim lock nut Tightening torque To be installed Tightening torque 107.9~127.4N.m (11.0~13.0kgf.m) 79.6~94.0ft.lbs (1)Details of A and D (2 locations)
  • Page 80 WSM KX080-3 Service Machine body i.Bonnet (11) (10) (12) (13) (14) (15) (1)Damper (gas) (2)Headed pin (3)Plain washer (4)Snap pin (5)Grip (6)Bolt (7)Hinge (1, hood back) (8)Bolt (9)Plain washer (10)Snap pin (11/)Hinge (2, hood back) (12)Bolt (13)Hood (back) (14)Lock assembly (hood)
  • Page 81 WSM KX080-3 Service Machine body (17) (18) (19) (10) (11) (12) (13) (15) (14) (16) (20) (21) (22) (23) (24) (1)Cover assembly (front) (2)Bolt (3)Cover assembly (right) (4)Stay (rearview mirror) (5)Bolt (6)Rearview mirror assembly (7)Hinge (1, right cover) (8)Bolt (9)Lock assembly...
  • Page 82 WSM KX080-3 Service Machine body (1)Bracket (2, left cover) (2)Bolt (3)Cover (arch, left) (4)Bolt (5)Bracket (left cover) (6)Bolt II-S-38...
  • Page 83 WSM KX080-3 Service Machine body (16) (10) (11) (12) (13) (17) (18) (19) (14) (15) (1)Swivel frame (2)Frame (center) (3)Bolt (4)Grommet (360) (5)Grommet (450) (6)Clamp (7)Bolt (8)Leaf spring (9)Bolt (10)Pump assembly (fuel, filler) (11)Bolt (12)Cover (center) (13)Bolt (14)Tool box (2)
  • Page 84 WSM KX080-3 Service Machine body (10) (11) (12) (1)Hinge (tank cover) (2)Bolt (3)Cover (tank) (4)Guide (tank cover) (5)Bolt (6)Bracket (tank cover) (7)Bolt (8)Link (2, tank cover) (9)Link (1, tank cover) (10)Fuel tube (11)Plain washer (12)Snap pin II-S-40...
  • Page 85 WSM KX080-3 Service Machine body J.Sound absorber and insulator Part name Q'ty Location Hood (back) Trim (hood) Sound absorber (1, hood) Sound absorber (2 hood) Sound absorber (3, hood) Sound absorber (4, hood) Sound absorber (5, hood) Sound absorber (6, hood)
  • Page 86 WSM KX080-3 Service Machine body Part name Q'ty Location Cover (right) Trim (1, right cover) Trim (2, right cover) Trim (3, right cover) Trim (4, right cover) Trim (5, right cover) Sound absorber (1, right cover) Sound absorber (2, right cover)
  • Page 87 WSM KX080-3 Service Machine body Cover (arch, left) 50(1.97in.) Part name Q'ty Location Cover (arch, left) Trim (1, arch cover L) Trim (2, arch cover L) Trim (3, arch cover L) Grommet (50) Sound absorber (left cover) Cover (arch, top)
  • Page 88 WSM KX080-3 Service Machine body 15(0.59in.) 12(0.47in.) Cover (1, arch) Part name Q'ty Location Cover (1, arch) Sound absorber (arch cover 1) Trim (1, arch cover 1) Trim (2, arch cover 1) Trim (3, arch cover 1) (10) Cover (2, arch)
  • Page 89 WSM KX080-3 Service Machine body 5(0.20in.) Part name Q'ty Location Frame (1, arch) Sound absorber (1, arch) Trim (arch, top) Trim (arch, left) Trim (arch, bottom) Trim (arch, shroud) Trim (arch, hydraulic tank) II-S-45...
  • Page 90 WSM KX080-3 Service Machine body (4)To be applied in the weight groove (5)To be applied along these lines Part name Q'ty Location (6)To be applied along these lines Weight (870) Sound absorber (weight) Sound absorber (R, weight) Sound absorber (L, weight)
  • Page 91 WSM KX080-3 Service Machine body (1)Part code (2)Part name (3)Q’ty (4)Location (5)Cover (tank) Sound absorber (1, tank cover) Sound absorber (2, tank cover) Sound absorber (3, tank cover) (6)To be applied along these lines (7)To be applied along these lines...
  • Page 92 WSM KX080-3 Service Machine body k. Counterweigt 1.Attaching the weight Tightening torque Three M20 bolts at the back (1)Stay (hood lock) 367.7~431.5N.m (37.5~44.0kgf.m) (2)Shim (T2) (3)Bolt 271.2~318.3ft.lbs (4)Plug (M24) (5)Weight (870) Apply screw adhesive (Loctite 271). (6)Bolt (7)Washer (8)Spring washer (9)Cover (weight) 2.Fitting the stay (hook lock), cover...
  • Page 93 WSM KX080-3 Service Machine body 3.Attaching the additional weight Tightening torque Three M16 bolts 259.5~304.0N.m(26.5~31.0kgf.m) 191.4~224.2ft.lbs Apply screw adhesive (Loctite 271). (1)Before attaching the weight (200, additional), peel the label (reflector, red, EU) off the weight (870). (2)Weight (200, additional)
  • Page 94 WSM KX080-3 Service Machine body l. Clearances of cover 1.Clearance between cover (left) and weight (870) Clearance A shown at left 8~12mm(0.31~0.47inch) 2.Clearance between hood (back) and each side Clearance B shown at left 16~20mm(0.63~0.79inch) 3.Clearance between hood (back) and weight Clearance C shown at left 8~12mm(0.31~0.47inch)
  • Page 95 WSM KX080-3 Service Machine body m. Labels List of labels Location Part name Q'ty Remarks Label (blade) Control cover (right, top) Label (control pattern A) Control cover (left, top) Nameplate (PC board, CE) Label (bar code) Frame cover (left) Label (reflector, white, EU)
  • Page 96 WSM KX080-3 Service Machine body Location Part name Q'ty Remarks Marking (LWA) Label (new-vehicle sticker) Frame cover (left) II-S-52...
  • Page 97 WSM KX080-3 Service Machine body (10) 0.5(0.02in.) 45(1.8in.) 110(4.3in.) 550(21.7in.) (42) 100(3.9in.) (1)Label (blade) (2)Label (control pattern A) (3)Nameplate (PC board, CE) (4)Label (bar code) (5)Label (reflector, white, EU) (6)Marking (model number, left) (7)Label (attachment switching) (8)Marking(model number, right) (9)Label (lever lock)
  • Page 98 WSM KX080-3 Service Machine body (10)Label (greasing) (11)Label (reflector, white, EU) (12)Label (fuel filler) (13)Label (fuel pump) (14)Label (third line, EU) (15)Label (hydraulic 2) II-S-54...
  • Page 99 WSM KX080-3 Service Machine body (1)Label (muffler, warning) (2)Label (access prohibited) (2 locations: left and right) (3)Marking (K, emblem) (4)Nut (speed) (3 pcs.) (5)Washer (plate) (3 pcs.) (6)Label (control caution) (7)Label (reflector, red, EU) (2 locations: left and right) II-S-55...
  • Page 100 WSM KX080-3 Service Machine body (16) (18) (17) 15(0.59in.) 5(0.20in.) 10(0.39in.) (16)Label (muffler, warning) (17)Label (fan, warning) (18)Label (burn caution) II-S-56...
  • Page 101 WSM KX080-3 Service Machine body (25) (24) 150(5.9in.) (26) (27) (28) 50(2.0in.) (24)Marking (Kubota 1) (2 locations: on both sides) (25)Label (hoisting) (2 locations: on both sides) (26)Label (swing caution) (2 locations: on both sides) (27)Label (hoisting) (2 locations: on both sides)
  • Page 102 WSM KX080-3 Service Machine body (29) (30) 30(1.2in.) (31) 90(3.5in.) (32) (29)Label (windshield lock, EU) (to be applied on the window pane’s inner face) (30)Label (emergency exit) (to be applied on the window pane’s inner face) (31)Label (inspection) (to be applied on the window pane's inner face) (32)Label (swing) too.
  • Page 103 WSM KX080-3 Service Machine body (33)Nameplate (ROPS, cabin) (34)Label (anti-theft) (2 locations) (to be applied on the window pane's inner face) (35)Label (seat belt) (36)Label (hoisting load, EU) (to be applied on the window pane's inner face) (37)Label (manual) (38)Label (control, SP)
  • Page 104 WSM KX080-3 Service Machine body (39)Label (hoisting prohibited, EU) (4 locations) (40)Marking (LPA) (41)Marking (LWA) II-S-60...
  • Page 105 WSM KX080-3 Service Machine body n. Swivel bearing (Pass through the left and right vertical rib holes and connect into position.) 1.Fitting the bearing (swivel) Set the bearing with its specific inner race zone ("S" mark) at the right side of the machine.
  • Page 106 WSM KX080-3 Service Machine body o. Undercarriage 1.Upper roller 1)Upper roller 2)Bolt Bolt tightening torque 77.5~90.2N.m (7.9~9.2kgf.m) 57.2~66.5ft.lbs Apply screw adhesive (Loctite 271). (3)(4)(5) (3)Bolt (4)Nut (5)Spring washer (6)Carrier roller (7)Machine back (8)Machine front II-S-62...
  • Page 107 WSM KX080-3 Service Machine body 2.Track roller Sprocket and track roller out of alignment (Idler to be loosely in center) Within 2 mm (0.08in.) (reference) Bolt tightening torque 166.7~196.1N.m (17.0~20.0kgf.m) 123.0~144.6ft.lbs * Apply screw adhesive (Loctite 271). Carefully remove oil, fat and paint.
  • Page 108 WSM KX080-3 Service Machine body 3. Front idler 4.Grease tension cylinder 5.Grease tension spring 6.Rubber track removing II-S-64...
  • Page 109 WSM KX080-3 Service Machine body p. Track adjustment 1.Grease management No grease leak is allowed. * Wipe off grease deposits around. 2.Fitting to the track frame Make sure the crawler slides smoothly. * Do not force it into position. 3.Spring preset length *Set the cotter pin into the hole closest to the dimension specified at left.
  • Page 110 WSM KX080-3 Service Machine body q. Swivel frame and track frame 1.Swivel frame assy 2.Swivel bearing 3.Track frame II-S-66...
  • Page 111 WSM KX080-3 Mechanism III Engine III. Engine Mechanism Section A. Engine ............. III-M-3 a.
  • Page 112 WSM KX080-3 Mechanism III Engine III-M-2...
  • Page 113 WSM KX080-3 Mechanism III Engine A.Engine a. Engine specifications Unit KX080-3 Remarks Model V3800DI-E2-BH Number of cylinder 100 x 120 Bore x Strok 3.94 x 4.72 3769 Displacement 230.01 kW/rpm 47.8 / 2000 Max. output/rpm PS/rpm 65.0 / 2000 New engine s tolerance: 5% HP/rpm 64.1 / 2000...
  • Page 114 WSM KX080-3 Mechanism III Engine Engine electric components Unit KX080-3 Remarks Engine model V3800DI-E2-BH Bosch P type Fuel injection pump type mini-pump Nozzle type Bosch P type 18.6 / 23.5 Fuel injection pressure 190 / 240 kgf/cm 1st stage/2nd stage...
  • Page 115 WSM KX080-3 Mechanism III Engine b. Performance curve V3800DI-E2-BH (SAE) III-M-5...
  • Page 116 WSM KX080-3 Mechanism III Engine V3800DI-E2-BH (ISO) III-M-6...
  • Page 117 WSM KX080-3 Mechanism III Engine c. Different installation from V3800 basic model. 1. Starter moter (1) Starter moter 1G524-6301-0 2. Oil filter (1) Oil cooler (2) oil filter III-M-7...
  • Page 118 WSM KX080-3 Mechanism III Engine III-M-8...
  • Page 119 WSM KX080-3 Service Engine III Engine Service Section A. Troubleshooting ......III-S-3 B.
  • Page 120 WSM KX080-3 Service Engine III-S-2...
  • Page 121 WSM KX080-3 Service Engine A. Troubleshooting Refer to the following Engine WSM III-S-3...
  • Page 122 WSM KX080-3 Service Engine B. Serviceing specifications Refer to the following Engine WSM III-S-4...
  • Page 123 WSM KX080-3 Service Engine C. Disassemble and Reassmble a. Pump coupling 1.Disconnect the hoses and fit the plugs. 2.Hang the hydraulic pump with nylon sling. 3.Dismount the pump assy. 4.Pump housing. 5.Pump coupling. III-S-5...
  • Page 124 WSM KX080-3 Service Engine 6.When reassembling 1) Applying grease to the spline Apply a proper amount of grease. (Be careful not to allow it overflow.) Be careful to keep the rubber free of grease. Wipe off grease, if on the rubber, immediately.
  • Page 125 WSM KX080-3 Service Engine b. Radiator 1. Overall view (1) Receiver (2) Condenser (3) Oil cooler (4) Radiator III-S-7...
  • Page 126 WSM KX080-3 Service Engine 3.Stretch (A) of the fan out of the shroud (fan) Around the fan Reference dimension: 21 mm(0.83inch) Minimum stretch: Over 15 mm(0.59inch) Keep the entire stretch as small as possible. 4.Clearance (B) between fan and shroud (fan) Around the fan Reference dimension: 20 mm(0.79inch)
  • Page 127 WSM KX080-3 Service Engine Part name Q'ty Radiator assembly Shroud (fan) Cover (fan) Bracket (1, oil cooler) Bracket (2, oil cooler) Rubber (radiator mount) Hose (upper, WP) Hose (lower, WP) Base (drain) Plug Rubber-fitted washer Hose (drain, 1) Hose (drain, 2)
  • Page 128 WSM KX080-3 Service Engine c. Air cleaner 1.Overall view, engine room. (1)Air cleaner assy. 2.Air cleaner assy 3.Inlet hoses 4.Double elements III-S-10...
  • Page 129 WSM KX080-3 Service Engine 5.Laying the hose (1, inlet) See the figure. (5)(6)(7)(8) (2)(3)(4) (9)(10) (1)Bolt (2)Hose (2, inlet) (3)Hose clamp (66-88) (4)Hose clip (58-75) (5)Hose (1, inlet) (6)Hose clip (58-75) (7)Hose (3, inlet) (8)Hose clip (58-75) (9)Hose (3, inlet)
  • Page 130 WSM KX080-3 Service Engine d. Muffler 1.Overall view. Note : After mounting the new muffler and starting engine, some smoke may wme out from the engine room. This smoke is resulted from the initial burning of bandage around the muffler pipe.
  • Page 131 WSM KX080-3 Service Engine 2.Tightening the flange (muffler) clamp Tightening torque 3.9~5.9N.m(0.4~0.6kgf.m)28.2~42.7ft.lbs 3.Ensuring the clearance at the pipe (muffler) outlet Clearance: Over 25 mm(1.0inch) (A) Front 4.Tightening sequence * (A): Tighten up first. Tightening torque 39.2~45.1N.m(4.0~4.6kgf.m)28.9~33.3ft.lbs * (B): Tighten up second.
  • Page 132 WSM KX080-3 Service Engine e.Fuel tank (3)(4) (1)(2) 1.Fitting the sensor assembly (fuel) (RD809-5114 ) Tightening torque 3~4N.m(0.3~0.4kgf.m)2.2~3.0ft.lbs Position the assembly so that the connector socket faces the machine front. 2.Fitting the sensor assembly (fuel filler) (RD809- 5138 ) and gauge (fuel) (RD809-5112 ) Do not force them into position.
  • Page 133 WSM KX080-3 Service Engine 5.Fitting the washer-fitted elbow (68881-6446 ) (1)(2)(3) Position the elbow as shown at left. Note: Be careful not to confuse the O ring (fuel) setup. (Part code of O ring) RD809-5128 O ring (P18) 6.Adaptor tightening torque G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs...
  • Page 134 WSM KX080-3 Service Engine 9.Attaching the cushions Attach the cushions as shown in the figure. * Wipe clean the cushions beforehand. (1)Cushion (9, fuel tank) * (2)To be attached along this line (3)Cushion (3, fuel tank) (4)Cushion (7, fuel tank)
  • Page 135 WSM KX080-3 Service Engine f. Fuel hose Fuel tube Fuel tube length Protective tube length 1.Routing condition 705mm(27.8in.) 800mm(31.5in.) Make sure the hoses are out of contact with sharp edges, hot zones and moving parts. 300mm(11.8in.) 400mm(15.7in.) Do not clamp the fuel hose and electrical cable 1650mm(65.0in.)
  • Page 136 WSM KX080-3 Service Engine 3.Routes of the fuel feed and return hoses ’? ?@ ˆÓ Šë Œ¯ ?A ”M ‚¢ ‚ ‚ ¯ ‚é ‚È ?B - 4 9 0 - T O Y O R A D I A T O R...
  • Page 137 WSM KX080-3 Service Engine (1)Cord band (2)Pass both the fuel feed and return hoses through the guide. (3)Fuel feed hose (4)Fuel return hose (5)Fuel return hose (6)Fuel feed hose (7)Pass both the fuel feed and return hoses through the guide.
  • Page 138 WSM KX080-3 Service Engine (1)Hose (1, fuel, filler) (2)Hose clamp (22-32) (3)Swing hose (4)Boom hose (5)Hose (1, fuel, filler) (6)Hose clamp (22-32) (7)Pump assembly (fuel, filler) (8)Bolt (9)Connect to the fuel tank. III-S-20...
  • Page 139 WSM KX080-3 Service Engine g. Compressor 1.Fitting the bracket (compressor) and bracket (pulley) Fit the brackets in position as shown at left. Tightening torque 17.7~20.6N.m(1.8~2.1kgf.m)13.1~15.2ft.lbs 48.1~55.9N.m(4.9~5.7kgf.m)35.5~41.2ft.lbs 2.Fitting the compressor Fitting the bushing (compressor) Fit the parts in position as shown at left.
  • Page 140 WSM KX080-3 Service Engine h.Control cable 1.Connecting the cable (acceleration) Connect the cable in the order as shown in the figure. 2.Routing the cable (acceleration) Lay the cable in the route as shown at left. (12) (13) (10) (11) (15)
  • Page 141 WSM KX080-3 Service Engine i. Fan belt 1.Fitting the oil switch Tightening the oil switch Fit the oil switch in position as shown at left. PT1/8 size 7.8~9.3N.m(0.8~0.95kgf.m)5.8~6.9ft.lbs 2.Fitting the plate (clamp,2) Fit the plate in position as shown at left.
  • Page 142 WSM KX080-3 Service Engine j. Engine stop lever 1.Fitting the sensor (rpm) Tightening the flange bolt Fit the sensor in position as shown at left. Tightening torque 7.8~9.3N.m(0.8~0.95kgf.m)5.8~6.9ft.lbs 2.Fitting the plate (bus bar) Install the plate between No. 1 and No. 2 nuts at the air intake of the engine inlet, as shown at left.
  • Page 143 WSM KX080-3 Service Engine k. Engine bracket 1. Overall view. III-S-25...
  • Page 144 WSM KX080-3 Service Engine 2.Fitting the engine bracket Tightening torque 77.5~90.2N.m(7.9~9.2kgf.m)57.2~66.5ft.lbs 196.1~225.6N.m(20.0~23.0kgf.m) 144.6~166.4ft.lbs Apply screw adhesive (Loctite 271). 3.Fitting the anti-vibration rubber Fit the rubber as shown in the figure. Double nut tightening torque No. 1 nut 88.2~107.8N.m(9.0~11.0kgf.m)65.1~79.5ft.lbs No. 2 nut 166~191N.m(17.0~19.5kgf.m)122.4~140.9ft.lbs...
  • Page 145 WSM KX080-3 Service Engine l. Engine assy 1. Remove and dismount the following parts. 1)Radiator assy 2)Air cleaner assy 3)Bonnet and arch 4)Wireharness 5)Fuel hoses 6)Mount bracket III-S-27...
  • Page 146 WSM KX080-3 Service Engine III-S-28...
  • Page 147 Still some pages contain common specifications on V3800DI series engine. Therefore, some date may differ from the engine mounted on constructinon machinery. In that case, please come to the specifications in the front pages of KX080-3 WSM engine chapter. July 2006...
  • Page 148 WSM KX080-3 Service Engine III-S-30...
  • Page 149 WSM KX080-3 Service Engine General ..............III -S-32 1. ENGINE IDENTIFICATION ...... III -S-32 [1] MODEL NAME AND ENGINE SERIAL NUMBER ..............III -S-33 [2] CYLINDER NUMBER ............... III -S-34 2. GENERAL PRECAUTIONS ............III -S-35 3. MAINTENANCE CHECK LIST ............
  • Page 150 WSM KX080-3 Service Engine 1. ENGINE IDENTIFICATION [1] MODEL NAME AND ENGINE SERIAL NUMBER When contacting the manufacture, always specify your engine model name and serial number. The engine model and its serial number need to be identified before the engine can be serviced or parts replaced.
  • Page 151 So, 3A indicates that the engine was manufactured in January, 2003. W1011076 [2] CYLINDER NUMBER The cylinder numbers of kubota diesel engine are designated as shown in the figure. The sequence of cylinder numbers is given as No.1, No.2, No.3 and No.4 starting from the gear case side.

  • Page 152: General Precautions

    Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.
  • Page 153 *Replacing intake air line Replacing battery * 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.
  • Page 154 WSM KX080-3 Service Engine • When changing or inspecting, be sure to level and stop the engine. NOTE Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low- sulfur fuel on-road vehicle engines.
  • Page 155 WSM KX080-3 Service Engine 4. CHECK AND MAINTENANCE [1] DAILY CHECK POINTS Checking Engine Oil Level 1. Level the engine. 2. To check the oil level, draw out the dipstick (1), wipe it clean, reinsert it, and draw it out again.
  • Page 156 WSM KX080-3 Service Engine Checking and Replenish Coolant 1. Without recovery tank : Remove the radiator cap (1) and check to see that the coolant level is just below the port. With recovery tank (2) : Check to see that the coolant level lies between FULL (A) and LOW (B).
  • Page 157 WSM KX080-3 Service Engine [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine.
  • Page 158 WSM KX080-3 Service Engine [3] CHECK POINT OF EVERY 50 HOURS Checking Fuel Hose and Clamp Bands 1. If the clamp (2) is loose, apply oil to the threads and securely retighten it. 2. The fuel hose (3) is made of rubber and ages regardless of the period service.
  • Page 159 WSM KX080-3 Service Engine [4] CHECK POINTS OF EVERY 250 HOURS Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbs).
  • Page 160 WSM KX080-3 Service Engine Cleaning Fuel Filter (Element Type only) 1. Close the fuel cock (3). 2. Unscrew the retaining ring (6) and remove the filter cup (5), and rinse the inside with kerosene. 3. Take out the element (4) and dip it in the kerosene to rinse.
  • Page 161 WSM KX080-3 Service Engine [5] CHECK POINTS OF EVERY 500 HOURS Changing Engine Oil • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine.
  • Page 162 WSM KX080-3 Service Engine Replacing Fan Belt 1. Remove the alternator. 2. Remove the fan belt (1). 3. Replace new fan belt. 4. Install the alternator. 5. Check the fan belt tension. 10.0 to 12.0 mm / 98 N Deflection (A) Factory spec.
  • Page 163 WSM KX080-3 Service Engine Anti-Freeze • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.
