Kubota KX080-4 Workshop Manual
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Kubota KX080-4 Workshop Manual

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Table of Contents

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WORKSHOP MANUAL
KUBOTA EXCAVATOR
KX080-4
KiSC issued 08, 2015 A

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Summary of Contents for Kubota KX080-4

  • Page 1 WORKSHOP MANUAL KUBOTA EXCAVATOR KX080-4 KiSC issued 08, 2015 A...

  • Page 2: Table Of Contents

    CONTENTS TO THE READER SERVICING TO THE READER 1. PUMP............3-S1 2. CONTROL VALVE........3-S17 I INFORMATION 3. SWIVEL MOTOR ........3-S26 CONTENTS 4. SWIVEL JOINT ........3-S41 INFORMATION 5. TRAVEL MOTOR........3-S49 1. SAFETY FIRST ..........I-1 6. CYLINDER..........3-S69 2.
  • Page 3 • Refer to the information of the engine below. • Engine model : V2607-CR-E4B, V2607-CR-TE4B, V3307-CR-TE4B • Web PDF-Code : No.9Y111-06740 • Hard Copy-Code : No.9Y121-06740 • CD-ROM-Code : No.9Y131-06740 January, 2013 © KUBOTA Corporation 2013 KiSC issued 08, 2015 A...
  • Page 4 Record of Revisions Last digit of the Code Date Main Revised Point and Corrective Measures Remarks • Add the contents of pump assembly and disassembly, 2015.08.05 S. M the contents of cabin glass removal and mounting. KiSC issued 08, 2015 A...
  • Page 5 INFORMATION KiSC issued 08, 2015 A...

  • Page 6: In The Interest Of Work

    INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. IN THE INTEREST OF WORK SAFETY ..................I-2 [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS:......................I-2 (1) Precautions Before Working on the Machine ..............I-2 (2) Precautions Before Working on the Equipment..............I-3 3.

  • Page 7: Safety First

    KX080-4, WSM INFORMATION 1. SAFETY FIRST SAFETY FIRST • This "Safety Alert Symbol" is used in this manual and on labels on equipment to indicate important issues and warn of the danger of personal injury. Read and follow these warnings carefully.

  • Page 8: In The Interest Of Work Safety

    KX080-4, WSM INFORMATION 2. IN THE INTEREST OF WORK SAFETY [1] WORKING SAFELY WITH THE EQUIPMENT MEANS ALWAYS FOLLOWING THESE INSTRUCTIONS: (1) Precautions Before Working on the Machine Before starting any service or maintenance work • Read all the general and safety instructions in this manual, as well as the decals on your equipment.

  • Page 9: Precautions Before Working On The Equipment

    KX080-4, WSM INFORMATION (2) Precautions Before Working on the Equipment • Stop the machine on a hard and level location and make sure the area around the machine is free of obstacles and hazardous materials. When parking the machine indoors, select a spot that can be properly ventilated.
  • Page 10 KX080-4, WSM INFORMATION • The engine, muffler, radiator, hydraulic line, etc., have parts that remain very hot even after the engine has been stopped. Be sure to avoid these parts, as touching them can result in burns. Radiator coolant, hydraulic fluid and oil also remain hot. Therefore, do not attempt to remove caps and plugs, etc., before...
  • Page 11 KX080-4, WSM INFORMATION • Grease is under high pressure inside the hydraulic cylinder. It is very dangerous to loosen a grease nipple quickly as it may shoot off. Always loosen grease nipples slowly. • And never face a grease nipple while loosening it.

  • Page 12: Labels Displayed To Promote Work Safety

    KX080-4, WSM INFORMATION 3. LABELS DISPLAYED TO PROMOTE WORK SAFETY [1] LOCATIONS RY9212158INI0003US0 KiSC issued 08, 2015 A...
  • Page 13 KX080-4, WSM INFORMATION RY9212158INI0004US0 KiSC issued 08, 2015 A...
  • Page 14 KX080-4, WSM INFORMATION RY9212158INI0005US0 KiSC issued 08, 2015 A...
  • Page 15 KX080-4, WSM INFORMATION RY9212158INI0006US0 KiSC issued 08, 2015 A...
  • Page 16 KX080-4, WSM INFORMATION RY9212158INI0007US0 I-10 KiSC issued 08, 2015 A...

  • Page 17: Label Maintenance

    KX080-4, WSM INFORMATION RY9212158INI0008US0 [2] LABEL MAINTENANCE Thoroughly Read, Understand and Follow Safety Precautions on Labels • Always keep labels in a clean, undamaged state. • If labels get dirty, wipe them off with soapy water and a soft cloth.

  • Page 18: Main Specifications

    2987 psi Fuel tank capacity 115 L (30.4 U.S.gal) NOTE • Above dimensions are based on the machine with KUBOTA original bucket and 2100 arm. • Specifications subject to change without notice. • With unloaded digging bucket. • Firm compacted soil.

  • Page 19: Dimensions

    57.5 in. 253.9 in. 84.6 in. 98.0 in. • Above dimensions are based on the machine with KUBOTA original bucket. • Above dimensions are based on the machine with rubber track. • Specifications subject to change without notice. RY9212158INI0002US0 I-13...
  • Page 20 GENERAL KiSC issued 08, 2015 A...
  • Page 21 GENERAL CONTENTS 1. CHECKING EXCAVATOR IDENTIFICATION ................G-1 2. ENGINE IDENTIFICATION ......................G-2 [1] MODEL NAME AND SERIAL NUMBER ................G-2 [2] E4B ENGINE .......................... G-3 [3] CYLINDER NUMBER ......................G-4 3. MUFFLER FULL ASSEMBLY IDENTIFICATION ................. G-5 [1] PART NUMBER AND SERIAL NUMBER ................G-5 4.

  • Page 22: General

    KX080-4, WSM GENERAL 1. CHECKING EXCAVATOR IDENTIFICATION When consulting with your local KUBOTA dealer about this mini-excavator, please provide the model of the mini-excavator, its frame and engine numbers and the number of hours on the hour meter. (1) Mini-excavator Nameplate...

  • Page 23: Engine Identification

    KX080-4, WSM GENERAL 2. ENGINE IDENTIFICATION [1] MODEL NAME AND SERIAL NUMBER Be sure to check the engine nameplate and serial number when you wish to consult about the engine. The model and serial number of the engine need to be checked prior to servicing the engine or replacing any of its parts.

  • Page 24: E4B Engine

    Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission regulations depends on the engine output classification. Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the respective countries affected by Nonroad Emission regulations. For KUBOTA Engines, E4B will be the designation that identifies engine models affected by the next emission phase (See the table below).

  • Page 25: Cylinder Number

    KX080-4, WSM GENERAL [3] CYLINDER NUMBER You can see the cylinder numbers of KUBOTA diesel engine in the figure. The sequence of cylinder numbers is No.1, No.2, No.3 and No.4 and it starts from the gear case side. RY9212134GEG0005US0 KiSC issued 08, 2015 A...

  • Page 26: Muffler Full Assembly Identification

    KX080-4, WSM GENERAL 3. MUFFLER FULL ASSEMBLY IDENTIFICATION [1] PART NUMBER AND SERIAL NUMBER Diesel Particulate Filter (hereinafter referred to as the "DPF") Muffler Full Assembly Serial Number The DPF muffler full assembly serial number is an identified number for the DPF muffler full assembly.
  • Page 27 KX080-4, WSM GENERAL You must keep the records of the filter comp (DPF) part number and serial number before you remove the DPF for cleaning. (1) Body (DPF Outlet) Part Number and (3) Catalyst (DOC) Part Number and Serial Number...

  • Page 28: General Precautions

    Whenever a special tool is required, use the special tool that KUBOTA recommends. Make any special tools that are not used very frequently according to the diagrams in this manual. Always use genuine KUBOTA parts to maintain the performance and safety characteristics of the machine.
  • Page 29 KX080-4, WSM GENERAL Floating Seal • Be sure to wipe off any oil from the O-ring or surfaces that touch the O-ring. (For wheel motors, apply a light film) • When putting an O-ring into a floating seal, make sure the O-ring does not twist.
  • Page 30 KX080-4, WSM GENERAL Tightening Bolts and Nuts • Tighten bolts and nuts to their specified torque. • Tighten nuts and bolts alternately top/bottom (a) (b), left/right so the torque is distributed evenly. (A) Top/Bottom Alternately (C) Diagonally Across the Center...
  • Page 31 KX080-4, WSM GENERAL Installing and Removing Quick Couplings • To remove a quick hose coupling, push the fitting in the direction of the arrow and pull on the plastic part in the opposite direction. • To attach a quick coupler, push it in firmly in the direction of the arrow.

  • Page 32: Handling Precautions For Electrical Parts And Wiring

    KX080-4, WSM GENERAL 5. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING Follow the precautions below for handling electrical parts and wiring to ensure safety and prevent damage to the machine and nearby equipment. IMPORTANT • Inspect electrical wiring for damage and/or loose connections.
  • Page 33 KX080-4, WSM GENERAL • Insert grommet securely. (1) Grommet (A) Correct (B) Incorrect RY9212001GEG0027US0 • Clamp wiring securely but do not damage wires with the clamp. (1) Clamp (Spiral Clamp Around Wire) (3) Clamp (2) Wire (4) Welding Mark RY9212001GEG0028US0 •...

  • Page 34: Fuses

    KX080-4, WSM GENERAL • Do not modify harnesses. The diameter of wires in each harness is determined after calculating its capacity. • Modifying harnesses may cause a malfunction or a fire. (A) Wiring Diagram (a) Standard Wiring (B) Diagram of Modification...
  • Page 35 KX080-4, WSM GENERAL • Hold the connectors when separating them. • Do not pull on the wire harness to separate the connectors. (A) Correct (B) Incorrect RY9212001GEG0034US0 Pull on the harness from the connector and make sure the harness does not come off. (Pull with 3 kgf (30 N, 7 lbf) or less of...

  • Page 36: Washing The Machine With A High-Pressure Washer

    KX080-4, WSM GENERAL • The plastic covers of connectors must cover them completely. (1) Cover (A) Correct (B) Incorrect RY9212001GEG0037US0 [4] WASHING THE MACHINE WITH A HIGH-PRESSURE WASHER Using a high-pressure washer incorrectly can lead to personal injury and/or damage, break or cause parts of the machine to fail, so use the power washer properly according to its operator's manual and labels.

  • Page 37: Tightening Torques

    KX080-4, WSM GENERAL 6. TIGHTENING TORQUES [1] TORQUES FOR GENERAL USE NUTS AND BOLTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of bolt...

  • Page 38: Torque For Hydraulic Hose Fittings

    KX080-4, WSM GENERAL [2] TORQUE FOR HYDRAULIC HOSE FITTINGS (1) Torque for Hydraulic Hose Fittings Union nut (metal seal type) Union nut (ORS type) 7.8 to 11.8 N·m 0.8 to 1.2 kgf·m – – 5.7 to 8.7 lbf·ft 24.5 to 29.2 N·m 35.2 to 43.1 N·m...

  • Page 39: Hose Clamp Screw Torque

    KX080-4, WSM GENERAL [3] HOSE CLAMP SCREW TORQUE Type 1 2.5 to 3.4 N·m 10- 14 6C040-58721 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft 2.5 to 3.4 N·m 12- 16 09318-89016 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft 2.5 to 3.4 N·m...
  • Page 40 KX080-4, WSM GENERAL Type 2 2.5 to 3.4 N·m 13- 20 RB101-63631 25 to 35 kgf·cm 1.8 to 2.5 lbf·ft 4.9 to 5.9 N·m 15- 25 RC101-64581 50 to 60 kgf·cm 3.6 to 4.3 lbf·ft 4.9 to 5.9 N·m 19- 28 R1401-63211 50 to 60 kgf·cm...

  • Page 41: Oil And Water Capacity Table

    KX080-4, WSM GENERAL 7. OIL AND WATER CAPACITY TABLE Item KX080-4 Notes Engine oil (when filter changed) 9.7 L (2.6 U.S.gal) API type, CJ-4 Coolant 10.5 L (2.77 U.S.gal) Antifreeze Kubota LLC-N-50F Mixture ratio 50% Reserve tank 1.3 L (0.34 U.S.gal) Fuel (full) 115 L (30.4 U.S.gal)

  • Page 42: Maintenance Intervals

    KX080-4, WSM GENERAL 8. MAINTENANCE INTERVALS Hour meter indication Check points Measures Interval 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 check Daily check 1 Coolant every change 2 years 2 Fuel...
  • Page 43 KX080-4, WSM GENERAL Hour meter indication Check points Measures Interval 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 800 1000 every 24 Oil separator element replace *4 @ 1500 hrs every 25 EGR cooler...
  • Page 44 *4 : Consult your local KUBOTA Dealer for this service. • 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 45: Machine Body

    MACHINE BODY KiSC issued 08, 2015 A...

  • Page 46: Servicing

    SERVICING CONTENTS 1. FRONT ............................1-S1 [1] BOOM ASSEMBLY/DISASSEMBLY ..................1-S1 [2] TABLE OF DIMENSIONS .....................1-S3 (1) Bucket..........................1-S3 (2) Front Pin ..........................1-S4 (3) Front Bushings ........................1-S5 (4) Arm ..........................1-S6 (5) Blade ..........................1-S7 2. SWIVEL FRAME..........................1-S8 [1] WEIGHT ASSEMBLY/DISASSEMBLY .................1-S8 [2] CABIN REMOVAL AND MOUNTING ..................1-S8 [3] FUEL TANK ASSEMBLY/DISASSEMBLY ................1-S11 [4] HYDRAULIC OIL TANK ASSEMBLY/DISASSEMBLY............1-S14 [5] ASSEMBLY/DISASSEMBLY OF ENGINE RELATED COMPONENTS......1-S16...
  • Page 47 5. SWIVEL GEAR BACKLASH PERFORMANCE .................1-S40 KiSC issued 08, 2015 A...

  • Page 48: Front

    KX080-4, WSM MACHINE BODY 1. FRONT [1] BOOM ASSEMBLY/DISASSEMBLY CAUTION • Wear protective gear, such as a helmet, eye protection, etc., during assembly/disassembly. • For group work, decide on signals for communication, make sure everyone understands and uses them and be very careful about safety.
  • Page 49 KX080-4, WSM MACHINE BODY 5. Remove all the arm cylinder and bucket cylinder hoses. (1) Arm cylinder hose (2) Bucket cylinder hose RY9212148MBS0021US0 6. Suspend the boom temporarily and remove the pin at the base of the boom. (1) Pin RY9212148MBS0022US0 7.

  • Page 50: Table Of Dimensions

    KX080-4, WSM MACHINE BODY [2] TABLE OF DIMENSIONS (1) Bucket NOTE • Kubota Japan bucket KX080-4 KX080-4 KX080-4 KX080-4 600 mm 105 mm 300 mm 462 mm (13) (19) 23.62 in. 4.13 in. 11.81 in. 18.19 in. 620 mm 120 mm...

  • Page 51: Front Pin

    KX080-4, WSM MACHINE BODY (2) Front Pin KX080-4 Item (Pin dia. X length) 100 × 474 mm 3.94 × 18.66 in. 70 × 183 mm 2.76 × 7.20 in. 70 × 168 mm 2.76 × 6.61 in. 80 × 437 mm 3.15 ×...

  • Page 52: Front Bushings

    KX080-4, WSM MACHINE BODY (3) Front Bushings KX080-4 KX080-4 Item Point used Item Point used (I.D. X O.D. X Length) (I.D. X O.D. X Length) 100 × 115 × 64 mm 70 × 82 × 80 mm Swing bracket top Arm ends 3.94 ×...

  • Page 53: Arm

    KX080-4, WSM MACHINE BODY Bushing shape (A) Flanged bushing (B) Normal bushing (a) I.D. (b) O.D. (c) Length RY9212148MBS0036US0 (4) Arm (A) Arm tip (B) Bucket link 1 KX080-4 KX080-4 KX080-4 KX080-4 260 mm 1745 mm 66 mm 70 mm...

  • Page 54: Blade

    KX080-4, WSM MACHINE BODY (5) Blade Item KX080-4 70 × 98 mm I.D. X Length 2.76 × 3.86 in. 70 × 28 mm I.D. X Length 2.76 × 1.10 in. 2200 mm Width 86.61 in. 500 mm Height 19.69 in.

  • Page 55: Swivel Frame

    KX080-4, WSM MACHINE BODY 2. SWIVEL FRAME [1] WEIGHT ASSEMBLY/DISASSEMBLY 1. Remove the left and rear hoods. CAUTION It takes at least 2 people to remove the rear hood. Rear hood weight Approx. 27 kg (60 lbs) (1) Rear hood...
  • Page 56 KX080-4, WSM MACHINE BODY 2. Disconnect the cabin harness and the washer harness. (1) Cabin harness (2) Washer harness RY9212148MBS0044US0 3. Suspend the cabin with the crane and remove the cabin mounting bolts (nine) and nuts (two). 259.9 to 304.0 N·m Bolt 26.5 to 31.0 kgf·m...
  • Page 57 KX080-4, WSM MACHINE BODY Installation of cabin rubber vibration dampers (1) Nut (3) Rubber vibration damper (5) Bolt (6) Rubber vibration damper (2) Bolt (4) Nut 107.9 to 127.4 N·m Nut (1) 11.0 to 13.0 kgf·m 79.6 to 94.0 lbf·ft 103.0 to 117.7 N·m...

  • Page 58: Fuel Tank Assembly/Disassembly

    KX080-4, WSM MACHINE BODY [3] FUEL TANK ASSEMBLY/DISASSEMBLY 1. Remove the cover. (1) Cover RY9212148MBS0048US0 2. After draining the fuel, remove the fuel hose. (1) Water drain cock (2) Fuel hose RY9212148MBS0049US0 3. Remove the electrical wiring and the fuel hose.
  • Page 59 KX080-4, WSM MACHINE BODY Fuel hose circuit (1) Outside air (6) Fuel filter (a) 110 mm (4.3 in.) 30 mm (1.2 in.) (2) Strainer (Eur. only) (7) Engine (b) 45 mm (1.8 in.) (g) 75 mm (3.0 in.) (3) Fuel tank (8) Fuel check valve (c) 65 mm (2.6 in.)
  • Page 60 KX080-4, WSM MACHINE BODY Fuel Supply and Return Hose Routing • (a): Fuel hose supply side • (b): Fuel hose return side • (c): Air bleed • (d): Pass the return hose outside the electric pump. Install so the electric pump and hose do not interfere with each other.

  • Page 61: Hydraulic Oil Tank Assembly/Disassembly

    KX080-4, WSM MACHINE BODY [4] HYDRAULIC OIL TANK ASSEMBLY/DISASSEMBLY 1. After draining the hydraulic oil, remove the front, right and tank covers. (1) Front cover (3) Tank cover (2) Right cover RY9212148MBS0150US0 2. Remove the cover, electric fan, center cover and center frame.
  • Page 62 KX080-4, WSM MACHINE BODY 9. Remove the battery support mounting bolts and slide the battery support to the right side of the machine. IMPORTANT • Apply a thread lock (Loctite 271). 196.1 to 225.6 N·m Tightening torque Bolt 20.0 to 23.0 kgf·m 144.6 to 166.4 lbf·ft...

  • Page 63: Assembly/Disassembly Of Engine Related Components

    KX080-4, WSM MACHINE BODY [5] ASSEMBLY/DISASSEMBLY OF ENGINE RELATED COMPONENTS (1) DPF Muffler 1. Remove the rear and left hoods and the air cleaner. CAUTION • For hood removal, a minimum of 2 persons is needed. Rear hood weight Approx. 27 kg (60 lbs)
  • Page 64 KX080-4, WSM MACHINE BODY 5. Remove the 4 flange nuts, bracket mounting bolts, drain pipe and then the DPF muffler. CAUTION • It takes at least 2 people to remove the DPF muffler. IMPORTANT • Record the machine number, engine number and DPF muffler number.