  • Page 164 WSM KX080-3 Service Engine [6] CHECK POINT OF EVERY 1000 HOURS Checking Valve Clearance • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the high pressure pipes and the head cover. 2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (gear case side) comes to the compression top dead center.
  • Page 165 WSM KX080-3 Service Engine [7] CHECK POINTS OF EVERY 1 OR 2 MONTHS Recharging • When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.
  • Page 166 WSM KX080-3 Service Engine Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
  • Page 167 WSM KX080-3 Service Engine [8] CHECK POINTS OF EVERY 1500 HOURS • Check the injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
  • Page 168 WSM KX080-3 Service Engine [9] CHECK POINTS OF EVERY 3000 HOURS Checking Turbocharger (Turbine Side) 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one.
  • Page 169 WSM KX080-3 Service Engine Injection Timing 1. Make sure of matching the injection timing align mark (1) of the injection pump unit and the plate (gearcase), as shown in the illustration. 2. Remove the injection pipes. 3. Remove the stop solenoid.
  • Page 170 5. Set the speed control lever to the maximum speed position. 6. Run the starter to increase the pressure. 7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. (Fuel Tightness of Delivery Valve) 1.
  • Page 171 WSM KX080-3 Service Engine [10] CHECK POINTS OF EVERY 1 YEAR Changing Engine Oil • Be sure to stop engine before changing engine oil. 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine.
  • Page 172 WSM KX080-3 Service Engine [11] CHECK POINTS OF EVERY 2 YEARS Replacing Fan Belt 1. Remove the alternator. 2. Remove the fan belt (1). 3. Replace new fan belt. 4. Install the alternator. 5. Check the fan belt tension. 10.0 to 12.0 mm / 98 N Deflection (A) Factory spec.
  • Page 173 WSM KX080-3 Service Engine Changing Radiator Coolant (L.L.C.) (Continued) (Anti-freeze) • There are two types of anti-freeze available: use the permanent type (PT) for this engine. • Before adding anti-freeze for the first time, clean the radiator interior by pouring fresh, soft water and draining it a few times.
  • Page 174 WSM KX080-3 Service Engine Replacing Fuel Hose and Clamp Bands 1. Loosen the clamp (2) and remove the fuel hose (3). 2. Replace new fuel hose (3) and new clamp (2). 3. Tighten the clamp (2). • Stop the engine when attempting the check and change prescribed above.
  • Page 175 WSM KX080-3 Service Engine 5. SPECIAL TOOLS Diesel Engine Compression Tester Code No: 07909-30208 (Assembly) 07909-31251 (G) 07909-30934 (A to F) 07909-31271 (I) 07909-31211 (E and F) 07909-31281 (J) 07909-31231 (H) Application: Use to measure diesel engine compression and diagnostics of need for major overhaul.
  • Page 176 WSM KX080-3 Service Engine • The following special tools are not provided, so make them referring to the figure. Injection Pump Pressure Tester Application: Use to check fuel tightness of injection pumps. Pressure gauge full scale : More than 29.4 MPa...
  • Page 177 WSM KX080-3 Service Engine Small End Bushing Replacing Tool Application: Use to press out and to press fit the small end bushing. [Press out] 157 mm (6.181 in.) 14.5 mm (0.571 in.) 120 mm (4.7244 in.) 30.0 mm dia. (1.1811 in. dia.) 32.95 mm dia.
  • Page 178 WSM KX080-3 Service Engine Gear Case Oil Seal Replacing Tool Application: Use to press fit the oil seal. 148.8 mm (5.8582 in.) 50 mm (1.9685 in.) 18.8 mm (0.7401 in.) 13.7 to 13.9 mm (0.5394 to 0.5472 in.) 11 mm (0.433 in.) 18 mm dia.
  • Page 179 WSM KX080-3 Service Engine Auxiliary Socket for Fixing Crankshaft Sleeve Application: Use to fix the crankshaft sleeve of the diesel engine. Rmax = 12.5 S 94.5 to 95.0 mm dia. (3.7205 to 3.7402 in. dia.) 40 mm dia. (1.5748 in. dia.) 30 mm dia.
  • Page 180 WSM KX080-3 Service Engine Balancer Bushing Replacing Tool 1 Components Parts 1) Shaft 498 mm (19.61 in.) 318.8 to 319.2 mm (12.5512 to 12.5669 in.) 102.8 to 103.2 mm (4.0472 to 4.0630 in.) 60 mm (2.36 in.) 8 mm (0.31 in.) 5 mm (0.20 in.)
  • Page 181 WSM KX080-3 Service Engine 3) Piece 2 Chamfer 0.1 mm (0.004 in.) 1 mm (0.04 in.) Chamfer 1mm (0.04 in.) 54.3 to 54.4 mm dia. (2.1378 to 2.1417 in. dia.) 34.025 to 34.05 mm dia. (1.3396 to 1.3406 in. dia.) 48.5 mm dia.
  • Page 182 WSM KX080-3 Service Engine Balancer Replacing Tools 3, 4, 5 Application: Use to press fit the bushing. • This special tool is not provided, so make it referring to the figure. Name of Part Q’ty. Bracket Flange Nut Washer Shaft...
  • Page 183 WSM KX080-3 Service Engine 2) Shaft 44 mm dia. (1.73 in. dia.) 12 mm (0.47 in.) Chamfer 1 mm (0.04 in.) 3 mm (0.12 in.) 3 mm (0.12 in.) 30 mm (1.18 in.) 38 mm (1.50 in.) 35 mm (1.38 in.) P1.25...
  • Page 184 WSM KX080-3 Service Engine 4) Joint 1 P1.25 Chamfer 1 mm (0.04 in.) 30 mm dia. (1.18 in. dia.) 13 mm dia. (0.51 in. dia.) Chamfer 3 mm (0.12 in.) 3 mm (0.12 in.) 45 mm (1.77 in.) 75 mm (2.95 in.) 57 mm (2.24 in.)
  • Page 185 WSM KX080-3 Service Engine 7) Piece 3 26 mm (1.02 in.) 18 mm (0.71 in.) 16.5 to 17.0 mm (0.6496 to 0.6693 in.) 1.5 mm (0.06 in.) 53.0 to 53.2 mm dia. (2.0866 to 2.0945 in dia.) 49.55 to 49.75 mm dia. (1.9508 to 1.9587 in dia.) 16 mm (0.63 in.)
  • Page 186 WSM KX080-3 Service Engine Engine Stand Application: Use to support engine. 480 mm (18.90 in.) 50 mm (1.97 in.) 108.5 mm (4.272 in.) 262.5 mm (10.33 in.) 12.5 mm (0.492 in.) 237.5 mm (9.350 in.) 142.5 mm (5.610 in.) 95 mm (3.74 in.) 14 mm dia.
  • Page 187 WSM KX080-3 Service Engine Nozzle Adaptor for Measuring Cylinder Compression Pressure Application: Use for measuring diesel engine compression pressure. 5 mm (0.1969 in.) 3 mm dia., 44.5 to 45 mm depth (0.1181 in. dia., 1.7520 to 1.7717 in. depth) 115.9 to 116.1 mm (4.5630 to 4.5709 in.) 105 mm (4.1339 in.)
  • Page 188 WSM KX080-3 Service Engine Jig for Governor Connecting Rod Application: Use for connecting the governor connecting rod to the rack pin of the fuel injection pump assembly. 1 mm radius (0.0394 in. radius) Chamfer 0.2 mm (0.0079 in.) Chamfer 2 mm (0.0787 in.) 35 mm dia.
  • Page 189 WSM KX080-3 Service Engine Mechanism ..................III -S-73 1. FEATURE ................. III -S-74 2. ENGINE BODY ..............III -S-74 [1] CYLINDER BLOCK ..........III -S-74 [2] HALF-FLOATING HEAD COVER ............... III -S-75 [3] CYLINDER HEAD ..... III -S-75 [4] CENTER DIRECT INJECTION SYSTEM (E-CDIS) ..................
  • Page 190 WSM KX080-3 Service Engine III-S-72...
  • Page 191 E-CDIS. Thus, this engine achieves high combustion efficiency and complies with various regulations of exhaust gas. Based upon the conventional model, Kubota developed a unique governor system and various new mechanisms which reduces exhaust emission, noise and vibration and realize durability and high torque.
  • Page 192 WSM KX080-3 Service Engine 2. ENGINE BODY [1] CYLINDER BLOCK This engine employs separate type crankcases - the crankcase 1 (1) with combustion part and the crankcase 2 (2) which supports the crankcase 1 (1) and reduces noise. Since it is a hanger type, you can easily assemble / disassemble it.
  • Page 193 WSM KX080-3 Service Engine [3] CYLINDER HEAD This engine employs four valve system, the cylinder head is provided with double intake passenge in order to ensure appropriate air suction and give an optimum swirl. (1) Intake (2) Exhaust W1013336 [4] CENTER DIRECT INJECTION SYSTEM (E-CDIS)
  • Page 194 WSM KX080-3 Service Engine V3 series DI engine has two intake valves and two exhaust valves per each cylinder. The rocker arm (1) contacts a bridge arm (2) instead of the valves stem tip. The bridge arm then contacts both intake valves or bath exhaust valves and causes two valves to open simultaneously.
  • Page 195 WSM KX080-3 Service Engine 3. LUBRICATING SYSTEM [1] OIL COOLER V3 series engine has a water-cooled oil cooler that not only cools hot oil, but also warms the cool engine oil shoftly after start up. As shown in the figure, the oil flows inside the...
  • Page 196 WSM KX080-3 Service Engine 4. COOLING SYSTEM [1] THERMOSTAT Conventional thermostatically-controlled valves (outlet water temperature control type) open against the flow of coolant. In this design, the pressure (steam pressure + water pump’s discharge pressure) affects the open/close performance of such valve. In other words,...
  • Page 197 WSM KX080-3 Service Engine [2] BOTTOM BYPASS SYSTEM Bottom bypass system is introduced in V3 series for improving the cooling performance of the radiator. While the temperature of coolant in the engine is low, the thermostat is held closed and the coolant is allowed to flow through the bypass pipe and to circulate in the engine.
  • Page 198 Engine 5. FUEL SYSTEM [1] GOVERNOR The engine employs the separated fuel injection pump in combination with Kubota’s own small multi- function mechanical governor, which enable more dependability. It also employs the torque limiting mechanism to control the maximum peak torque so that it complies with the regulations of exhaust gas.
  • Page 199 WSM KX080-3 Service Engine At Idling Turn the speed control lever (6) clockwise to idle the engine. It tensions the governor spring (3) to pull the fork lever 2 (1). When the fork lever 2 is pulled, it moves the torque spring pin (7) and the fork lever 1 (5) in the direction of the arrow A to restrain the weight.
  • Page 200 WSM KX080-3 Service Engine To stop engine When the stop solenoid is turned off, the spring tension of the solenoid is released, the rod extrudes and the stop lever moves the control rack in the direction of the arrow B which stops the engine.
  • Page 201 WSM KX080-3 Service Engine [2] 2 STAGE DI NOZZLE Exhaust and noise regulations are becoming increasingly strict, particularly in regard to the reduction of NOx (nitrogen oxides) and particulates. The two-spring nozzle holder has been developed to reduce NOx (nitrogen oxides) and particulates from direct injection diesel engine exhaust.
  • Page 202 WSM KX080-3 Service Engine A-B : First Spring’s Set Force B-C-D : Combined Force of First and Second Springs P1 : First Opening Pressure P2 : Second Opening Pressure L : Full Needle Valve Lift l : Needle Valve Pre-lift X1 : Cam Angle (<Symbol>×)
  • Page 203 WSM KX080-3 Service Engine 6. TURBOCHARGER SYSTEM [1] BOOST COMPENSATOR The boost compensator is controlled by the boost pressure of the control mechanism which controls transient smoke caused by oversupply of fuel when the engine starts and accelerates. When the boost pressure is lower than working pressure of the boost actuator (1), it prevents oversupply of fuel to reduce transient smoke.
  • Page 204 WSM KX080-3 Service Engine 7. INTAKE SYSTEM [1] INTAKE AIR HEATER The intake air heater is introduced in order to further improve the starting performance and to reduce the white smoke at cold starting. The intake air heater is mounted on the intake manifold.
  • Page 205 WSM KX080-3 Service Engine Service ............... III -S-89 1. TROUBLESHOOTING ............III -S-93 2. SERVICING SPECIFICATIONS ..............III -S-100 3. TIGHTENING TORQUES [1] TIGHTENING TORQUES FOR GENERAL USE SCREWS, BOLTS ................III -S-100 AND NUTS [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS ................
  • Page 206 WSM KX080-3 Service Engine III-S-88...

  • Page 207: Troubleshooting

    WSM KX080-3 Service Engine 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel Start Air in the fuel system Vent air Water in the fuel system Change fuel and repair or replace fuel system...
  • Page 208 WSM KX080-3 Service Engine Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace Not Smooth Air cleaner clogged Clean or replace Fuel leak due to loose injection pipe retaining nut Tighten retaining nut Injection pump malfunctioning...
  • Page 209 WSM KX080-3 Service Engine Reference Symptom Probable Cause Solution Page Deficient Output Incorrect injection timing Adjust Engine’s moving parts seem to be seizing Repair or replace Injection pump malfunctioning Repair or replace Deficient nozzle injection Repair or replace nozzle Compression leak...
  • Page 210 WSM KX080-3 Service Engine Reference Symptom Probable Cause Solution Page High Oil Pressure Different type of oil Use specified type of Relief valve defective Replace Engine Overheated Engine oil insufficient Replenish Fan belt broken or elongated Replace or adjust Coolant insufficient...
  • Page 211 WSM KX080-3 Service Engine 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Cylinder Head Surface Flatness – 0.05 mm 0.0020 in. Top Clearance 0.72 to 0.90 mm – 0.0283 to 0.0354 in. Compression Pressure V3800DI-E2B 3.92 MPa / 2.90 MPa /...
  • Page 212 WSM KX080-3 Service Engine ENGINE BODY (Continued) Item Factory Specification Allowable Limit Valve Stem to Valve Guide Clearance (Intake) 0.055 to 0.085 mm 0.1 mm 0.0022 to 0.0033 in. 0.0039 in. Valve Stem O.D. (Intake) 6.960 to 6.975 mm –...
  • Page 213 WSM KX080-3 Service Engine ENGINE BODY (Continued) Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.15 mm 0.0006 to 0.0018 in. 0.0059 in. Rocker Arm Shaft O.D. 15.973 to 15.984 mm –...
  • Page 214 WSM KX080-3 Service Engine ENGINE BODY (Continued) Item Factory Specification Allowable Limit Timing Gear Idle Gear 1 to Crank Gear Backlash 0.049 to 0.193 mm 0.22 mm 0.0019 to 0.0076 in. 0.0087 in. Idle Gear 1 to Cam Gear Backlash 0.049 to 0.189 mm...
  • Page 215 WSM KX080-3 Service Engine ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Ring Gap Top Ring 0.30 to 0.45 mm 1.25 mm 0.0118 to 0.0177 in. 0.0492 in. Second Ring 0.30 to 0.45 mm 1.25 mm 0.0118 to 0.0177 in.
  • Page 216 WSM KX080-3 Service Engine LUBRICATING SYSTEM Item Factory Specification Allowable Limit Engine Oil Pressure At Idle Speed – 49 kPa 0.5 kgf/cm 7 psi At Rated Speed 196 to 392 kPa 147.1 kPa 2.0 to 4.0 kgf/cm 1.5 kgf/cm 28 to 57 psi 21.3 psi...
  • Page 217 WSM KX080-3 Service Engine FUEL SYSTEM Item Factory Specification Allowable Limit Injection Timing 0.21 to 0.24 rad – (12 to 14 °) before T.D.C. Pump Element Fuel Tightness – 18.63 MPa 190 kgf/cm 2702 psi Delivery Valve Fuel Tightness 10 seconds 5 seconds 18.63...
  • Page 218 WSM KX080-3 Service Engine 3. TIGHTENING TORQUES Screws, bolts and nuts must be tightened to the specified torque using a torque wrench, several screws, bolts and nuts such as those used on the cylinder head must be tightened in proper sequence and the proper torque.
  • Page 219 WSM KX080-3 Service Engine [2] TIGHTENING TORQUES FOR SPECIAL USE SCREWS, BOLTS AND NUTS Note • For “*” marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter “M” in Size x Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads.
  • Page 220 WSM KX080-3 Service Engine Item Size x Pitch N·m kgf·m ft-lbs Governor housing mounting screw M6 x 1.0 9.8 to 11.3 1.00 to 1.15 7.23 to 8.32 Anti-rotation nut M5 x 0.8 2.8 to 4.0 0.29 to 0.41 2.1 to 3.0 Balancer shaft set screw M8 x 1.25...
  • Page 221 WSM KX080-3 Service Engine 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Engine Body Compression Pressure 1. After warming up the engine, stop it and remove the air cleaner, the muffler, high pressure pipes, cylinder head cover, overflow pipe, all nozzle holders and all nozzle gaskets.
  • Page 222 WSM KX080-3 Service Engine Checking Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the high pressure pipes and the head cover. 2. Align the 1TC mark of flywheel and the convex of flywheel housing timing windows so that the first piston (gear case side) comes to the compression top dead center.
  • Page 223 WSM KX080-3 Service Engine (2) Lubricating System Engine Oil Pressure 1. Remove the oil switch and set a pressure tester (Code No. 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
  • Page 224 WSM KX080-3 Service Engine Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
  • Page 225 WSM KX080-3 Service Engine Thermostat Valve Opening Temperature 1. Push down the thermostat valve and insert a string between the valve and the valve seat. 2. Place the thermostat and a thermostat in a container with water and gradually heat the water.
  • Page 226 WSM KX080-3 Service Engine (4) Fuel System Injection Timing 1. Make sure of matching the injection timing align mark (1) of the injection pump unit and the plate (gearcase), as shown in the illustration. 2. Remove the injection pipes. 3. Remove the stop solenoid.
  • Page 227 17.65 MPa (from 190 to 180 kgf/cm , from 2702 to 2560 psi). 9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop. 10 seconds 18.63 17.65 MPa...
  • Page 228 WSM KX080-3 Service Engine Caution • Check the nozzle injection pressure and condition after confirming that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
  • Page 229 WSM KX080-3 Service Engine (5) Electrical System Caution • To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal. • Never remove the battery cap while the engine is running.
  • Page 230 WSM KX080-3 Service Engine Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
  • Page 231 WSM KX080-3 Service Engine Motor Test Caution • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery.
  • Page 232 WSM KX080-3 Service Engine Alternator on Unit Test (Before testing) • Before alternator on unit test, check the battery terminal connections, circuit connection, fan belt tension, charging indicator lamp, fuses on the circuit, and abnormal noise from the alternator. • Prepare full charged battery for the test.
  • Page 233 WSM KX080-3 Service Engine (6) Turbocharger Turbine Side 1. Check the exhaust port (3) and inlet port (5) side of turbine housing (1) to see if there is no exhaust gas leak. 2. If any gas leak is found, retighten the bolts and nuts or replace the gasket (2) / (4) / (6) with new one.
  • Page 234 WSM KX080-3 Service Engine [2] DISASSEMBLING AND ASSEMBLING (1) Draining Oil and Coolant Draining Engine Oil 1. Start and warm up the engine for approx. 5 minutes. 2. Place an oil pan underneath the engine. 3. Remove the drain plug (1) to drain oil.
  • Page 235 WSM KX080-3 Service Engine Caution • While the engine is running and or just after it stops, the turbocharger is hot, be careful not to touch the turbocharger. • NOTE • When detaching and attaching the turbocharger assembly, be very careful not to allow dust, dirt and other foreign matter in the oil pipes.
  • Page 236 WSM KX080-3 Service Engine (3) Cylinder Head and Valves Cylinder Head Cover and Nozzle Holder 1. Remove the injection pipes (2). 2. Remove the cylinder head cover (1). 3. Remove the over flow pipe (3). 4. Remove the nozzle holder clamps (4), nozzle holder assembly (5) and nozzle gaskets.
  • Page 237 WSM KX080-3 Service Engine Rocker Arm and Push Rod 1. Remove the rocker arm (3) as a unit. 2. Remove the push rods (1). 3. Remove the bridge arm (4). (When reassembling) • When putting the push rods onto the tappets (2), check to see if their ends are properly engaged with the grooves.
  • Page 238 WSM KX080-3 Service Engine Cylinder Head and Tappet 1. Loosen the pipe band, and remove the water return pipe (1). 2. Disconnect the fuel pipe (2) first and then the fuel filter (3). 3. Remove the IN. / EX. Manifold.
  • Page 239 WSM KX080-3 Service Engine Selecting Cylinder Head Gasket Replacing the Cylinder Head Gasket 1. Make sure to note the notch (a), (b) or (c) of cylinder head gasket (1) in advance. 2. Replace the same notch (a), (b) or (c) as the original cylinder head gasket (1).
  • Page 240 WSM KX080-3 Service Engine (4) Thermostat Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
  • Page 241 WSM KX080-3 Service Engine (5) Injection Pump Unit Injection Pump Unit (Removing the fuel injection pump unit) 1. Detach the gear cover for the fuel injection pump unit from the gearcase. 2. Place the piston of the 4th cylinder at the top dead center in the compression stroke.
  • Page 242 WSM KX080-3 Service Engine Injection Pump Unit (Continued) (Reassembling the fuel injection pump unit) 1. Place the piston of the 4th cylinder at the top dead center in the compression stroke. Fix the flywheel with the flywheel stopper. 2. Place the injection pump gear (1) back into the gear case position.
  • Page 243 WSM KX080-3 Service Engine Governor Housing Assembly 1. Remove the injection pump unit from the engine. (See the “Injection Pump Unit”.) 2. Remove the governor lubricating pipe (3). 3. Remove the stop solenoid (1). 4. Detach the sight cover (2) from the injection pump unit.
  • Page 244 WSM KX080-3 Service Engine Governor Fork Lever Assembly 1. Pull off the governor fork lever shaft (1) with the extra bolt (Dia : 4 mm, Pitch : 0.7 mm, Length : more than 25 mm) (2). 2. Unhook the governor spring (3) at the governor fork lever (4) side.
  • Page 245 WSM KX080-3 Service Engine Governor Lever 1. Remove the speed control lever (1) and the return spring (2). 2. Remove the governor lever assembly (4) from the governor housing. 3. Remove the start spring (5) and the stop spring (3).
  • Page 246 WSM KX080-3 Service Engine Fuel Camshaft and Governor Weight 1. Separate the governor housing assembly from the injection pump unit. (See the “Injection Pump Unit”.) 2. Remove the governor sleeve (1). 3. Remove the injection pump assembly (2). 4. Remove the fuel camshaft lock screws.
  • Page 247 WSM KX080-3 Service Engine Fuel Camshaft and Governor Weight (Continued) (When reassembling) • Fix the fuel camshaft with lock bolts as the key way of fuel camshaft (9) is upward. • Install the injection pump assembly to the injection pump housing.
  • Page 248 WSM KX080-3 Service Engine Replacing Injection Pump Assembly (If necessary) • The injection pump can be replaced with the crankshaft in whatever position. 1. Disconnect all injection pipes (1). 2. Disconnect the fuel pipe (6) and fuel overflow pipe (4).
  • Page 249 WSM KX080-3 Service Engine Installing Procedure of Injection Pump Assembly 1. Install the fuel injection pump assembly (1) in its unit (2), and tighten the mounting screws and nuts like the figure, which the injection pump assembly (1) keeps tilted.