  • Page 65: Engine

    KX080-4, WSM MACHINE BODY 7. Remove the exhaust temperature sensor from the DPF muffler as needed. • Tools: Flare nut wrench IMPORTANT • Never use the spanner to prevent the nut break. • If the exhaust temperature sensor does not be loosened, apply the lubricant (KURE CRC) on the screw part and leave it for a day and restart the work.
  • Page 66 KX080-4, WSM MACHINE BODY 4. Remove the electrical wiring and air cleaner pipe mounted on the arch. (1) Air cleaner pipe (2) Electrical wiring RY9212148MBS0062US0 5. Suspend the arch and remove the five arch mounting bolts. Remove the arch. IMPORTANT •...
  • Page 67 KX080-4, WSM MACHINE BODY 10. Disconnect all the connections and clamps to the engine. (1) Engine electrical wiring RY9212148MBS0067US0 11. Remove the pump mounting bolts and disconnect from the pump connector. 12. Suspend the engine and remove the bolts and nuts holding the engine to its mounts.

  • Page 68: Assembling Operating Levers

    KX080-4, WSM MACHINE BODY [6] ASSEMBLING OPERATING LEVERS (1) Travel Lever (1) Left travel lever (a) 260 ± 5 mm (10.2 ± 0.2 in.) (2) Right travel lever (b) When in neutral (3) Grip (c) 15 to 21 mm (0.59 to 0.83 in.) (d) Fwd/rear deviation of l/r levers to be within 2mm (0.08 in.)

  • Page 69: Track Frame

    KX080-4, WSM MACHINE BODY 3. TRACK FRAME [1] SWIVEL BEARING ASSEMBLY/DISASSEMBLY 1. Remove the swivel frame. RY9212148MBS0073US0 2. Suspend the swivel bearing with a crane, remove the swivel bearing mounting bolts on the bottom side, then remove the swivel bearing.

  • Page 70: Track

    KX080-4, WSM MACHINE BODY [2] TRACK WARNING • The backhoe is equipped with an overload warning system. When changing the rubber track to an iron track, or vice versa, it is necessary to change the preset code in either case.

  • Page 71: Assembly/Disassembly Of Iron Tracks

    KX080-4, WSM MACHINE BODY Assembling the Rubber Track 1. Jack up the machine with the front and the blade and with it lifted slightly off the ground, wedge the track onto the sprocket and set it on the frame. 2. Wedge steel pipes into the track and rotate the sprocket backwards in direction A.
  • Page 72 KX080-4, WSM MACHINE BODY 5. Lower the machine to the ground and mount tools a, b, and c to the track. IMPORTANT • With tool b in place, mount tool c. (1) Master pin (a) Tool a (b) Tool b...
  • Page 73 KX080-4, WSM MACHINE BODY 2. Raise the track using a crane and mesh it with the sprocket. (1) Sprocket RY9212148MBS0083US0 3. Operate the travel lever forward slowly and wind the track on. When the track is sufficiently pulled on to where the track link joint is at the front idler, lower the mini-excavator and place a block under the track to support it.

  • Page 74: Steel Track Removal/Installation Tools

    KX080-4, WSM MACHINE BODY (3) Steel Track Removal/Installation Tools No. in Name of part Figure Guide (outside) Guide (inside) Stopper plate Pusher 1 Pusher 2 Spring RY9212148MBS0088US0 (a)Guide (outside) 189.5 to 190.5 mm (7.46 to 7.50 in.) 21.0 mm (0.83 in.) 20.0 mm (0.79 in.)
  • Page 75 KX080-4, WSM MACHINE BODY (b)Guide (inside) 150.0 mm (5.91 in.) 19.0 mm (0.75 in.) 3.2 mm (0.13 in.) 15.5 mm (0.61 in.) 27.6 mm (1.09 in.) 28.5 mm (1.12 in.) 34.0 mm (1.34 in.) 39.5 to 40.5 mm (1.56 to 1.59 in.) 100.0 mm (3.94 in.)
  • Page 76 KX080-4, WSM MACHINE BODY (d)Pin 2.0 mm (0.08 in.) 23.4 to 23.6 mm (0.92 to 0.93 in.) 132.7 to 133.3 mm (5.22 to 5.25 in.) 30°(0.52 rad) RY9212148MBS0092US0 (e)Pusher 1 50.0 mm (1.97 in.) 2.0 mm (0.08 in.) 23.4 to 23.6 mm (0.92 to 0.93 in.) 65.0 mm (2.56 in.)

  • Page 77: Front Idler

    KX080-4, WSM MACHINE BODY [3] FRONT IDLER (1) Assembly/Disassembly of Front Idler 1. Remove the track. (Refer to the chapter Assembly/Disassembly of the Rubber Track.) IMPORTANT • Jack up the machine with the front-end and the blade and place blocks under the frame.
  • Page 78 KX080-4, WSM MACHINE BODY 3. Remove the floating seal. 4. Remove the shaft. (1) Spring Pin (3) Floating Seal (2) Bracket (4) Shaft RY9212148MBS0007US0 Assembly Procedures 1. Mount the O-rings on the shaft. IMPORTANT • Apply engine oil to the O-rings.

  • Page 79: Grease Cylinder

    KX080-4, WSM MACHINE BODY 6. Fill with engine oil via the plug hole in the bracket. 7. Install the plug. Type SAE #30CD engine 80 cc Lubricant 4.88 cu.in 10.0 N·m Tightening torque Plug 1.0 kgf·m 7.4 lbf·ft Apply thread lock compound (Loctite 503 or equivalent)

  • Page 80: Tensioner

    KX080-4, WSM MACHINE BODY [5] TENSIONER (1) Tensioner Assembly/Disassembly 1. Remove the track front idler and grease cylinder. (Refer to the the Track and Front Idler and Grease Cylinder sections for their assembly/disassembly procedures.) 2. Remove the tensioner from the track frame.

  • Page 81: Track Rollers

    KX080-4, WSM MACHINE BODY [6] TRACK ROLLERS (1) Track Roller Assembly/Disassembly CAUTION • As the grease cylinder is under high pressure, loosening the grease nipple all at once may cause the nipple to go flying and/or grease to spray out.

  • Page 82: Carrier Rollers

    KX080-4, WSM MACHINE BODY [7] CARRIER ROLLERS (1) Carrier Roller Assembly/Disassembly CAUTION • As the grease cylinder is under high pressure, loosening the grease nipple all at once may cause the nipple to go flying and/or grease to spray out.

  • Page 83: Table Of Dimensions

    KX080-4, WSM MACHINE BODY [8] TABLE OF DIMENSIONS (1) Rubber Track Item KX080-4 KX080-4 Country sold 20 mm 20 mm Lug height 0.79 in. 0.79 in. 30 mm 30 mm Link height 1.18 in. 1.18 in. 450 mm 450 mm Track width 17.72 in.

  • Page 84: Idler Sprocket

    KX080-4, WSM MACHINE BODY (3) Idler Sprocket Item KX080-4 Front Idler 390 / 384 mm O.D. (A)/(B) 15.35 / 15.12 in. 38 / 32 mm Guide width (A)/(B) 1.50 / 1.26 in. 98 mm Width 3.86 in. Sprocket 493 / 481 mm O.D.

  • Page 85: Measuring Machine Performance

    KX080-4, WSM MACHINE BODY 4. MEASURING MACHINE PERFORMANCE [1] MEASURING FRONT PERFORMANCE (1) Measuring Swivel Gear Backlash Purpose • Measure the degree of overall wear in the front and replace pins and/or bushings or add shims as needed. • When there is a great deal of play, it may cause wear in the swivel bearing teeth, swivel motor pinion gear and front pins and bushings.

  • Page 86: Measuring Swivel Bearing Play

    KX080-4, WSM MACHINE BODY (2) Measuring Swivel Bearing Play Purpose • Assesses the degree of wear in the ball bearings and race surfaces of the swivel bearing according to the amount of wear in the inner and outer races. [Measurement preparation] 1.

  • Page 87: Swivel Gear Backlash Performance

    KX080-4, WSM MACHINE BODY 5. SWIVEL GEAR BACKLASH PERFORMANCE Item Factory specification Notes ≤ 70 mm Front play measurement ≤ 2.76 in. Factory spec. 1.24 mm when new 0.05 in. Swivel bearing play 2.48 mm Usage limit 0.10 in. RY9212158MBS0004US0...

  • Page 88: Engine

    ENGINE KiSC issued 08, 2015 A...

  • Page 89: General

    GENERAL CONTENTS 1. SPECIFICATIONS........................2-G1 2. DIMENSIONS ..........................2-G2 3. PERFORMANCE CURVES......................2-G3 4. FAN DRIVE..........................2-G4 KiSC issued 08, 2015 A...

  • Page 90: Specifications

    KX080-4, WSM ENGINE 1. SPECIFICATIONS KX080-4 Model V3307-CRS-T4 No. of cylinders Cylinder Bore X Stroke 94.0 x 120 mm (3.70 x 4.72 in.) Total displacement 3331 cm (203.3 cu.in.) Idling RPM 1000 min Rated RPM 2000 min Maximum RPM 2220 min 47.2 kW/2000 min...
  • Page 91 KX080-4, WSM ENGINE 2. DIMENSIONS 802.9 mm (31.57 in.) 280 mm (11.02 in.) 759.8 mm (29.91 in.) 321 mm (12.64 in.) 578.1 mm (22.76 in.) 233.6 mm (9.20 in.) 32.6 mm (1.28 in.) 310.2 mm (12.21 in.) 290 mm (11.42 in.) 113 mm (4.45 in.)

  • Page 92: Performance Curves

    KX080-4, WSM ENGINE 3. PERFORMANCE CURVES (a) Engine RPM (e) Output (HP) A : SI unit (b) Output (kW) Torque (ft/lb) B : US units of work (c) Torque (N·m) (g) Fuel consumption (g/HPh) (d) Fuel consumption (g/kWh) RY9212148END0003US0 2-G3...

  • Page 93: Fan Drive

    KX080-4, WSM ENGINE 4. FAN DRIVE (1) Bimetallic Strip (4) Feed Orifice (6) Collection Orifice A : At High Temperature (2) Piston (5) Torque Transmission (7) Oil Collection Chamber B : At Low Temperature (3) Flat Spring (Valve) Chamber [At high temperature] •...

  • Page 94: Hydraulic System

    HYDRAULIC SYSTEM KiSC issued 08, 2015 A...

  • Page 95: Mechanism

    MECHANISM CONTENTS 1. DIAGRAM OF HYDRAULIC CIRCUIT..................3-M1 [1] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 STANDARD SPECIFICATION)....3-M1 [2] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 ANGLE BLADE SPECIFICATION)..3-M2 2. HYDRAULIC DEVICE LAYOUT ....................3-M3 3. PUMP ............................3-M4 [1] SPECIFICATIONS........................ 3-M4 [2] PIST PUMP HORSEPOWER CONTROL CURVE...............

  • Page 96: Shockless Valves........................... 3-M52

    [4] BLADE PILOT VALVES...................... 3-M49 (1) Specifications........................ 3-M49 (2) Function and Structure ....................3-M50 9. SHOCKLESS VALVES ......................3-M52 [1] SPECIFICATIONS ......................3-M52 [2] FUNCTION AND STRUCTURE ..................3-M52 10. SOLENOID VALVE........................3-M54 [1] UNLOAD VALVE ........................ 3-M54 (1) Specifications........................ 3-M54 (2) Function and Structure ....................

  • Page 97: Diagram Of Hydraulic Circuit

    HYDRAULIC SYSTEM KX080-4, WSM 1. DIAGRAM OF HYDRAULIC CIRCUIT [1] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 STANDARD SPECIFICATION) 3-M1 KiSC issued 08, 2015 A...

  • Page 98: Diagram Of Hydraulic Circuit (Kx080-4 Angle Blade Specification)

    HYDRAULIC SYSTEM KX080-4, WSM [2] DIAGRAM OF HYDRAULIC CIRCUIT (KX080-4 ANGLE BLADE SPECIFICATION) 3-M2 KiSC issued 08, 2015 A...

  • Page 99: Hydraulic Device Layout

    KX080-4, WSM HYDRAULIC SYSTEM 2. HYDRAULIC DEVICE LAYOUT (1) Pump (7) Arm Cylinder (13) Travel Pilot Valve (19) Angle Solenoid Valve (2) Control Valve (8) Bucket Cylinder (14) Blade Pilot Valves (20) Boom Shockless Valve (3) Swivel Motor (9) Swing Cylinder...

  • Page 100: Pump

    KX080-4, WSM HYDRAULIC SYSTEM 3. PUMP [1] SPECIFICATIONS P1,P2: Piston pump discharge PLS: Load pressure Pi : EP mode limit pressure PS: Suction pressure pressure PPS: Valve inlet pressure Pave: average pressure CH: Air bleed P3: Gear pump discharge pressure...

  • Page 101: Pist Pump Horsepower Control Curve

    KX080-4, WSM HYDRAULIC SYSTEM [2] PIST PUMP HORSEPOWER CONTROL CURVE (1) P3 = At No Load (2 MPa) (1) Pi = 3.6 MPa (P mode) (2) Pi = 0 MPa (E mode) (a) Discharge flow rate: Q (b) Discharge pressure: P...

  • Page 102: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM [3] FUNCTION AND STRUCTURE (1) Operating Principles (1) Piston (4) Swash-plate (7) Suction port A : Discharge side (2) Retainer plate (5) Cylinder block (8) P1 discharge port B : Suction side (3) Shoe (6) Valve plate (9) P2 discharge port There are 10 pistons (1) built into the cylinder block (5) and it is coupled to the axle via a spline.

  • Page 103: Horsepower Control

    KX080-4, WSM HYDRAULIC SYSTEM (2) Horsepower Control Horsepower control is a matter of controlling the discharge flow of the piston pump in such a way that the total consumed horsepower (torque) of the pump does not exceed the specified horsepower (torque) of the engine.

  • Page 104: Flow Control (Ls Control)

    KX080-4, WSM HYDRAULIC SYSTEM 2. When pressure P increases (when the load increases) When the piston pump discharges pressure P rises due to the load, the horsepower control spool (4) in the middle of the diagram moves to the right. This connects...
  • Page 105 KX080-4, WSM HYDRAULIC SYSTEM 1. When the control valve is open wide If the control valve is opened wide (9) in order to quickly actuates the actuator, the pressure differential between the pump discharge pressure P and the load pressure drops temporarily, moving the spool (7) of the L/S regulator (6) to the right;...
  • Page 106 KX080-4, WSM HYDRAULIC SYSTEM 2. When the control valve is slightly open When the control valve is only slightly open, it produces a large difference in pressure between the pump discharge pressure P and the load pressure, so the spool (5) of the L/S regulator (4) moves to the left and the discharge pressure P and the control pin (1) are connected.

  • Page 107: Gain Control

    KX080-4, WSM HYDRAULIC SYSTEM (4) Gain Control There is an orifice (1) in the discharge circuit of the pilot pump (2) that leads to the spool of the L/S regulator for differential pressures that arise from acceleration in engine RPM. This orifice makes it possible to control...

  • Page 108: Control Valve

    KX080-4, WSM HYDRAULIC SYSTEM 4. CONTROL VALVE [1] SPECIFICATIONS (1) Swivel right (Pbk5) (7) Travel left forward (Pbk2) (13) Bucket dump (Pb2) (18) Boom down (Pa4) (2) Swivel left (Pak5) (8) Travel left reverse (Pak2) (14) Bucket crowd (Pa2) (19) Swing right (Pb5)
  • Page 109 KX080-4, WSM HYDRAULIC SYSTEM Item Notes 31.4 MPa Boom 320 kgf/cm 4554 psi 30.4 MPa 310 kgf/cm 4409 psi 31.4 MPa 320 kgf/cm 4554 psi 31.4 MPa Bucket 320 kgf/cm 4554 psi 27.4 MPa Overload relief valve At 5 L/min...
  • Page 110 KX080-4, WSM HYDRAULIC SYSTEM Hydraulic Circuit Diagram (Angle Spec.) (1) P3 bypass valve (8) Independent travel valve A : Main spool pressure (a) Other (2) Swivel (9) Arm receiver characteristics (b) Swing, angle (3) Blade (10) Bucket B : Independent travel valve,...

  • Page 111: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM [2] FUNCTION AND STRUCTURE (1) Unload Valve Section When in neutral (1) Independent travel valve (3) Micro-orifice (4) PLS pressure passage (5) Notch section (2) LS drain plug • Pump discharge pressure PPS and maximum load pressure PLS act on either end of the unload spool.
  • Page 112 KX080-4, WSM HYDRAULIC SYSTEM During fine operation of LS section (1) Independent travel valve (3) Micro-orifice (5) Notch (a) To each spool section section (4) PLS pressure passage (2) LS drain plug • When the spool section is switched, the oil in the pump pressure passage passes through the main spool and is discharged to the cylinder port.
  • Page 113 KX080-4, WSM HYDRAULIC SYSTEM During operation of LS section (1) Independent travel valve (3) Micro-orifice (5) Notch (a) To each spool section section (4) PLS pressure passage (2) LS drain plug • When the spool section is switched, the oil in the pump pressure passage passes through the main spool and is discharged to the cylinder port.

  • Page 114: Mono-Block Section Operation (Ls Control)

    KX080-4, WSM HYDRAULIC SYSTEM (2) Mono-Block Section Operation (LS Control) When in neutral (1) Independent travel valve (5) Main spool (9) Pump pressure passage (a) From unload valve to tank section (6) Compensator spool (10) Overload relief valve circuit (2) LS drain plug...
  • Page 115 KX080-4, WSM HYDRAULIC SYSTEM When Pb port pressurized (1) Independent travel valve (5) Main spool (9) Pump pressure passage (a) From unload valve to tank section (6) Compensator spool (10) Overload relief valve circuit (2) LS drain plug (7) Load check valve...

  • Page 116: Arm Regenerative Function

    KX080-4, WSM HYDRAULIC SYSTEM (3) Arm Regenerative Function (1) Independent travel valve (5) Main spool (9) Pump pressure passage (13) LS pressure guide orifice section (6) Compensator spool (10) Unload spool (2) LS drain plug (7) Load check valve (11) Arm regenerative sleeve...

  • Page 117: Swing Section Operation (Ls Control)

    KX080-4, WSM HYDRAULIC SYSTEM (4) Swing Section Operation (LS Control) (1) Independent travel valve section (2) LS drain plug (3) Micro-orifice (4) PLS pressure passage (5) Main spool (6) Compensator spool (7) Load check valve (8) Shuttle valve (9) Pump pressure passage...

  • Page 118: Travel Section Operation (Open Center Control)

    KX080-4, WSM HYDRAULIC SYSTEM (5) Travel Section Operation (Open Center Control) (1) Independent travel valve (3) Travel left section (5) PP2 signal pressure (a) To pump section (4) Main spool (b) To unload valve (2) Travel right section [In neutral] •...
  • Page 119 KX080-4, WSM HYDRAULIC SYSTEM (Continued) [When Pak1 (Pak2) port pressurized] • When the main spool is shifted, it closes the PT notch, cutting off the connection between the center bypass passage and the tank circuit. • At the same time, it generates a PP2 signal pressure (refer to the explanation of the signal circuit) and switches the main spool of the independent travel valve.

  • Page 120: Blade Section Operation (Open Center Control)

    KX080-4, WSM HYDRAULIC SYSTEM (6) Blade Section Operation (Open Center Control) (1) Independent travel valve (4) Main spool (7) Bridge passage (9) AUX2 section (5) Load check valve (8) Center bypass passage (10) Swivel (2) Blade section (6) Parallel passage...

  • Page 121: Anti-Drift Function

    KX080-4, WSM HYDRAULIC SYSTEM (7) Anti-Drift Function (1) Independent travel valve (6) Compensator spool (11) Piston (a) From unload valve to tank section (7) Load check valve (12) Spool circuit (2) LS drain plug (8) Shuttle valve (13) Poppet A...