  • Page 250 WSM KX080-3 Service Engine Installing Procedure (Continued) 1. Move the stop lever (1) and visually check to see if the fuel injection pump control rack comes smoothly back to the start position by the counter force of the start spring.
  • Page 251 WSM KX080-3 Service Engine (6) Water Pump and Oil Cooler Water Pump 1. Remove the pipe band and the water pipe (1). 2. Remove the water pump (2). (When reassembling) • When mounting the water pump, take care not to forget mounting the O-ring and not to let it out of position.
  • Page 252 WSM KX080-3 Service Engine (7) Gear Case and Timing Gears Gear Case Cover 1. Remove the gear case cover. (When reassembling) • Confirm that the liquid gasket coating surface is free of water, dust and oil in order to maintain sealing effect.
  • Page 253 WSM KX080-3 Service Engine Idle Gear 1 and Idle Gear 2 (for Balancer Model) 1. Remove the idle gear mounting screw (1). 2. Draw out the idle gear (2) and (3). (When reassembling) • When install the idle gear (2) and (3), be sure to place the 4th...
  • Page 254 WSM KX080-3 Service Engine Plate (Gear Case) 1. Remove the three plate mounting screws(1). Detach the plate (2). (When reassembling) • Apply Three Bond 1217D adhesive or equivalent over the shaded zones on both sides of the gasket that will be sandwiched between the crankcase and plate.
  • Page 255 WSM KX080-3 Service Engine Connecting Rod Cap 1. Remove the connecting rod screws (1) from connecting rod cap. 2. Remove the connecting rod caps. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.) •...
  • Page 256 WSM KX080-3 Service Engine Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (8), and separate the connecting rod (7) from the piston (6). (When reassembling) • Be sure to fix the crankpin bearing and the connecting rod are same I.D.
  • Page 257 WSM KX080-3 Service Engine (9) Flywheel and Crankshaft Flywheel 1. Install the stopper to the flywheel so that the flywheel does not turn. • NOTE • Do not use an impact wrench. Serious damage will occur. 2. Detach the flywheel screws.
  • Page 258 WSM KX080-3 Service Engine Flywheel Housing 1. Remove the flywheel housing. (When reassembling) • Tighten the flywheel housing mounting screws with even force on the diagonal line. • Make sure the crank cases 1 and 2 are clean. Install them in position, referring to the flywheel housing’s contoured face.
  • Page 259 WSM KX080-3 Service Engine Crankcase 1 and Crankcase 2 (When reassembling) • Match the crankcase 1 and 2, referring to the flywheel housing’s contoured face. • Tighten the crankcase 2 mounting screws loosely. • Tighten up the jig to the specified torque same as the flywheel housing screw.
  • Page 260 WSM KX080-3 Service Engine Crankshaft 1. Remove the main bearing case. 2. Remove the crankshaft. (When reassembling) • Reassemble the main bearing case having the same number as the one engraved on the crankcase, and set the casting mark “F / W SIDE”...
  • Page 261 WSM KX080-3 Service Engine (10) Intake Air Heater Intake Air Heater 1. Remove the inlet hose. 2. Disconnect the lead. 3. Remove the flange and the intake air heater. NOTE • When assembling the intake air heater at the side of intake manifold, assemble the intake air heater as the heater lines are vertical.
  • Page 262 WSM KX080-3 Service Engine Pulley 1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut using a M24 box wrench. 58.3 to 78.9 N·m Tightening torque Pulley nut 5.95 to 8.05 kgf·m 43.0 to 58.2 ft-lbs...
  • Page 263 WSM KX080-3 Service Engine Reassembling the Brush 1. Fit the brush with its sliding face in the clockwise direction when viewed from front. IMPORTANT • Be sure to keep the 2 brushes deep in the brush holder. Otherwise the rotor and the rear section can not be fitted into the position.
  • Page 264 WSM KX080-3 Service Engine [3]SERVICING (1) Cylinder Head Top Clearance 1. Remove the cylinder head (remove the cylinder head gasket completely). 2. Bring the piston to its top dead center fasten 1.5 mm dia. 5 to 7 mm long fuse wires to 3 to 4 spots on the piston top with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.
  • Page 265 WSM KX080-3 Service Engine Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with the detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
  • Page 266 WSM KX080-3 Service Engine Clearance between Valve Stem and Valve Guide 1. Remove carbon from the valve guide section. 2. Measure the valve stem O.D. with an outside micrometer. 3. Measure the valve guide I.D. of the cylinder head at the most wear part as shown in the figure below with a small hole gauge.
  • Page 267 WSM KX080-3 Service Engine Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
  • Page 268 WSM KX080-3 Service Engine Free Length and Tilt of Valve Spring 1. Measure the free length (B) with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the spring on a surface plate, place a square on the side of the spring, and check to see if the entire side is contact with the square.
  • Page 269 WSM KX080-3 Service Engine Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
  • Page 270 WSM KX080-3 Service Engine (2) Timing Gears Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear. 3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.
  • Page 271 WSM KX080-3 Service Engine Camshaft Side Clearance 1. Set a dial indicator with its tip on the camshaft. 2. Measure the side clearance by moving the cam gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the camshaft stopper.
  • Page 272 WSM KX080-3 Service Engine Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with an inside micrometer. 3. If the clearance exceeds the allowable limit, replace the camshaft.
  • Page 273 WSM KX080-3 Service Engine Balancer Shaft Side Clearance 1. Set a dial indicator with tip on the balancer shaft. 2. Measure the side clearance by moving the balancer shaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the balancer shaft.
  • Page 274 WSM KX080-3 Service Engine Oil Clearance between Piston Pin and Small End Bushing 1. Measure the O.D. of the piston pin where it contacts the bushing with an outside micrometer. 2. Measure the I.D. of the piston pin bushing at the connecting rod small end with a cylinder gauge.
  • Page 275 WSM KX080-3 Service Engine Connecting Rod Alignment • NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check the bushing for wear beforehand. 1. Remove the piston pin from the piston.
  • Page 276 WSM KX080-3 Service Engine (4) Crankshaft Crankshaft Side Clearance 1. Set a dial indicator with its tip on the end of the crankshaft. 2. Measure the side clearance by moving the crankshaft to the front and rear. 3. If the measurement exceeds the allowable limit, replace the thrust bearings.
  • Page 277 WSM KX080-3 Service Engine Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
  • Page 278 WSM KX080-3 Service Engine Oil Clearance between Crankpin and Crankpin Bearing (Continued) IMPORTANT • STD size crankpin bearing. To replace it with a specific STD service part, make sure the crankpin bearing has the same ID color as the connecting rod.
  • Page 279 WSM KX080-3 Service Engine Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1. Clean the crankshaft journal and crankshaft bearing. 2. Put a strip of press gauge on the center of the journal. • IMPORTANT • Never insert the press gauge into the oil hole of the journal.
  • Page 280 WSM KX080-3 Service Engine (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.’s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.’s.
  • Page 281 WSM KX080-3 Service Engine Clearance between Outer Rotor and Pump Body 1. Measure the clearance between the outer rotor and the pump body with a feeler gauge. 2. If the clearance exceeds the allowable limit, replace the oil pump rotor assembly.
  • Page 282 WSM KX080-3 Service Engine Commutator and Mica 1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn. 2. Measure the commutator O.D. with an outside micrometer at several points.
  • Page 283 WSM KX080-3 Service Engine Armature Coil 1. Check the continuity across the commutator and armature coil core with an ohmmeter. 2. If it conducts, replace the armature. 3. Check the continuity across the segments of the commutator with an ohmmeter.
  • Page 284 WSM KX080-3 Service Engine Rotor 1. Measure the resistance across the slip rings with an ohmmeter. 2. If the resistance is not the factory specification, replace it. 3. Check the continuity across the slip and core with an ohmmeter. 4. If infinity is not indicated, replace it.
  • Page 285 WSM KX080-3 Mechanism IV Hydraulic System I . Hydraulic system Mechanism Section A. General ............IV-M-3 a.
  • Page 286 WSM KX080-3 Mechanism IV Hydraulic System E. Travel pilot valve (with damper) ......... .IV-M-66 a.
  • Page 287 WSM KX080-3 Mechanism IV Hydraulic System A.General a. Features of the hydraulic system Maiin feature points Feature contents Travel: P1 right travel, P2 left travel hree pump system ne cylin er bloc Front attachment control: P1 and P2 confluence for LS circuit t o eli ery ports.
  • Page 288 WSM KX080-3 Mechanism IV Hydraulic System b. Main specifications of hydraulic components Hydraulic component Maker Main specifications 1 Pump RD809-6111 36 cc x 2 + 33 + 8.1 cc/rev 72 x 2 + 67 + 16 L/min (19.0 x + 17.7 + 4.23 GPM) LS control valve: Differential pressure 1.5 MPa, 15.3 kgf/cm...
  • Page 289 WSM KX080-3 Mechanism IV Hydraulic System Hydraulic component Maker Main specifications 10 Left-right pilot valve Right (common) RC448-6172 Control angle: 19 deg. Left RD809-6140 Pilot pressure: 0.83 2.65 MPa, 8.5 27.0 kgf/cm 384 psi Right: Proportional control switch, left: ON-OFF...
  • Page 290 WSM KX080-3 Mechanism IV Hydraulic System IV-M-6...
  • Page 291 WSM KX080-3 Mechanism IV Hydraulic System c. Hydraulic components layout (10) (12) Main pump P1 delivery port (13) P2 delivery port (14) P3 pump P3 delivery port (11) Pilot pump LS valve (15) Unload valve accumulator SP 1 proportional valve...
  • Page 292 WSM KX080-3 Mechanism IV Hydraulic System d. Hydraulic Circuit Diagram Main components location IV-M-8...
  • Page 293 WSM KX080-3 Mechanism IV Hydraulic System 2. Pilot pump circuit IV-M-9...
  • Page 294 WSM KX080-3 Mechanism IV Hydraulic System 3. Hydraulic Circuit Diagram IV-M-10...

  • Page 295: Hydraulic Pump

    WSM KX080-3 Mechanism IV Hydraulic System .Hydraulic pump a. Main specifications Pump displacement (CC rev) 36 2 Pump flow rate (L min) 72 2 16 L min (19.0 17.7 4.23 Stand y flow rate (L min) 22 L min (5.81...
  • Page 296 WSM KX080-3 Mechanism IV Hydraulic System IV-M-12...
  • Page 297 WSM KX080-3 Mechanism IV Hydraulic System b. Outer view IV-M-13...
  • Page 298 WSM KX080-3 Mechanism IV Hydraulic System c. Structure P1, P2 (Variable displacement pump + Horsepower control + LS control) Fixed gear pump (Swivel, dozer SP2) P4 : Pilot pump (Used also for LS engine rpm proportional control) IV-M-14...
  • Page 299 WSM KX080-3 Mechanism IV Hydraulic System d. Functional parts 1 (3) (4) Function : The force to tilt the tilting swash plate toward the large flow side is produced by repositioning the turning center of the tilting swash plate and generat- ing the self-tilting moment.
  • Page 300 WSM KX080-3 Mechanism IV Hydraulic System e. Functional parts 2 (1) Orifice for P1 + P2 average pressure (2) High-pressure selector check valve (3) Engine rpm proportional gain control orifice (4) Response improvement check valve at P3 under pressure (5) PPS control pressure from CV (Control valve)
  • Page 301 WSM KX080-3 Mechanism IV Hydraulic System f. Pump control circuit (18) (1) PLS control pressure from CV (2) LS differential pressure setting spring (3) Engine rpm proportional gain control piston (17) (4) Response improvement check valve at P3 under pressure...
  • Page 302 WSM KX080-3 Mechanism IV Hydraulic System 1. LS control 1 Pmax Pmax LS-control valve When the machine is working under the stable load condition, load sensing pressure (PLS) and pump swash plate angle are at certain stable values. Therefore, LS control spool stays balancing according to the following equation.
  • Page 303 WSM KX080-3 Mechanism IV Hydraulic System 2. LS control 2 Pmax Pmax LS-control valve When an operator shifts the control lever to the inching movement of the front attachment, main spool notch opening area of the control valve is regurated to limit the oil flow through.
  • Page 304 WSM KX080-3 Mechanism IV Hydraulic System 3. LS control 3 Pmax Pmax LS-control valve When an operator shifts the control lever to full stroke, main spool notch area of the control valve opens fully. Therefore, pressure value before the spool notch (P...
  • Page 305 WSM KX080-3 Mechanism IV Hydraulic System 4. Hose power control 1 Operating condition : Pmax Within the horsepower zone Low Pc pressure, LS control zone, 0~100k = 80k, P Pmax LS-control valve Under this operating condition, average pressure ( ) is being applied the horse power spool to push the spring to increase the swash plate angle.
  • Page 306 WSM KX080-3 Mechanism IV Hydraulic System 5. Hose power control 2 Operating condition : Pmax Within the horsepower zone Low Pc pressure, LS control zone, 0~250k = 200k, P Pmax LS-control valve Under this operating condition, average pressure ( ) is being applied the horse power spool to push in...
  • Page 307 WSM KX080-3 Mechanism IV Hydraulic System 6. Hose power control 3 Operating condition : Pmax Horse power control zone = 150k = 200k Pmax LS-control valve Under this heavy load operating condition, average pressure ( ) and P pressure are being applied the...
  • Page 308 WSM KX080-3 Mechanism IV Hydraulic System g. FYI (For Your Information) 1. LS pump swash plate control mechanism KX080-3 Large-diameter piston for control Tilting center Fa: Assist spring (when F = low pressure) Clockwise moment of the cylinder block = (L...
  • Page 309 WSM KX080-3 Mechanism IV Hydraulic System 2. Horse power control mechanism max(P Approx. 3.8 Approx. 9.0 Approx. 3.0 Spool Pmax P (Independent of horse power control) (Tilting moment assist spring) IV-M-25...
  • Page 310 WSM KX080-3 Mechanism IV Hydraulic System C.Control Valve a. Feature Section composition Center open valve ( 14): 3-gang; Swivel, dozer, SP2 P3 confluence valve ( 14) Center open valve ( 14): 2-gang; Travel left and right Travel selector valve ( 18) Center closed valve (LS) ( 18): 4-gang monoblock;...
  • Page 311 WSM KX080-3 Mechanism IV Hydraulic System (2) Flow rate Approx. flow rate : LPM (GPM) Boom 110 (29.1) Down 68 (18.0) Crowded 130 (34.3) Dump 95 (25.1) Bucket Crowded 90 (23.8) Dump 90 (23.8) 100 (26.4) Swing Right 38 (10.0) Left 55 (14.5)
  • Page 312 WSM KX080-3 Mechanism IV Hydraulic System IV-M-28...
  • Page 313 WSM KX080-3 Mechanism IV Hydraulic System c. Ccontrol valve 1. Overall view of control valve Thread depth 20 Machine Front Tightening torque Tightening torque (4 locations) Spool setup direction ID Spool draw-out allowance 188.6 (dozer, swing) (possible at both sides)
  • Page 314 Equipped with S/P2 spool stroke adjustment mechanism: Adjustable range; 2 8 mm 10 Pump LS control pressure difference setting: 1.5 MPa Poppet Spool section assembly S/PS 11. Genuine Kubota part code: RO809-61131 Spring Spool section assembly Dozer Plug assembly Spool section assembly Swivel...
  • Page 315 WSM KX080-3 Mechanism IV Hydraulic System 3. Swing section Tightening torque Four ID grooves Tightening torque (4 locations) One spool setup direction ID groove Section A-A ID No. Part name Q’ty Remarks Valve housing Spool Spring seat Spring seat Spring...
  • Page 316 WSM KX080-3 Mechanism IV Hydraulic System Control valve; Uni-block section assy Section J-J Boom S/P1 Bucket Section A-A Section K-K IV-M-32...
  • Page 317 WSM KX080-3 Mechanism IV Hydraulic System Tightening torque (8 locations) Section B-B (Check poppet for arm regeneration) Tightening torque Tightening torque (2 locations) Section C-C Section L-L IV-M-33...
  • Page 318 WSM KX080-3 Mechanism IV Hydraulic System Tightening torque Tightening torque (6 locations) Two ID grooves without filter Tightening torque (4 locations) Tightening torque Section D-D 5. Boom Tightening torque (2 locations) Section E-E IV-M-34...
  • Page 319 WSM KX080-3 Mechanism IV Hydraulic System 6. S/P1 Tightening torque (2 locations) Section F-F 7. Bucket Tightening torque (2 locations) Section G-G IV-M-35...
  • Page 320 WSM KX080-3 Mechanism IV Hydraulic System 8. Arm Tightening torque (2 locations) Section H-H Tightening torque Tightening torque (2 locations) Tightening torque One ID groove Tightening torque Tightening torque Tightening torque Section I-I IV-M-36...
  • Page 321 WSM KX080-3 Mechanism IV Hydraulic System 9. Travel independent valve View X Tighten up until the plug breaks down (M4). Breaking torque: About 7 N-m (reference) View X Tightening torque (2 locations) Tightening torque: 19-22 N-m Tighten up until the plug breaks down (M6).
  • Page 322 WSM KX080-3 Mechanism IV Hydraulic System Travel, R section Travel upstream (next to travel independent valve) Tightening torque Tightening torque (4 locations) ID No. Part name Q’ty Remarks Valve housing Spool Spring seat Spring seat Spring Plug O-ring O-ring JISB2401,1A, G70...
  • Page 323 WSM KX080-3 Mechanism IV Hydraulic System Travel, L section Travel downstream (next to confluence valve) No O-ring is installed around the mating surface Tightening torque (2 locations) Tightening torque (4 locations) ID No. Part name Q’ty Remarks Valve housing Spool...
  • Page 324 WSM KX080-3 Mechanism IV Hydraulic System Combined valve No O-ring is installed around this surface No O-ring is installed around this surface Tightening torque Tightening torque (4 locations) Two ID grooves ID No. Part name Q’ty Remarks Valve housing Spool...
  • Page 325 WSM KX080-3 Mechanism IV Hydraulic System 13.S/P2 valve Tightening torque (2 locations) Tightening torque (4 locations) Tightening torque 7.8 9.8N m ID No. Part name Q’ty Remarks Valve housing Spool Cap assembly Spring seat Spring Poppet (check valve) Spring (check valve)
  • Page 326 WSM KX080-3 Mechanism IV Hydraulic System Dozer section Tightening torque (2 locations) Tightening torque (4 locations) Spool setup direction ID groove ID No. Part name Q’ty Remarks Valve housing Spool Spring seat Spring seat Spring Poppet (check valve) Spring (check valve)
  • Page 327 WSM KX080-3 Mechanism IV Hydraulic System 15.Swivel section Tightening torque (2 locations) Tightening torque (4 locations) ID No. Part name Q’ty Remarks Valve housing Spool Spring seat Spring seat Spring Poppet (check valve) Spring (check valve) Plug (check valve) O-ring...
  • Page 328 WSM KX080-3 Mechanism IV Hydraulic System 16.Outlet section, P3 bypass valve One ID groove Section A-A ID No. Part name Q’ty Remarks Valve housing Spool Plug Spring Poppet Spring seat Spring Plug Plug assembly Plug assembly O-ring JISB2401,1B, P18 O-ring...
  • Page 329 WSM KX080-3 Mechanism IV Hydraulic System d. Layout, delivery circuit and external pipe flow (1) P3 bypass confluence (2) P3 bypass signal branch (3) LS system detection external circuit (4) To oil cooler via swivel motor and back- pressure check valve...
  • Page 330 WSM KX080-3 Mechanism IV Hydraulic System e. Inlet section of mono-block valve (1) Delivery for LS system signal (PP3) (LS system control detected) (2) Arm s regenerative spool Monoblock inlet (3) Tank circuit LS relief, unload relief, arm regenerative spool (4) LS system unload relief 2.5 MPa...
  • Page 331 WSM KX080-3 Mechanism IV Hydraulic System f. Center closed valve section (Bucket, S/P 1, Boom) (1) Spiral groove air bleeding circuit (2) AI signal circuit (3) Tank circuit (4) Return check valve (5) Pressure compensating valve (Compensating spool) (6) Check valve for PLS signal high-pressure selection...
  • Page 332 WSM KX080-3 Mechanism IV Hydraulic System g. Center closed valve section (Arm) (1) Spiral groove air bleeding circuit (2) Tank circuit (3) Main spool with arm regeneration (4) Return check valve (Load check valve) (5) Pressure compensating valve (Compensating spool)
  • Page 333 WSM KX080-3 Mechanism IV Hydraulic System h. Arm regenerative flow (10) (1) Spool shift direction at arm crowding regeneration (2) PC flow (3) PC flow + Regenerative flow (4) Regenerative flow (5) Tank flow (6) Regenerative spool (7) Relief, unload section...
  • Page 334 WSM KX080-3 Mechanism IV Hydraulic System i. Swing section (Center closed valve) S : enter close type section (Spool ia. (1) Return check valve (Load check valve) (2) AI signal circuit (3) Pump circuit (4) Tank circuit (5) Neutral-position pressure relief land abolished...
  • Page 335 WSM KX080-3 Mechanism IV Hydraulic System j. P1 and P2 inlets and travel selector valve (10) (1) P2 inlet (2) Signal circuit to pump PPS (3) Tank circuit (4) To left-travel P circuit (5) Tank circuit (6) To Travel Right...
  • Page 336 WSM KX080-3 Mechanism IV Hydraulic System l. P3 inlet and P3 confluence section (12) (11) (4) (5) (10) (1) Tank circuit to swivel motor and oil cooler Travel + LS system control to get the (2) LS system action signal inlet port...
  • Page 337 WSM KX080-3 Mechanism IV Hydraulic System m.SP2 section (Mechanical flow adjustment) enter open type al e section ith mechanical ma imum flo a uster (1) Mechanical maximum flow adjuster (2) AI signal circuit (3) Tank circuit (4) P3 parallel feeder circuit (5) Mechanical maximum flow adjuster n.
  • Page 338 WSM KX080-3 Mechanism IV Hydraulic System o. P3 bypass confluence valve (1) To AI pressure switch (2) AI aperture (3) AI signal delivery (PP1) (4) P3 bypass confluence valve (5) Drain (6) P3 bypass circuit to monoblock P2 (7) Boom up signal...
  • Page 339 WSM KX080-3 Mechanism IV Hydraulic System p. LS bleed Monobloc en ( ircuit bet een S signal processing an This section is located between boom and swing section. (1) Passage to LS system ( 14) AI circuit (2) AI signal circuit...
  • Page 340 WSM KX080-3 Mechanism IV Hydraulic System IV-M-56...
  • Page 341 WSM KX080-3 Mechanism IV Hydraulic System IV-M-57...
  • Page 342 WSM KX080-3 Mechanism IV Hydraulic System IV-M-58...
  • Page 343 WSM KX080-3 Mechanism IV Hydraulic System IV-M-59...
  • Page 344 WSM KX080-3 Mechanism IV Hydraulic System IV-M-60...
  • Page 345 WSM KX080-3 Mechanism IV Hydraulic System IV-M-61...
  • Page 346 WSM KX080-3 Mechanism IV Hydraulic System IV-M-62...
  • Page 347 WSM KX080-3 Mechanism IV Hydraulic System IV-M-63...