  • Page 122: P3 Bypass Section Operation (Simultaneous Boom Up + Swivel Operation)

    KX080-4, WSM HYDRAULIC SYSTEM (8) P3 Bypass Section Operation (Simultaneous Boom Up + Swivel Operation) (1) Boom section (4) Main spool (7) Switch spool (a) From P3 port (2) P3 bypass section (5) Compensator spool (8) Check valve (3) Swivel section (6) Pump pressure passage •...

  • Page 123: Signal Circuit

    KX080-4, WSM HYDRAULIC SYSTEM (9) Signal Circuit (1) Independent travel valve (7) Micro-orifice (13) Travel right (19) Main spool signal passage section (8) Ring gap (14) Arm section (2) Communication valve section (9) Swivel (15) Bucket (20) Area receiving pressure: A1...
  • Page 124 KX080-4, WSM HYDRAULIC SYSTEM (Continued) [When AI signal pressure rises (idling signal)] • It switches the main spool of each section to either the A or the B port side and cuts off the passage that connects the PP1 port micro-orifice downstream and the tank circuit.

  • Page 125: Swivel Motor

    KX080-4, WSM HYDRAULIC SYSTEM 5. SWIVEL MOTOR [1] SPECIFICATIONS (1) Port A (2) Port B (3) Port M (4) Drain port (5) Port SH (6) Port PG (7) Reverse check valve (8) Hydraulic timer (9) Swivel left relief valve (cSL)

  • Page 126: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM [2] FUNCTION AND STRUCTURE (1) Operating Principles [A] Motor • The pressurized oil from port A (1) goes through valve plate (3), enters piston (5) inside cylinder block (4) and presses against the swash-plate (6). The...
  • Page 127 KX080-4, WSM HYDRAULIC SYSTEM [D] Parking Brake a)When the parking brake is operated • When the brake release pressure is interrupted, springs press the brake piston (1) against the disc (2) that meshes with the spline on the circumference of the cylinder block (3).
  • Page 128 KX080-4, WSM HYDRAULIC SYSTEM [F] Reverse Check Valve • When the motor is stopped, the reverse check valve prevents the swivel body from turning in reverse when it is stopped due to accumulated pressure by linking the motor's main line and makeup line for a certain period of time.
  • Page 129 KX080-4, WSM HYDRAULIC SYSTEM d)When reversing 1 • After valve unit braking makes it stop, the motor tries to turn in reverse due to accumulated pressure in its main line. • This reverse pressure makes the shuttle valve (sleeve) inside the check valve seat on the low-pressure side of the check valve;...

  • Page 130: Travel Motor

    KX080-4, WSM HYDRAULIC SYSTEM 6. TRAVEL MOTOR [1] SPECIFICATIONS (1) Port A (2) Port B (3) Travel 2-speed signal (4) Drain port (5) 2-speed switch valve (6) Anticavitation valve (check valve) (7) Relief valve (cTR) (8) Counterbalance valve (spool) Item...

  • Page 131: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM [2] FUNCTION AND STRUCTURE (1) Operating Principles [A] Motor • Nine pistons (2) are built into the cylinder block (1), and the end section of the block is in contact with a valve plate (3), which has two half-moon shaped ports (port C and port D for switching between high and low pressure).
  • Page 132 KX080-4, WSM HYDRAULIC SYSTEM [B] Brake Valve a)During normal operation • Oil supplied by the pump enters port A and opens the check valve (1). The oil passes through the check valve and goes from port C into the hydraulic motor, providing rotary force to the motor.
  • Page 133 KX080-4, WSM HYDRAULIC SYSTEM [C] Relief Valve (A)At start up • Until the shockless piston (1) reaches the end of its stroke, the oil is released by the setting pressure (low pressure relief) of the poppet (2). • When the shockless piston (1) reaches the end of its...
  • Page 134 KX080-4, WSM HYDRAULIC SYSTEM [D] Parking Brake • The parking brake is a negative brake composed of a rotating disc (friction material) (4), an opposing plate (5) a brake piston (3) and a spring (1). • When the travel motor is stopped (the travel lever in neutral), the parking brake takes effect.

  • Page 135: Hydraulic Cylinder

    KX080-4, WSM HYDRAULIC SYSTEM 7. HYDRAULIC CYLINDER [1] SPECIFICATIONS Boom Bucket Blade Swing Angle 82 mm 70 mm 70 mm 82 mm 82 mm 60 mm 3.23 in. 2.76 in. 2.76 in. 3.23 in. 3.23 in. 2.36 in. 82 mm...

  • Page 136: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM [2] FUNCTION AND STRUCTURE (1) Operating Principles • Cushion Function The device is equipped with a cushion to prevent spilling of earth or the like when it reaches the end of the cylinder. RY9212148HYM0050US0 Cushion function on the lift end of the boom...
  • Page 137 KX080-4, WSM HYDRAULIC SYSTEM Cushion function on dumping end of arm (1) Port (3) Cushion Plunger A : Before Cushion Enters (2) Cushion Chamber (4) Piston B : After Cushion Enters RY9212148HYM0029US0 3-M41 KiSC issued 08, 2015 A...

  • Page 138: Pilot Valve

    KX080-4, WSM HYDRAULIC SYSTEM 8. PILOT VALVE [1] CONTROL PILOT VALVES (1) Specifications (1) Port P (7) Independent operation torque (a) Secondary pressure (e) Pushrod stroke (mm) (2) Port 1 (Left) (ports 1, 3) (kgf/cm Operating angle (deg) (3) Port 2 (Front)

  • Page 139: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM (2) Function and Structure [A] Function The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control valve spool.

  • Page 140: Travel Pilot Valve

    KX080-4, WSM HYDRAULIC SYSTEM [2] TRAVEL PILOT VALVE (1) Specifications (1) Port 1 (L Bwd) (5) Operating torque (a) Secondary pressure (e) Pushrod stroke (mm) (2) Port 2 (L Fwd) (6) Secondary pressure (kgf/cm Operating angle (deg) (3) Port 3 (R Bwd)

  • Page 141: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM (2) Function and Structure [A] Function The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control valve spool.
  • Page 142 KX080-4, WSM HYDRAULIC SYSTEM 3. When the control lever has been actuated (when shorted) Once the pushrod on cam (1) exceeds a stroke of 3.3mm (0.13 in.), the pushrod (2) touches the spool (3) at point B and the spool (3) stops providing control by balancing the pressure.

  • Page 143: Swing Pilot Valve

    KX080-4, WSM HYDRAULIC SYSTEM [3] SWING PILOT VALVE (1) Specifications (1) Port 1 (P) Port P (a) Secondary pressure (e) Pushrod stroke (mm) (2) Port 2 (T) Port T (kgf/cm Pedal operating angle (deg) (3) Operating torque (b) Secondary pressure (MPa) (4) Secondary pressure (c) Operating torque (N·m)

  • Page 144: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM (2) Function and Structure [A] Function The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control valve spool.

  • Page 145: Blade Pilot Valves

    KX080-4, WSM HYDRAULIC SYSTEM [4] BLADE PILOT VALVES (1) Specifications (1) Port 1 (P) Port P (a) Secondary Pressure (e) Pushrod stroke (mm) (2) Port 2 (T) Port T (kgf/cm Operating Angle (deg) (b) Secondary Pressure (MPa) (g) Down (c) Operating Torque (N·m) (h) Up (d) Operating Torque (kgf·m)
  • Page 146 KX080-4, WSM HYDRAULIC SYSTEM (2) Function and Structure [A] Function The pilot valve is the valve that controls the direction and volume of the stroke of the control valve, and lowers the primary pressure from the unload valve to a secondary pressure only as much as is necessary to move the control valve spool.
  • Page 147 KX080-4, WSM HYDRAULIC SYSTEM 3. Pre-detent operation Pre-detent is activated at a specified operating angle. When steel ball (2) in the stepped section of the disc (1) passes the step, operating torque increases owing to compression of the spring (3). Due to this...

  • Page 148: Specifications

    KX080-4, WSM HYDRAULIC SYSTEM 9. SHOCKLESS VALVES [1] SPECIFICATIONS (1) Port 1 (Pilot valve side, boom up) (2) Port 2 (Pilot valve side, boom down) A : Port A (control valve side, boom up) B : Port B (control valve side,...
  • Page 149 KX080-4, WSM HYDRAULIC SYSTEM b) During boom down operation (return circuit operation) • The return oil from the control valve enters port A (A), passes through the orifice (3) and is discharged to port 1 (1). When it does, the resistance to passing...

  • Page 150: Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM 10. SOLENOID VALVE [1] UNLOAD VALVE (1) Specifications (1) PAC Port (Accumulator) (3) Port B (Pilot Operation, Swivel (5) Port P (to Control Valve) (7) Pilot Primary Relief Valve (2) Port A (2-Speed Travel Parking Brake)

  • Page 151: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM (2) Function and Structure [A] Function The unload valve consists of two directional change valves operated by solenoid, a check valve and a relief valve; it perform functions such as unloading control pressure from the pilot pump (returning oil to the hydraulic oil tank) and supplying control pressures to pilot valves for operation and travel, as well as to the swivel motor (for the parking brake) and the travel motor (for switching the two speeds).
  • Page 152 KX080-4, WSM HYDRAULIC SYSTEM 2. When the solenoid is on When the solenoid (1) is energized, the solenoid's pushrod presses the spool (2) down, connecting port P to port A and cutting off port A and port T, so the oil from port P flows to port A.

  • Page 153: Aux Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM [2] AUX SOLENOID VALVE (1) Specifications Proportional Control Solenoid Valve This valve is an electromagnetic solenoid valve. Normally a solenoid valve is turned off and on via 12V battery voltage, but this valve is controlled via pulsed signals from the computer built into the ECU and the meter panel.

  • Page 154: Function And Structure

    KX080-4, WSM HYDRAULIC SYSTEM (2) Function and Structure The pressure from port P is supplied or cut off from port A or port B by the solenoid valve used when operating the AUX. RY9212095HYM0019US0 1. When the solenoid is off When the solenoid is off, port P and port B are cut off by the spool.

  • Page 155: Angle Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM [3] ANGLE SOLENOID VALVE (1) Specifications A : Port A (Left) B : Port B (Right) P : Port P T : Port T Maker Nishina Industrial Rated Voltage DC 12 V 220 ml/min or less Leak Volume at Temp.

  • Page 156: Ep Mode Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM [4] EP MODE SOLENOID VALVE (1) Specifications Item Specifications 3.9 MPa Max operating pressure 40 kgf/cm (input pressure) 570 psi 1.0 MPa Allowable back pressure 10 kgf/cm (pressure T) 100 psi Maximum proportional valve operating flow volume 10.0 L/min (2.64 U.S.gals./min)

  • Page 157: Servicing

    SERVICING CONTENTS 1. PUMP ............................3-S1 [1] PUMP DISASSEMBLY / ASSEMBLY ...................3-S1 [2] PUMP DISASSEMBLY PROCEDURES ................3-S4 (1) Disassembly Procedures....................3-S7 (2) Assembly Procedures....................3-S12 2. CONTROL VALVE........................3-S17 [1] CONTROL VALVE REMOVAL ....................3-S17 [2] CONTROL VALVE ASSEMBLY/DISASSEMBLY..............3-S19 3. SWIVEL MOTOR........................3-S26 [1] SWIVEL MOTOR REMOVAL AND INSTALLATION ............3-S26 [2] SWIVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES ........3-S28 (1) Disassembly Procedures....................3-S30 (2) Assembly Procedures....................3-S34...
  • Page 158 11. ROUTING OF HYDRAULIC HOSES ..................3-S112 [1] HYDRAULIC HOSE SPECIFICATIONS ................3-S112 [2] HIGH-PRESSURE HOSES ....................3-S113 (1) Deliver Hose Routing....................3-S113 (2) PLS Hose Routing .......................3-S116 (3) Front Hose Routing......................3-S117 (4) Boom Hose Routing.....................3-S120 (5) Undercarriage Hose Routing ..................3-S121 (6) Angle Blade Hose Routing...................3-S122 [3] LOW-PRESSURE HOSES ....................3-S123 (1) Suction Pipe and Hose Routing...................3-S123 (2) Drain Hose Routing .....................3-S124...
  • Page 159 [3] TRAVEL SYSTEM TROUBLESHOOTING................3-S167 [4] SWIVEL SYSTEM TROUBLESHOOTING ................3-S168 [5] TROUBLESHOOTING MULTIPLE OPERATIONS ............3-S169 KiSC issued 08, 2015 A...

  • Page 160: Pump

    KX080-4, WSM HYDRAULIC SYSTEM 1. PUMP [1] PUMP DISASSEMBLY / ASSEMBLY CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot enough to cause a burn, so always let it cool down before starting any work.
  • Page 161 KX080-4, WSM HYDRAULIC SYSTEM 5. Suspend the pump with a crane and remove the pump mounting bolts (two). Use the crane to remove the pump. 196.1 to 225.6 N·m Tightening torque Bolt 20.0 to 23.0 kgf·m 144.6 to 166.4 lbf·ft Pump weight Approx.
  • Page 162 KX080-4, WSM HYDRAULIC SYSTEM Pump Connector and Housing Assembly Diagram (1) Connector (3) Pump housing (5) Parallel pin (6) Spring pin (2) Connector mounting bolt (4) Housing mounting bolt • (a) Apply grease to the spline. IMPORTANT • Align the spring pin before tightening the connector mounting bolts.

  • Page 163: Pump Disassembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM [2] PUMP DISASSEMBLY PROCEDURES Part Name Q'ty Part Name Q'ty Plug (17) Port block Orifice (18) Gasket Swash plate (19) Bolt Collar (20) Bolt Shoe (21) Bearing case Retainer plate (22) Bolt Spring (23) Piston (24)
  • Page 164 KX080-4, WSM HYDRAULIC SYSTEM Part Name Q'ty Part Name Q'ty Holder (17) Orifice Spring seat (18) Orifice Spring (19) Plug Spring (20) O-ring Spring (21) Spool Spring seat (22) Bolt O-ring (23) Bushing Valve sleeve (24) Spring seat Spool (25)
  • Page 165 KX080-4, WSM HYDRAULIC SYSTEM Part Name Q'ty Part Name Q'ty Socket head bolt (10) Ball Plug (11) Seat Orifice (12) O-ring Plug (13) O-ring O-ring (14) Valve seat Orifice (15) Oil pressure pump Plug (16) Plain washer O-ring (17) Bolt...

  • Page 166: Disassembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (1) Disassembly Procedures 1. Remove the hex socket bolts and then the gear pump. • Tool to use: 10 mm hex socket CAUTION • Don't pinch your fingers between the port block and the gear pump.
  • Page 167 KX080-4, WSM HYDRAULIC SYSTEM 6. Remove the plug. • Tool to use: 6 mm hex socket (1) Plug RY9212148HYS0390US0 7. Remove the collar and ball. • Tool to use: Magnet (1) Collar (2) Ball RY9212148HYS0391US0 8. Remove the plug. • Tool to use: 6 mm hex socket...
  • Page 168 KX080-4, WSM HYDRAULIC SYSTEM 11. Remove the O-rings. IMPORTANT • Take care not to scratch the surface of the port. (1) O-Ring RY9212148HYS0395US0 12. Remove the orifices. • Tool to use: 3 mm hex socket (1) Orifice (2) Orifice RY9212148HYS0396US0 13.
  • Page 169 KX080-4, WSM HYDRAULIC SYSTEM Horsepower Control Valve Components (1) Horsepower Control Valve (4) Pin (2) Nut (5) Plug (3) Spool RY9212148HYS0400US0 16. Remove the gasket, spring ASSY and the cylinder block ASSY. CAUTION • Be careful not to cut your fingers on the gasket.
  • Page 170 KX080-4, WSM HYDRAULIC SYSTEM 18. Remove the shaft. • Tool to use: plastic hammer CAUTION • Be careful not to hit your fingers with the hammer. (1) Shaft RY9212148HYS0405US0 19. Remove the shaft from the bearing case. • Tool to use: plastic hammer CAUTION •...

  • Page 171: Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (2) Assembly Procedures 1. Mount the thrust washer and bearing on the shaft. 2. Install the snap ring. CAUTION • Be careful not to hit your fingers with the hammer. (1) Shaft (3) Bearing (2) Thrust Washer...
  • Page 172 KX080-4, WSM HYDRAULIC SYSTEM 7. Install the spring ASSY and the gasket. IMPORTANT • Take care to orient the spring ASSY correctly and not to drop it. • Be careful not to cut your fingers on the gasket. (1) Spring ASSY...
  • Page 173 KX080-4, WSM HYDRAULIC SYSTEM 11. Adjust the horsepower control valve to the measurement M taken before disassembly. • Tool to use: ruler, 24, 41 mm wrench, 8 mm hex socket IMPORTANT • Pay attention to the initial position. 68.6 N·m Nut (1) 6.70 kgf·m...
  • Page 174 KX080-4, WSM HYDRAULIC SYSTEM 15. Install the O-rings. IMPORTANT • Take care not to scratch the surface of the port. (1) O-Ring RY9212148HYS0422US0 16. Install the L/S regulator. • Tool to use: 5 mm hex socket 12.65 N·m Tightening torque Socket head bolt (2) 1.29 kgf·m...
  • Page 175 KX080-4, WSM HYDRAULIC SYSTEM 20. Install the O-rings. 21. Mount the port block on the case. • Tool to use: 10, 16 mm hex socket CAUTION • Don't pinch your fingers between the port block and the case. 196.0 N·m Socket head bolt (1) 19.99 kgf·m...

  • Page 176: Control Valve

    KX080-4, WSM HYDRAULIC SYSTEM 2. CONTROL VALVE [1] CONTROL VALVE REMOVAL 1. Remove the cover. 2. Attach a vacuum pump and depressurize the inside of the tank. (1) Cover RY9212158HYS0044US0 3. Disconnect all the hoses and wiring connected to the control valve.
  • Page 177 KX080-4, WSM HYDRAULIC SYSTEM Control valve adapter angles (angle spec.) (1) P3 bypass (11) AUX1 (A) P1 (a) 5° (0.09 rad) (2) Swivel (12) Boom (B) P2 (b) 6 ° (0.10 rad) (3) Blade (13) Swing (C) P3 (c) 15 ° (0.26 rad)

  • Page 178: Control Valve Assembly/Disassembly

    KX080-4, WSM HYDRAULIC SYSTEM [2] CONTROL VALVE ASSEMBLY/DISASSEMBLY Precautions during Disassembly / Assembly Precautions during Disassembly 1. Generally, hydraulic devices are precision machined, and disassembly should therefore be conducted in a clean environment to prevent entry of debris into the narrow interstices formed in the device structure.
  • Page 179 KX080-4, WSM HYDRAULIC SYSTEM LS Section Components Name of part Torque 8.8 to 11.0 N·m Hex socket bolt 0.9 to 1.1 kgf·m 6.5 to 8.1 lbf·ft Spring seat Spring Plate O-ring Spool 59.0 to 69.0 N·m Relief valve 6.0 to 7.0 kgf·m ASSY 43.5 to 50.9 lbf·ft...
  • Page 180 KX080-4, WSM HYDRAULIC SYSTEM Mono-block Section Components A : Boom section C : Bucket section D : Arm section E : Emergency valve B : AUX1 section • In the N. Am. spec., part E is different as it has an anti-drift valve.
  • Page 181 KX080-4, WSM HYDRAULIC SYSTEM Name of part Torque O-ring Plate Spring Spool (10) O-ring (11) Plug (12) Plug 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft) (13) O-ring (14) Plug 106.0 to 141.0 N·m (10.8 to 14.4 kgf·m, 78.2 to 104.0 lbf·ft)
  • Page 182 KX080-4, WSM HYDRAULIC SYSTEM Independent Travel Valve and Travel Section Components Name of part Torque 28.0 to 30.0 N·m Plug 2.9 to 3.1 kgf·m 20.7 to 22.1 lbf·ft O-ring Filter Spring Body assembly 8.8 to 11.0 N·m Hex socket bolt 0.9 to 1.1 kgf·m...
  • Page 183 KX080-4, WSM HYDRAULIC SYSTEM Communication Valve and AUX2 Section Components Name of part Torque 8.8 to 11.0 N·m Hex socket bolt 0.9 to 1.1 kgf·m 6.5 to 8.1 lbf·ft Spring seat Spring Plate O-ring 59.0 to 69.0 N·m Relief valve ASSY 6.0 to 7.0 kgf·m...
  • Page 184 KX080-4, WSM HYDRAULIC SYSTEM A : Communication valve B : AUX2 section RY9212148HYS0376US0 Blade, Swivel and P3 Bypass Section Components Name of part Torque 8.8 to 11.0 N·m Hex socket bolt 0.9 to 1.1 kgf·m 6.5 to 8.1 lbf·ft Spring seat...

  • Page 185: Swivel Motor

    KX080-4, WSM HYDRAULIC SYSTEM 3. SWIVEL MOTOR [1] SWIVEL MOTOR REMOVAL AND INSTALLATION CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot enough to cause a burn, so always let it cool down before starting any work.
  • Page 186 KX080-4, WSM HYDRAULIC SYSTEM 5. Remove the 8 swivel motor mounting bolts and remove the swivel motor. 259.9 to 304.0 N·m Tightening torque Bolt 26.5 to 31.0 kgf·m 191.7 to 224.2 lbf·ft Swivel motor weight Approx. 80 kg (180 lbs)

  • Page 187: Swivel Motor Disassembly/Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM [2] SWIVEL MOTOR DISASSEMBLY/ASSEMBLY PROCEDURES (To be continued) 3-S28 KiSC issued 08, 2015 A...
  • Page 188 KX080-4, WSM HYDRAULIC SYSTEM (Continued) Part Name Part Name Part Name Plug (36) O-ring (71) Spool O-ring (37) Cover (72) Spring Orifice (38) Orifice (73) O-ring Hex socket bolt (39) Knock pin (74) Plug Body (40) (75) Housing Plug (41)

  • Page 189: Disassembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (1) Disassembly Procedures 1. Mount the swivel motor on an assembly platform. 2. Remove the hex socket bolts and then the body. • Tool to use: 6 mm hex socket (1) Hex socket bolt (2) Body RY9212148HYS0098US0 3.
  • Page 190 KX080-4, WSM HYDRAULIC SYSTEM 7. Remove the large and small springs. (1) Spring, large (2) Spring, small RY9212148HYS0103US0 8. While pressing down on the brake piston with a rag, blow air through the brake release oil passage hole and remove the brake piston.
  • Page 191 KX080-4, WSM HYDRAULIC SYSTEM 12. Remove the shaft. Remove the hex socket bolts and then the housing. • Tool to use: 12 mm hex socket (1) Shaft (3) Housing (2) Hex socket bolt RY9212148HYS0108US0 13. Remove the plate. (1) Plate RY9212148HYS0109US0 14.
  • Page 192 KX080-4, WSM HYDRAULIC SYSTEM 17. Remove the housing from the assembly platform and then remove the collar. CAUTION • If the plate comes off, the shaft may fall, so take care in handling it. • Always have the bottom of the shaft touching the ground when removing the collar and plate.

  • Page 193: Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (2) Assembly Procedures • Prior to assembly, clean all of the parts and make sure there is no dirt or other debris sticking to them. • Always replace all of the O-rings, backup rings and oil seals with new ones.
  • Page 194 KX080-4, WSM HYDRAULIC SYSTEM 6. Put the housing on the assembly platform and install the plug. 7. Install the holder and the washer. 15.7 ± 0.8 N·m Tightening torque Plug 1.6 ± 0.1 kgf·m 11.6 ± 0.6 lbf·ft • Tool to use: 5 mm hex socket IMPORTANT •...
  • Page 195 KX080-4, WSM HYDRAULIC SYSTEM 12. Install the plate and O-ring. IMPORTANT • Apply grease to the O-ring. (1) Plate (2) O-ring RY9212148HYS0128US0 When parts inside the gear case have been replaced, take measurement C between the inner race and the housing and then select the correct plate.
  • Page 196 KX080-4, WSM HYDRAULIC SYSTEM 15. Install the swash-plate. IMPORTANT • Install with the tapered side down. • Apply grease to the back of the swash-plate. (1) Swash-plate RY9212148HYS0132US0 16. Turn the assembly platform 1.6 rad (90°) and install the cylinder block.
  • Page 197 KX080-4, WSM HYDRAULIC SYSTEM Brake piston hole alignment positions Install so the pin hole is at position . (a) 0.393 rad (22.5 °) RY9212148HYS0137US0 20. Install the large and small springs and the O-ring. IMPORTANT • Apply grease to the O-ring.
  • Page 198 KX080-4, WSM HYDRAULIC SYSTEM 23. Install the cover. IMPORTANT • Take care so the valve plate does not fall off. 177.0 ± 10.0 N·m Tightening torque Hex socket bolt 18.0 ± 1.0 kgf·m 130.5 ± 7.5 lbf·ft • Tool to use: 12 mm hex socket...

  • Page 199: Special Tools

    KX080-4, WSM HYDRAULIC SYSTEM (3) Special Tools (a) Oil seal installation tool 150 mm (5.9 in.) 94.8 - 94.9 mm ( 3.73 - 3.74 in.) 30 mm ( 1.18 in.) 15 mm (0.59 in.) 1 mm (0.04 in.) bevel • If angle is not specified, there must not be any burrs.

  • Page 200: Swivel Joint

    KX080-4, WSM HYDRAULIC SYSTEM 4. SWIVEL JOINT [1] REMOVAL AND INSTALLATION OF THE SWIVEL JOINT CAUTION • When removing a hydraulic device after operating the mini-excavator, lower the bucket and blade to the ground and turn off the engine. • Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot enough to cause a burn, so always let it cool down before starting any work.
  • Page 201 KX080-4, WSM HYDRAULIC SYSTEM 6. To prevent the swivel joint from falling, support the bottom of the body with a hydraulic jack, then remove the swivel joint mounting bracket and remove the swivel joint. IMPORTANT • Apply a thread lock (Loctite 271).
  • Page 202 KX080-4, WSM HYDRAULIC SYSTEM Adapter angle (angle spec.) A : 2-speed pilot E : Right forward Angle Right (a) 15 ° (0.26 rad) B : Blade down F : Left backward J : Angle Left (b) 30 ° (0.52 rad)

  • Page 203: Swivel Joint Disassembly / Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM [2] SWIVEL JOINT DISASSEMBLY / ASSEMBLY PROCEDURES Components Part Name Notes Angle Standard Spec Specification 40.2 ± 3.9 N·m Plug (PT1/4) – 4.1 ± 0.4 kgf·m 29.6 ± 2.9 lbf·ft 71.1 ± 2.5 N·m Plug (PT3/8) 7.2 ±...

  • Page 204: Disassembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (1) Disassembly Procedures 1. Prior to disassembly, mark the alignment of the shaft and body. RY9212148HYS0002US0 2. Remove the hex socket bolts and then the bottom cover. • Tool to use: 10 mm hex socket (1) Bottom cover RY9212148HYS0003US0 3.
  • Page 205 KX080-4, WSM HYDRAULIC SYSTEM 6. Use a press to remove the shaft. IMPORTANT • Spread a protective mat to prevent the shaft from hitting if it falls. • Be careful so the shaft does not fall all of a sudden.

  • Page 206: Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (2) Assembly Procedures • Prior to assembly, clean all of the parts and make sure they are not damaged and there is no dirt or other debris sticking to them. • After washing parts, blow them dry to remove any detergent. (Be particularly careful to remove any detergent around port holes and bolt holes.)
  • Page 207 KX080-4, WSM HYDRAULIC SYSTEM 5. After inserting the collar, install the circlip. IMPORTANT • Install the circlip with the rounded side down. • Tool to use: snap ring pliers (1) Circlip RY9212148HYS0014US0 6. Install the O-ring on the bottom cover.

  • Page 208: Travel Motor

    KX080-4, WSM HYDRAULIC SYSTEM 5. TRAVEL MOTOR [1] REMOVAL AND INSTALLATION OF THE TRAVEL MOTOR CAUTION • Before removing hydraulic devices, lower the bucket and blade to the ground and stop the engine. • Each of the devices and the hydraulic oil are hot right after stopping the mini-excavator. The oil is hot enough to cause a burn, so always let it cool down before starting any work.

  • Page 209: Travel Motor Disassembly / Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM [2] TRAVEL MOTOR DISASSEMBLY / ASSEMBLY PROCEDURES (To be continued) 3-S50 KiSC issued 08, 2015 A...
  • Page 210 KX080-4, WSM HYDRAULIC SYSTEM (Continued) Part Name Part Name Part Name Wire (32) Ball (63) Poppet Plug (33) Swash-plate (64) Backup ring O-ring (34) Piston ASSY (65) O-ring Cover (35) Retainer plate (66) Seat O-ring (36) Retainer holder (67) Plug...

  • Page 211: Disassembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (1) Disassembly Procedures [A] Gear Case 1. Mount the travel motor to the assembly platform and remove the plug. • Tool to use: 8 mm hex socket (1) Plug RY9212158HYS0002US0 2. Remove the wire. • Tool to use: Slotted screwdriver...
  • Page 212 KX080-4, WSM HYDRAULIC SYSTEM 5. Remove the drive gear, planetary gear B, needle bearing, and the holder. (1) Drive gear (3) Needle bearing (2) Planetary gear B (4) Holder RY9212158HYS0046US0 6. Remove the plate and the sun gear. • Tool to use: Torx T40...
  • Page 213 KX080-4, WSM HYDRAULIC SYSTEM 9. Remove the parallel pin. • Tool to use: Magnet IMPORTANT • If the parallel pin will not come out using a magnet, use the following procedure. Drill a hole in the parallel pin and cut threads in the hole.
  • Page 214 KX080-4, WSM HYDRAULIC SYSTEM 13. Remove the floating seal from the gear case side. • Tool to use: Slotted screwdriver (1) Floating seal RY9212148HYS0025US0 14. Remove one of the angular bearing. • Tool to use: pin punch and a hammer IMPORTANT •...
  • Page 215 KX080-4, WSM HYDRAULIC SYSTEM [B] Motor 1. Remove the shockless valve. • Tool to use: 22 mm socket (1) Shockless valve RY9212158HYS0006US0 2. Remove the plug, spring, spring seat and spool in order. • Tool to use: 30 mm socket...
  • Page 216 KX080-4, WSM HYDRAULIC SYSTEM 6. Remove the hex socket bolts and then the base plate. • Tool to use: 10 mm hex socket (1) Hex socket bolt (2) Base plate RY9212158HYS0010US0 7. Remove the springs and valve plate from the base plate.
  • Page 217 KX080-4, WSM HYDRAULIC SYSTEM 10. Turn the assembly stand 1.6 rad (90°) and remove the cylinder block sub-assembly, swash-plate and shaft in order. (1) Cylinder block sub-assembly (3) Shaft (2) Swash-plate RY9212158HYS0052US0 11. Use a press to press Plate A down inside the cylinder block and then remove the circlip.

  • Page 218: Assembly Procedures

    KX080-4, WSM HYDRAULIC SYSTEM (2) Assembly Procedures [A] Motor • Prior to assembly, clean all of the parts and make sure they are not damaged and there is no dirt or other debris sticking to them. • Always replace all of the O-rings, backup rings, oil seals and floating seals with new ones.
  • Page 219 KX080-4, WSM HYDRAULIC SYSTEM 4. Install the shaft and swash-plate in order. (1) Shaft (2) Swash-plate RY9212158HYS0016US0 5. Install plate B, the spring, plate A and the circlip in order inside the cylinder block. Use a press to press on the inside of the cylinder block and install the circlip.
  • Page 220 KX080-4, WSM HYDRAULIC SYSTEM 9. Install the disc and plate in order. IMPORTANT • Install the plates and discs alternately. (1) Disc (2) Plate RY9212158HYS0020US0 10. Install the brake piston. IMPORTANT • Apply grease to the O-ring and backup ring.
  • Page 221 KX080-4, WSM HYDRAULIC SYSTEM 14. Install the ball and plug in order. 19.6 ± 1.0 N·m Tightening torque Plug 2.0 ± 0.1 kgf·m 14.4 ± 0.7 lbf·ft • Tool to use: 5 mm hex socket (1) Ball (2) Plug RY9212158HYS0057US0 15.
  • Page 222 KX080-4, WSM HYDRAULIC SYSTEM [B] Gear Case 1. Set one of the angular bearings in the gear case and use a press to mount it. Turn the gear case over and install the other angular bearing with the press. RY9212158HYS0027US0 2.
  • Page 223 KX080-4, WSM HYDRAULIC SYSTEM 5. Apply a little gear oil on the sliding surface of the floating seal. [4 places, every 1.6 rad (90°)] (1) Floating seal (2) Gear case RY9212148HYS0032US0 6. Install the gear case on the flange holder.
  • Page 224 KX080-4, WSM HYDRAULIC SYSTEM 8. Drill a hole midway between the ring nut and the flange holder and install a parallel pin. • Tool to use: 6 mm drill bit IMPORTANT • Be sure to cover the screw holes with adhesive tape or the like prior to drilling the hole.
  • Page 225 KX080-4, WSM HYDRAULIC SYSTEM 12. Install the holder, needle bearing, planetary gear B and drive gear in order. (1) Holder (3) Planetary gear B (2) Needle bearing (4) Drive gear RY9212158HYS0065US0 13. Install the plate. IMPORTANT • Clean screw holes prior to installation.

  • Page 226: Special Tools

    KX080-4, WSM HYDRAULIC SYSTEM (3) Special Tools (a) Cover removal tool 80 mm (3.1 in.) 13 mm (0.51 in.) 60 mm (2.4 in.) R3/8 12.5 mm (0.492 in.) M12 x P1.25 25 mm (0.98 in.) 315 mm (12.4 in.) 2 mm (0.08 in. bevel) 5 mm (0.2 in.
  • Page 227 KX080-4, WSM HYDRAULIC SYSTEM (d)Tool for pressing cylinder block 27.8 to 28.2 mm (1.095 to 1.110 in.) 39.9 to 40.0 mm (1.571 to 1.574 in.) 11.9 to 12.0 mm (0.469 to 0.472 in.) 34.7 to 35.3 mm (1.366 to 1.390 in.) 2.9 to 3.1 mm (0.114 to 0.122 in.)

  • Page 228: Cylinder

    KX080-4, WSM HYDRAULIC SYSTEM 6. CYLINDER [1] TIGHTENING TORQUE KX080-4 Notes Maker 56.9 ± 10.7 N·m Screw torque 5.8 ± 1.1 kgf·m 42.0 ± 7.9 lbf·ft Screw size M12 × 1.75 Tap with punch in two places 3070 N·m Boom Piston torque 313.1 kgf·m...
  • Page 229 KX080-4, WSM HYDRAULIC SYSTEM KX080-4 Notes Maker Koretsune Seiko 1500 ± 80 N·m Piston torque 153.0 ± 8.2 kgf·m Angle 1106.4 ± 59.0 lbf·ft 550 ± 60 N·m Head torque 56.1 ± 6.1 kgf·m 405.7 ± 44.3 lbf·ft RY9212158HYS0033US0 3-S70...

  • Page 230: Pilot Valve

    KX080-4, WSM HYDRAULIC SYSTEM 7. PILOT VALVE [1] CONTROL PILOT VALVES Part Name Handle Bellows Spring pin Lever Seal Plug O-ring Pushrod Spring seat (10) Secondary pressure spring (11) Shim (12) Return spring (Ports 1 and 3) (13) Return Spring (Port 2)

  • Page 231: Disassembly

    KX080-4, WSM HYDRAULIC SYSTEM (1) Disassembly CAUTION • All of the parts are precision parts, so be very careful in handling them and take care not to drop or hit parts against each other. • If you hit a part too hard while working on it, it may result in burrs or other damage, thus preventing installation as well as oil leaks and/or compromised performance, so be careful when handling parts.
  • Page 232 KX080-4, WSM HYDRAULIC SYSTEM 4. After mounting tool (b) on the U-joint, use tool (a) to turn the U-joint counterclockwise and loosen it. • Tool (a): U-joint clamping tool • Tool (b): Bushing (two) CAUTION • When removing the U-joint, take care that it does not pop off.
  • Page 233 KX080-4, WSM HYDRAULIC SYSTEM 7. Remove the reducing valve ASSY and the return spring. IMPORTANT • Tag the return springs to positively ID which port they go (1) Return Spring (a) Reducing Valve ASSY RY9212148HYS0156US0 8. To disassemble a reducing valve, press the spring seat in and...

  • Page 234: Assembly

    KX080-4, WSM HYDRAULIC SYSTEM 10. Remove the O-ring and seal from the plug. IMPORTANT • Use a mini slotted screwdriver. • Be careful not to scratch the inside surface of the plug. Components of the Plug (1) Seal (3) O-Ring...
  • Page 235 KX080-4, WSM HYDRAULIC SYSTEM 3. Install the washer, secondary pressure spring and spring seat on the spool in order. IMPORTANT • Do not depress the spring seat more than 6 mm (0.24 in.). • Be careful not to scratch the spool.
  • Page 236 KX080-4, WSM HYDRAULIC SYSTEM 7. Install the plug on the pushrod. IMPORTANT • Apply hydraulic oil to the pushrod. (1) Pushrod (3) O-Ring (2) Plug RY9212148HYS0165US0 8. Install the plug ASSY into the case. If the return spring is too stiff, use the plate to install the ASSY.
  • Page 237 KX080-4, WSM HYDRAULIC SYSTEM 12. Install the adjusting nut. Hold a wrench on the head of the round plate nut while tightening the nut. • Tools to use: 22 mm and 32 mm wrenches 70.0 ± 5.0 N·m Tightening torque Adjusting nut 7.0 ±...

  • Page 238: Special Tools

    KX080-4, WSM HYDRAULIC SYSTEM (3) Special Tools 29 mm ( 1.142 in.) 26.5 mm ( 1.043 in.) 23.5 mm (0.925 in.) (nut width) 19 mm ( 0.748 in.) 13 mm (0.512 in.) 69 mm (2.717 in.) 54 mm (2.126 in.) 50 mm (1.968 in.)

  • Page 239: Travel Pilot Valve

    KX080-4, WSM HYDRAULIC SYSTEM [2] TRAVEL PILOT VALVE Part Name Part Name Part Name Bellows (14) Plug (27) Hex socket bolt Set screw (15) O-ring (28) Damper casing (16) Pushrod (29) Plug Set screw (17) Seat (30) O-ring Lock nut...

  • Page 240: Disassembly

    KX080-4, WSM HYDRAULIC SYSTEM Travel pilot valve adapter angles Point used Tape color Left backward Blue Left forward Right backward Green Right forward Yellow Pressure sensor None Port P White Port T None (a) 20 ° (0.35 rad) A : Front side...
  • Page 241 KX080-4, WSM HYDRAULIC SYSTEM 4. Put a rod against the camshaft and tap it out gently with a hammer. • Tools to use: rod (8mm ( 0.31 in.) or less) and hammer (1) Camshaft RY9212148HYS0233US0 5. Remove the cam with the set screw and lock nut in place.
  • Page 242 KX080-4, WSM HYDRAULIC SYSTEM 9. Remove the plug with its grease cap and gasket intact. 10. Take out the seat and damping spring. IMPORTANT • Be careful as the piston may pop out due to the force of the spring.
  • Page 243 KX080-4, WSM HYDRAULIC SYSTEM 15. To disassemble the reducing valve, rest the bottom of the spool on a flat work surface, press the spring seat in and while compressing the secondary pressure spring, shift the spring seat to the side and remove it via the larger hole.