  • Page 348 WSM KX080-3 Mechanism IV Hydraulic System i. FYI (For Your Information) 1. LS load s maximum pressure detection method (KX121-3, /s, KX161-3 /s, U45-3 ) to unload valve to Pump PLS port (KX080-3) to unload valve to Pump PLS port...
  • Page 349 WSM KX080-3 Mechanism IV Hydraulic System 2. SP2 flow control : Mechanical oil flow adjustment enter open type al e section ith mechanical ma imum flo a uster (1) Mechanical maximum flow adjuster (2) AI signal circuit (3) Tank circuit...
  • Page 350 WSM KX080-3 Mechanism IV Hydraulic System E.Travel pilot valve (with damper) a. Outline The damper-embedded pilot valve, RCVD8C, is a reducing-type valve using 4 secondary-pressure-control- ling reducing valves contained in a single valve casing. The outlet pressure varies according to the angle of the operating section.
  • Page 351 WSM KX080-3 Mechanism IV Hydraulic System c. Structure Casing O-ring Spring Plate, part Rod, push Spring Plug Washer 1 Bush Plug Washer 2 Cam shaft O-ring Seat, spring O-ring Retaining rings Set screw O-ring Bush Block Screw, hex. S. H. O.
  • Page 352 WSM KX080-3 Mechanism IV Hydraulic System (1) Damper narrowed (2) Secondary pressure spring (3) Operating force spring (4) Operating angle control: 9 deg. (5) Shuttle valve (6) Travel alarm switching port 2 locations IV-M-68...
  • Page 353 WSM KX080-3 Mechanism IV Hydraulic System d. Function The damper-embedded pilot valve includes in its main body a damping function to prevent hunting (lever hunting) in the man-machine system. The following explains the operation of the damper-embedded pilot valve, separating it into 2 sections: a.
  • Page 354 WSM KX080-3 Mechanism IV Hydraulic System 2. Operation section damping mechanism 2.1 When the operating section is at the neutral position As shown in the assemble cross-section drawing, the push rod is pushed upward by the damping spring (336, 337) through the piston (224).
  • Page 355 WSM KX080-3 Mechanism IV Hydraulic System Operation when the lever is tilted from the neutral position (1) Push rod (2) Orifice (3) Piston (4) Piston chamber (5) When the lever is tilted from the neutral position toward direction, the oil in the right (left) piston cham- ber passes out the orifice.
  • Page 356 WSM KX080-3 Mechanism IV Hydraulic System Lever stroke state and the operation when the lever is tilted in reverse direction (1) When the lever is tilted from the neutral position to the reverse position, the push rod is pushed upward...
  • Page 357 WSM KX080-3 Mechanism IV Hydraulic System Operation when the lever is tilted from the neutral position Tank port (1) Push rod (2) Orifice (3) Piston (4) Piston chamber (5) When the lever is tilted from the neutral position toward direction, the oil in the right (left) piston cham- ber passes out the orifice.
  • Page 358 WSM KX080-3 Mechanism IV Hydraulic System F. Swivel motor a. General 1. Swivel motor outer view PF3/8(G3/8) Vent port (2) PF3/4-A G3/4 JIS B2351 O-type (3) PF1/4-A G1/4 (4) PF1/4-A G1/4 (5) 1-M20x2.5 Drilled hole- 18 (6) 2-PF1/2-A G1/2 (7) Vent port...
  • Page 359 WSM KX080-3 Mechanism IV Hydraulic System 2. Swivel motor structure O-ring Spring O-ring O-ring Holder Intermediate disc O-ring Guide Swash-plate O-ring Bearing Friction disc Valve plate Housing Cylinder block Bearing Brake piston Snap ring Piston Spring Sleeve O-ring Shaft Shoe holder...
  • Page 360 WSM KX080-3 Mechanism IV Hydraulic System 3. Structure of reduction gear case Swivel Motor (MSG-44P-21) Plate Thrust washer Oil seal Drive gear Shaft O-ring Sleeve Thrust washer Bearing Screw Housing Sun gear Bearing Support 1 Plate Sleeve Thrust washer Race...
  • Page 361 WSM KX080-3 Mechanism IV Hydraulic System 4. Structure of brake valve A: Counterbalance valve B: Delay valve C: Check valve D: Shock-absorbing valve Covering Stopper O-ring Washer Valve cone O-ring Retaining ring Discharge port O-ring Piston Housing O-ring Spring O-ring...
  • Page 362 WSM KX080-3 Mechanism IV Hydraulic System b. Function of swivel motor 1. Hydraulic motor Nine pistons (2) are fitted in the cylinder block (1), and the valve plate (3) is attached at the end with two half- moon-shaped ports B and C. The cylinder block (1) turns itself and is connected by the key with the shaft (4).
  • Page 363 WSM KX080-3 Mechanism IV Hydraulic System Function 2 This brake valve has a shock-free mechanism and works in two stages. Section A1 Section A First stage When the brake valve is activated, the pressure in chamber B (P1) is kept lower than that in chamber C.
  • Page 364 WSM KX080-3 Mechanism IV Hydraulic System 4. Negative brake function Parking brake The separator discs (1) are in mesh with the housing, and the friction discs (2) with the cylinder barrel (3). The separator discs (1) and the friction discs (2) are pushed against the housing (6) by the springs (4) and the brake piston (5).
  • Page 365 WSM KX080-3 Mechanism IV Hydraulic System c. Parking brake and hydraulic timer (1) Parking brake (if equipped with parking brake) The parking brake is of wet multi-disk type and hydraulically released. With shaft-lock mechanism, the brake is engaged and disengaged by switching the external signal pressure.
  • Page 366 WSM KX080-3 Mechanism IV Hydraulic System Fig. 3 (1) To brake cylinder chamber C (2) Drain (3) Spring (4) To brake cylinder chamber C (5) Drain (6) To brake cylinder chamber C (7) Drain The above function is explained in a diagram below.
  • Page 367 WSM KX080-3 Mechanism IV Hydraulic System d. Anti Swivel Back Valve 1. Outline Anti swivel back valve makes the Main port connect to Drain line in a second in order to prevent Swivel back of upper carriage at swing stop motion.
  • Page 368 WSM KX080-3 Mechanism IV Hydraulic System (11) (10) (1) Flow control valve 1 (2) Check valve 1 (3) Flow control valve 2 (4) Check valve 2 (5) Damping chamber 1 (6) Sleeve (7) Orifice A (8) Damping chamber 2 (9) To make-up valve (This serves as drain on this motor.)
  • Page 369 WSM KX080-3 Mechanism IV Hydraulic System 3. Function Hy raulic circuit iagram ypical nti S i el ac al e (1) Flow control valve 1 (2) Damper chamber 1 (3) Check valve 1 (4) Sleeve (5) Orifice A (6) Check valve 2...
  • Page 370 WSM KX080-3 Mechanism IV Hydraulic System (Neutral condition) Check valve stands in center position by spring force when control valve is not operated. (P1 and P2 have same pressure.) (Acceleration and operating condi- tion) Check valve is pushed and block the passage when swivel motor is operated.
  • Page 371 WSM KX080-3 Mechanism IV Hydraulic System (Swivel back condition 1) After swivel stop, the swivel motor start to swivel back due to the swivel back pressure. This pressure pushes the sleeve in the direction of the check valve (Low pres- sure side) and makes sleeve contact with check valve.
  • Page 372 WSM KX080-3 Mechanism IV Hydraulic System 4. Swivel motor, swivel back prevention mechanism Pressure in the line Acceleration Constant rotating Deceleration Without swivel back prevention valve Time ( sec.) At P At P and P are blocked and P become same pressure by the valve seat.
  • Page 373 WSM KX080-3 Mechanism IV Hydraulic System e. High-pressure selector valve (for swivel brake release signal) 1. Outline Section A-A Section B-B Circuit diagram Used to select maximum pressure of the pilot signal for left/right swivel and arm crowd. Used to release the swivel motor’s negative brake at maximum pressure.
  • Page 374 WSM KX080-3 Mechanism IV Hydraulic System 2. Release function of negative valve Reaction force Swivel motor Digging force arm bottom left right If, Moment by digging force Swivel motor negative braking force ; Friction plates might be burned out. IV-M-90...

  • Page 375: Specifications

    WSM KX080-3 Mechanism IV Hydraulic System G.Travel motor a. General 1. GM motor This product is a rotary hydraulic actuator. The reduction gears, hydraulic motor, brake valve and parking brake are compactly integrated in this actuator. It has been developed and manufactured for construction machinery that requires low-speed rotations and high-level torques.
  • Page 376 WSM KX080-3 Mechanism IV Hydraulic System b. Outer view Direction of rotation Direction (view X) Inlet port Outlet port Clockwise Counter clockwise IV-M-92...
  • Page 377 WSM KX080-3 Mechanism IV Hydraulic System c. Structure 1. Basic structure of GM motor (1) Brake valve (2) Hydraulic motor (3) Parking brake (4) Two-speed select mechanism (5) Second reduction section (6) Reduction gears (7) First reduction section 1) Reduction gears The speed reducer consists of two sections: first reduction section with spur gears and second reduction section with pericycloid-toothed differential gears.
  • Page 378 WSM KX080-3 Mechanism IV Hydraulic System 2. Sectional view IV-M-94...
  • Page 379 WSM KX080-3 Mechanism IV Hydraulic System Section A-A Section B-B IV-M-95...
  • Page 380 WSM KX080-3 Mechanism IV Hydraulic System 3. Parts list Parts name Q’ty Parts name Q’ty Shoe Spindle kit Piston assembly Spindle assembly Piston Spindle Shoe Hold flange Reamer bolt Shaft Swash plate RV gear assembly Cylinder block RV gear kit...
  • Page 381 WSM KX080-3 Mechanism IV Hydraulic System d. Function 1. Reduction gears 1) Function The speed reducer consists of two sections: first reduction section with spur gears and second reduction section with pericycloid-toothed differential gears. The high speed of the hydraulic motor is reduced for low- speed, large-torque rotation.
  • Page 382 WSM KX080-3 Mechanism IV Hydraulic System 2) The tooth faces of RV gears A (4) and B (5) are in constant mesh with the pins (17) (number of pins: Zp). During the eccentric movement by the RV (17) gears A and B, their contact points shift sequen- tially rolling over the faces.
  • Page 383 WSM KX080-3 Mechanism IV Hydraulic System 2. Hydraulic drive This chapter describes the hydraulic motor, brake valve, parking brake and the hydraulic motor’s two-speed select mechanism, which are all used in the hydraulic drive. 1) Functions 1-1 Hydraulic motor The hydraulic motor is of swash-plate axial piston type. The force of pressure oil coming from the pump is converted to rotational movement.
  • Page 384 WSM KX080-3 Mechanism IV Hydraulic System 2-2 Brake valve The ports A and B serve to let in and out hydraulic oil. Discussed here is how the hydraulic oil (pressure oil) is supplied to the port A. The oil through the port B flows in the opposite direction. The hydraulic motor also runs in the opposite direction.
  • Page 385 WSM KX080-3 Mechanism IV Hydraulic System 2. Stopping (braking) When the pressure oil is interrupted, the hydraulic motor gets stopped. Here are the details. When the pressure oil to the port A is blocked, the pres- sure at the port A and in the chamber b drops. Accord- ingly the spool (323) starts sliding from left to the neutral position by the force of spring (328).
  • Page 386 WSM KX080-3 Mechanism IV Hydraulic System 2-3 Relief mechanism behavior 1. Starting The pressure oil from the pump is introduced from the port A to C. The oil through the port C, connected with the hydraulic motor, gives a rotational force to the motor.
  • Page 387 WSM KX080-3 Mechanism IV Hydraulic System Pressure at port C in the above behavior Time R/V B open Let s suppose, however, that the piston h is already at its stroke end depending on how the machine stopped immediately before. In such case, the valve e of relief valve B does not open. The pressure at the port C is thus as shown in the chart below.
  • Page 388 WSM KX080-3 Mechanism IV Hydraulic System 2. Stopping The hydraulic motor runs by the supply of pressure oil from the port A to C. When no pressure oil comes from the port A, the counterbalance valve returns to the neutral position.
  • Page 389 WSM KX080-3 Mechanism IV Hydraulic System Pressure at the hydraulic motor (port D) with the pressure oil flow blocked Time Piston d shifted R/V A open The pressure with the piston d being shifted is commonly called the primary relief pressure (low).
  • Page 390 WSM KX080-3 Mechanism IV Hydraulic System 2-4 Two-seed select mechanism (manual two-speed selection) 1. Low-speed stage At the low-speed stage, the pilot pressure is not supplied from the port P. In such state, the spool (371) is pushed to the left by the force of spring (381). The pressure oil at the port F stays blocked.
  • Page 391 WSM KX080-3 Mechanism IV Hydraulic System 2. High-speed stage At the high-speed stage, the pilot pressure of over 1.96 MPs (20 kgf/cm ) is supplied from the port P. In such state, the spool (371) surpasses the force of spring (381) and is pushed to the right. The pressure oil at port F is then introduced through the spool (371) into the chamber S.
  • Page 392 WSM KX080-3 Mechanism IV Hydraulic System 2-5 Parking brake 1. Running The pressure oil is supplied from the pump to the (116) (115) (104) port A or B. The spool (323) of brake valve shifts (112) to the left or right, which opens the port E. Now the pressure oil flows through the port E into the cylinder c .
  • Page 393 WSM KX080-3 Mechanism IV Hydraulic System H.Cylinder a. Shockless valve of Boom cylinder pilot line (1) Structure (1) Plunger (2) Ring (3) Spring (4) Body (5) Spool (6) Spring (8) Orifice (9) Retainer (11) Collared plug (12) Collared plug Fig. 1.
  • Page 394 WSM KX080-3 Mechanism IV Hydraulic System (2) Function (Let s discuss the ports A and 1 here. The same is true of the ports B and 2.) Port A to Port 1: Flow control See Fig. 2. The pressure oil out of port A flows this way: through the hole (b) of plunger (1), orifice (8), the lateral hole (a) of plunger (1) and into the port 1.
  • Page 395 WSM KX080-3 Mechanism IV Hydraulic System Port 1 to Port A: Free flow See Fig. 3. The pressure oil supplied out of port 1 flows through the hole (a) and orifice first and then through the hole (b) up to the port A.
  • Page 396 WSM KX080-3 Mechanism IV Hydraulic System I. Boom cylinder holding valve a. Outline The holding valve has been developed for hydraulic shovels. This control valve prevents the cylinder against gravity fall in the non-operating status and against sudden fall in case of hose burst.
  • Page 397 WSM KX080-3 Mechanism IV Hydraulic System d. Holding valve installation 1. Main parts (1) Main control valve to the holding valve (2) Holding valve to boom cylinder bottom side (3) Pilot secondary line (4) Drain line (5) Overload relief valve...
  • Page 398 WSM KX080-3 Mechanism IV Hydraulic System e. Main parts function Holding valve (manual open type) Main part’s function Name Function Poppet To stop a leak between main relief valve and cylinder. Equipped with load check function. Spool Activated over the stroke by the cylinder-actuated pilot pressure to control the flow rate from cylinder to main relief valve.
  • Page 399 WSM KX080-3 Mechanism IV Hydraulic System f. Circuit function 1. Newtral position When the spool stays neutral (with no pilot pressure applied), the poppet seat (a), spool seat (b), sliding spool seal (c) and relief valve poppet seat (d) all serve to stop a leak from the cylinder. In this way, the cylin- der is prevented against gravity fall.
  • Page 400 WSM KX080-3 Mechanism IV Hydraulic System 2. With oil flowing from A-port to B-port (from main control valve to cylinder) The oil from A-port flows against the cylinder pressure and the poppet s return spring force. It then gets the poppet open and flows on to B-port.
  • Page 401 WSM KX080-3 Mechanism IV Hydraulic System 3. With oil flowing from B-port to A-port (from cylinder bottom side to main control valve) (1) When the pilot pressure is applied, the pressure in the pilot chamber (e) rises. The oil from the pilot chamber flows along the pilot line and through the orifices (f) and (g) into the drain port.
  • Page 402 WSM KX080-3 Mechanism IV Hydraulic System (3) When the pilot pressure rises higher, the poppet spring chamber (i) gets connected to the A-port side with the spool internal passage in between. The poppet s orifice (j) then causes a pressure difference between B-port and poppet spring chamber, which gets the poppet open.
  • Page 403 WSM KX080-3 Mechanism IV Hydraulic System 4. Over-pressure in the cylinder (relief valve activated) (1) If the cylinder pressure rises above the relief valve s pressure setting, the relief valve opens itself to gen- erate a pressure in the chamber (k).
  • Page 404 WSM KX080-3 Mechanism IV Hydraulic System 5. Manual release of cylinder bottom oil When the boom cylinder is required to get down, screw in the screw plug, which pushes the piston (1) and (2) and results in opening the oil passage of control spool.
  • Page 405 WSM KX080-3 Mechanism IV Hydraulic System J. Solenoid valve a. Solenoid proportional control valve Hydraulic symbol Max. working pressure. 7 MPa (Press. in port P) Allowable back pres- 1.0 MPa and below sure. (Press. in port T) Max flow proportional...
  • Page 406 WSM KX080-3 Mechanism IV Hydraulic System (1) Type of connection : equivalent to amp econoseal J senies connectors mark II (+) gap hausing (Gap housing : 174354 -2, Terminal : 173706 - 1) (2) Tightening torque : 7 1 N m...
  • Page 407 WSM KX080-3 Mechanism IV Hydraulic System 101 Casing Al alloy 171 Rexabox head bolts M5 x 0.8 7.0 601 Proportional reducing valve 901 Name plate IV-M-123...
  • Page 409 WSM KX080-3 Service Hydraulic system Hydraulic system Ser ice Section A. Troubleshooting I -S-3 a.Case - Study : Abnormal speed -S-4 b.Case - Study : The power is weak -S-5 c.Case - Study : Poor Manipulation and Abnormal Operation -S-6 d.LS control system troubleshooting...
  • Page 410 WSM KX080-3 Service Hydraulic system D. Disassembling and Reassembling I -S-59 a.Coupling flange -S-59 b.Pump : -S-60 c.Gear pump (P3, Pp) -S-77 d.Control valve -S-82 e.Pilot valve -S-106 f.Dozer pilot valve -S-107 gSwing pilot valve -S-108 h.Travel pilot valve -S-111 i.Swive.
  • Page 411 WSM KX080-3 Service Hydraulic system A.Troubleshooting a. Case - Study : Abnormal speed Fig.1 Main relief valve Problems Probable causes Remedies Ref.Fig. The speed of all 1) The engine rpm is low. 1) Adjust the accelerator cable or link. Sleeve "E"...
  • Page 412 WSM KX080-3 Service Hydraulic system a. Case - Study : Abnormal speed Fig. 4 Relief valve layout Problems Probable causes Remedies Ref.Fig. The speed of a certain 1) Swing: The swing pilot valve malfunctions. 1) Check the function of pilot valve.
  • Page 413 WSM KX080-3 Service Hydraulic system b. Case - Study : The power is weak. Problems Probable causes Remedies Ref.Fig. Fig. 13 Pump control The entire actuator power is 1) Poor operation or maladjustment of the main relief valve 1) Disassemble, clean and reset the main relief valve.
  • Page 414 WSM KX080-3 Service Hydraulic system c. Case - Study : Poor Manipulation and Abnormal Operation Problems Probable causes Remedies Ref.Fig. Fig. 12 High pressure selection valve The engine stalls at the 1) The control pin has got stuck. 1) Eliminate the cause of the stick completely or Fig.13...
  • Page 415 WSM KX080-3 Service Hydraulic system c. Case - Study : Poor Manipulation and Abnormal Operation Problems Probable causes Remedies Ref.Fig. Swivel stop can’t be not locked. The swivel slow return check-valve is clogged with dirt. Disassemble and clean the check-valve.
  • Page 417 LS control system troubleshooting (1) General The core of the hydraulic system corprated in KX080-3 is a combination of horsepower control and LS control. Trouble with the hydraulic system is therefore attributed chiefly to hydraulic equipment such as pumps and control valves.
  • Page 418 Hydraulic system (3) Procedures for LS Control Valve Troubleshooting In the event of hydraulic trouble with the LS controller for KX080-3, complete the following basic check items and check the manipulation of the hydraulic pilot system. (1) Basic check items: Quantity of oil, quality of oil, filter clogging, oil leak, air suction, engine condi-...
  • Page 419 WSM KX080-3 Service Hydraulic system 5) Compensation spool 1. The compensation spool moves based on a balance between the PC pressure and the load pres- sure. However, the symptom depends on the position in which a stick occurs. 2. If a stick occurs in the stroke-0 position, i.e. in a state of the so-called under lap, the cylinder speed decreases, since the opening in the spool is small.
  • Page 420 WSM KX080-3 Service Hydraulic system (4) Procedures for LS control Pump Troubleshooting 1) General The pump mainly exercises the following two types of control. 1. Exercises horse power control over the hydraulic system to prevent the maximum horsepower of the engine from being exceeded. That is, prevention of engine stall.
  • Page 421 WSM KX080-3 Service Hydraulic system 2) Fundamentals of LS Pump Troubleshooting (Defective Portions and Symptoms) Failure symtom Pump performance Portion contributable to the failure of The speed of the work machines is The engine stalls in certain condi- pump swash plate control low, since the required flow is not tions.
  • Page 422 WSM KX080-3 Service Hydraulic system e. Pump component trouble causes and remedy (1) General precaution The pump works normally for a long period of time as far as it is operated under appropriate condition. If it will not work as planned, it is necessary first to check to see if the cause of trouble is derived from either the pump itself or other equipment.
  • Page 423 WSM KX080-3 Service Hydraulic system Failure symptom Suspected causes Remedy 5. Suction resistance develops exces- Reduce suction resistance. sively, resulting in generation of cavi- tation abnormal temperature, abnormal hydraulic oil viscosity and other causes. 3. Pump generates abnormal noise. 1. Air is sucked in due to lowering of Supply oil and eliminate air under no- oil level in the tank.
  • Page 424 WSM KX080-3 Service Hydraulic system f. Control valve component troubleshooting --Control valve in general-- Failure symptom Suspected causes Remady 1. Spool will not stroke. (Machine will 1. Oil temperature is raised abnor- Remove something which hampers oil not pick up speed.) mally.
  • Page 425 WSM KX080-3 Service Hydraulic system --Relief valve, unload valve and high pressure selector valve -- Trouble Possible cause Remady 1. Pressure will not be raised at all. 1. Main poppet, sleeve or pilot poppet Replace the relief valve. is seized and kept open, or dust exists at the valve seat.
  • Page 426 WSM KX080-3 Service Hydraulic system g. Travel motor component troubleshooting In case of any trouble arising during running, investigate the cause and take an appropriate remedial measure by referring to the Table of Troubleshooting shown below. (1) Main function Trouble...
  • Page 427 WSM KX080-3 Service Hydraulic system (2)Counterbalance valve function Trouble Possible Cause Remedy 1. Motor will not rotate or rotates but Plunger does not switch. slow. 1) Hydraulic pressure is not gener- Check whether piping is damaged ated. or not. 2) Foreign matter exists between Remove foreign matter completely.
  • Page 428 WSM KX080-3 Service Hydraulic system (3) Hi-Low speed function Trouble Possible Cause Remedy Machine turns during traveling. Spool does not switch. 1)Foreign matter exists between the Remove foreign matter completely. spool and the valve body. Repair damaged part assemble it after cleaning. If the damage and leakage are severe, replace the part.