  • Page 244: Assembly

    KX080-4, WSM HYDRAULIC SYSTEM 20. Remove the seat from the casing. • Tool to use: magnet or L-shaped piece of wire (1) Seat RY9212148HYS0247US0 IMPORTANT • Take care not to scratch steel balls or the surfaces they touch. (1) Steel ball...
  • Page 245 KX080-4, WSM HYDRAULIC SYSTEM 3. Install the return spring and reducing valve ASSY into the casing. IMPORTANT • Install them in the same position as before disassembly. NOTE • When installing the reducing valve ASSY, do not hit the bottom of the spool on the corners of the casing with any force.
  • Page 246 KX080-4, WSM HYDRAULIC SYSTEM 7. Install the pushrod into the plug. 8. Install the seat on the pushrod. IMPORTANT • Apply hydraulic oil to the pushrod prior to assembly. • Install it in the same position as before disassembly. (1) Plug...
  • Page 247 KX080-4, WSM HYDRAULIC SYSTEM 13. While holding the cam down, insert the camshaft from the outside. (1) Cam (2) Camshaft RY9212148HYS0262US0 14. Install the set screw. • Tool to use: torque wrench NOTE • Wipe clean any excess thread lock compound from the set screws.

  • Page 248: Special Tools

    KX080-4, WSM HYDRAULIC SYSTEM (3) Special Tools (a)Special tool (1) Center hole OK [ 2mm (0.08 in.) (c) 20 mm (0.79 in.) or less] (d) 2 mm (0.08 in.) (e) 32 mm (1.26 in.) 12 (-0.25, -0.40) mm (0.42 in.) 0.52 rad (30 °)

  • Page 249: Disassembly

    KX080-4, WSM HYDRAULIC SYSTEM Swing pilot valve adapter angles Point used Tape color Left Pea green Right Orange Port P White Port T None (A) Right swing (B) Left swing (a) 45 ° (0.79 rad) RY9212148HYS0269US0 (1) Disassembly 1. Clamp the pilot valve in a vise.
  • Page 250 KX080-4, WSM HYDRAULIC SYSTEM 5. Remove the cam. IMPORTANT • Handle the cam and the ball as an assembly. (Cannot be disassembled) • Mark the relationship between the cam and the cover. (1) Cam (2) Ball RY9212148HYS0174US0 6. Remove the hex socket bolt.
  • Page 251 KX080-4, WSM HYDRAULIC SYSTEM 9. Remove the reducing valve ASSY, secondary pressure spring and return spring from the casing. IMPORTANT • Mark the relationship of the casing holes. (1) Secondary Pressure Spring A : Reducing Valve ASSY (2) Return Spring RY9212148HYS0178US0 10.

  • Page 252: Assembly

    KX080-4, WSM HYDRAULIC SYSTEM 13. Remove the plug from the pushrod. (1) Plug (2) Pushrod RY9212148HYS0182US0 14. Remove the gasket from the plug. CAUTION • Use a mini slotted screwdriver to remove it. • Be careful not to scratch the inside surface of the plug.
  • Page 253 KX080-4, WSM HYDRAULIC SYSTEM 3. Clamp the casing in a vise. Install the return spring in the casing. IMPORTANT • Install it in the same position as before disassembly. (1) Casing (2) Return spring RY9212148HYS0187US0 4. Install the reducing valve ASSY A to the casing.
  • Page 254 KX080-4, WSM HYDRAULIC SYSTEM 6. Install the gasket on the plug. IMPORTANT • Be careful that the gasket faces the right direction. (The gasket has an uneven shape ; put the end with a larger diameter in first.) • Apply hydraulic oil on the circumference and lip of the gasket.
  • Page 255 KX080-4, WSM HYDRAULIC SYSTEM 10. Install the cover on the casing. IMPORTANT • Install it in the same position as before disassembly. • Note that the cover will ride up due to the springs. (1) Cover (2) Casing RY9212148HYS0194US0 11. Install the hex socket bolts.
  • Page 256 KX080-4, WSM HYDRAULIC SYSTEM 15. Install the hex socket bolt. 6.9 ± 1.0 N·m Tightening torque Hex socket bolt 0.7 ± 0.1 kgf·m 5.1 ± 0.7 lbf·ft • Tool to use: hex socket 3 mm RY9212148HYS0199US0 16. Apply grease to the ends of the pushrods.
  • Page 257 KX080-4, WSM HYDRAULIC SYSTEM [4] BLADE PILOT VALVES Part Name Part Name Part Name Casing (12) Spring seat 1 (23) Set screw Port plate (13) Spring seat 2 (24) Detent plug Select O-ring (14) Washer 2 thick- (25) Holder ness...
  • Page 258 KX080-4, WSM HYDRAULIC SYSTEM Adapter angles Point used Tape color Down Brown Pink Port P White Port T None (A) Front side (a) 45 ° (0.79 rad) RY9212158HYS0072US0 3-S99 KiSC issued 08, 2015 A...

  • Page 259: Disassembly

    KX080-4, WSM HYDRAULIC SYSTEM (1) Disassembly • To ensure parts that are reused are installed in the same place as before disassembly, mark the parts as needed during disassembly. RY9212158HYS0073US0 1. Clamp the pilot valve in a vise. 2. Remove the bellows from the cover.
  • Page 260 KX080-4, WSM HYDRAULIC SYSTEM 8. If the plug stays in the casing, use a slotted screwdriver to get the plug out. • Tool to use: Slotted screwdriver IMPORTANT • Take care not to use too much force with the screwdriver when removing the plug so you don't damage it.

  • Page 261: Assembly

    KX080-4, WSM HYDRAULIC SYSTEM (2) Assembly 1. Assemble the reducing valve. Install the secondary pressure setting spring and the spring seat in that order on the spool, then press the spring seat down and install the two half-circle shaped pieces of washer 1 on the spring seat so they don't overlap.
  • Page 262 KX080-4, WSM HYDRAULIC SYSTEM 4. Install the return spring and reducing valve into the casing. NOTE • When installing the reducing valve, do not hit the bottom of the spool on the corners of the casing with any force. (1) Return Spring...
  • Page 263 KX080-4, WSM HYDRAULIC SYSTEM 8. After inserting the disc and the camshaft, tighten the set screws. • Tool to use: 4 mm hex socket NOTE • Wipe clean any excess thread lock compound from the set screws. • Apply a thread lock (Loctite 241) to the set screws.
  • Page 264 KX080-4, WSM HYDRAULIC SYSTEM 13. Apply an anti-rust oil to the parts inside the cover. 14. Install the bellows on top of the cover. (1) Cover (2) Bellows RY9212158HYS0095US0 3-S105 KiSC issued 08, 2015 A...

  • Page 265: Shockless Valves

    KX080-4, WSM HYDRAULIC SYSTEM 8. SHOCKLESS VALVES Components Name of Torque part 44.2 to 54.0 N·m Plug 4.5 to 5.5 kgf·m 32.6 to 39.8 lbf·ft O-ring Spring Orifice Ring Spool Orifice Ball Body 23.8 to 29.2 N·m (10) Plug 2.4 to 3.0 kgf·m 17.6 to 21.5 lbf·ft...

  • Page 266: Swivel Shuttle Valve

    KX080-4, WSM HYDRAULIC SYSTEM 9. SWIVEL SHUTTLE VALVE Components Name of part Q'ty Torque Body 23.8 to 29.2 N·m Plug 2.4 to 3.0 kgf·m 17.6 to 21.5 lbf·ft O-ring 13.2 to 16.2 N·m 1.4 to 1.7 kgf·m Seat 9.74 to 11.90 lbf·ft...

  • Page 267: Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM 10. SOLENOID VALVE [1] UNLOAD VALVE Components Name of part Torque 15.7 ± 1.6 N·m Hex nut 1.6 ± 0.2 kgf·m 11.6 ± 1.2 lbf·ft Adjuster screw 3.9 N·m Hex socket bolt 0.4 kgf·m 2.9 lbf·ft...

  • Page 268: Aux Proportional Control Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM [2] AUX PROPORTIONAL CONTROL SOLENOID VALVE Components Name of part Torque 7.0 ± 1.0 N·m Bolt 0.7 ± 0.1 kgf·m 5.2 ± 0.7 lbf·ft Solenoid O-ring O-ring O-ring O-ring Body RY9212148HYS0279US0 Adapter angles (1) AUX1 solenoid valve...

  • Page 269: Angle Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM [3] ANGLE SOLENOID VALVE Components Name of part Torque 26.5 ± 2.7 N·m Plug 2.7 ± 0.3 kgf·m 19.5 ± 2.0 lbf·ft O-ring Spring Spool Body 3.9 N·m Hex socket bolt 0.4 kgf·m 2.9 lbf·ft Solenoid O-ring 26.5 ±...

  • Page 270: Ep Mode Solenoid Valve

    KX080-4, WSM HYDRAULIC SYSTEM [4] EP MODE SOLENOID VALVE Components Name of part Torque 7.0 ± 1.0 N·m Bolt 0.7 ± 0.1 kgf·m 5.2 ± 0.7 lbf·ft Solenoid O-ring O-ring O-ring O-ring Body RY9212148HYS0283US0 Adapter angles (A) Port A (to tank)

  • Page 271: Routing Of Hydraulic Hoses

    KX080-4, WSM HYDRAULIC SYSTEM 11. ROUTING OF HYDRAULIC HOSES [1] HYDRAULIC HOSE SPECIFICATIONS (a) Total Length RY9212004HYS0147US0 (1) C Type (Straight) (a) 45 ° (2) CR4 Type (45°) (b) 90 ° (3) CR9 Type (90°) (4) QM Type (Quick) (5) Q Type (Quick)

  • Page 272: High-Pressure Hoses

    KX080-4, WSM HYDRAULIC SYSTEM [2] HIGH-PRESSURE HOSES (1) Deliver Hose Routing (a) Pump (c) 3-way valve (d) Swivel motor (e) Swivel joint (b) Control valve (To be continued) 3-S113 KiSC issued 08, 2015 A...
  • Page 273 KX080-4, WSM HYDRAULIC SYSTEM (Continued) Hose Fitting Function Point used Total length Tape color Hose class Type Size 2890 mm White PA2810 CR9·C 1-14UNS Pump (P1) to C/V (P1) 113.8 in. 2950 mm White PA2810 CR9·C 1-14UNS Pump (P2) to C/V (P2) 116.1 in.
  • Page 274 KX080-4, WSM HYDRAULIC SYSTEM Delivery Hose Clamp Positions (1) Swing cylinder bottom side (4) P2 (6) P3 (9) PPS (2) Swing cylinder rod side (5) EP mode solenoid valve port A (7) P4 (10) EP mode solenoid valve port P...

  • Page 275: Pls Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (2) PLS Hose Routing Hose Fitting Function Point used Total length Tape color Hose class Type Size 2880 mm White PFH04 C·C 9/16UNF Pump (PLS) to C/V (PLS) 113.4 in. 750 mm P4 distribution block (tank...

  • Page 276: Front Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (3) Front Hose Routing (a) Boom holding valve hose (Eur. only) (To be continued) 3-S117 KiSC issued 08, 2015 A...
  • Page 277 KX080-4, WSM HYDRAULIC SYSTEM (Continued) Hose Fitting Function Guard Point used Total Tape Hose Type Size length color class 2600 mm Green C/V (Boom up) to boom Boom up PA2810 C·C 1-14UNS 102.4 in. White cylinder (bottom) 3470 mm Colgate...
  • Page 278 KX080-4, WSM HYDRAULIC SYSTEM Front Hose Clamp Positions (1) Brown (AUX1 Lo) (3) Orange (Bucket crowd) (5) Yellow (Arm dump) (7) Pink (AUX2 Hi) (2) Red (Bucket dump) (4) Blue (Arm crowd) (6) Pink (AUX1 Hi) (8) Brown (P1 Lo) NOTE •...

  • Page 279: Boom Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (4) Boom Hose Routing (1) AUX2 (High) (4) Arm dump (7) Bucket crowd (10) AUX2 (Low) (2) Boom up (5) Arm crowd (8) AUX1 (Low) (11) Velcro tape (3) AUX1 (High) (6) Bucket dump (9) Boom down...

  • Page 280: Undercarriage Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (5) Undercarriage Hose Routing (a) Blade Cylinder (c) Travel Motor L (e) Swivel Joint 15 ° (0.3 rad) (b) Blade Bulkhead Fitting (d) Travel Motor R Hose Fitting Function Guard Point used Total Tape Hose class...

  • Page 281: Angle Blade Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (6) Angle Blade Hose Routing (a) Control Valve (c) Travel Motor L (e) Blade Cylinder (g) Blade Bulkhead Fitting (b) Swivel Joint (d) Travel Motor R Angle Cylinder (h) 15 ° (0.3 rad) Hose Fitting Function...

  • Page 282: Low-Pressure Hoses

    KX080-4, WSM HYDRAULIC SYSTEM [3] LOW-PRESSURE HOSES (1) Suction Pipe and Hose Routing (1) Suction hose 1 (2) Suction hose 2 (3) Suction pipe NOTE • (a): Tighten bands from the base plate side (bottom). Function Point used Oil tank to suction pipe...

  • Page 283: Drain Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (2) Drain Hose Routing (a) Return Pipe (c) 3-Way Valve (e) Swivel Motor Oil Cooler (b) Hydraulic Oil Tank (d) Control Valve Hose Fitting Function Guard Point used Total Tape Hose Type Size length color class...

  • Page 284: Pilot Hoses

    KX080-4, WSM HYDRAULIC SYSTEM [4] PILOT HOSES (1) Deliver Hose Routing (a) Pump (c) Collector Block (d) Unload Valve (e) Swivel Joint (b) Line Filter Hose Fitting Function Point used Total length Tape color Hose class Type Size 360 mm PF1406 C·C...

  • Page 285: Port P Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (2) Port P Hose Routing (a) Control Valve (c) Swivel Motor (e) AUX2 Solenoid Valve (g) Unload Valve (b) Swivel Shuttle Valve (d) AUX1 Solenoid Valve P4 Distribution Block Hose Fitting Function Point used Total length...

  • Page 286: Port T Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (3) Port T Hose Routing Hose Fitting Function Point used Total length Tape color Hose class Type Size 610 mm Light blue PLT04 C·CR9 C/V (Dr2) to tank 24.0 in. 510 mm Center green PA0308 C·C Unload valve (T) to tank 20.1 in.

  • Page 287: Ports P And T Pilot Valve Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (4) Ports P and T Pilot Valve Hose Routing (a) Boom Shockless Valve (d) Collector Block (g) Blade P/V (A) Angle Specification (b) Travel P/V (e) Control P/V Left (h) EP Mode Solenoid Valve (c) Swing P/V...
  • Page 288 KX080-4, WSM HYDRAULIC SYSTEM (Continued) Hose Fitting Function Point used Total length Tape color Hose class Type Size 1495 mm Collector block (P) to blade Blade P White PLT04 C·Q 1/4·Q 58.9 in. P/V (P) 235 mm P/V right P...

  • Page 289: Pilot Valve Hose Routing

    KX080-4, WSM HYDRAULIC SYSTEM (5) Pilot Valve Hose Routing (a) Swivel Shuttle Valve (c) TPSS Valve (e) Control Right P/V (g) Blade P/V (b) Boom Shockless Valve (d) Control Left P/V Bulkhead Fitting Hose Fitting Function Point used Total length...
  • Page 290 KX080-4, WSM HYDRAULIC SYSTEM Hose Fitting Function Point used Total length Tape color Hose class Type Size 1400 mm Blade P/V (up) to bulkhead (13) Blade up Pink PLT04 Q·QM 55.1 in. fitting 1400 mm Blade P/V (down) to (14)
  • Page 291 KX080-4, WSM HYDRAULIC SYSTEM (Continued) Hose Fitting Function Point used Total length Tape color Hose class Type Size 1845 mm Shuttle valve to C/V (swivel Swivel left Gray PLT04 Q·CR9 Q·1/4 72.6 in. left) 1405 mm Shuttle valve to C/V (swivel...

  • Page 292: Measuring Hydraulic Device Performance

    KX080-4, WSM HYDRAULIC SYSTEM 12. MEASURING HYDRAULIC DEVICE PERFORMANCE [1] PISTON PUMP AIR BLEEDING PROCEDURE Purpose • When disassembling or replacing hydraulic equipment and/or hoses, etc., after changing the hydraulic fluid and using the vacuum pump, and before operating the machine, always air bleed the pump to prevent pump scorching or cavitation.

  • Page 293: Release Of Pressure In The Hydraulic System

    KX080-4, WSM HYDRAULIC SYSTEM [2] RELEASE OF PRESSURE IN THE HYDRAULIC SYSTEM Purpose • It is necessary to release the pressure in the hydraulic system when removing/mounting hydraulic devices and as preparation for taking measurements. Always release the pressure in such cases.

  • Page 294: Manual Boom Lowering Procedure

    KX080-4, WSM HYDRAULIC SYSTEM 4. Operate each control lever for the boom, arm, bucket and swivel to full stroke. 5. Operate each of the travel levers, blade levers, swing pedals and angle blade switches to full stroke. 6. Use the AUX enable switch to turn the AUX ports ON and then operate each of the AUX port knob switches full stroke.

  • Page 295: Measuring The Flow Rate

    KX080-4, WSM HYDRAULIC SYSTEM [4] MEASURING THE FLOW RATE (1) Measuring Main Pump Flow Purpose • Measuring the amount of oil discharged from the main pump allows an assessment of its performance. • If the discharge volume is lower than the factory specification, something may be wrong with the main pump or the engine.
  • Page 296 KX080-4, WSM HYDRAULIC SYSTEM  If measuring the flow of P3 (gear pump) 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine. 2. Follow the chapter Releasing Pressure in the Hydraulic System and release pressure in the hydraulic lines.

  • Page 297: Measuring The Aux Proportional Settings

    KX080-4, WSM HYDRAULIC SYSTEM (2) Measuring the AUX Proportional Settings Purpose • Measuring the maximum amount of oil flow at each step allows an assessment of solenoid valve performance. • Prior to performing this test, make sure that each attachment is operating at the factory spec. speed and check the amperage of each solenoid valve.

  • Page 298: Measuring Aux Discharge Flow

    KX080-4, WSM HYDRAULIC SYSTEM (3) Measuring AUX Discharge Flow Purpose • Measuring the flow at the AUX discharge port allows you to confirm AUX port discharge while under load. RY9212148HYS0349US0 [Measurement preparations] 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine.

  • Page 299: Measuring Pressure

    KX080-4, WSM HYDRAULIC SYSTEM [5] MEASURING PRESSURE (1) Main Relief Valve Measuring Procedure Purpose • Verification of correct pressure setting. • If the measured value is low, there may be a problem with the relief valve and/or leaks in other hydraulic devices.
  • Page 300 KX080-4, WSM HYDRAULIC SYSTEM Adjusting the Main Relief Valve CAUTION • Only adjust the valve if the pressure setting of the main relief valve is lower than specification. • If the pressure is raised above the setting value, it may cause damage to equipment, so never raise the pressure above the setting value.

  • Page 301: Measuring Pilot Secondary Pressure

    KX080-4, WSM HYDRAULIC SYSTEM (2) Measuring Pilot Secondary Pressure Purpose • Measure the pressure between the control valves and the oil from each pilot valve and solenoid and make sure they are at specified values. • If the pressure is lower than the factory specification, in general it indicates something may be wrong with the pilot valve or solenoid valve.

  • Page 302: Measuring Ep Proportional Solenoid Pressure

    KX080-4, WSM HYDRAULIC SYSTEM (3) Measuring EP Proportional Solenoid Pressure Purpose • Measuring the pressure from the EP proportional solenoid valve to the pump allows assessment of the performance of the EP solenoid valve. RY9212148HYS0326US0 [Measurement preparations] 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine.

  • Page 303: Measuring The Overload Relief Valve Pressure

    KX080-4, WSM HYDRAULIC SYSTEM (4) Measuring the Overload Relief Valve Pressure IMPORTANT • If it is necessary to check the overload relief pressure on this machine, measure the main relief pressure of each circuit (boom, arm, bucket, blade, AUX and angle) and if the main relief pressures are within factory specifications, the overload relief valve is judged to be normal.
  • Page 304 KX080-4, WSM HYDRAULIC SYSTEM Angle Specification (1) Blade rod (2) Blade bottom (3) Arm rod (4) Arm bottom (5) Bucket rod (6) Bucket bottom (7) AUX1. High (8) AUX1. Low (9) Boom bottom (10) Boom rod (11) Angle rod (12) Angle bottom...

  • Page 305: Pressure Measuring Kit

    KX080-4, WSM HYDRAULIC SYSTEM (5) Pressure Measuring Kit Name of part Q'ty Support Pipe joint (M12-G1/4) Bolt (M10 x 35) Nut (M10) Test hose CAUTION • Use a test hose that can withstand pressure up to the measurement pressure. A : Nozzle Tester...

  • Page 306: Adjusting Swivel Relief Valve Pressure

    KX080-4, WSM HYDRAULIC SYSTEM (6) Adjusting Swivel Relief Valve Pressure IMPORTANT • When checking the relief pressure of the swivel motor on the machine, measure the main relief pressure and if the main relief pressure is within factory specifications, the swivel relief valve is considered to be normal.

  • Page 307: Measuring Swivel Performance

    KX080-4, WSM HYDRAULIC SYSTEM [6] MEASURING SWIVEL PERFORMANCE (1) Measuring Swivel Motor Drain Volume Purpose • Measuring the drain volume when operating allows an assessment of swivel motor performance. IMPORTANT • Swivel motor performance is used along with swivel block performance and measurement of swivel speed to make a comprehensive assessment.

  • Page 308: Measuring Swivel Block Performance

    KX080-4, WSM HYDRAULIC SYSTEM [Measurement when turning] 1. Position each of the switches as follows. Eco mode Accelerator dial Auto-idle switch AC switch switch Max RPM P mode 2. The position for measurement should be with maximum extension of the boom cylinder, arm cylinder and bucket cylinder.

  • Page 309: Measuring Swivel Speed

    KX080-4, WSM HYDRAULIC SYSTEM (3) Measuring Swivel Speed Purpose • Measure how long it takes to swivel 3 times to assess the overall performance of the swivel drive system (main and pilot lines). [Measurement preparation] 1. Repeat swivel left and right operations to sufficiently warm up the swivel motor.

  • Page 310: Measuring Travel Performance

    KX080-4, WSM HYDRAULIC SYSTEM [7] MEASURING TRAVEL PERFORMANCE (1) Measuring Travel Motor Drain Volume Purpose • Measuring the drain volume when operating and when locked allows an assessment of the travel motor performance. • Travel motor performance is used along with travel block performance, travel speed and travel drift to make a comprehensive assessment.

  • Page 311: Measuring Travel Block Performance

    KX080-4, WSM HYDRAULIC SYSTEM [Measurement when turning] 1. Position each of the switches as follows. Travel speed Accelerator Eco mode Auto-idle AC switch switch dial switch switch Max RPM P mode Max RPM P mode 2. Operate the travel lever on the side to be measured full stroke and while maintaining a uniform travel speed, measure the drain volume coming from the test hose in 1 minute.

  • Page 312: Measuring Travel Speed

    KX080-4, WSM HYDRAULIC SYSTEM (3) Measuring Travel Speed Purpose • Measure how long it takes to travel a distance to assess the overall performance of the travel drive system (main and pilot lines). [Measurement preparation] 1. Adjust the left and right crawlers to their specified dimensions and operate the travel motor to thoroughly warm it up.

  • Page 313: Measuring Cylinder Speed

    KX080-4, WSM HYDRAULIC SYSTEM [8] MEASURING CYLINDER SPEED (1) Measuring Hydraulic Cylinder Operating Time Purpose • Measure the amount of time it takes to operate each of the hydraulic cylinders to assess the overall performance of the front drive system (main and pilot lines).
  • Page 314 KX080-4, WSM HYDRAULIC SYSTEM Swing cylinder 1. Arm cylinder fully compressed, bucket cylinder fully extended, and bucket bottom approximately 1.0 m (40 in.) above ground level. 2. Operate the swing pedal full stroke and measure how long it takes to swing full stroke to the right and to the left.

  • Page 315: Measuring Hydraulic Cylinder Drift

    KX080-4, WSM HYDRAULIC SYSTEM (2) Measuring Hydraulic Cylinder Drift Purpose • Measure how far a cylinder drops to asses leakage inside the cylinder, control valve and/or holding valve. • When measuring a cylinder that has just been replaced, insure to purge any air prior to taking the measurements.

  • Page 316: Measuring Swing Cylinder Deviation

    KX080-4, WSM HYDRAULIC SYSTEM (3) Measuring Swing Cylinder Deviation Purpose • Measure how far the cylinder deviates to assess leakage inside the cylinder and/or control valve. • When measuring a cylinder that has just been replaced, insure to purge any air prior to taking the measurements.

  • Page 317: Hydraulic Device Performance Standards

    KX080-4, WSM HYDRAULIC SYSTEM 13. HYDRAULIC DEVICE PERFORMANCE STANDARDS [1] FLOW RATE (1) Main Pump Discharge Flow Rate Data (Measured Values) (1) P Mode (Pi = 3.6 MPa, (2) E Mode (Pi = 0 MPa, (3) P Mode(P3 = 20.6 MPa)
  • Page 318 KX080-4, WSM HYDRAULIC SYSTEM (Continued) 10.0 12.5 15.0 Pressure kgf/cm 15.3 51.0 76.5 102.0 127.5 153.0 217.96 725.5 1087.8 1450.4 1813.0 2175.6 142.0 141.1 139.8 138.6 137.6 123.9 P mode 37.5 37.3 36.9 36.6 36.6 32.7 142.0 141.0 128.6 107.2 87.1...

  • Page 319: Flow Rate Data For Aux Proportional Control (Measured Values)

    KX080-4, WSM HYDRAULIC SYSTEM (2) Flow Rate Data for AUX Proportional Control (Measured Values) (1) Left (Max) (1) Left (Idle) (A) AUX1 (a) Max Flow Setting (2) Right (Max) (2) Right (Idle) (B) AUX2 (Limit Value) (b) Flow Volume L/min The relationship between pressure P, flow Q and lever knob operation (limit value) changes proportionally as shown in the figures above.

  • Page 320: Aux Discharge Flow Rate Data (Measured Values)

    KX080-4, WSM HYDRAULIC SYSTEM (3) AUX Discharge Flow Rate Data (Measured Values) (1) P Mode (a) Pressure (MPa) (A) AUX1 (2) E Mode (b) Flow Rate L/min (B) AUX2 CAUTION • Measured values may vary depending on the machine. • This measurement data is of the values set for the max discharge flow rate. (limit=max)

  • Page 321: Relief Pressure (Measured Values)

    KX080-4, WSM HYDRAULIC SYSTEM [2] RELIEF PRESSURE (MEASURED VALUES) Item Notes Travel right main pressure (aTR) 30.0 ± 0.5 MPa 306 ± 5 kgf/cm 4351 ± 73 psi Travel left main pressure (aTL) 27.5 ± 0.5 MPa Main LS pressure (aLS) 281 ±...

  • Page 322: Swivel Performance

    KX080-4, WSM HYDRAULIC SYSTEM Item Notes Left (b6L) 22.5 ± 1.0 MPa AUX1 230 ± 10 kgf/cm 3260 ± 145 psi Measurement location: P1, P2 Right (b6R) pressure test ports 22.5 ± 1.0 MPa Bottom (b8B) 230 ± 10 kgf/cm 3260 ±...

  • Page 323: Cylinder Speed

    KX080-4, WSM HYDRAULIC SYSTEM [5] CYLINDER SPEED Item Notes Ground to max 3.1 ± 0.3 sec lift Boom Max lift to ground 3.4 ± 0.3 sec Crowd 3.4 ± 0.3 sec Dump 3.2 ± 0.3 sec Crowd 3.1 ± 0.3 sec...

  • Page 324: Troubleshooting

    KX080-4, WSM HYDRAULIC SYSTEM 14. TROUBLESHOOTING [1] TROUBLESHOOTING ALL ACTUATORS When all actuators are slow or fail to work • Likely to be a problem in the pilot system and/or with the engine. • Check for problems in hydraulic oil level and/or quality.
  • Page 325 KX080-4, WSM HYDRAULIC SYSTEM Boom operation slow or jerky Cause Remedy Notes Anti-drop check valve sticking or • Inspect the anti-drop check valve damaged 1. Remove the anti-drop check valve from the control valve. 2. Check the inside and inspect for abnormalities.
  • Page 326 KX080-4, WSM HYDRAULIC SYSTEM Slow during multiple operations Cause Remedy Notes Seat of unload LS valve (aUN) faulty • Measure unload LS valve pressure 1. Disassemble and clean or replace the relief valve Seat of main LS valve (aLS) faulty •...
  • Page 327 KX080-4, WSM HYDRAULIC SYSTEM Won't switch to high-speed travel • Check whether the travel speed switch is switching in the tester mode. Cause Remedy Notes Faulty 2nd speed solenoid valve at • Check 2nd speed solenoid valve operation unload unit 1.
  • Page 328 KX080-4, WSM HYDRAULIC SYSTEM Swivel drifts • Identify whether the fault is in the main system or the pilot system. Cause Remedy Notes Slow return valve faulty Clean or replace the slow return valve Anti-void valve faulty Clean or replace the anti-void valve...

  • Page 329: Electrical System

    ELECTRICAL SYSTEM KiSC issued 08, 2015 A...

  • Page 330: Contents

    SERVICING CONTENTS 1. LAYOUT OF ELECTRICAL DEVICES AND WIRING ROUTING..........4-S1 [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING ........4-S1 [2] PRECAUTIONS ON HANDLING ELECTRICAL CONNECTORS .........4-S1 [3] LAYOUT AND WIRING ROUTING..................4-S3 2. METER PANEL OPERATION ....................4-S10 [1] NAMES AND FUNCTIONS OF METERS ................4-S10 [2] USER SETTINGS MODE ....................4-S10 (1) Log Record ........................4-S11 (2) Periodic Check ......................4-S11...
  • Page 331 (3) Testing the AI Switch .....................4-S80 [4] ANTI-THEFT (AT) SYSTEM ....................4-S83 (1) Anti-Theft System Errors ....................4-S83 [5] POWER SUPPLY SYSTEM ....................4-S86 (1) Over Voltage........................4-S86 (2) 5 V Short System Error....................4-S87 [6] COMMUNICATION SYSTEM ....................4-S88 (1) CAN Communication Errors ..................4-S88 [7] AUX SYSTEM........................4-S94 (1) AUX1 / AUX2 (Thumb) System Errors................4-S94 [8] ECO MODE SYSTEM .......................4-S100 (1) EP System Errors ......................4-S100...

  • Page 332: Layout Of Electrical Devices And Wiring Routing

    KX080-4, WSM ELECTRICAL SYSTEM 1. LAYOUT OF ELECTRICAL DEVICES AND WIRING ROUTING [1] PRECAUTIONS ON HOW TO CLAMP THE ELECTRICAL WIRING 1. Do not touch the wiring or the area around it. Do not touch where uncovered. 2. Do not clamp to fuel hoses.
  • Page 333 KX080-4, WSM ELECTRICAL SYSTEM Colors of Wiring Color of wiring Color code Color of wiring Color code Black Blue / Green Green Blue / Orange L/Or Blue Blue / Red Pink Blue / White Blue / Yellow White Light Green / Blue...

  • Page 334: Layout And Wiring Routing

    KX080-4, WSM ELECTRICAL SYSTEM [3] LAYOUT AND WIRING ROUTING (1) RPM sensor (5) Fuel level gauge (b) Must not interfere with hood (d) To starter relay (2) Fuel filter heater (6) Ground cable lock bracket (e) To (+) battery terminal...
  • Page 335 KX080-4, WSM ELECTRICAL SYSTEM (1) DPF pressure differential (8) AC switch (13) Oil switch (a) To starter relay sensor (9) Engine ECU (14) Water level switch (b) Be sure to install fuel pump (2) Boost sensor (10) Travel alarm buzzer (optional)
  • Page 336 KX080-4, WSM ELECTRICAL SYSTEM (a) To main harness (b) To fuel sensor RY9212158ELS0019US0 4-S5 KiSC issued 08, 2015 A...
  • Page 337 KX080-4, WSM ELECTRICAL SYSTEM (1) DPF outlet temperature (3) DPF outlet temperature (5) DPF outlet temperature (7) Fuel temperature sensor sensor 0 (black) sensor 2 (white) sensor connector 1 (dark (2) DPF outlet temperature (4) DPF outlet temperature gray) (a) From engine harness...
  • Page 338 KX080-4, WSM ELECTRICAL SYSTEM (1) Horn (b) To engine harness (d) Harness connector To angle solenoid (a) To front (c) To AC unit (e) Ground (g) To travel pressure sensor RY9212158ELS0020US0 (1) Limit switch (2) Main ECU (a) To AC unit...
  • Page 339 KX080-4, WSM ELECTRICAL SYSTEM (1) Main ECU (2) CAN comm connector (4-pin) (3) CAN comm connector (2-pin) (4) Engine diagnosis tool connector (4-pin) RY9212148ELS0213US0 (1) Anti-theft antenna (4) DPF inhibit switch (7) Worklight switch (10) Relay connector (12-pin) (2) AI console...
  • Page 340 KX080-4, WSM ELECTRICAL SYSTEM (1) Relay box (2) Fuse box (condenser fan) (3) Slow-blow fuse box RY9212148ELS0216US0 (a) Arm bottom hoses and (b) To main harness (c) Clamp wiring clamps RY9212158ELS0022US0 4-S9 KiSC issued 08, 2015 A...

  • Page 341: Meter Panel Operation

    KX080-4, WSM ELECTRICAL SYSTEM 2. METER PANEL OPERATION [1] NAMES AND FUNCTIONS OF METERS Normal display (1) User Setting Switch (Switch 1) (8) Hour Meter - Engine Tachometer (2) Overload Warning Switch (Switch 2) (9) Fuel Gauge (3) AUX Port Enable Switch (Switch 3)

  • Page 342: Log Record

    KX080-4, WSM ELECTRICAL SYSTEM (1) Log Record • Allows you to check the hours in use for each day for up to 3 months prior. 1. Select Log Record. 2. Select the month and day of the hours in operation you wish to check to display the hours in use in the upper right of the screen.

  • Page 343: Set Clock

    KX080-4, WSM ELECTRICAL SYSTEM [Display when periodic check time exceeded] Ex.) 20 hours past time to change the engine oil Service hour meter: 520 hours (1) Hours Until Service (past 20 hours) RY9212148ELS0019US0 Periodic Check Items List (The following check items are displayed on the LCD screen at the corresponding hour meter time.)

  • Page 344: Various Settings

    KX080-4, WSM ELECTRICAL SYSTEM (5) Various Settings • Allows you to change the order of the date display and the clock display method. 1. Select Various Settings and then Calendar. 2. Select the date and clock display methods as desired.

  • Page 345: Service/Dealer Mode

    KX080-4, WSM ELECTRICAL SYSTEM [4] SERVICE/DEALER MODE • Turning the key ON while holding down SW5 puts the machine in the service/dealer mode. • Select a language. (Eur. spec.: 5 languages, US spec.:1 language, Canada spec.: 2 languages) • There are 2 items in the service/dealer mode, namely "Diagnosis" and "Setting," which allow you to check/set the content in the tables below.
  • Page 346 KX080-4, WSM ELECTRICAL SYSTEM Mode Item Description Notes Moves the AI motor position when the (A) AI Motor Drive accelerator dial is replaced. Operates AUX2 via the AUX1 knob. Or (B) Exchange (AUX1) (2/Thumb) operates AUX1 via the AUX2 knob.

  • Page 347: Diagnosis

    KX080-4, WSM ELECTRICAL SYSTEM (1) Diagnosis [A] Tester • Makes it possible to check the data from each sensor and switch. • Determines when a setting is outside parameters and when a switch or solenoid is irregular in terms of continuity.
  • Page 348 KX080-4, WSM ELECTRICAL SYSTEM (Continued) Scre Content displayed Description/std. value Notes Engine RPM • Current value (n/min) Battery voltage • Battery voltage ± 0.5V Oil switch • Prior to engine start: ON • After engine start: OFF Charge • Key in the Start position: ON Starter •...
  • Page 349 KX080-4, WSM ELECTRICAL SYSTEM Scre Content displayed Description/std. value Notes • Current value: 0.25 to 4.75 V AUX2 • Setting value: left or right • Setting value: neutral Only for models equipped • Operating: 0.5 to 2.0 A with AUX2 proportional Amperage •...
  • Page 350 KX080-4, WSM ELECTRICAL SYSTEM Scre Content displayed Description/std. value Notes Multi-purpose1 switch 1 (AI control dial) • Press switch: ON • Release switch: OFF Multi-purpose2 switch 2 (AUX left knob) Multi-purpose switch • With output signal from ECU: ON solenoid •...
  • Page 351 KX080-4, WSM ELECTRICAL SYSTEM Scre Content displayed Description/std. value Notes ECU (main) • Program version • Program creation date (Y/M/D) Serial No. • Serial no. (different number each machine) ECU (AS) • Program version Only on RX series (Japan) • Program creation date (Y/M/D) Serial No.

  • Page 352: Setting

    KX080-4, WSM ELECTRICAL SYSTEM (2) Setting [A] AI Set • Make the setting when the AI motor, accelerator dial or governor sensor is touched. Also make the setting when part(s) are replaced. 1. Select Setting → AI set. 2. Follow the instructions on the meter panel.
  • Page 353 KX080-4, WSM ELECTRICAL SYSTEM (C) (w/o attach) Start Point Set • Make setting when the AUX1 proportional valve, spool and/or AUX1 knob is replaced. • Use this setting method when an attachment is not available. 1. Place the mini excavator on flat hard ground, lower the bucket and the blade, and stop the engine.
  • Page 354 KX080-4, WSM ELECTRICAL SYSTEM (B) (w/attach) Start Point Set • Make setting when the AUX2 proportional valve, spool and/or AUX2 knob is replaced. • Mount an attachment on the AUX2 port and make the setting. 1. Select Setting → AUX2/Thumb Set → (w/attach) Start Point Set.
  • Page 355 KX080-4, WSM ELECTRICAL SYSTEM [D] AS Set (Japan Spec. Only) [Display when not the Japan spec.] RY9212148ELS0042US0 [E] Crane Set (Japan Spec. Only) [Display when not the Japan spec.] RY9212148ELS0043US0 [F] Overload Warning (Eur. Spec. Only) • Sets/changes the overload warning pressure.
  • Page 356 Multipurpose Operating Has multi-purpose switch connector spec.: YES 2-piece boom spec.: 2 (11) Arm Type Other specs.: 1 (12) Compartment W/ eco mode spec.:1 (KX080-4) (13) Force Mode W/AC mode spec.:2 No AC spec.: 0 (14) Common Rail System (15)
  • Page 357 KX080-4, WSM ELECTRICAL SYSTEM [H] Others (A) AI Motor Drive • Moves the AI motor position when the accelerator dial is replaced. 1. Select Setting → Others → AI Motor Drive. 2. Press switch 2 or 3 to move the lever position.
  • Page 358 KX080-4, WSM ELECTRICAL SYSTEM (E) Annual Guidance • Turns on the display of annual check guidance. Or turns it off. 1. Select Setting → Others → Annual Guidance. 2. Select the desired operating method. 3. Press SW5 to make the setting.
  • Page 359 KX080-4, WSM ELECTRICAL SYSTEM (F) Periodic Check Set • When the meter is replaced, sets the periodic check time prior to replacement to prevent a discrepancy in the periodic check time. 1. Select Setting → Others → Periodic Check Set.
  • Page 360 KX080-4, WSM ELECTRICAL SYSTEM (I) Multipurpose Mode • Enabling the multi-purpose switch function on machines equipped with AUX1 and AUX2 makes 10 modes available for use. • Depending on the selected mode, it becomes necessary to add equipment to the machine, such as ON/OFF switches, solenoid valves, wire harness, hydraulic hoses, etc.
  • Page 361 KX080-4, WSM ELECTRICAL SYSTEM (b) Names of Parts (1) Multi-Purpose Switch A (A) N.A. Spec. (2) Indicator (B) Australia/Eur. Spec. (3) Multi-Purpose Switch B (4) AUX2/Thumb Hold Switch (5) AUX2/Thumb Knob RY9212148ELS0050US0 (c) Description of Each Mode Mode No. 01: Enables the AUX2 hold switch.
  • Page 362 KX080-4, WSM ELECTRICAL SYSTEM Mode No. 02: (Ex.) Switches swivel/swing operation ON/OFF. • Pressing multi-purpose switch A or multi-purpose switch B turns and keeps the multi-purpose signal ON. Pressing the switch again turns the multi-purpose signal OFF. (1) Multi-Purpose Switch A...
  • Page 363 KX080-4, WSM ELECTRICAL SYSTEM Mode No. 08: Operates the hydraulic quick hitch or for using Tiltrotator • The multi-purpose signal is ON only while multipurpose switches A and B are pressed simultaneously. • Enables a spring-locked hydraulic quick hitch (1) Multi-Purpose Switch A...
  • Page 364 KX080-4, WSM ELECTRICAL SYSTEM (K) Opening Select • Changes the opening display screen. 1. Select Setting → Others → Opening select. 2. Select the number of the desired display method. 3. Press SW5 to make the setting. Number Screen display...