  • Page 429 WSM KX080-3 Service Hydraulic system B.Specifications a.Specifications of pump Unit KX080-3 Remarks Manufacturer KYB Co.,Ltd. Model PSVL2-36C-4 Kubota part No. RD809-6111-0 Rated pump rpm 2000 29.4 Main relief kgf/cm2 pressure a1/a2 4267 20.6 Main relief Rated load pressure kgf/cm2 pressure a4 2987 3.92...
  • Page 430 WSM KX080-3 Service Hydraulic system b.Relief Valve pressure setting (1)Main relief valve(bench data) Valve location Operating work Unit KX080-3 Remarks 29.4±0.3 KX080-3: Travel main relief valve a1 300±3 kgf/cm at 43 L/min (11.36 USGPM) 4264±44 29.4±0.3 KX080-3: Travel main relief valve a2 300±3...
  • Page 431 WSM KX080-3 Service Hydraulic system (3) Overload relief valve (bench data) valve location Operating work Unit KX080-3 Remarks 31.4 ±0.3 Boom up/down Bucket Control valve ±3 kgf/cm dump/crowd Arm dump 4554 ±44 30.4 ±0.3 Control valve Arm crowd ±3 kgf/cm 4409 ±44...
  • Page 432 WSM KX080-3 Service Hydraulic system (4) verload relief valve (at the measurement port on the machine valve location Operating work Unit KX080-3 Remarks +1.0 31.5 -1.0 Boom up/down Bucket Control valve at 1500 rpm kgf/cm dump/crowd Arm dump +145 4569 -145 +1.0...
  • Page 433 WSM KX080-3 Service Hydraulic system (5) Pilot system pressure valve location Operating work Unit KX080-3 Remarks +0.2 -0.0 Primary pilot pressure At bench kgf/cm +0.5 -0.5 Primary pilot All pilot lines at kgf/cm pressure at machine machine port +0.3 -0.0...
  • Page 434 Total Displacement cu.in/rev 55.48 L/min Max.oil flow Rated flow rate USGPM 17.44 Motor speed 72.6 KX080-3: at 66 L/min (17.44 USGPM) 21.6 Relief valve pressure KX080-3: at 66 L/min (17.44 USGPM) kgf/cm (at bench) 3129 Theoretical output torque kgf.m 96.9 KX080-3 : at 21.6MPa(220kgf/cm2, 3129psi)
  • Page 435 6637.9 KX080-3: at 24.5MPa Theoretical torque (300kgf/cm2, 4267 psi) 5160 kgf.m 526.2 ft.lbf 3805.8 31.6 Theoretical speed KX080-3 : at 72 L/min (19.02 USGPM) 52.7 29.4 Relief valve pressure kgf/cm 4267 Climbing ability deg. 55.2 Slip 70% theoretical torque 5633 Oil temp.:50±5°C(122±9°F)
  • Page 436 WSM KX080-3 Service Hydraulic system Unit KX080-3 Remarks L/min 0.50 On new machine US gal/ 0.13 Drain amount while rotating L/min 1.00 On new machine US gal/ 0.26 Hi-speed change pressure 20.0 70.0 kgf/cm Min./Max Parking brake ; Braking kgf.m torque ft.lbf...
  • Page 437 WSM KX080-3 Service Hydraulic system e.Cylinder (1) Speed KX080-3 Unit Remarks Canopy sec. GL to Max. height (exclude cushion time) Cabin sec. 3.1 to 3.7 Boom cylinder Canopy sec. Down Max. height to GL Cabin sec. 3.1 to 3.7 cushion sec.
  • Page 438 WSM KX080-3 Service Hydraulic system (3) Specifications and dimensions 1)Cylinder specifications Unit KX080-3 Remarks ø115xø65 Tube I.D.xRod O.D. ø4.53xø2.56 Stroke 34.57 1369 Min. retraction length 53.90 Manufacturer KYB Co.,Ltd. Parts No. RD809-6750-0 Boom Seal kit No. RD809- Piston tightening torque kgf.m...
  • Page 439 WSM KX080-3 Service Hydraulic system Unit KX080-3 Remarks ø90xø55 Tube I.D. x Rod O.D. ø3.54xø2.17 Stroke 29.41 1138 Min. retraction length 44.80 Manufacturer KYB Co.,Ltd. Bucke Parts No. RD809-6780-0 Seal kit No. RD809- Piston tightening torque kgf.m ft.lbf Piston screw size...
  • Page 440 WSM KX080-3 Service Hydraulic system KX080-3 Unit Port screw size Remarks Boom G 1/2" KYB Co.,Ltd. 2.76 2.76 3.54 3.54 2.56 4.53 5.28 2.24 2.76 G 1/2" KYB Co.,Ltd. 2.36 2.36 3.35 3.35 2.36 3.94 4.65 2.17 2.28 Bucket G 1/2"...
  • Page 441 WSM KX080-3 Service Hydraulic system 3)Tightening torque (1) Boom cylinder Tightening torque Thread size Unit Adhesive KX080-3 KX080-3 N·m 350-400 Cylinder head kgf·m 35.7-40.8 ft·lbs 258.1-295.0 N·m 600±120 Piston kgf·m 61.2±12.2 ft·lbs 442.5±88.5 N·m Set screw kg·m M8x1.25 ft·lbs 14.8...
  • Page 442 WSM KX080-3 Service Hydraulic system (4) Swing cylinder Tightening torque Thread size Unit Adhesive KX080-3 KX080-3 N·m Cylinder head 66.3 ft·lbs 479.5 N·m 2800 Piston 285.5 M48x2 ft·lbs 2065.0 N·m Set screw kg·m ft·lbs (5) Blade cylinde Tightening torque Thread size...
  • Page 443 WSM KX080-3 Service Hydraulic system C.Testing a. Testing Instruments & special tools (1) Gauges and special tools for pressure testing 1. Pressure hose , 427 psi 2. Pressure gauge; 2.94 MPa, 30kgf/cm For Secondary pilot pressure test. 3. Pressure gauge; 5.88 MPa, 60kgf/cm , 853psi For primary pilot pressure test.
  • Page 444 WSM KX080-3 Service Hydraulic system (2) Flow meter and special tools for flow testing 1. Flow meter; Flowtech Inc. make 2. Loading handle 3. Male-female joint 1” × 1” 4. joint 1” × 1/2” 5. Hose 1/2” 6. O-ring Drawing of (3) Male - female joint 1” × 1”...
  • Page 445 WSM KX080-3 Service Hydraulic system b. Precautions in handling the pump (1) Points to remember when replacing the pump or using a vacuum pump (Without taking the following steps, unusual noise may be heard and what’s worse, the pump may get damaged.)
  • Page 446 WSM KX080-3 Service Hydraulic system (2) Air bleeding method in case the hydraulic oil in the tank looks cloudy with air bub- bled (Without taking the following steps, unusual noise may heard and what’s worse, the pump may get damaged.) Be sure to keep the engine running at the idling speed in the following procedure.
  • Page 447 WSM KX080-3 Service Hydraulic system c. Pilot pressure (1) Primary pressure 1. Remove the side cover of the tank. 2. Set a pressure gauge to the measuring port. 3. Start the engine and run it at the maximum speed. Take 2 or 3 measurements to have an exact read- ing.
  • Page 448 WSM KX080-3 Service Hydraulic system (2) Secondary pressure [Ex: Measurement with the arm crowd] 1. Remove the side cover of the tank. 2. Connect a T joint to the arrow-marked point and set the pressure gauge there. 3. Start the engine and run it at the maximum speed.
  • Page 449 WSM KX080-3 Service Hydraulic system d. Main relief valve : LS system (Measurement methed) 1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there.
  • Page 450 WSM KX080-3 Service Hydraulic system e. Main relief valve : Travel system 1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there.
  • Page 451 WSM KX080-3 Service Hydraulic system f. Unload valve (Measurement method) 1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there.
  • Page 452 WSM KX080-3 Service Hydraulic system g. Overload relief valve • Measurement method 1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there.
  • Page 453 WSM KX080-3 Service Hydraulic system • Location of the relief valve (A) Machine front (B) Cab side ORV : Overload Relief valve 1) LS unload valve (b6) 2) LS main relief valve (a2) 3) Travel main relief valve (a1) 4) Travel main relief valve (a2)
  • Page 454 WSM KX080-3 Service Hydraulic system h. Swivel brake valve pressure (Measurement method) 1. Set the pressure gauge to the coupler at the main pump discharge side. Or remove the plug off the main pump discharge side and set the pressure gauge there.
  • Page 455 WSM KX080-3 Service Hydraulic system • Adjustment of the brake 1. Loosen the lock nut of the relief valve. 2. Using a hex wrench, turn the adjusting screw to reach the specified setting. Then tighten up the lock nut. 3. Run the engine at 1500 rpm. Move the levers and feel the pressure setting.
  • Page 456 WSM KX080-3 Service Hydraulic system i. Measuring the main pump Max. flow rate [Precautions] 1. Park the machine on a flat, solid ground. 2. Connect a vacuum pump. 3. Disconnect the hose from port P (delivery). 4. Connect joint A and measuring hose to pipe joint T of the pump (port P).
  • Page 457 WSM KX080-3 Service Hydraulic system [Measurement] 1. Raise the engine speed to the maximum rpm. 2. Gradurally close the flowmeter’s loading valve and measure the flowrate and engine rpm at each pressure point in the P-Q curve. 3. Take the measurements 3 times.
  • Page 458 WSM KX080-3 Service Hydraulic system j. Measuring the main pump’s stand-by flow rate Preparations are almost same as in pump’s Max. flow rate. 1 ~ 5. Same as in pump’s Max. flowrate. 6. Disconnect hose PLs and attach plug (1/4) to this hose’s end.
  • Page 459 WSM KX080-3 Service Hydraulic system k. LS control pressure The actual measurement of LS control differential pressure requires special equipment such as a dif- ferential pressure instrument. General maintenance shops do not have such a expertise measuring device. This section introduces a simple method that makes use of the swivel motion or travel opera- tion.
  • Page 460 WSM KX080-3 Service Hydraulic system l. Traveling motor drain amount 1. Disconnect the drain hose from the travel motor and connect another hose (the pressure gauge hose will do) where the drain hose was discon- nected. 2. Float the crawlers as shown as below.
  • Page 461 WSM KX080-3 Service Hydraulic system m.Swivel motor drain amount 1. Remove right side cover. 2. Locate front attachment to traveling position. Bucket should be located 1 m above from ground. 3. Remove drain hose of the swivel motor and recieve drain oil in a suitable reservoir.
  • Page 462 WSM KX080-3 Service Hydraulic system n. Swivel motor block performance 1. Locate the machine on the 20 deg. slope. 2. The front position is of arm dump and bucket crowd. Keep the boom so that the boom end pin is alignedwith the bucket pin.
  • Page 463 WSM KX080-3 Service Hydraulic system o. Traveling motor block performance 1. Park the machine on a 20deg. slope. Keep front at traveling position. 2. Put marks on the truck frame and the crawler. 3. Measure 10 minutes slip-distance without engine run- ning.
  • Page 464 WSM KX080-3 Service Hydraulic system p. Operating speed (1) Checking each operating speed. [Important points] 1. Measure full stroke operating time with no load on the standard bucket. 2. Make several mesurement and use average time for judgement. 3. Two different measurements are expected for the forward and backward movements as well as the right and left swivelings.
  • Page 465 WSM KX080-3 Service Hydraulic system (4) Bucket cylinder 1. Position the boom and arm as showm at left. 2. Measure the bucket cylinder full stroke operating time. (5) Swing cylinder 1. Position the boom, arm and bucket as showm at left.
  • Page 466 WSM KX080-3 Service Hydraulic system (7) Swivel speed 1. Position the boom, arm and bucket as showm at left. 2. Measure three times rotation time. (8) Traveling speed 1. Travel the machine untill getting max. speed. 2. After getting max. speed, measure the 10 mm (33 ft) traveling time.
  • Page 467 WSM KX080-3 Service Hydraulic system D.Disassembling and Reassembling a. Coupling flange 1. Apply a proper amount of grease on the splines. • Otherwise the splines may get burnt, making it difficult to remove the pump. 2. Keep the rubber free from grease. Immediately wipe it clean if stained with grease.
  • Page 468 WSM KX080-3 Service Hydraulic system b.Pump 1. Pump assy dismount 1. Disconnect the delivery hoses 2. Plug the joints. 3. Remove the section hose below the pump. 4. Wound the nylon sling around the pump and remove the mounting bolts.
  • Page 469 WSM KX080-3 Service Hydraulic system 6. View after pump discounting. IV-S-61...
  • Page 470 WSM KX080-3 Service Hydraulic system 2.Adaptor and joint 1)Fitting the adaptor Position the adaptor in position as shown at left. 2)Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs G3/8 size 37.2~42.1N.m(3.8~4.3kgf.m)27.4~31.1ft.lbs G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs G3/4 size 117.6~127.4N.m(12.0~13.0kgf.m)86.7~94.0 ft.lb 3)Bolt tightening torque 196.1~225.6N.m(20.0~23.0kgf.m)144.6~166.4 ft.lbs...
  • Page 471 WSM KX080-3 Service Hydraulic system 4)Fitting the flange (Suction) Be careful to install the O ring in position. 5)Bolt tightening torque 77.5~90.2N.m(7.9~9.2kgf.m)57.2~66.5ft.lbs 6)Fitting the hydraulic hose (3/16) Lay the hose in the route as shown at left. Make sure the hose is tightly hooked. Press-fit the hose until it clicks.
  • Page 472 WSM KX080-3 Service Hydraulic system 3.Disassembly and reassembly 1)Outer view Delivery port. (1)Inlet port. (2)LS control valve. IV-S-64...
  • Page 473 WSM KX080-3 Service Hydraulic system (1)Horse power control valve. (2)Horse power sensing spools. (4)P3 Delivery port (1)Horse power control valve (4) P delivery port (5) P port (6) P port IV-S-65...
  • Page 474 WSM KX080-3 Service Hydraulic system 4.Remove gear pump. Bolt size : Wrench : Tightening torque : (1)LS control valve. (2)Section port for P (3)Delivery port of P (4)Horsepower sensing line of P IV-S-66...
  • Page 475 WSM KX080-3 Service Hydraulic system 5. Remove LS control valve 1) Remove the mounting bolts. Bolt size : Wrench : 2) LS control valve. 5 ports 1) Pump pressure sensing line 2) HPC pilot line 3) HPC pilot line 4) Pilot pump pressure after the fixd orifice...
  • Page 476 WSM KX080-3 Service Hydraulic system 6. Remove horsepower control valve 1) Horsepower control valve punch the mating mark before disassembling. 2) Take out the valve assy. 3) Inner parts. 4) Average pressure sensing puppet. IV-S-68...
  • Page 477 WSM KX080-3 Service Hydraulic system 5) Max pump pressure selection check valve. 6) Check valve for Pc bypass. IV-S-69...
  • Page 478 WSM KX080-3 Service Hydraulic system 7. Remove the valve block assy 1) Remove the mounting bolts. Bolt size : Wrench : Tightening torque : 2) Rear view of the valve block. 3) Separate the valve block. (1)Gasket (2)Knock pins 4) View from above.
  • Page 479 WSM KX080-3 Service Hydraulic system 5) Control pin. 6) Control pin body. 7) Take out the valve plate. 8) Take out the spacer ring. IV-S-71...
  • Page 480 WSM KX080-3 Service Hydraulic system 8. Remove the cylinder block assy 1) Take out the gasket. 2) Take out the control spring assy. 3) Springs (1)Inner control spring (2)Outer control spring (3)Assist spring (4)Spring seat 4) Take out the cylinder block assy.
  • Page 481 WSM KX080-3 Service Hydraulic system 6) Inner parts of the cylinder block (1)Pistons (2)Cylinder (3)Cone (4)Springs 7) Springs 8) Piston 9) Spring seat IV-S-73...
  • Page 482 WSM KX080-3 Service Hydraulic system 9. Remove the main shaft 1) Remove the mounting bolts. Bolt size : Wrench : Tightening torque : 2) Punch out the main shaft. 3) Take out the shaft and the flange. 4) Take out the shaft.
  • Page 483 WSM KX080-3 Service Hydraulic system 5) Remove the snap ring. 6) Punch out the bearing. 7) Disassembled parts. (1)Main shaft (2)Bearing (3)Snap ring IV-S-75...
  • Page 484 WSM KX080-3 Service Hydraulic system 10. When reassembling 1) Install the snap ring 2) Install the flange (1)Knock pin 3) Tighten the flange bolt 4) Assemble the pistons and springs. In principle, each piston should be in the original cylinder barrel.
  • Page 485 WSM KX080-3 Service Hydraulic system c.Gear pump (P Disassemble and reassemble 1. Outer view 1) Output shaft 2) P delivery port 3) P delivery port 2. Remove mounting bolts L-wrench=M10 Tightening torque: 3. Mounting bolts M12 x 152 IV-S-77...
  • Page 486 WSM KX080-3 Service Hydraulic system 4. Remove the end cover. 5. Remove the casing of the pump 3. 6. Take out the gears and the plates. 1) P pears 12T x 43.55 2) Plates 7. Remove the snap ring. IV-S-78...
  • Page 487 WSM KX080-3 Service Hydraulic system 8. Separate the front flange and pilot pump housing 1) Front flange 2) Output shelf 3) Pilot pump gear, T12 x 10.60 4) Plates 9. Inner parts 1) Pressure side (delivery) 2) Suction side 10. Remove the side cover. Take out the yoke gear.
  • Page 488 WSM KX080-3 Service Hydraulic system 11. When reassembling Securely check the direction and face of the plate. 1) Delivery side 2) Suction side 12. Oil passage 1) Pump 3 sensing line 13. Oil passage 2) Pilot pump delivery port 14. Oil passage...
  • Page 489 WSM KX080-3 Service Hydraulic system 16. Securely check the direction and face of side plate. 17. Check the seal; rings and knock pin. IV-S-81...
  • Page 490 WSM KX080-3 Service Hydraulic system d.Control valve 1.Adaptor and joint 1)Fitting the valve assembly (control), bracket (1, valve), bracket (2, valve) and bracket (3, valve) Set them up in the following steps. a)Fit the three brackets (1, valve) (2, valve) and (3, valve) onto the valve assembly (control).
  • Page 491 WSM KX080-3 Service Hydraulic system 4)Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs G3/8 size 37.2~42.1N.m(3.8~4.3kgf.m)27.4~31.1ft.lbs G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs G3/4 size 117.6~127.4N.m(12.0~13.0kgf.m86.7~94.0ft.lbs G1-1/4 size 220.5~230.3N.m(22.5~23.5kgf.m) 162.6~169.9ft.lbs 7/8-14UNF size 55.9~60.8N.m(5.7~6.2kgf.m)41.2~44.8ft.lbs 5)Tightening torque of the adaptor of port T1 Pipe joint (SG12, G12) Valve assembly (return) Pipe...
  • Page 492 WSM KX080-3 Service Hydraulic system 1.Fitting the valve assembly Fit the assembly in position as shown at left. Tightening torque 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs (26) (25) (C/V) (36) (27) (37) (28) (38) (29) (39) (40) (22) (35) (41) (42) (10) (30) (43) (11)
  • Page 493 WSM KX080-3 Service Hydraulic system (a)[PS bypass] (b)[Swivel] (left) (c)[Dozer] (bottom) (d)[S/P2] (low) (e)[Confluence valve] (f)[Travel] (left backward) (g)[Travel] (right backward) (h)[Travel independent valve] (i)[Arm] (bottom) (j)[Bucket] (bottom) (k)[S/P] (low) (l)[Boom] (rod) (m)[Swing] (left) (n)(Right) (o)(Rod) (p)(HIGH) (q)(Left forward) (r)(Right forward)
  • Page 494 WSM KX080-3 Service Hydraulic system IV-S-86...
  • Page 495 WSM KX080-3 Service Hydraulic system 2.Disassembly and reassembly (a)Valve assy disassembly 1. Lift down the control valve any by using the crane. 2. Lifting eye-bolt M10x1.5 3. View from above. 4. View from side. 5. Swing shut valve portion. IV-S-87...
  • Page 496 WSM KX080-3 Service Hydraulic system 6. Unload valve area. 7. Dozer, swivel section area. 8. Side view. 9. Side view, pilot port. 10. Side view, mono block pilot port. IV-S-88...
  • Page 497 WSM KX080-3 Service Hydraulic system 11. Side view Pilot port and S/P2 section. 12. P confluence section. 13. Screen and orifice (P 14. Screen and orifice (P 15. LS main relief valve inside. IV-S-89...
  • Page 498 WSM KX080-3 Service Hydraulic system 16. P3 bypass spool 17. Plug with orifice (P 18. Compensation spool in the swing section. (1)Compenstaion spool (2)High pressure selection poppet 19. Load check poppet and spring. 20. Swing section and end port plate.
  • Page 499 WSM KX080-3 Service Hydraulic system 21.Swing section and boom section (Mono- block) 22.Am section (Mono-block) and inlet section (Travel independent valve) 23.Inlet section (Travel independent valve) and travel R section. 24.Travel R and travel L section. 25.Travel L and P inlet section.
  • Page 500 WSM KX080-3 Service Hydraulic system 26. P inlet section and SP2 section. 27. SP2 section and dozer section. 28. Dozer section and swivel section. 29. Swivel section and P3 confluence section. IV-S-92...
  • Page 501 WSM KX080-3 Service Hydraulic system (b)Each section and inner parts 1.Inlet section (P1,P2) (Travel independent valve) 1) Outer view 2) Other side 3) Inner parts IV-S-93...
  • Page 502 WSM KX080-3 Service Hydraulic system 2. Travel R section 1) Outer view 2) Other side 3) Inner parts 4) Spiral notch-type drain groove of the spool IV-S-94...
  • Page 503 WSM KX080-3 Service Hydraulic system 3. Travel L section 1) Outer view 2) Other side 3) Inner parts IV-S-95...
  • Page 504 WSM KX080-3 Service Hydraulic system 4. P inlet section 1) Outer view 2) Other side 3) Inner parts 4) P confluence spool 5) Pilot port IV-S-96...
  • Page 505 WSM KX080-3 Service Hydraulic system 6) Pilot pressure passage 7) Orifice (P 8) Screen (P 9) P3 confluence section and spool. IV-S-97...
  • Page 506 WSM KX080-3 Service Hydraulic system 5. S valve section 1) Outer view 2) Other side 3) Adjusting bolt of SP2 spool. 4) Inner parts IV-S-98...
  • Page 507 WSM KX080-3 Service Hydraulic system 6. Dozer section 1) Outer view (1) Dozer section 2) Other side 3) Inner parts IV-S-99...
  • Page 508 WSM KX080-3 Service Hydraulic system 7. Swivel section 1) Outer view 2) Other side 3) Inner parts IV-S-100...
  • Page 509 WSM KX080-3 Service Hydraulic system 8. P confluence valve 1) Outer view 2) Other side 3) Inner parts IV-S-101...
  • Page 510 WSM KX080-3 Service Hydraulic system 9. Mono-block valve assy 1) Outer view 2) Other side LS main relief valve Unload valve 3) Boom valve section. 4) Arm valve section IV-S-102...
  • Page 511 WSM KX080-3 Service Hydraulic system 5) Inner parts (1)LS main relief valve (2)Unload valve 6) Inner parts Arm section (1)Main spool (2)Pressure compensation spool (3)check valve 7) Side view (4)Unload valve 8) Side view, P IV-S-103...
  • Page 512 WSM KX080-3 Service Hydraulic system 10. Swing valve section 1) Outer view 2) Other side 3) Inner parts 4) Anti-void valve (2)Spool ID mark IV-S-104...
  • Page 513 WSM KX080-3 Service Hydraulic system 11. End plate 1) Tie rod 2) Tightening method of tie rod. IV-S-105...
  • Page 514 WSM KX080-3 Service Hydraulic system e. pilot valve 1.Fitting the adaptor Port P Filter Pipe joint Ports T, 1, 2, 3 and 4 Pipe joint 2.Adaptor tightening torque G1/4 size Left P/V 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs Location Hose tape color 3.Fitting direction of the valve...
  • Page 515 WSM KX080-3 Service Hydraulic system f.Dozer pilot valve 1. Adapter and joint 1)Fitting the adaptor Port P Filter Pipe joint Pipe joint Ports T, 1 and 2 Fit the adaptor in position as shown at left. 2)Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7t.lbs...
  • Page 516 WSM KX080-3 Service Hydraulic system g.Swing pilot valve 1.Fitting the adaptor Port P Filter Pipe joint Port T Pipe joint Ports 1 and 2 Pipe joint 2.Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 3.Fitting direction of the valve Position the valve with ports P and T facing the (4)(5) machine left side.
  • Page 517 WSM KX080-3 Service Hydraulic system 6.Fitting the valve assembly (pilot OFF) Tightening torque 48.1~55.9N.m(4.9~5.7kgf.m)35.5~41.2ft.lbs 7.Applying the non-slip sheet (swing pedal) Apply the sheet as shown at left. (1)Non-slip sheet (swing pedal) (2)Valve assembly (pilot OFF) (3)Bolt (4)Pedal (swing) (5)Bolt (6)Non-slip sheet (swing pedal)
  • Page 518 WSM KX080-3 Service Hydraulic system 7. Pilot valve disassemble (Dozer, swing) 1. Overall structure 2. Remove the rubber boot and pivot link. 3. Inner parts of push rod and spool Shims : t=1.0 and 0.5mm IV-S-110...
  • Page 519 WSM KX080-3 Service Hydraulic system h.Travel pilot valve 1.Fitting the adaptor Ports P and T Pipe joint (bushing G1/4) Pipe joint (cross, G1/4) Plug Ports 1, 2, 3 and 4 Pipe joint 2.Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs (11) 3.Plug tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs...
  • Page 520 WSM KX080-3 Service Hydraulic system 7.Troubleshooting and corrective measures failureonlywitha singlepart, but caused bya failure involving more than one part. For this reason, be aware of the fact that Troubleshooting is not easy. Some assumed corrections may also be necessary other than causes are listed in the table below.
  • Page 521 WSM KX080-3 Service Hydraulic system 8. Disassembling procedures 1) Operational precautions in general 1. Prepare a solid and rattle-free working bench that is wide enough to place parts on and that does not allow the parts to drop or move.
  • Page 522 WSM KX080-3 Service Hydraulic system 3.Unscrew the Allen screw (522) with an Allen wrench. Remove the pedal (520). 4.Unscrew the Allen screw (473) with an Allen wrench. Remove the block (431). 5.Remove the bellows (501) from the cover (201) by pulling the bellows upward.
  • Page 523 WSM KX080-3 Service Hydraulic system 7.Putting a round bar (<|)8 or less) on one end of the cam axis (413), tap the bar gently with a hammer to pull out the axis. 8.Remove the cam (420) as an assemblywith the setscrew (471) and lock nut (472) attached.
  • Page 524 WSM KX080-3 Service Hydraulic system 11.Pull out the push rod from the plug. Note down the positional relationship between the plug and the push rod. Take care not to scratch the push rod surface. Be careful because the plug may be pushed out while the push rod is removed.
  • Page 525 WSM KX080-3 Service Hydraulic system 15.Remove the spring seat (218) from the casing. Note down the positional relationship between the spring seat and the hole in the casing. 16.Remove the steel balI (225) usingadevice, such as a magnet. Take care not to losethe steel ball.
  • Page 526 WSM KX080-3 Service Hydraulic system 19.Remove the reducing valve section assembly and the return spring (335) from the casing. Note down the positional relationship with the casing hole. 20.Place the cover (201) with its side downward on aflattable. Puttingthespecial tool 1 on thebush (412), tap the tool with a hammer to pulI out the bush.
  • Page 527 WSM KX080-3 Service Hydraulic system 22.To dismantle the reducing valve section assembly, stand upright the spool (301) bottom end on a flat work bench, push down the spring seat (311) then remove 2 semicircular washers 1 (215) usinga small flat-head screwdr iver tip.
  • Page 528 WSM KX080-3 Service Hydraulic system 26.Remove the 0-ring (212) from the plug. 27.Fix the Casing (101) on a vice using cushion sheets. Unscrew the Plug (153) with an Allen wrench. (RCVD8CC only) 28.Pull out the Seat (191) from the Casing (101).
  • Page 529 WSM KX080-3 Service Hydraulic system 30.Cleaning the parts 1) Put the parts into the kerosene contained in a rough-cleaning container, and clean them. (Rough-cleaning) If the parts are washed immediately after put into the kerosene, they are easily scratched. Wait until contaminations and oily substances are detached and floated on the surface of the kerosene.
  • Page 530 WSM KX080-3 Service Hydraulic system 9. Assembling instructions 1) Operational precautions in general (1)As done for disassembling, prepare a working bench and tools. (2)Pay attention as done for disassembling. (3)Before assembling, remove bits of metal or foreign material from all the parts, and also check that there is no burrs or dents on the parts.
  • Page 531 WSM KX080-3 Service Hydraulic system 3.Tighten the Plug (153) with the torque specified. (RCVD8CC only) 4.Attach the washer 3 (313), the washer 2 (217), the secondary-pressure-setting spring (324), and the spring seat (311) to the spool (301) in this order.
  • Page 532 WSM KX080-3 Service Hydraulic system 6.Install the return spring (335) into the casing. Install it at the previous position before it was disassembled. 7.Install reducing valve section subassembly, assembled in 1 and 2 above, into the casing. Install it at the previous position before it was disassembled.
  • Page 533 WSM KX080-3 Service Hydraulic system 9.Tentatively set the locking ring (221) in the casing hole using pliers. Set the locking ringwhere it was before the disassembly. Set the locking ring horizontally. Take care not to damage the casing inside surface.
  • Page 534 WSM KX080-3 Service Hydraulic system 13.Install the damping spring (336) in the casing. Install it at the previous position before it was disassembled. 14.Install the damping spring (337) in the casing. Install it at the previous position before it was disassembled.
  • Page 535 WSM KX080-3 Service Hydraulic system 17.Install the NHU packing (210) into the pIug. When you install the NHU packing, pay attention to its direction. (Refer to the following figure.) Apply a thin fiIm of grease to the NHU packing before installing it.
  • Page 536 WSM KX080-3 Service Hydraulic system 21.Press the bush (412) to the cover (201) using special tool 1 then Iightly tap to press it in with a hammer. Be careful because the end of the bush comes out of the cover.
  • Page 537 WSM KX080-3 Service Hydraulic system 25.Install the cam (420) into the cover. Install it at the previous position before it was disassembled. 26.Holding down the cam (420), insert the cam shaft (413) from outside. 27.Apply Loctite #241 or equivalent to the surface of the setscrew (423).
  • Page 538 WSM KX080-3 Service Hydraulic system 29.Adjust the setscrew (471) height so the cam (420) top surface can be parallel with the cover bottom surface, rotate the cam to the right and left to check that it can be in a...
  • Page 539 WSM KX080-3 Service Hydraulic system 33.Install the block (431) and tighten the Al len screw (473) with the torque specified. 34.Install the pedal (520) and tighten the Al len screw (522) with the torque specified. 35.Attach the pedal cover (521)
  • Page 540 WSM KX080-3 Service Hydraulic system 3)Special jig for disassembling/reassembling (1) Special jig 1 (for removing and pressing the bush) 1)Center hole allowed (*2 or less) (2) Special jig 2 (for fitting the locking ring) IV-S-132...
  • Page 541 WSM KX080-3 Service Hydraulic system i.Swive. motor 1.Fitting the adaptor Fit the adaptor in position as shown at left. 2.Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs G3/8 size 37.2~42.1N.m(3.8~4.3kgf.m)27.4~31.1ft.lbs G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs G3/4 size 117.6~127.4N.m(12.0~13.0kgf.m)86.7~94.0 ft.lbs 3.Fitting direction of the motor Fit the motor in position as shown at left.
  • Page 542 WSM KX080-3 Service Hydraulic system j.Travel motor (Wheel motor) 1.Adaptor and joint 1)Fitting direction of the track frame Make sure the port side faces the machine front. 2)Tightening torque for the travel motor Track frame sprocket Motor mounting bolt 259.9~304.0N.m(26.5~31.0kgf.m) 191.7~224.2ft.lbs...
  • Page 543 WSM KX080-3 Service Hydraulic system 2.Hose routing See (2/2). As shown in Fig. 2, keep the hoses free from too tight contact, such as twist or crossing, inside the track frame. Dozer (14) (15) (16) (14)Fig. 2 Hose route S/J side...
  • Page 544 WSM KX080-3 Service Hydraulic system Travel motor servicing (GM090N, Nabtesco make) a. Handling precautions 1. Positioning (Refer to the Dimensional Outline Drawing.) Before setting up the motor, remove the oil level check port plug and make sure the reduction gears lube oil (gear oil) is up to the check port level.
  • Page 545 WSM KX080-3 Service Hydraulic system NOTE Before getting the motor started, be sure to fill the motor casing with hydraulic oil. Oil amount required in the casing: 0.5 liters (0.13 US gal.) Otherwise the hydraulic motor may reach its service life earlier than expected.

  • Page 546: Mobilube

    WSM KX080-3 Service Hydraulic system b. Maintenance and inspection 3. Changing the lube oil The reduction gears have been delivered filled 1. Daily inspection with lube oil (gear oil). Before running the GM motor, check the following points daily. 1. Types and recommended brands of gear oil...
  • Page 547 WSM KX080-3 Service Hydraulic system NOTE Oil may gush out when removing the plugs. Turn them slowly to relieve the internal pressure. (1)Stop the GM motor so that the oil level check 1)Oil level check port (PF 3/8) 2)Oil filler port (PF 3/8)
  • Page 548 WSM KX080-3 Service Hydraulic system c. Troubleshooting Phenomenon 1 Phenomenon 2 Possible cause Correction Relief pressure setting too low Make correct setting. No pressure rise Pump defective Repair. Directional control valve defective Repair. Failure to run Brake valve defective Replace or repair the brake valve.

  • Page 549: Xd-3

    WSM KX080-3 Service Hydraulic system 1. SERVICE OUTLINE 1-1. Tools 1-1.1. Standard tools Applicable parts Name Description Remarks Q'ty (Usage method or parts No.) Dial type, approx. 45N JIS B 4650 33, 121, 126, 143, 144, 152, 154 Torquewrench Dialtype, approx. 180N...
  • Page 550 WSM KX080-3 Service Hydraulic system 1-1.2. Equipment and materials Applicable parts Name Description Remarks Q'ty (Usage method or parts No.) For disassembling General work stand And reassembling works One for drain Forwashing GMY motor and parts Washing sink One for rinsing...
  • Page 551 WSM KX080-3 Service Hydraulic system 1-1.4. Manufacturing tools Tool name : Work stand To be used for safe and easy disassembly and reassembly of GM motor. Tool name : Fixture To be used for holding together hub [1] and spindle [2] when disassembly and reassembly.
  • Page 552 WSM KX080-3 Service Hydraulic system Tool name : Retainer (3) To be used for pushing oil seal [132] when installing it in spindle [2]. Tool name : Retainer (4) To be used for installing RV gear sub-assembly on spindle [2].
  • Page 553 WSM KX080-3 Service Hydraulic system Tool name : Aluminum rod To be used for removing oil seal [132] and collar [11] from spindle [2]. To be used for removing ball bearing [21] from hub [1]. Tool name : PF eye bolt To be used for lifting cover [8] off hub [1] with a crane and wire rope.
  • Page 554 WSM KX080-3 Service Hydraulic system Tool name : F/S installationtool (1) To be used for installing floating seal on hub [1] Tool name : F/S installation tool (2) To be used for installing floating seal on hub [1] and spindle [2]...
  • Page 555 WSM KX080-3 Service Hydraulic system 1-2. Tightening torque Applicable Bolt/Nut Used Hexagonal parts Tightening Torque 2 surface width Q'ty Nominal (Structural N.m (kgf.m) Name Designation drawing) 49.0 N.m Reamerbolt M24 X2.0 36mm 5 kgf.m) 36 ft.lbs 58.8 9.81 N.m Hexagon socket plug PF3/8 1.0 kgf.m)
  • Page 556 WSM KX080-3 Service Hydraulic system 2. DISASSEMBLY parts due to moisture or dirt. If you have to interrupt work before completion, be 2-1. Preparation careful to take measures to protect Perform following preparations before against rust or dust. disassembling. (5) Place a counter mark on mating faces of parts when disassembling.
  • Page 557 WSM KX080-3 Service Hydraulic system 2-3.Disassembly procedure (1 ) Washing the travel motor 1) Fasten the eyebolts in the screw holes for mounting the spindle [2]. Note : Fasten the 2 eye bolts in the screw holes for mounting the spindle [2] so they are positioned symmetrically.
  • Page 558 WSM KX080-3 Service Hydraulic system (3) Lubricating oil drain Note : If disassembling the rear flange only, proceed to below 1) of item (7). 1) Invert the travel motor. 2) Loosen and remove the hexagon socket plug [33] (1 plugs), [34] (2 plugs).
  • Page 559 WSM KX080-3 Service Hydraulic system 3) Using an electric drill, make a 2mm (0.08 in.) diameter hole at the punch mark. Note : Be sure to centerthe drill on the punch mark, and keep drilling until the ring starts rising. After drilling clear through the wall of hub [1], be sure to wipe off the chippings completely.
  • Page 560 WSM KX080-3 Service Hydraulic system 8)Remove the O-ring [29] from the cover [8]. Note : Do not reuse the O-ring [29] which has been removed. (5) Input gear removal 1) Removethe snap ring [24] from the shaft [15]. 2) Remove the input gear [6], from the shaft [15].
  • Page 561 WSM KX080-3 Service Hydraulic system 2)Remove spur gears [7] from each crankshaft [9]. (7) Remove the rear flange 1)Invert the travel motor. Note : The following task is carried out to facilitate plug removal disassembling the rear flange [201] inside. Plugs must be loosened to the degree where they can be removed by hand.
  • Page 562 WSM KX080-3 Service Hydraulic system 7)Remove the rear flange [201] from the spindle [2]. Note : Grip the rear flange [201] with both hands and remove by carefully straight upward. removed forcefully wrenching or beating, the timing plate [109] could fall and become damaged.
  • Page 563 WSM KX080-3 Service Hydraulic system 3) Remove the parallel pins [242] from the rear flange [201]. 4) Remove the ball bearing [150] from the rear flange [201]. (9) Disassembly of plugs inside rear flange 1) Remove the plugs [224] (2 plugs) from rear flange [201].
  • Page 564 WSM KX080-3 Service Hydraulic system 6) Remove the spring [230] (2 springs), valve [227] (2 valves) from the rear flange [201]. (10) Disassembly of SRV mounted into the rear flange 1) Loosen and remove the plug [282] (2 plugs) from the rear flange [201].
  • Page 565 WSM KX080-3 Service Hydraulic system 4) Loosen and remove the plugs [289] (2 plugs) from the rear flange [201]. 5) Remove the O-ring [238] from the plug [289]. Note : Do not reuse the O-ring [238] which has been removed.
  • Page 566 WSM KX080-3 Service Hydraulic system 9) Remove the plugs [285], steel-ball [296] from the rear flange [201]. (11)Disassembly of pilot valve from the rear flange 1) Remove the plug [221], spool [271], spring [281] from the rear flange [201]. 2) Remove the O-ring [292]from the plug [221].
  • Page 567 WSM KX080-3 Service Hydraulic system (13)Disassembly of hydraulic motor parts Note : Oil spills from the travel motor when faced sideways, so place a container under the travel motor. 1) Tilt the travel motor 90 degrees. 2) Extract the oil from inside the travel motor.
  • Page 568 WSM KX080-3 Service Hydraulic system 6)Remove the piston assembly (piston [105], shoe [106]) and retainer plate [107] from the cylinder block [104]. Note : When removing, grip the retainer plate [107] with both hands and remove together with the retainer plate [107].
  • Page 569 WSM KX080-3 Service Hydraulic system (14)Removal of spring inside cylinder block 1) Place the cylinder block [104] on the press bench. Note : The spring is removed only when replacing. The spring is removed by lining up the shaft centers of the...
  • Page 570 WSM KX080-3 Service Hydraulic system 2) Draw out the shaft [102] and ball bearing [149] from the spindle [2]. Note : The speed reducer side shaft can be drawn out easily after tapping the tip of the shaft gently with a plastic hammer.
  • Page 571 WSM KX080-3 Service Hydraulic system (17)Removal of hold flange 1)Invert the travel motor 2)Fasten the fixtures (2 fixtures) to the hub [1] and spindle [2] and fix in place. At this time, fasten the fixtures so they are positioned symmetrically.
  • Page 572 WSM KX080-3 Service Hydraulic system 7) Remove the hold flange [3] from the spindle [2]. 8) Write the counter mark of the hold flange [3] and spindle [2] on the hold flange [3] and spindle [2] with an oil base paint marker.
  • Page 573 WSM KX080-3 Service Hydraulic system (20)Removal of ball bearing, RV gear assembly and pin 1)Remove the floating-seal [31] from the hub [1]. Note : When removing the ball bearing [21], tap the end face of the pins equally in 3-4 places around the circumference a little at a time so as not to wrench the ball bearing [21].
  • Page 574 WSM KX080-3 Service Hydraulic system (22) Removal of spindle mounted parts 1) Takethefloating seal [31] out of the spindle [2]. 2) Remove the outer rings ( 3 rings) of the tapered roller bearing [22] from the spindle [2]. Note : The mounting surfaces of the outer ring...
  • Page 575 WSM KX080-3 Service Hydraulic system (24) Rough washing of various parts 1) Divide the hub [1], spindle [2], cover [8], rear flange [101] parts (4 parts) and other parts (hereinafter referred to as "internal parts"). 2) Place the hub [1], spindle [2], cover [8] and rear flange [101] into the washing tank and wash.
  • Page 576 WSM KX080-3 Service Hydraulic system 2) Wipe away the white kerosene adhering to each part with a clean waste cloth. Note : Dry the inside surfaces of the hub [1], spindle [2] and hold flange [3] by blowing with compressed air in a place free of dust and moisture.
  • Page 577 WSM KX080-3 Service Hydraulic system 0.0016in. 0.0016in. (9.9kgf . m) (9.9kgf . m) 71.6ft . lbs 71.6ft . lbs IV-S-169...
  • Page 578 WSM KX080-3 Service Hydraulic system 4. ASSEMBLY Renewal parts required pre-load adjustment of the ball bearing [21] : Hub [1], Assembly, as a rule, assembly is carried out by spindle kit, collar [11], ball bearing [21]. performing the procedure for disassembly (2) Renewal parts required for shaft direction inreverse.
  • Page 579 WSM KX080-3 Service Hydraulic system (1) Hub section assembly 1) Fasten 2 eyebolts in the screw holes of the they symmetrically positioned. 2) Hookthe hook and wire in the eyebolts, hoistthe hub [1] with a crane, and set the hub [1] on the workbench.
  • Page 580 WSM KX080-3 Service Hydraulic system (2) Spindle section assembly 1)Apply oil to the O-ring of the floating seal [31], and mount the floating seal in the floating seal groove of the spindle [2]. Note : Separate the O-ring parts of floating seal [31], and Oil it all around, and then combine itwith the seal ring part.
  • Page 581 WSM KX080-3 Service Hydraulic system (3) Mount the RV gear assembly. 1)I nstall RVgearA[4] inthehub [1]. 2) Install the crankshaft [9] in the hub [1]. Note : Match the inner race of the tapered roller bearing [22] of the crank shaft...
  • Page 582 WSM KX080-3 Service Hydraulic system (4) Hold flange mounting 1) Insertthe ball bearing [21] inthe hub [1]. Note : The fit of the ball bearing [21] outer diameter and hub [1] inner diameter is press fit. Press fit gradually and uniformly by tapping the pin punch.
  • Page 583 WSM KX080-3 Service Hydraulic system (5) Reamer bolt fastening Note : If grease adheres to the screw section corresponding to the reamer bolt [19] of the spindle [2], degrease with degreaser and wash. 1)Apply bonding agent to screw section of the spindle [2].
  • Page 584 WSM KX080-3 Service Hydraulic system Note : f using by replacing the snap ring [20] only with a new part, select the same type of snap ring [20] as before disassembly or one which is similar from among the 15 types.
  • Page 585 WSM KX080-3 Service Hydraulic system Caution When mounting the snap ring [25], if the tip of the pliers slips out of the hole of the snap ring, the snap ring [25] couldjump out. Note : Mount with the acute angle of the snap ring end face facing up.
  • Page 586 WSM KX080-3 Service Hydraulic system 2) Invert the travel motor 3) Apply lithium grease to the lip section of the oil seal [132], and press fit the oil seal [132] in the oil seal hole of the spindle [2] with the retainer (2) and hammer.
  • Page 587 WSM KX080-3 Service Hydraulic system 10)Fitting the motor shaft [102] slowly into the spindle [2]. 11)Insert the swash plate [103] into the spindle [2]. Note : Apply lithium grease to the swash plate [103] where matching surface of spindle [2].
  • Page 588 WSM KX080-3 Service Hydraulic system (10) Assembly of hydraulic motor parts 1) Place the needle rollers [151] (3 rollers) in the holes of the cylinder block [104], and thrust ball [108] on the top. 2)Mount the 9 piston assemblies in the retainer plate [107].
  • Page 589 WSM KX080-3 Service Hydraulic system 2) Mount the O-rings [135], [141] in the O-ring grooves of the piston [112]. At this time, apply a thin coat of grease to the O-rings [135], [141]. 3) Mountthe piston [112] in the spindle [2].
  • Page 590 WSM KX080-3 Service Hydraulic system Note : Apply hydraulic fluid to the spool [223] and insert The spool [223] into the rear flange [201] When mounting the spool [223], match the hole center of the rear flange [201] with the shaft center of the spool [223]...
  • Page 591 WSM KX080-3 Service Hydraulic system 3) Mount the piston-seal [293] on the valve [287]. Note : The piston-seal [293] is consist of O- ring and tefron-ring. Apply grease to the O-ring and tefron- ring. First mount the O-ring and after mount tefron-ring.
  • Page 592 WSM KX080-3 Service Hydraulic system 2) Fit the parallel pins [241] (2 pins) in the pin holes of the rear flange [201]. 3) Apply grease to the mating face with the rear flange [201] of the timing plate [109]. Note : Mounting of the timing plate [109] is carried out until the timing plate [109] adheres to the rear flange [201].