  • Page 365: Settings When Replacing Electronic Devices

    KX080-4, WSM ELECTRICAL SYSTEM [5] SETTINGS WHEN REPLACING ELECTRONIC DEVICES (1) When Replacing the Meter or Main ECU Content displayed Explanation Press switch 5 "Yes" to overwrite data. Press switch 1 "No" when checking whether another machine's meter or ECU Overwrite ECU with new data that is temporarily installed is working or not.

  • Page 366: Table Of Meter Panel Messages And Error History List

    KX080-4, WSM ELECTRICAL SYSTEM [6] TABLE OF METER PANEL MESSAGES AND ERROR HISTORY LIST (1) Red Warning Lamp Lit When needed, pressing switch 4 displays a detailed description. Screen display Pressing SW4 Message in fail record Reason detected/steps to take...
  • Page 367 KX080-4, WSM ELECTRICAL SYSTEM Screen display Pressing SW4 Message in fail record Reason detected/steps to take [Main ECU] a)AUX2 knob connector disconnected AUX2/thumb knob AUX2/thumb knob b)Break or short in harness [Main ECU] a)AUX2 right solenoid connector disconnected AUX2/thumb right SOL...

  • Page 368: Yellow Warning Lamp Lit

    KX080-4, WSM ELECTRICAL SYSTEM (2) Yellow Warning Lamp Lit When needed, pressing switch 4 displays a detailed description. Screen display Pressing SW4 Message in fail record Reason detected/steps to take Fuel low – – Displayed at 6 minute intervals. Water temperature rising.

  • Page 369: Other Screens

    KX080-4, WSM ELECTRICAL SYSTEM (3) Other Screens Screen display Pressing SW4 Message in fail record Reason detected/steps to take Switch 2 (crane) pressed on machine w/o – – overload warning When meter or ECU replaced without doing – – setup During setup after changing the meter or the –...
  • Page 370 KX080-4, WSM ELECTRICAL SYSTEM Screen display Pressing SW4 Message in fail record Reason detected/steps to take During communication with the key (Anti-theft – – spec. only) Displayed for 5 seconds when put in the E – – mode. Displayed for 5 seconds when –...

  • Page 371: Pm Clog Level And The State Of The Machine

    KX080-4, WSM ELECTRICAL SYSTEM (4) PM Clog Level and the State of the Machine Inhibit switch ON Clog Warning Engine Buzzer Screen Content displayed Status and correction Level lamp output Level 0 – – – – – Level 1 –...
  • Page 372 KX080-4, WSM ELECTRICAL SYSTEM Inhibit switch OFF Clog Warning Engine Contents Buzzer Engine RPM Screen Status and correction Level lamp output displayed Level 0 – – – – – – Exhaust More than 1900 engine RPM temperature needed: DPF regenerates ··PiPiPi··...
  • Page 373 KX080-4, WSM ELECTRICAL SYSTEM Clog Warning Engine Contents Buzzer Engine RPM Screen Status and correction Level lamp output displayed Blinking PiPiPiPi DPF is clogged. Needs Level 5 50 % – Replace the DPF (Red) (Continue) replacement. The engine rpm drops up to only 1900 rpm while pressing the AI switch.

  • Page 374: Table Of Engine System Error Numbers

    KX080-4, WSM ELECTRICAL SYSTEM (5) Table of Engine System Error Numbers Always happens  Symptom when error occurs May happen  Engine performance No. Dis- Error location Notes Limited Limited played Won't start RPM sensor system    Fuel/rail pressure system Fuel may run out.

  • Page 375: Power And Ground

    KX080-4, WSM ELECTRICAL SYSTEM 3. INSPECTIONS [1] POWER AND GROUND Battery Check the voltage between the terminals 1. Connect a circuit tester between the (+) and (-) terminals of the battery and measure the voltage across the terminals. 2. If the measurement is below factory specs, check the specific gravity of the electrolyte.
  • Page 376 KX080-4, WSM ELECTRICAL SYSTEM Ground Check whether GND wire(s) are securely connected to the body. RY9212148ELS0136US0 Fuses IMPORTANT • When replacing a fuse, always use the same capacity fuse and replace it after determining why it blew. (1) Fuse box...
  • Page 377 KX080-4, WSM ELECTRICAL SYSTEM Fuse Layout and Capacities A/C Controller (+B) (12) Cab Work Light Meter (+B) (13) Radio (AC) Blower Motor (14) Fuel Filter Heater Relay (15) ECU (+B) ECU (AC) (16) ECU (POWER) Room Light (17) Beacon Starter...

  • Page 378: Starting And Stopping Device

    KX080-4, WSM ELECTRICAL SYSTEM Slow-blow fuses IMPORTANT • When replacing a slow-blow fuse, always use the same capacity fuse and replace it after determining why it blew. (1) Slow-blow fuse box (2) Electric fan fuse RY9212148ELS0139US0 Inspecting slow-blow fuses • Measurement parameter : check continuity across its terminals...

  • Page 379: Relay Layout

    KX080-4, WSM ELECTRICAL SYSTEM Starter 1. Power supply to terminal B IMPORTANT • The battery voltage always exists at terminal B of the starter, so do not short it during inspection. 1. Connect the (+) side of the circuit tester to terminal B of the starter and the (–) side to the body and measure the voltage.
  • Page 380 KX080-4, WSM ELECTRICAL SYSTEM Testing the Starter Relay 1. Voltage check [Measurement Conditions] 1. Remove the starter relay. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- Connector Name Connector Name sure- Pin No. Pin No.

  • Page 381: Troubleshooting (Start-Up Equipment Version)

    Engine starts even with unregistered keys Checkpoint Cause Solution Check whether the As the anti-theft function is not working, even anti-theft system is Please contact Kubota service. unregistered keys can start the engine. "OFF" or not initialized. RY9212148ELS0135US0 4-S50 KiSC issued 08, 2015 A...

  • Page 382: Methods For Diagnosing Errors

    KX080-4, WSM ELECTRICAL SYSTEM 5. METHODS FOR DIAGNOSING ERRORS The most important thing in diagnosing a malfunction is inferring the cause of the problem. It is important because inferring the cause allows for a narrowing of the places that need to be inspected, and thus reducing wasted inspection work.

  • Page 383: Testing With A Circuit Tester

    KX080-4, WSM ELECTRICAL SYSTEM [3] TESTING WITH A CIRCUIT TESTER Testing Voltage and Continuity at a Connector To prevent damage to the connector terminal contacts and/or reducing the water-proofing of the connector when testing a connector for voltage and/or continuity, follow the guidelines below.

  • Page 384: Troubleshooting (Meter Panel Version)

    KX080-4, WSM ELECTRICAL SYSTEM 6. TROUBLESHOOTING (METER PANEL VERSION) [1] MACHINE RELATED SYSTEM (1) Engine Oil Pressure Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. When an error appears on the meter panel, stop the engine right away.
  • Page 385 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The oil switch connector is disconnected. 3. There is a break somewhere in the wiring.
  • Page 386 KX080-4, WSM ELECTRICAL SYSTEM 2. Continuity check [Measurement Conditions] 1. Key switch: OFF 2. Disconnect the connector to be tested. 3. Test the continuity based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.

  • Page 387: Charging System Errors

    KX080-4, WSM ELECTRICAL SYSTEM (2) Charging System Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Check whether the charging lamp (b) is lit in red or off.
  • Page 388 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Checking fuses Check whether the alternator fuse (10A) is blown. RY9212001ELS0064US0 2. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The alternator connector is disconnected.
  • Page 389 KX080-4, WSM ELECTRICAL SYSTEM 1. Voltage check [Measurement Conditions] 1. Disconnect the alternator connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.
  • Page 390 KX080-4, WSM ELECTRICAL SYSTEM [E] Steps to Take after Completing Repairs 1. Delete failure record 1. While in the service/dealer mode, select Delete Fail Record and delete the record. 2. After deleting the record, start the engine again and check to make sure the warning is not shown on the meter panel.

  • Page 391: Fuel Sensor Errors

    KX080-4, WSM ELECTRICAL SYSTEM (3) Fuel Sensor Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel Check whether or not the warning lamp (a) on the panel is blinking red. [Reason error screen displayed] • Connector disconnected •...
  • Page 392 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. Fuel sensor connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off.
  • Page 393 KX080-4, WSM ELECTRICAL SYSTEM 1. Voltage check [Measurement Conditions] 1. Disconnect the fuel sensor connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.

  • Page 394: Front-End Systems

    KX080-4, WSM ELECTRICAL SYSTEM [E] Steps to Take after Completing Repairs 1. Delete failure record 1. While in the service/dealer mode, select Delete Fail Record and delete the record. 2. After deleting the record, start the engine again and check to make sure the warning is not shown on the meter panel.
  • Page 395 KX080-4, WSM ELECTRICAL SYSTEM 3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Put the machinery operation lever lock in the [Unlock] position. 4. Operate the lever lock switch and lever lock solenoid and check the switch according to the following table.
  • Page 396 KX080-4, WSM ELECTRICAL SYSTEM 3. Causes when a short [Test Conditions] 1. Key switch : OFF 2. The lever lock switch connector wire and/or lever lock solenoid connector are pinched against or touching the body. If the insulation is damaged, repair it properly and check the lever lock switch and the lever lock solenoid again in the tester mode.
  • Page 397 KX080-4, WSM ELECTRICAL SYSTEM 2. Continuity check [Measurement Conditions] 1. Key switch: OFF 2. Disconnect the connector to be tested. 3. Test the continuity based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.

  • Page 398: Travel 2-Speed System Error

    KX080-4, WSM ELECTRICAL SYSTEM (2) Travel 2-Speed System Error [A] Error from the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.
  • Page 399 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. The 2-speed solenoid connector disconnected. 3. The 2-speed switch connector disconnected. 4. There is a break somewhere in the wiring.
  • Page 400 KX080-4, WSM ELECTRICAL SYSTEM [C] Testing with a Circuit Tester (a) Main ECU connector (c) Engine (solenoid) (e) 2-speed solenoid connector A : Angle Specification (b) 2-speed switch connector connector B : Standard Spec (d) Main (solenoid) connector • If connectors (c) (d) are removed, the engine will start but the machine will not operate.
  • Page 401 KX080-4, WSM ELECTRICAL SYSTEM 2. Continuity check [Measurement Conditions] 1. Key switch: OFF 2. Disconnect the connector to be tested. 3. Test the continuity based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.

  • Page 402: Angle System Errors

    KX080-4, WSM ELECTRICAL SYSTEM (3) Angle System Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.
  • Page 403 KX080-4, WSM ELECTRICAL SYSTEM 2. Causes when a short [Test Conditions] 1. Key switch: OFF 2. If the connector wiring is pinched and touching the body, or if the insulation is damaged, repair it properly and check the angle solenoid operation again in the tester mode.
  • Page 404 KX080-4, WSM ELECTRICAL SYSTEM [E] Steps to Take after Completing Repairs 1. Delete failure record 1. While in the service/dealer mode, select Delete Fail Record and delete the record. 2. After deleting the record, start the engine again and check to make sure the warning is not shown on the meter panel.

  • Page 405: Auto Idling (Ai) System

    KX080-4, WSM ELECTRICAL SYSTEM [3] AUTO IDLING (AI) SYSTEM (1) AI System Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red.
  • Page 406 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each device visually and physically 1. Causes when a break in wiring [Test Conditions] 1. Key switch : OFF 2. AI console connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off.
  • Page 407 KX080-4, WSM ELECTRICAL SYSTEM [D] Testing the Equipment Itself 1. Testing the accelerator sensor [Measurement Conditions] 1. Key switch : OFF 2. Disconnect the accelerator sensor from the machine and test it separately. Factory specification Min. Max. Accelerator sensor 4 to 8 1 kΩ...

  • Page 408: Testing The Ai Pressure Switch

    KX080-4, WSM ELECTRICAL SYSTEM (2) Testing the AI Pressure Switch [A] Checking the Meter Panel 1. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Check the operation of the AI pressure switch according to the table below.
  • Page 409 KX080-4, WSM ELECTRICAL SYSTEM [C] Testing with a Circuit Tester (a) AI pressure switch (b) Main (signal) connector (c) Engine (signal) connector (d) Main ECU connector connector • If connectors (b) (c) are removed, the engine will crank but not start.
  • Page 410 KX080-4, WSM ELECTRICAL SYSTEM [D] Testing the Equipment Itself 1. Testing the AI pressure switch [Test Conditions] 1. Key switch: OFF 2. Disconnect the AI pressure switch connector from the control valve and attach the tester. 3. Start the engine and check continuity when it is operating and when not operating.

  • Page 411: Testing The Ai Switch

    KX080-4, WSM ELECTRICAL SYSTEM (3) Testing the AI Switch [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. When the AI switch (a) on the panel is pressed, check whether the AI lamp (b) lights or is off.
  • Page 412 KX080-4, WSM ELECTRICAL SYSTEM [C] Testing with a Circuit Tester 1. Voltage check [Measurement Conditions] 1. Disconnect the AI console connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- Connector Name Connector Name sure- Pin No.
  • Page 413 KX080-4, WSM ELECTRICAL SYSTEM [E] Steps to Take after Completing Repairs 1. Delete failure record 1. While in the service/dealer mode, select Delete Fail Record and delete the record. 2. After deleting the record, start the engine again and check to make sure the warning is not shown on the meter panel.

  • Page 414: Anti-Theft (At) System

    KX080-4, WSM ELECTRICAL SYSTEM [4] ANTI-THEFT (AT) SYSTEM (1) Anti-Theft System Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.
  • Page 415 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Causes when a break in wiring [Measurement Conditions] 1. Key switch : OFF 2. Anti-theft connector disconnected. 3. There is a break somewhere in the wiring. Pull on the harness and make sure the connector/harness does not come off.
  • Page 416 KX080-4, WSM ELECTRICAL SYSTEM 2. Continuity check [Measurement Conditions] 1. Key switch: OFF 2. Disconnect the connector to be tested. 3. Test the continuity based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No. Connector Name (- terminal side) Pin No.

  • Page 417: Power Supply System

    KX080-4, WSM ELECTRICAL SYSTEM [5] POWER SUPPLY SYSTEM (1) Over Voltage [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.

  • Page 418: Short System Error

    KX080-4, WSM ELECTRICAL SYSTEM (2) 5 V Short System Error [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.

  • Page 419: Communication System

    KX080-4, WSM ELECTRICAL SYSTEM [6] COMMUNICATION SYSTEM (1) CAN Communication Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.
  • Page 420 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Checking fuses 1. Check if the 5A ECU (+B) fuse is blown. RY9212158ELS0008US0 2. Causes when a break in wiring [Test Conditions] 1. Key switch: OFF 2. Check whether the joint connector is disconnected.
  • Page 421 KX080-4, WSM ELECTRICAL SYSTEM 3. Causes when a break in wiring [Test Conditions] 1. Key switch: OFF 2. Check if the relay connector (16 pin) is disconnected. 3. Check whether the engine ECU connector is disconnected. (a) Relay connector (16-pin)
  • Page 422 KX080-4, WSM ELECTRICAL SYSTEM [C] Testing with a Circuit Tester (a) Main ECU connector (d) Joint connector Main (signal) connector (h) Engine ECU (58 pin) (b) Meter panel connector (e) Engine (signal) connector (g) Engine ECU (96 pin) connector (c) CAN comm connector...
  • Page 423 KX080-4, WSM ELECTRICAL SYSTEM CAN communication error (main) 1. Voltage check [Measurement Conditions] 1. Disconnect the ECU connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No.
  • Page 424 KX080-4, WSM ELECTRICAL SYSTEM CAN communication error (CRS) 1. Voltage check [Measurement Conditions] 1. Disconnect the ECU connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Meas urem Connector Name (+ terminal side) Pin No.

  • Page 425: Aux System

    KX080-4, WSM ELECTRICAL SYSTEM [7] AUX SYSTEM (1) AUX1 / AUX2 (Thumb) System Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red.
  • Page 426 KX080-4, WSM ELECTRICAL SYSTEM [B] Inspecting each Device Visually and Physically 1. Causes when a break in wiring [Test Conditions] 1. Key switch: OFF 2. AUX1/AUX2 solenoid connector disconnected. 3. AUX control lever connector disconnected. 4. There is a break somewhere in the wiring.
  • Page 427 KX080-4, WSM ELECTRICAL SYSTEM 1. Voltage check (AUX hold switch) [Measurement Conditions] 1. Disconnect the AUX1/AUX2 control lever connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No.
  • Page 428 KX080-4, WSM ELECTRICAL SYSTEM 4. Continuity check (AUX1/AUX2 switch) [Measurement Conditions] 1. Key switch: OFF 2. Disconnect the connector to be tested. 3. Test the continuity based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No.
  • Page 429 KX080-4, WSM ELECTRICAL SYSTEM 1. Continuity check (AUX1 solenoid) [Measurement Conditions] 1. Key switch: OFF 2. Disconnect the connector to be tested. 3. Test the continuity based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No.
  • Page 430 KX080-4, WSM ELECTRICAL SYSTEM [E] Steps to Take after Completing Repairs 1. Delete failure record 1. While in the service/dealer mode, select Delete Fail Record and delete the record. 2. After deleting the record, start the engine again and check to make sure the warning is not shown on the meter panel.

  • Page 431: Eco Mode System

    KX080-4, WSM ELECTRICAL SYSTEM [8] ECO MODE SYSTEM (1) EP System Errors [A] Checking the Meter Panel 1. Information displayed on the meter panel 1. Check whether or not the warning lamp (a) on the panel is blinking red. 2. Press the info button (b) and check the additional content.
  • Page 432 KX080-4, WSM ELECTRICAL SYSTEM 3. Tester mode 1. Select the tester mode. 2. Start the engine. 3. Put the machine's lever lock in the unlock position and press the EP switch. 4. Operate the EP switch and check operation of the EP switch and EP solenoid based on the table below.
  • Page 433 KX080-4, WSM ELECTRICAL SYSTEM [C] Testing with a Circuit Tester (a) EP Solenoid Connector (b) Travel Pressure Sensor (c) Main ECU Connector Connector RY9212148ELS0198US0 1. Voltage check (EP solenoid) [Measurement Conditions] 1. Disconnect the EP solenoid connector. 2. Key switch: ON 3.
  • Page 434 KX080-4, WSM ELECTRICAL SYSTEM 3. Voltage check (travel pressure sensor) [Measurement Conditions] 1. Disconnect the travel pressure sensor connector. 2. Key switch: ON 3. Measure the voltage based on the table below. Mea- sure- Connector Name (+ terminal side) Pin No.
  • Page 435 KX080-4, WSM ELECTRICAL SYSTEM [E] Steps to Take after Completing Repairs 1. Delete failure record 1. While in the service/dealer mode, select Delete Fail Record and delete the record. 2. After deleting the record, start the engine again and check to make sure the warning is not shown on the meter panel.