  • Page 593 WSM KX080-3 Service Hydraulic system 2) Fitthe parallel pins [43] (2 pins) in the spindle [2]. 3) Put 0.5 liters of hydraulic fluid in the spindle [2]. 4) Match the parallel pins [43] (2 pins) mounted in the spindle [2] with the pin holes of the rear flange [201] and mount the rear flange [201] in the spindle [2].
  • Page 594 WSM KX080-3 Service Hydraulic system 7)Tighten the plugs [224] to the specified torque. Tightening torque :353 39.2 N-m (36 4.0kgf-m) 260 29 ft-lbs 8)Tighten the plugs [282] to the specified torque. Tightening torque : 98.1 19.6 N-m (10 2.0kgf-m) 72.3 14.5 ft-lbs 9)Tighten the plugs [289] to the specified torque.
  • Page 595 WSM KX080-3 Service Hydraulic system 3)Mountthe input gear[6] on the shaft [15]. Note : Apply grease to the steel ball [36] so it doesn't fall out when mounting the cover [8]. 4)Fit the steel ball [36] in the steel ball mounting hole of the input gear [6].
  • Page 596 WSM KX080-3 Service Hydraulic system 5)Tighten plugs [33] to the specified torque. Tightening torque : 58.8 9.81 N-m (6 1.0kgf-m) 43.4 7.2 ft-lbs 6)Mount the O-rings [35] on the plugs [34] (2plugs). Tighten the plugs [34] to the specified tongue.
  • Page 597 WSM KX080-3 Service Hydraulic system (19) Pre-load adjustment of ball bearing Note : In order to ensure the proper life for the baa bearing [21], it is necessary to provide a certain pre-load. Therefore, if replacing a part that influences the amount of pre-load,...
  • Page 598 WSM KX080-3 Service Hydraulic system 4)Next find the "D" dimension of the hold flange [3]. 5)Adjust hold flange with measurements taken in 2) ~ 4) and following procedure. "C" dimension specified dimension of the hold flanae. 1) Depth micrometer 2) Jig I.
  • Page 599 WSM KX080-3 Service Hydraulic system (20) Shaft direction clearance adjustment of the tapered roller bearing Note : If the following parts are replaced, the shaft direction clearance of the tapered roller bearing [22] must be adjusted to specified value thickness adjustment of the snap ring [20].
  • Page 600 WSM KX080-3 Service Hydraulic system 4)Place a thickness gauge between the ring [20] and tapered roller bearing [22] and measure the clearance. 5)Ring [20] thickness measurement Set thickness (MAX.) of the ring MAX. = Thickness of thickness gauge + Thickness of Currently mounted ring Set thickness (MIN.) of the ring...
  • Page 601 WSM KX080-3 Service Hydraulic system {for 3.43MPa 35kgf/cm 498psi} {for 5 liter 1.32usgal.} (113~131°F) (104~176°F) (228psi) / when 10 r.p.m (0.13usgal) / when 10 r.p.m IV-S-193...
  • Page 602 WSM KX080-3 Service Hydraulic system 3.CLEARANCE ADJUSTMENT PARTS DIMENSIONS TABLE IV-S-194...
  • Page 603 WSM KX080-3 Service Hydraulic system 1) Hub Spindle kit *Spindle assembly 2) **Spindle 3) **Hold flange 19) *Reamer bolt RV gear assembly *RV gear kit 4) **RV gear A 5) **RV gear B 9) *Crank shaft 12) *Specer 22) *Tapered roller bearing...
  • Page 604 WSM KX080-3 Service Hydraulic system k.Rotary joint (Swivel joint) 1.Adaptor and joint 1)Fitting direction of the hydraulic adaptor Fit the adaptor in position as shown in the figure. 2)Hydraulic adaptor tightening torque 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 37.2~42.1N.m(3.8~4.3kgf.m)27.4~31.1ft.lbs 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.1ft.lbs 3)Fitting the swivel joint assembly...
  • Page 605 WSM KX080-3 Service Hydraulic system l. Holding valve 1) Boom cylinder 2) Holding Valve assy IV-S-197...
  • Page 606 WSM KX080-3 Service Hydraulic system 1. Fitting the adaptor Fit the adaptor in position as shown at left. 2. Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs 3. Assembling procedure (1)Fit the valve assembly (holding) in position. (2)Place the bracket (1, H/V) and bracket (2, H/V) in position, and tighten the bolts temporarily.
  • Page 607 WSM KX080-3 Service Hydraulic system m. Hydraulic tank (1) Tank assy (2) Oil gauge (3) Return filter (4)Connector (5) Tank cap IV-S-199...
  • Page 608 WSM KX080-3 Service Hydraulic system 1.Tightening the filter assembly (return) 12 13 17 18 77.5~90.2N.m(7.9~9.2kgf.m)57.2~66.5 ft.lbs 2.Fitting the gauge (oil tank) Tightening torque 8.0~10.0N.m(0.82~1.0kgf.m)5.9~7.4 ft.lbs 3.Fitting the cover assembly (hydraulic tank) Tightening torque 48.1~55.9N.m(4.9~5.7kgf.m)35.5~41.2 ft.lbs Fitting direction Place the assembly with the breather facing the machine front as shown at left.
  • Page 609 WSM KX080-3 Service Hydraulic system n.Filters 1.Fitting the adaptor (1)(2) Fit the adaptor in position as shown at left. 2.Adaptor tightening torque G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs G3/4 size 117.6~127.4N.m(12.0~13.0kgf.m) 96.7~94.0ft.lbs G1-1/4 size 220.5~230.3N.m(22.5~23.5kgf.m) 162.6~169.9ft.lbs 3.Fitting the pipe (return) Tightening torque 62.8~72.6N.m(6.4~7.4kgf.m)46.3~53.5ft.lbs...
  • Page 610 WSM KX080-3 Service Hydraulic system o.Three way change valve 1.Fitting the valve assembly (3-way) Fit the assembly in position as shown at left. No. 1 port Pipe joint (SG6, 1U) (RD809-6151D) No. 2 port Pipe joint (LG6, G6) (RD809-6917D) No. 3 port...
  • Page 611 WSM KX080-3 Service Hydraulic system p.Pilot primary line and T port block 1.Fitting the adaptor (2)(3) Ports 1 and 2 Straight pipe joint Ports 3, 4, 5, 6, 7 and 8 Pipe joint Pipe joint Port 9 Pipe joint (4)(5)
  • Page 612 WSM KX080-3 Service Hydraulic system q.Swivel shuttle valve 1.Fitting the adaptor Position the adaptor in position as shown at left. 2.Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 3.Plug tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 4.Fitting direction of the valve Position the vale with the nameplate facing the machine front.
  • Page 613 WSM KX080-3 Service Hydraulic system r.pilot hose relay plate 1.Fitting the bracket (pilot hose) Position the bracket in position as shown at left. 2.Bolt tightening torque 48.1~55.9N.m(4.9~5.7kgf.m)35.4~41.2ft.lbs 3.Connecting the quick-coupling hoses Connect the hoses to the holes. Match the numbers of holes in the figure and those of the hoses in the table, as shown at left.
  • Page 614 WSM KX080-3 Service Hydraulic system s.Pilot hose relay adapter 1.Fitting the adaptor Position the adaptor in position as shown at left. 2.Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 3.Quick-coupling adaptor Pipe joint Pipe joint Make sure the hose connection is free from detrimental scratches.
  • Page 615 WSM KX080-3 Service Hydraulic system (1)Bracket (pilot hose) (relay plate) (2)Valve assembly (swivel shuttle) (shuttle valve) (3)Valve assembly (pilot, OFF) (swing P/V) (4)Front (5)Valve assembly (PV, travel) (travel P/V) (6)Adaptor (pilot hose, 2) (relay adaptor) (7)Adaptor (pilot hose, 1) (P4, T collective block)
  • Page 616 WSM KX080-3 Service Hydraulic system t.Unload valve 1. Fitting the adaptor (2)(3) Fit the adaptor in position as shown at left. 2. Adaptor tightening torque (4)(5) G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs G3/8 size 37.2~42.1N.m(3.8~4.3kgf.m)27.5~31.1ft.lbs G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs 3. Fitting the valve assembly (unload) Tightening torque 48.1~55.9N.m(4.9~5.7kgf.m)35.4~41.2ft.lbs...
  • Page 617 WSM KX080-3 Service Hydraulic system u.SP1 and SP2 solenoid valve (1)(2) 1. Fitting the adaptor Fit the adaptor in position as shown at left. 2. Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 3. Quick-coupling adaptor Pipe joint(QL, G1/4-8,4) (RP812-6197D) (5)(6) Make sure the hose connection is free from detrimental scratches.
  • Page 618 WSM KX080-3 Service Hydraulic system v.Pilot pump relay block (1)(2) 1. Fitting the adaptor Fit the adaptor in position as shown at left. (3)(4) (5)(6) 2. Adaptor tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs (7)(8) 3. Plug tightening torque G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs 4.
  • Page 619 WSM KX080-3 Service Hydraulic system w.Pilot line filter 1.Fitting the adaptor Fit the adaptor in position as shown at left. Pipe joint (L, F1/2,-F3/8) (69251-6185D) 2.Adaptor tightening torque G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs 3.Fitting the filter assembly (hydraulic) Bolt tightening torque 9.8~11.3N.m(1.0~1.15kgf.m)7.2~8.3ft.lbs Fitting direction of the filter Make sure the label faces toward the arch wall.
  • Page 620 WSM KX080-3 Service Hydraulic system x.Cylinders 1 .Fitting the adaptor of each cylinder Fit the adaptors at the angle specified in the figure. 2. Adaptor tightening torque G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~47.0ft.lbs (1)(Swing cylinder) (2)Pipe joint (LG4, 11/16U) (3)Pipe joint (SG4, 11/16U)
  • Page 621 WSM KX080-3 Service Hydraulic system (1)(Arm cylinder) (2)Clamp Bolt (3)Pipe joint (SG4, 13/16U) (4)Pipe joint (bushing, 1/2) Pipe joint (SG4, 1U) (5)(Bucket cylinder) (6)Pipe joint (LG4, 13/16U) (7)Pipe joint (LG4, 1U) IV-S-213...
  • Page 622 WSM KX080-3 Service Hydraulic system y.Hydraulic hose 1.Metallic sealing type Tighten to the specified torque. G1/4 size 24.5~29.4N.m(2.5~3.0kgf.m)18.1~21.7ft.lbs G3/8 size 37.2~42.1N.m(3.8~4.3kgf.m)27.5~31.1ft.lbs G1/2 size 58.8~63.7N.m(6.0~6.5kgf.m)43.4~49.0ft.lbs 2.Quick-coupling type G1-1/4 size Couple the hose in position as shown at left. Finally, make sure the hose does not come off.
  • Page 623 WSM KX080-3 Service Hydraulic system z.Hose route 1.Pilot hose 1 Pilot hoses Location Tapecolor Q'ty (P4, T) Collective block ~ P/V (left) (P) P/V boost White (P4, T) Collective block ~ Dozer P/V (P) Dozer P/V boost White Dozer P/V (P) ~ P/V (right) (P)
  • Page 624 WSM KX080-3 Service Hydraulic system 2.Pilot hose 2 Pilot hoses Location Tapecolor Q'ty P/V (swivel left) – Shuttle valve Swivel (left) Gray P/V (swivel right) – Shuttle valve Swivel (left) Sky-blue P/V (arm crowded) – Relay adaptor Arm (crowded) Blue Relay adaptor –...
  • Page 625 3.Pilot hose 3 Location Tapecolor Q'ty Pump ~ Line filter P4 (feed) Life filter ~ Selector valve (C) P4 (feed) Selector valve (B) ~ (P4, T) Collective block (P) P4 (feed) Selector valve (B) ~ R/J travel bi-speed (A) Travel bi-speed boost Yellowish green (a)Pump assembly (piston) (b)Filter assembly (hydraulic)
  • Page 626 4.Pilot hose 4 Location Tapecolor Q'ty Selector valve (B) ~ SP2 solenoid valve (P) SP2 (feed) Blue SP2 solenoid valve (P) ~ SP1 solenoid valve (P) SP1 (feed) Selector valve (P) ~ P4 distribution block (tank side) Distribution block (feed) White P4 distribution block (tank side) ~ C/V (PP1) AI boost...
  • Page 627 5.Pilot hose 5 Location Tapecolor Q'ty Shuttle valve – C/V (swivel left) Swivel (right) Sky-blue Shuttle valve – C/V (swivel right) Swivel (left) Gray Relay plate – C/V (arm dump) Arm (dump) Blue Shuttle valve – C/V (arm crowded) Arm (crowded) Yellowish green Relay plate –...
  • Page 628 6.High and low pressure hose 1 Location Tapecolor Q'ty Pump (P1) ~ C/V (P1) Delivery (P1) Red, White Pump (P2) ~ C/V (P2) Delivery (P2) Red, White Pump (P3) ~ C/V (P3) Delivery (P3) Red, White Pump (PPS) ~ C/V (PPS) LS signal Blue Pump (PLS) ~ C/V (PLS)
  • Page 629 7.High and low pressure hose 2 Location Tapecolor Q'ty C/V (T1) ~ Return pipe Return (T1) Black C/V (T2) ~ Swivel motor (M) Swivel makeup Swivel motor (M) ~ Oil cooler Return (T2) Black Oil cooler ~ Return pipe Return (T2) Swivel motor (Dr) ~ Return pipe Swivel drain Pink...
  • Page 630 WSM KX080-3 Service Hydraulic system 8.Pump delivery IV-S-222...
  • Page 631 WSM KX080-3 Service Hydraulic system 9.Suction (1)Hose (1, suction) Hose clamp (68-85) Hose clamp (77-95) (2)Pipe (suction) Bolt (3)Hose (2, suction) Hose clamp (68-85) Hose clamp (77-95) IV-S-223...
  • Page 632 WSM KX080-3 Service Hydraulic system 10.Swivel frame partition 1.Applying position of the cushion (1, delivery) Apply the cushion to the position, shown in the figure, on the swivel frame. 2.Applying position of the sticker (2, delivery) Apply the sticker to the position, shown in the figure, on the plate (delivery) .
  • Page 633 WSM KX080-3 Service Hydraulic system 11.Hose route : Oil cooler (10) (11) (12) (1)Oil cooler holder (receiver) Bolt tightening torque 17.7~20.6N.m(1.8~2.1kgf.m)13.1~15.2ft.lbs (2)Condenser Support (condenser) Joint (receiver) Bolt tightening torque 7.8~9.3N.m(0.8~0.95kgf.m)5.8~6.9ft.lbs (3)Adaptor tightening torque (4)G3/4 size 117.6~127.4N.m(12.0~13.0kgf.m)86.7~94.0 ft.lbs (5)Hose (discharger) (6)Guide bar...
  • Page 634 12.Front hoses and pipes (1)Pipe (right, F, SP) (2)O-ring (1UNF) (3)Bolt (4)Pipe (right, F, SP2) (4)(5) (5)O-ring (13/16UNF) (6)Pipe (left, F, SP2) (7)O-ring (13/16UNF) (8)Pipe (left, F, SP) (1)(2)(3) (6)(7) (9)ring (1UNF) (29)(30)(31) (10)Bolt (32)(33)(34) (11)Plate (SP) (38) (39) (12)Bolt (13)Adaptor (SP, 1U) (40) (41) (14)O-ring (1UNF)
  • Page 635 WSM KX080-3 Service Hydraulic system (7)(8)(9) (2)(3)(4) (10)(11)(12)(13) (5)(6) (1)Stay (2, wire harness clamp) (2)Clamp (4, front) (3)Clamp (front) (4)Bolt (5)Clamp assembly (6)Bolt (7)Clamp (4, front) (8)Clamp (front) (9)Bolt (10)Bracket (clamp) (11)Clamp (pipe, front) (12)Bolt (13)Bolt IV-S-227...
  • Page 636 WSM KX080-3 Service Hydraulic system (12) (13) (14) (15) (16) (10)(11) (17)(18) (19)(20) (1)Stay (1, wire harness clamp) (2)Cushion (hose, dummy) (3)S/P1 (4)Bucket (orange) (5)Bucket (red) (6)Arm (blue) (7)Arm (yellowish green) (8)S/P1 (9)Cushion (10)Clamp (2P, front) (11)Bolt (12)S/P2 (13)Dummy (14)Dummy...
  • Page 637 aa.Hose route : 1.List of pilot hoses (upper structure) (swivel frame, C/V side) Dimension Location Part name Q’ty Tape color Hose configuration Remarks mm (inch) Pump ~ Line filter Hydraulic hose (3/8) 360(14.2) G 3 / 8 G 3 / 8 Life filter ~ Selector valve (accumulator) 2050(80.7) Hydraulic hose (3/8)
  • Page 638 2.List of pilot hoses (drain) (upper structure) (hydraulic system) Dimension Location Part name Q ty Tape color Hose configuration Remarks mm (inch) C/V (Dr1) ~ C/V (Dr2) Hydraulic hose (1/4DR1-DR2) 255(10.0) Two pieces of sky-blue tape 610(24.0) C/V (Dr2) ~ Tank Hydraulic hose (1/4, P3DR) Sky-blue to be wound around the center of hose...
  • Page 639 3.List of pilot hoses (upper structure) (platform, control system) Dimension Location Part name Q’ty Tape color Hose configuration Remarks mm(inch) (P4, T) Collective block ~ P/V (left) (P) Hydraulic hose (1/4P, L-PV) 1390(54.7) White Quick Quick (P4, T) Collective block ~ Dozer P/V (P) Hydraulic hose (1/4P, dozer PV) 1190(46.9) White...
  • Page 640 5.List of high-pressure hoses (upper structure) (swivel frame, C/V side) Dimension Location Part name Q’ty Tape color Hose configuration Remarks mm (inch) Pump (P1) — C/V (P1) Hydraulic hose (5/8) 2890(113.8) Red, White Pump (P2) — C/V (P2) Hydraulic hose (5/8) 2940(115.7) Red, White Pump (P3) —...
  • Page 641 6.List of high-pressure hoses (upper structure) (swivel frame, C/V side) Q’ty Dimension Tape Location Part name Hose configuration Remarks mm (inch) color C/V (SP1 high pressure) ~ Boom back (pipe) Hydraulic hose (5/8) 3260(128.3) Pink With corrugated tube 3-way valve ~ Boom back (pipe) Hydraulic hose (5/8) 3680(144.9) Brown...
  • Page 642 WSM KX080-3 Service Hydraulic system IV-S-234...
  • Page 643 Electrical wiring diagram ..........V-M-32 C. Kubota Intelligent Control System Refer to WSM (Minor Change) : Code No. 97899-61260...
  • Page 644 WSM KX080-3 Mechanism V Electrical System V-M-2...
  • Page 645 Development concept 1. Features of KX080-3 system Basic electrical system structure is same as KX-3 and KX-3S series and some new values are added. Newly added features of KX080-3 electrical system are as below. Feature points enefits Ser ice port ( ) eli ery Required max.
  • Page 646 WSM KX080-3 Mechanism V Electrical System 2. Electrical system : Functional comparison 0 0-3 North America Function EU-version Oceanea KICS;Kubota Intelligent Control System, LCD(liquid crystal display) with character and illustration Yes (delete Yes (delete Maintenance indication upon hour meter method:manual)
  • Page 647 Kubota s 3-ton and higher-capacity export machines are now standard equipped with this system. The top-end model KX080-3 is also equipped with the speed limit function (the world s first on mini-back- hoes) to differentiate this model from our competition.
  • Page 648 WSM KX080-3 Mechanism V Electrical System 3. How to operate servcie port 1 1. When the lock lever is raised, the service port activation switch is off. 2. Let the engine warm up after start-up for approx. 10 minutes under no load conditions.
  • Page 649 WSM KX080-3 Mechanism V Electrical System 3-2Action mode of first service port operation It is possible to select four action mode of the first service port operation by pushing the ser- vice port activation switch. Each time the service port activation switch is pushed, the action mode changes from 1 through 4.
  • Page 650 WSM KX080-3 Mechanism V Electrical System 4. Setting of limited flow volume 1. Turn the starter key to the RUN position while pushing the flow volume setting switch. 2. Release the hand from the switch after the engine starts. 3. Ten stages can be adjusted for Max. flow vol- ume right (1) and left (2) independently.
  • Page 651 WSM KX080-3 Mechanism V Electrical System (1) Flow volume setting switch (2) Service port activation switch (3) Display selector switch (4) Service port switch V-M-9...
  • Page 652 WSM KX080-3 Mechanism V Electrical System 5. One way flow operation 1. Push the one way hold lock switch, and oil flows into the port (2) continually. Push the switch again to stop the operation. 2. The one way flow operation stops when the first service port switch is pushed.
  • Page 653 WSM KX080-3 Mechanism V Electrical System 6. Second service port operation 1. Turn the starter key to the RUN position. 2. Lower the lock lever. 3. Press the right switch (A) to send oil to the port (1). 4. Press the left switch (B) to send oil to the port (2).
  • Page 654 WSM KX080-3 Mechanism V Electrical System 7. Instrument panel, switch Depicted contents (1) Second service port switch (2) First service port switch (3) Horn switch (4) One way hold lock switch (5) Two travel speed switch (6) Beacon light switch...
  • Page 655 WSM KX080-3 Mechanism V Electrical System 8. FYI (For Your Information) To those who want to know more Following charts show the theoretical approach to recognize the principle of speed limit control. 1. Control knob vs output voltage 2. Output voltage vs current calculated...
  • Page 656 WSM KX080-3 Mechanism V Electrical System c. Fuel supply pump 1. Main parts (1) Control box (2) Fuel supply pump (3) Hoses (4) Suction inlet and filter (5) Fuel tank V-M-14...
  • Page 657 WSM KX080-3 Mechanism V Electrical System 2. How to use To avoid serious injury or death: Do not use the fuel supply pump for gasoline or hydraulic oil. Doing so could result in explosion or damage. Only use the fuel supply pump for diesel fuel.
  • Page 658 WSM KX080-3 Mechanism V Electrical System 4. Push the switch (black button (3)). The pump stops automatically once the fuel tank is full. To stop the pump on the way, the switch (red but- ton (4)) is pushed. (3) Switch (black button)
  • Page 659 WSM KX080-3 Mechanism V Electrical System 3. Electrical system function 3-1Circuit diagram (1) Battery, 12 V (2) Mini-fuse, 5 A (3) SBF (slow blow fuse), 30 A (4) Start switch (5) Relay 1 (6) Mini-fuse, 5 A (7) Relay 2...
  • Page 660 WSM KX080-3 Mechanism V Electrical System 3-2 When the start switch is pushed: (1) Battery, 12 V (2) Mini-fuse, 5 A (3) SBF (slow blow fuse), 30 A (4) Start switch (5) Relay 1 (6) Mini-fuse, 5 A (7) Relay 2...
  • Page 661 WSM KX080-3 Mechanism V Electrical System 3-3 When fuel level sensor detects the full amount of fuel; Without the battery voltage, 4 min. timer turns off condition. (1) Battery, 12 V (2) Mini-fuse, 5 A (3) SBF (slow blow fuse), 30 A...
  • Page 662 WSM KX080-3 Mechanism V Electrical System 3-4 When pushing stop switch during supplying the fuel; (11) (10) Function chart Main key SW Fuel supply pump start SW Control unit (4 min. timer) Fuel supply pump stop SW Fuel supply pump...
  • Page 663 WSM KX080-3 Mechanism V Electrical System 3-5 When pushing start switch after the full fuel level; V-M-21...
  • Page 664 WSM KX080-3 Mechanism V lectrical System d. Intake air heater control 1. Location of main components V-M-22...
  • Page 665 WSM KX080-3 Mechanism V Electrical System 2. Outline of control system 2-1. Control points Pre-heating is automatically made according to the engine s water temperature at a cold starting. Once the engine has got started, the post-heating is also controlled to prevent bluish-white smoke.
  • Page 666 WSM KX080-3 Mechanism V Electrical System 2-3. Air intake heater (1) Heater body (2) Heater element (3) Heater element (4) Heater element (5) Insulater (1) Max. limit temperature (2) Heater temperature (3) Time (1) Relay 1 (2) Relay 2 (3) Body earth...
  • Page 667 WSM KX080-3 Mechanism V Electrical System 2-4. Air intake heater relay (Code : No. N300-75211) 1) Outer view 2) Drawing (1) Terminal (2) Housing (3) Label : Gray Front Rear Down Left Right 3) Diagram (1) Connecter V-M-25...
  • Page 668 WSM KX080-3 Mechanism V Electrical System V-M-26...
  • Page 669 WSM KX080-3 Mechanism V Electrical System B.Electrical components and circuit diagram a. Components layout (54) (55) (56) (57) (58) (59) (60) (61) (62) (63) (11) (12) (13) (53) (52) (51) (49) (50) (14) (15) (16) (17) (18) (48) (47) (19)
  • Page 670 WSM KX080-3 Mechanism V Electrical System Roomlamp (11) Dualpressuresw Antenna,radio (12) Watertemp.sensor Lightrelay (13) Compressor,A/C Speaker (14) Intakeairheater Washermotor (15) Enginespeedsensor Wipersw (16) Enginestopsolenoid Cablightsw (17) Alternator Overloadwarningsw (18) Startermotor Wipermotor (19) Engineoilsw (10) Headlamp (20) TravelHi-Lamp (21) Beaconlightsw (22)
  • Page 671 WSM KX080-3 Mechanism V Electrical System V-M-29...
  • Page 672 WSM KX080-3 Mechanism V Electrical System V-M-30...
  • Page 673 WSM KX080-3 Mechanism V Electrical System V-M-31...
  • Page 674 WSM KX080-3 Mechanism V Electrical System e. Electrical wiring diagram V-M-32...
  • Page 675 WSM KX080-3 Service Electrical system V. Electrical system Service Section A. Troubleshooting ....... V-S-3 ...................
  • Page 676 WSM KX080-3 Service Electrical system V-S-2...
  • Page 677 WSM KX080-3 Service Electrical system A.Troubleshooting a. General guideline (1) How to diagnose The most important point in troubleshooting is to determine "Probable Causes". Once the probable causes are determined, parts to be checked can be limited to those associated with such probable causes.
  • Page 678 WSM KX080-3 Service Electrical system b. Troubleshooting flow chart (1) Starter motor failure to turn on Key switch at START position, but the starter fails to turn on to start the engine. Are both the right and left Turn off both the lever lock switches.
  • Page 679 WSM KX080-3 Service Electrical system (2) Auto release malfunction 1. Turning sensor out of contact or broken. The auto release function fails. The 2. Relay. starter motor may wrongly get acti- vated. Does the key switch return Check the key switch.
  • Page 680 WSM KX080-3 Service Electrical system (3) AI system failure Auto idling malfunction. Auto idling malfunction. Control lever at NEUTRAL position, but the engine fails AI switch is on? to reach the idling speed. AI pressure sensor coupler disconnected? AI pressure switch circuit broken?
  • Page 681 WSM KX080-3 Service Electrical system B.Wire harness installation a. Precautions (1) No contact with the peripheral parts along the route Unprotected members not to be in contact (2) Checking the routes 1. Fuel hose not to be clamped together 2. Couplers, terminals, etc. to be connected tight enough to withstand usual pulling force 3.
  • Page 682 WSM KX080-3 Service Electrical system b. Engine earth, starter switch (1) Tightening torque of the cable fixing nut to the sel-motor terminal Tightening torque 5.9 ~ 11.8 N·m (0.6 ~ 1.2 kgf·m) 4.34~8.68ft.lbs (2) Installation of starter switch (RC411-5346 ) 1.
  • Page 683 WSM KX080-3 Service Electrical system c. Checking cables, wires and battery 1) Check connections for looseness, rust and stains. 2) Check terminals and wires for corrosion by battery electro- lyte, etc. 3) Check terminals and wires for open circuit or impending open circuit.
  • Page 684 WSM KX080-3 Service Electrical system d.Wireharness route (1)To main wire harness (2)Run sensor V-S-10...
  • Page 685 WSM KX080-3 Service Electrical system 1)Battery (2)Main wire harness (3)To fuel tank V-S-11...
  • Page 686 WSM KX080-3 Service Electrical system (1)To machine front (2)AI motor (3)To machine front V-S-12...
  • Page 687 WSM KX080-3 Service Electrical system (1)To left control (2)Fuse box (3)Front of the step (4)To front of the operator's seat (5)To right control (meter) V-S-13...
  • Page 688 WSM KX080-3 Service Electrical system (1)Cover (right, top) (2)Lamp (HI) (3)Meter assembly (EU) (4)Switch (beacon) (5)Antenna (anti-theft) (6)Meter assembly (AI, SC) (7)Switch assembly (A/C) V-S-14...
  • Page 689 WSM KX080-3 Service Electrical system (1)To main wire harness (2)To main wire harness V-S-15...
  • Page 690 WSM KX080-3 Service Electrical system C.Installation of main parts, couplers and harnesses a.Around the operator’s seat 1)Power source, outlet 4)Coupler, to heater relay 6)Compressure dutch relay 7)A/C blower relay 8)Buzzar, boom overload 14)Coupler, unload switch 15)Switch, unload 16)Coupler, S/P 2 switch...
  • Page 691 WSM KX080-3 Service Electrical system 1)Meter coupler, L (22p) 2)Meter coupler, S (20p) 3)Coupler, A/C SW 4)Coupler, hi-low SW 5)Coupler, AI SW 7)Coupler, hbeacomSW 8)Coupler, travel high lamp 11) 12) 16)Coupler, 17)Engine stop solenoid V-S-17...
  • Page 692 WSM KX080-3 Service Electrical system b.Front 1)Horn 2)Coupler, work lamp 3)Coupler, boom overload SW 4)Coupler, boom overload SW 5)Boom overload SW 6)Coupler, S/P 1, right 7)Fuse box 8)Amp. unit V-S-18...
  • Page 693 WSM KX080-3 Service Electrical system WorK lamp harness V-S-19...
  • Page 694 WSM KX080-3 Service Electrical system c.Fuel tank 1)Fuel sensor 2)Lead SW, fuel amount 3)Fuel supply pump 4)ON SW 5)OFF SW V-S-20...
  • Page 695 WSM KX080-3 Service Electrical system 1)Switch ON 2)Switch OFF 3)4min. controller 4)Fuse A 5)Stop relay (NC, blue) 6)Stop relay (NO, NC) 7)Fuse A 8)Fuse box 9)Fuse 10)Coupler 13)Fuel slide sensor 14)Lead sensor V-S-21...
  • Page 696 WSM KX080-3 Service Electrical system d.Starter, alternator, battery 1)Relay terminal 6)Alternator 7)Fuse box 8) Fuse box(Slow blow fuse) 9) Battery V-S-22...
  • Page 697 WSM KX080-3 Service Electrical system e.Fuses 1.Fuse capacities and Circuits 5A Room Light 20A Work Light 5A Meter Sub 10A Compressor(A/C) 15A Cigarette Lighter 15A Auxiliary 15A Wiper / Washer 5A Glow 10A Overload Warning 10A Starter 20A Blower Motor (A/C)
  • Page 698 WSM KX080-3 Service Electrical system f. Solenoid valve wiring (1) Unload solenoid valve (Travel Hi-Low solenoid) (2)Service port 1 proportional solenoid valve (3)Service port 2 solenoid valve V-S-24...
  • Page 699 WSM KX080-3 Service Electrical system g. Air conditioner wiring 1) Compressor harness 2) Blower harness coupler 3) Blower harness coupler 4) Dual pressure switch V-S-25...
  • Page 700 WSM KX080-3 Service Electrical system h.Cab wire harness 1.Couplers of cab harness 1)Main line to cab 2)GND 3)Auxiliary outlet 4)GND 2.Wire harness for woper motor 5)Wiper motor 3.Wire harness for washer tank 6)Washer motor V-S-26...
  • Page 701 WSM KX080-3 Service Electrical system 4.Wire harness for speaker and antenna 5.Wire harness for room lamp 3)Bulb of the room lamp 12V 10W 6.Auxiliary harness outlet 5)Outlet grommet V-S-27...
  • Page 702 WSM KX080-3 Service Electrical system 6)Pull out the grommet. 7)Remove the antenna and get the harness outside. 8)Auxiliary terminals for rotating lamp or rear work lamp. 9) Wire harness storage. 1)Inside the cap 2)Between the walls 3)Outside V-S-28...
  • Page 703 WSM KX080-3 Service Electrical system i.Circuit diagram of cab harness 1)Coupler, cab main 2)Coupler, earth V-S-29...
  • Page 704 WSM KX080-3 Service Electrical system V-S-30...
  • Page 705 B. System components; KX080-3 ........
  • Page 706 WSM KX080-3 Mechanism VI Air Conditioner VI-M-2...
  • Page 707 WSM KX080-3 Mechanism VI Air Conditioner A.Air conditioner system a. Introduction of air conditioner (1) Principle of air conditioner When your hand is wet and exposed to the wind or Alcohol evaporates. when you disinfect your hand with alcohol, you should feel your skin being cooled.
  • Page 708 WSM KX080-3 Mechanism VI Air Conditioner (2) Change of state of refrigerant The concept of the air conditioning system is as Spray follows. When liquid Freon is sprayed, it expands Rapid cooling and turns into very cold gas. It is so cold that it freezes and looks snow-white (even under atmo- spheric pressure).
  • Page 709 WSM KX080-3 Mechanism VI Air Conditioner (3) Function and construction ote : alues of temperature an pressure in belo Fig. are not specifications but ust sample ata. Evaporator Air conditioner body assembly Cold air supply opening The atomized refrigerant evaporates to turn...
  • Page 710 WSM KX080-3 Mechanism VI Air Conditioner b. Function and structure (1) System flow (1) Heat Sensitizing Tube (2) Expansion Valve (3) Evaporator (4) Blower Motor (5) Compressor (6) Engine Cooling Fan (7) Condenser (8) Receiver (9) Desiccant (10) Pressure Switch(Dual type)
  • Page 711 WSM KX080-3 Mechanism VI Air Conditioner (2) Refrigerant Cycle 1) Evaporation The refrigerant changes from liquid (wet vapor) to gas (superheated vapor) in the evaporator. The atom- ized refrigerant sent to the evaporator evaporates actively. At this time, the liquid (wet vapor) keeps on evaporating while drawing heat necessary for evaporation (latent heat) from air around the cooling fin (cabin air).
  • Page 712 WSM KX080-3 Mechanism VI Air Conditioner B.System components; KX080-3 a. Components and location Part name KX121-3, KX161-3 KX080-3 Remarks Unit assembly, air conditioner RD118-53703 RD809-53702 Thermostat Fin thermistor Compressor assembly, with clutch T2055-72253 Condenser T1065-72221 Tank, receiver T0070-79271 Holder, receiver...
  • Page 713 WSM KX080-3 Mechanism VI Air Conditioner b. Control panel Mounted on actual machine Hottest Coolest (1) Fan switch: Used to turn on and off the fan and to select the airflow in 3 steps. (2) Air conditioner switch: Used to turn on the compressor to start cooling.
  • Page 714 WSM KX080-3 Mechanism VI Air Conditioner C.Main components a. Compressor The compressor is installed on the engine and is driven by crank pulley through a belt. The compressor is a pump designed to raise the pressure of refrigerant. Raising the pressure means raising the temperature.
  • Page 715 WSM KX080-3 Mechanism VI Air Conditioner (4) Structure Function The basic internal construction of sliding-vane type compressor consists of a rotor fitted with five vanes, and a cylinder. Although its internal construction partially differs from that of the through-vane type compressor, the function is identical.
  • Page 716 WSM KX080-3 Mechanism VI Air Conditioner 2 Operation Fig. Operation of Sliding-vane Type Compressor 1) Suction The refrigerant gas exits from the evaporator by the operation of the compressor, enters the com- pressor s low-pressure chamber. As the rotor turns together with the vanes, the refrigerant gas is drawn from the suction port into the cylinder.
  • Page 717 WSM KX080-3 Mechanism VI Air Conditioner b. High pressure relief valve If the high pressure is abnormally high, the pressure relief valve open, and the refrigerant is released into the atmo- sphere, and the system is maintained. At that time, some of the refrigerant in the system is released into the atmosphere.
  • Page 718 WSM KX080-3 Mechanism VI Air Conditioner c. Magnetic clutch A magnetic clutch is used to connect and disconnect the compressor from the engine. The main components are the stator, rotor, and pressure plate. (1) Principle When the current is supplied to the coil, magnetic forces are generated in the iron II and attracts the iron I.
  • Page 719 WSM KX080-3 Mechanism VI Air Conditioner d. Condenser (1) Description The condenser is used to cool down the high temperature and high pressure gas refriger- ant and change it to a liquid refrigerant. The greater the amount of the heat released...
  • Page 720 WSM KX080-3 Mechanism VI Air Conditioner e. Receiver The receiver (3) serves the purpose of storing the liquid refrigerant. The amount of the liquid refrigerant flowing through the system varies with the operating condition of the air conditioner. To be accurate, the receiver stores excess amount of refriger- ant when the heat load is lowered.
  • Page 721 WSM KX080-3 Mechanism VI Air Conditioner f. Dual pressure switch (1) Location structure The pressure switch is installed on the liquid tube between the receiver and the expan- sion valve. It detects abnormally high and low pressure of the refrigerant and switches off the magnetic clutch.
  • Page 722 WSM KX080-3 Mechanism VI Air Conditioner g. Air Conditioner Unit Air conditioner unit (1) consists of evaporator (3), expansion valve (4), heater core (2), blower (5), etc.. (1) Air Conditioner Unit (2) Heater Core (3) Evaporator (4) Expansion Valve (5) Blower h.
  • Page 723 WSM KX080-3 Mechanism VI Air Conditioner i. Evaporator The purpose of evaporator (2) is just opposite to that of the condenser. The state of refrigerant immediately after the expansion valve (4) is 100% liquid. As soon as the liquid pressure drops, it starts to boil, and in doing so, absorbs heat.
  • Page 724 WSM KX080-3 Mechanism VI Air Conditioner k. Water valve The hot water valve (1) is connected with the got water valve cable (2) and con- trolled with the temperature control lever on the control panel. This lever is used to adjust the flow rate of hot water going into the heater.
  • Page 725 WSM KX080-3 Mechanism VI Air Conditioner l. A/C blower The blower is incorporated in the right- hand space of the air conditioner unit. It blows cool, warm of fresh air via the front and side blow ports into the cabin.
  • Page 726 WSM KX080-3 Mechanism VI Air Conditioner m.A/C blower resistor 1 Main functions are ; 1. Two resistors regulate the blower speed according to the A/C blower switch speed range. 2. Fuse prevents the blower from burning out. 2 Structure 3 Current flow...
  • Page 727 WSM KX080-3 Mechanism VI Air Conditioner n. Relays Battery (f) Load (1) Clutch relay (2) Blower relay VI-M-23...
  • Page 728 WSM KX080-3 Mechanism VI Air Conditioner D.Frost control Function The evaporator fin temperature is sensed. If detected too low, the compressor is interrupted to prevent the evaporator from freezing. a. KX121-3, 161-3 Thermostat Faston terminal 250 Activating temperature characteristic Evaporator fin temperature sensor Function The evaporator fin temperature is sensed by a refrigerant-filled capillary tube.
  • Page 729 WSM KX080-3 Mechanism VI Air Conditioner b. KX080-3 Sensor Evaporator fin temperature sensor Thermo amplifier Fin thermistor Connector 0901F, 5P or equivalent PBT-N-1 (black) Mating connector Yazaki part code 7283-1050 Specifications Rated voltage DC12V Measuring conditions DC13 0.2 V at 25 5°C...
  • Page 730 WSM KX080-3 Mechanism VI Air Conditioner E.Electric circuit diagram a. KX121-3, 161-3 Thermostat VI-M-26...
  • Page 731 WSM KX080-3 Mechanism VI Air Conditioner b. KX080-3 Fin thermister Thermo-amp VI-M-27...
  • Page 732 WSM KX080-3 Mechanism VI ir Conditioner VI-M-28...
  • Page 733 WSM KX080-3 Service VI Air Conditioner I. Air Conditioner (Service) Ser ice Section A. Servicing specifications ..........VI-S-3 a.
  • Page 734 WSM KX080-3 Service VI Air Conditioner VI-S-2...
  • Page 735 WSM KX080-3 Service VI Air Conditioner A.Servicing specifications a. Specifications of A/C system and components Item Specifications Remarks Outside air: 35 C Capacity 2.8 kW Inside air: 27 C, 50% Airflow 280 m Rotating speed of Comp: 1800 rpm Terminal voltage of blower motor: 13.5 V...
  • Page 736 WSM KX080-3 Service VI Air Conditioner Item Specifications Remarks Opening 3.43 4.1 MPa pressure High-pressure relief Installed in the compressor Closing 2.75 MPa or pressure more High-pressure OFF 3.14 MPa (DIFF 0.59 MPa) High-pressure cut Low-pressure OFF 0.196 MPa (DIFF 0.02 MPa) Low-pressure cut (prevention of operation without gas)
  • Page 737 WSM KX080-3 Service VI Air Conditioner b. Performance specifications Item Specifications Remarks 80, 82 Noise level at ear point db(A) Engine : MAx., Blower : MAX. Duct sealing capacity Air flow speed out of grille A (m/s) 17.0, 17.0 All outlet except A are closed.
  • Page 738 WSM KX080-3 Service VI Air Conditioner d. Ambient temperature vs normal high-low pressure range Conditions : Door ; open Blower ; High range Temp. control ; Max. cool Engine speed ; 1500 rpm Normal high pressure range 15(59) 20(68) 25(77)
  • Page 739 WSM KX080-3 Service VI Air Conditioner e. Tightening torques Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts, and nuts : See page G-11.) Item kgf m ft-lbs Cabin mounting nuts M14 nut 107.9 to 125.5...
  • Page 740 WSM KX080-3 Service VI Air Conditioner B.Regular check and service points a. Maintenance interval ; Air conditioner Indication on hour meter Reference Items Period Since then clean every 200 hrs 1 Inner air filter replace every 1000hrs clean every 200 hrs...
  • Page 741 WSM KX080-3 Service VI Air Conditioner C.Troubleshooting a. Procedure The chart shows the basic troubleshooting procedure. Car air conditioner troubles are roughly classified in the refrigeration cycle and electrical system. In this chapter the basic troubleshooting procedure is discussed. s ing the user...
  • Page 742 WSM KX080-3 Service VI Air Conditioner c. Troubleshooting from problem symptoms (except refrigeration cycle troubles) You will find the troubles easily using the table below. For details, refer to each troubleshooting chart. Main Inspection Areas Refer Problem Others page Fuse is blown out easily...
  • Page 743 WSM KX080-3 Service VI Air Conditioner e. Checking the refrigeration cycle Troubleshooting the refrigeration cycle hec ing the refrigeration cycle Using a gauge manifold hec ing the refrigerant amount Using the sight glass hec ing the refrigerant gas pressure Using a gauge manifold...
  • Page 744 WSM KX080-3 Service VI Air Conditioner Reference On the EPR (Evaporator Pressure Regulator) type car air conditioner, the low-pressure side level rises and drops from the level of about 0.18 MPa (1.8 kgf/cm ) at regular intervals, if the outside air temper- ature is low.
  • Page 745 WSM KX080-3 Service VI Air Conditioner (2) Using a gauge manifold 1. Using a gauge manifold, measure the pressures at the low-pressure and high-pressure sides of refrigeration cycle. 2. Attach a gauge manifold in position and place the machine in the following conditions.
  • Page 746 WSM KX080-3 Service VI Air Conditioner 2) Refrigerant shortage Phenomenon Possible cause Correction Too low pressure at both low-pressure Refrigerant too short. Gas leak. Pinpoint and repair the leaky spot. and high-pressure sides Add refrigerant. Bubbles flowing continuously in the...
  • Page 747 WSM KX080-3 Service VI Air Conditioner 4) Water mixed in the circuit Phenomenon Possible cause Correction Gradual drop to negative pressure at Water mixed (Water mixed in the refrig- Do the complete vacuuming before low-pressure side after a certain period...
  • Page 748 WSM KX080-3 Service VI Air Conditioner 6) No refrigerant circulation (clogged circuit) Phenomenon Possible cause Correction Negative pressure immediately shown Dust buildup or water freezing at the Replace the receiver with new one at low-pressure side if the circuit is...
  • Page 749 WSM KX080-3 Service VI Air Conditioner 8) Too open expansion valve Phenomenon Possible cause Correction Too high pressure at both low-pres- Too much refrigerant in low-pressure Replace the expansion valve with new sure and high-pressure sides pipe one. Frosty low-pressure pipe...
  • Page 750 WSM KX080-3 Service VI Air Conditioner 2. Checking for gas leak 1) Gas leak checking procedure in the engine room Check for gas leak in the cabin. No leak Is fluorescent dye added Check with a fluorescent gas leak detector with the machine (inspection lamp).
  • Page 751 WSM KX080-3 Service VI Air Conditioner 2) Gas leak checking procedure in the cabin (cooler unit) ith a fluorescent gas lea etector. Is fluorescent dye added Using the inspection lamp, see if fluorescent with the machine? dye remains at the tip of the drain hose .
  • Page 752 WSM KX080-3 Service VI Air Conditioner (4) Precautions Preparations Gauge manifold kit Dry-bulb thermometer CFC gas recovery unit Psychrometer Thickness gauge Circlip pliers Circuit tester Platform scale 1. Precautions for training (charging refrigerant) 1) Allow qualified personnel only to join the training.
  • Page 753 WSM KX080-3 Service VI Air Conditioner Training 1: Setting the gauge manifold 1) Close the gauge manifold s valves (for HI and LO). 2) Connect the charging hoses. (Connect the red one to HI and the blue one to LO.) 3) Slightly loosen the high-pressure and low-pressure valves to let air out of the hoses.
  • Page 754 WSM KX080-3 Service VI Air Conditioner (5) Check performance of air conditioning system 1) Calculate the relative humidity from the psychrometric graph by comparing the wet- and dry-bulb readings of the psychrometer at the air inlet. HOW TO READ THE GRAPH:...
  • Page 755 Conversion Tables...
  • Page 758 KUBOTA Corporation CONSTRUCTION MACHINERY DIVISION 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN EDITOR: CONSTRUCTION MACHINERY MANUFACTURING DEPT. SERVICE ENGINEERING SECTION HIRAKATA PLANT 1-1-1 NAKAMIYA-OHIKE, HIRAKATA-CITY, OSAKA, JAPAN PHONE :+81-72-840-2888 :+81-72-840-2886 KUBOTA Corporation Printed in Japan 2006. July. CMC.e. Code No.97899-61620...

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