  • Page 436: Cabin

    CABIN KiSC issued 08, 2015 A...

  • Page 437: Mechanism

    MECHANISM CONTENTS 1. AIR CONDITIONING SYSTEM ....................5-M1 [1] STRUCTURE ........................5-M1 [2] HOW THE MECHANISMS OF THE SYSTEM WORK ............5-M2 [3] COMPRESSOR........................5-M3 [4] AIR CONDITIONING UNIT....................5-M6 [5] CONDENSER........................5-M11 [6] RECEIVER ......................... 5-M12 [7] PRESSURE SWITCH......................5-M13 [8] ELECTRICAL SYSTEM......................

  • Page 438: Air Conditioning System

    KX080-4, WSM CABIN 1. AIR CONDITIONING SYSTEM [1] STRUCTURE (1) Control panel (3) AC Unit (5) Condenser (7) Heater core (2) External air intake (4) Compressor (6) Receiver (8) AC filter The cabin is equipped with a high-capacity, low-profile air conditioner that can circulate cabin air or bring in fresh air from outside.

  • Page 439: How The Mechanisms Of The System Work

    KX080-4, WSM CABIN [2] HOW THE MECHANISMS OF THE SYSTEM WORK (1) Capillary Tube (Heat Sensitive (7) Condenser A : Cooled Air E : High Pressure/Temperature Capillary Tube) (8) Receiver B : Low Pressure and (2) Expansion Valve (9) Dryer...

  • Page 440: Compressor

    KX080-4, WSM CABIN [3] COMPRESSOR The vane type of compressor installed in this system is composed of a cylinder (1) that is elliptical in cross-section, along with five vanes (3) attached to the rotor (2). This vane compressor has two each of intake and discharge ports.
  • Page 441 KX080-4, WSM CABIN Magnetic Clutch A magnetic clutch is a device that governs the mechanical linkage between the engine and the compressor. When the engine is rotating and the AC switch is on, air at cabin temperature comes out and...
  • Page 442 KX080-4, WSM CABIN Temperature Sensor A temperature sensor is installed on the head of the vane type of compressor. This sensor detects the temperature of the refrigerant and when the refrigerant becomes unusually hot, it cuts off the magnetic clutch, stopping the compressor.

  • Page 443: Air Conditioning Unit

    KX080-4, WSM CABIN [4] AIR CONDITIONING UNIT (A) Diagram of Linkages and Electrical Parts The diagram above was created for general explanations of the air conditioning unit, so it may differ from the air conditioning unit installed in the machine covered by this workshop manual. Similarly, this does not guarantee the parts used inside the air conditioning unit are the same.
  • Page 444 KX080-4, WSM CABIN Evaporator The evaporator takes the refrigerant, which has been made liquid by the condenser and cooled and put under low-pressure expansion valve, evaporating it, the heat and humidity of the air passing through the evaporator is removed, thus producing cool, dehumidified air.
  • Page 445 KX080-4, WSM CABIN Blower resistor Acts as the blower switch and controls the rpm of the blower motor by switching the degree of resistance. The fan speed can be switched to three levels, 1, 2 and 3, with 3 being the fastest.
  • Page 446 KX080-4, WSM CABIN Expansion Valve [Functions] The expansion valve works in the following two ways. 1. By spraying the liquid refrigerant, which is hot and under high pressure, it makes it expand rapidly, producing a low-temp, low-pressure refrigerant vapor. 2. It adjusts the amount of refrigerant according to the vaporized state of the refrigerant in the evaporator.
  • Page 447 KX080-4, WSM CABIN Fin Thermistor (for frost control) [Function] Senses the temperature of the fins of the evaporator and when they are too cold, it stops the compressor and prevents frost from forming before it happens. [How it Works] The sensor of the fin thermistor senses the...

  • Page 448: Condenser

    KX080-4, WSM CABIN Servo Motor (for adjusting temperature) The servo motor is composed of a motor, a potentiometer, movable contacts, etc., and operates according to signals from the AC's CPU. The servo motor uses a DC ferrite motor and rotates forward and reverse.

  • Page 449: Receiver

    KX080-4, WSM CABIN [6] RECEIVER The receiver is composed of a receiver tank, dryer, strainer and a receiver tube. [Receiver Tank] In the AC system, the rpm of the compressor changes in response to changes in the engine rpm, so the appropriate amount of refrigerant in the cooling circuit also changes.

  • Page 450: Pressure Switch

    KX080-4, WSM CABIN [7] PRESSURE SWITCH This dual type of switch detects unusually high and low pressures in the cooling cycle. If the pressure gets abnormally high or, due to a leak, abnormally low, it may damage the equipment or deteriorate the lubricating ability of the compressor oil, leading to scorching and breakdown.

  • Page 451: Electrical System

    KX080-4, WSM CABIN [8] ELECTRICAL SYSTEM (1) Electrical Circuits (1) Battery (13) Blower Switch (Shorting Type) (A) Fixed Voltage Circuit (h) (Free) (2) Slow-Blow Fuse (80A) (14) Compressor Clutch Relay (B) Servo Motor Drive Circuit Servo Motor Output1 (3) Slow-Blow Fuse (50A)

  • Page 452: Relays

    KX080-4, WSM CABIN (2) Relays Current flows in the components of the AC system to the blower motor and compressor's magnetic clutch. If all of the current were supplied via the main switch, the current would be too much for the switch, so the contacts of the main switch would be in danger of burning out.

  • Page 453: Blower Switch

    KX080-4, WSM CABIN (3) Blower Switch When the blower switch is in the LO, MI, or HI position (1) Battery (9) Headlight Switch (16) Compressor Magnetic Clutch (A) Fixed Voltage Circuit (2) Slow-Blow Fuse (80A) (10) Blower Motor Relay (17) Fin thermistor (Frost Sensor)

  • Page 454: Wiper

    KX080-4, WSM CABIN 2. WIPER [1] WIPER SWITCH This switch has four positions, namely (a), (b), (c) and (d) as indicated in the figure. When the starter key is in its [RUN] position and the switch is pressed to its (b) position, the wiper motor operates;...

  • Page 455: Wiper Motor

    KX080-4, WSM CABIN [3] WIPER MOTOR A cylindrical ferrite magnet and an armature are assembled inside the housing of the wiper motor. A worm gear and a helical gear are attached to the end of the armature and act as reduction gears and the rod...

  • Page 456: Servicing

    SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICE SPECIFICATIONS ......................5-S4 3. TORQUE .............................5-S5 4. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM ........5-S6 [1] USE OF SERVICE TOOLS ....................5-S6 (1) Manifold Gauge Set......................5-S6 (2) Refrigerant Charging Hoses ....................5-S8 (3) Vacuum Pump Adapter ....................5-S9 (4) Electric Gas Leak Tester ....................5-S9 (5) Canister Tap Valve ......................5-S9 (6) T-Joint..........................5-S10 (7) R134a Refrigerant Collection/Recycling Device............5-S10...
  • Page 457 [2] REMOVING GLASS ......................5-S52 [3] INSTALLING GLASS......................5-S53 [4] GLASS TRIM TYPE......................5-S54 [5] HOW TO REPLACE THE GLASS OF THE RIGHT-SIDE WINDOW ........5-S54 10. FRONT WINDOW........................5-S57 [1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP) ......5-S57 [2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP) ........5-S58 KiSC issued 08, 2015 A...

  • Page 458: Troubleshooting

    KX080-4, WSM CABIN 1. TROUBLESHOOTING Compressor Problem and/or Possible Cause Solution Situation Wearing of or damage to the compressor's Replace bearings Compressor valve damaged Replace Noise (compressor on) Belt slipping Adjust or replace Compressor bracket mounting bolt(s) loose Tighten Lines vibrating...
  • Page 459 KX080-4, WSM CABIN Problem and/or Possible Cause Solution Situation Thermistor broken Replace Hot water valve damaged Replace Not cooling effectively (other) Condenser clogged with dirt or debris Clean Expansion valve broken Replace Hot water valve damaged Replace Not heating effectively...
  • Page 460 KX080-4, WSM CABIN Problem and/or Possible Cause Solution Situation Not enough refrigerant Check with a manifold gauge Frost on the evaporator Clean or replace Not cooling effectively (low-pressure level too Error in the low-pressure line Replace low) (cracked or clogged)

  • Page 461: Service Specifications

    KX080-4, WSM CABIN 2. SERVICE SPECIFICATIONS Allowable Limit Item Factory specification Value 0.30 to 0.65 mm AC Compressor Magnetic Clutch Air Gap – 0.0118 to 0.0255 in. Electrical Magnetic Clutch Stator Coil 3.0 to 4.0 Ω – Resistance 0.15 to 0.20 MPa Pressure 1.5 to 2.0 kgf/cm...

  • Page 462: Torque

    KX080-4, WSM CABIN 3. TORQUE The following table indicates the specified tightening torque for nuts. Items N·m kgf·m lbf·ft Condenser mounting M8 nut 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 Compressor mounting M8 bolt 16.7 to 19.6 1.7 to 2.0 12.3 to 14.5...

  • Page 463: Precautions When Repairing The Refrigerant System

    KX080-4, WSM CABIN 4. PRECAUTIONS WHEN REPAIRING THE REFRIGERANT SYSTEM [1] USE OF SERVICE TOOLS (1) Manifold Gauge Set Always follow the warnings and regulations below when inspecting or repairing the air conditioning system. It is also extremely important that no one other than specially trained service personnel handles refrigerants.
  • Page 464 KX080-4, WSM CABIN • Hand tighten when connecting the charging hose to the canister's tap valve. Do not use pliers to tighten the charging hose. • Store refrigerant containers in a cool, dark place and never leave them in direct sunlight or in a hot place.

  • Page 465: Refrigerant Charging Hoses

    KX080-4, WSM CABIN With low and high pressure valves open The following circuits are formed. Port (A) → High-pressure gauge (2) Port (A) → Low-pressure gauge (1) Port (A) → Port (B) Port (A) → Port (C) Port (A) → Port (D) (Be sure to open the valve core.) CAUTION •...

  • Page 466: Vacuum Pump Adapter

    KX080-4, WSM CABIN (3) Vacuum Pump Adapter Purpose of the Vacuum Pump Adapter 1. After the AC cooling system is vacuumed, when the vacuum pump is stopped, there is a vacuum inside the hoses of the manifold gauge, so the oil of the vacuum pump flows back into the refrigerant charging hose.

  • Page 467: T-Joint

    KX080-4, WSM CABIN (6) T-Joint A T-joint (2) is used when using two refrigerant canisters (4) at the same time to make gas recharging more efficient. 1. Attach a refrigerant canister service valve on each side of the T-joint (2) and connect a refrigerant charging hose (1) to the T-joint.

  • Page 468: Inspecting And Charging The Refrigerant System

    KX080-4, WSM CABIN 5. INSPECTING AND CHARGING THE REFRIGERANT SYSTEM [1] CHECKING THE SYSTEM WITH A MANIFOLD GAUGE IMPORTANT • Be aware that the gauge pressure values noted in the following test are measured under identical conditions and they may vary somewhat from your gauge pressure values, depending on the prevailing conditions.
  • Page 469 KX080-4, WSM CABIN Without enough refrigerant 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too low. Low-pressure side (1) : 0.05 to 0.10 MPa (0.5 to 1.0 kgf/cm 7.1 to 14.2 psi) High-pressure side (2) : 0.69 to 0.98 MPa (7 to 10 kgf/cm...
  • Page 470 KX080-4, WSM CABIN Air mixed into the cycle 1. Symptoms that appear in the refrigerant cycle • Both high (2) and low (1) side pressures are too high. Low-pressure side (1) : 0.20 to 0.35 MPa (2.0 to 3.5 kgf/cm 28.4 to 49.8 psi)
  • Page 471 KX080-4, WSM CABIN Refrigerant fails to circulate 1. Symptoms that appear in the refrigerant cycle • Low-pressure side (1) becomes a vacuum and the high-pressure side (2) is at low pressure. Low-pressure side (1) : Vacuum; High-pressure side (2) : 0.49 to 0.59 MPa (5 to 6 kgf/cm 71.2 to 85.3 psi)

  • Page 472: Collection, Vacuuming And Charging

    KX080-4, WSM CABIN [2] COLLECTION, VACUUMING AND CHARGING IMPORTANT • Follow 4. Precautions when Repairing the Refrigerant Cycle when discharging, vacuuming and charging the refrigerant system. RY9212001CAS0026US0 (1) Collecting Refrigerant Get a R134a refrigerant collection/recycling device ready to use. 1. Connect the low-pressure hose (blue) (4) from the refrigerant collection/recycling machine to the low-pressure side charge valve (1).
  • Page 473 KX080-4, WSM CABIN Manifold gauge connections and vacuuming 1. Close the high-pressure (HI) and low-pressure (LO) valves of the manifold gauge. 2. Connect the L-shaped side of 2 charging hoses to quick joints and connect them to the compressor and receiver service valves.

  • Page 474: Charging From The High-Pressure Side

    KX080-4, WSM CABIN (3) Charging from the High-Pressure Side Charging from the High-pressure Side CAUTION • Important : do not start the engine. If the engine is running, the gas will flow back and burst either the service canister or a hose.

  • Page 475: Inspections And Troubleshooting

    KX080-4, WSM CABIN (5) Inspections and Troubleshooting [A] Checking the Quantity of AC Gas Checking with a manifold gauge manifold gauge values indicated below measurements taken under the specified conditions. Please note that the measurements you take will vary depending on the prevailing conditions.
  • Page 476 KX080-4, WSM CABIN Checking with the sight glass Conditions Doors All open Inside/outside air switch Inside Ambient air temperature 30 to 35 °C (86 to 95 °F) Engine RPM About 1500 rpm Temperature control Max cooling position Blower switch Criteria No air bubbles at all in the flow.

  • Page 477: Inspection And Disassembly

    KX080-4, WSM CABIN 6. INSPECTION AND DISASSEMBLY [1] CHECKS AND ADJUSTMENTS (1) Compressor Magnetic clutch 1. Start the engine. 2. With the AC switch on the AC control panel off, check and make sure that no scraping sounds or other noise comes from the pulley as it turns.
  • Page 478 KX080-4, WSM CABIN Adjusting clearance 1. Use a feeler gauge to check the clearance. 2. If the measurement is outside the factory specification, adjust the clearance. 0.30 to 0.65 mm Clearance Factory specification 0.0118 to 0.0255 in. [NOTE] Shim Thickness Part No.

  • Page 479: Relays

    KX080-4, WSM CABIN (2) Relays Blower motor inspection 1. Key switch: STOP 2. Check whether the blower motor fuse (30A) is blown. Criteria Regular: no break Irregular: has a break 3. Switch the blower motor and horn relays. 4. Start the engine, then turn the fan switch to [3] and check if it works.
  • Page 480 KX080-4, WSM CABIN Blower motor inspection 1. Key switch: STOP 2. Take out the blower motor relay. 3. Measure the resistance based on the table below. Mea- Relay terminal Relay terminal sure- (+ terminal side) (- terminal side) ment Factory spec: 92 to 112 Ω...

  • Page 481: Blower Motor

    KX080-4, WSM CABIN (3) Blower Motor Checking the Voltage 1. Remove the blower motor connector. 2. After starting the engine, set the fan switch on [3]. Measure the voltage based on the table below. Mea- sure- Connector Name Connector Name ment Pin No.

  • Page 482: Blower Resistor

    KX080-4, WSM CABIN (4) Blower Resistor Checking the Voltage 1. Remove the blower motor connector. 2. After starting the engine, set the fan switch off. 3. Measure the voltage based on the table below. Mea- Connector Name Connector Name sure-...

  • Page 483: Blower Switch

    KX080-4, WSM CABIN (5) Blower Switch Voltage check 1. Disconnect the blower switch connector. 2. Turn the key switch to the RUN position. 3. Measure the voltage based on the table below. Mea- Connector terminal Connector terminal sure- name (+ terminal...

  • Page 484: Servo Motor (For Temp Control)

    KX080-4, WSM CABIN (6) Servo Motor (for Temp Control) Voltage check 1. Disconnect the servo motor connector. 2. Turn the key switch to the RUN position. 3. Measure the voltage based on the table below. Mea- Connector terminal Connector terminal...

  • Page 485: Pressure Switch

    KX080-4, WSM CABIN (7) Pressure Switch When a pressure switch (inside the high-pressure/low-pressure switch) is operating normally, electricity is conducted (ON) and when an abnormal pressure occurs, it trips the switch, blocking the electricity (OFF). RY9212001CAS0046US0 Manifold gauge connections 1. Close the HI (high-pressure side) valve (3) and the LO (low-pressure side) valve (2) of the manifold gauge (1) securely.

  • Page 486: Disassembly And Assembly

    KX080-4, WSM CABIN [2] DISASSEMBLY AND ASSEMBLY (1) AC Unit Assembly/Disassembly (1) AC Unit (3) Filter (5) Collar (a) To rear duct (2) AC step (4) Bolt RY9212158CAS0005US0 5-S29 KiSC issued 08, 2015 A...

  • Page 487: Mounting And Removing The Compressor

    KX080-4, WSM CABIN (2) Mounting and Removing the Compressor (1) Compressor ASSY (3) V belt (5) Compressor bushing (a) Point to measure (2) Compressor bracket (4) Bolt compressor belt tension RY9212148CAS0029US0 Filling the Compressor with Oil When replacing the compressor •...
  • Page 488 KX080-4, WSM CABIN When replacing the compressor, press at point (a) on the drive belt and adjust the tension. IMPORTANT • Be careful that the compressor bushing faces the right direction. 98 N 20 to 25 mm Belt tension adjustment 10.0 kgf...

  • Page 489: Ac And Heater Hose Routing

    KX080-4, WSM CABIN (3) AC and Heater Hose Routing [A] AC Hose (1) Discharge hose (4) Liquid hose P2 (a) Compressor side (A) M24X1.5 connection (2) Suction hose 2 (5) Liquid hose P1 (b) Condenser side (B) M16X1.5 connection (3) Suction hose 1...
  • Page 490 KX080-4, WSM CABIN [B] Hose Routing (1) Discharge hose (3) Liquid hose (a) 25 ° (0.44 rad) (2) Suction hose 2 (4) Liquid hose P2 RY9212158CAS0007US0 5-S33 KiSC issued 08, 2015 A...

  • Page 491: Electric Condenser/Fan Mounting And Removal

    KX080-4, WSM CABIN (4) Electric Condenser/Fan Mounting and Removal (1) Condenser cover (4) Liquid hose (6) Cushion (a) Electrical wiring (2) Electric fan (5) Discharge hose (7) Condenser (3) Condenser base RY9212158CAS0008US0 5-S34 KiSC issued 08, 2015 A...
  • Page 492 KX080-4, WSM CABIN (1) Heater hose 3 (6) Heater hose 2 (a) Engine side discharge (e) To engine side (2) Liquid hose P1 (7) Liquid hose (b) Engine side return To AC unit side (3) Suction hose 1 (8) Discharge hose...

  • Page 493: Window Washer

    KX080-4, WSM CABIN 7. WINDOW WASHER [1] WIPER SWITCH Connector voltage 1. Remove the 6P connector from the wiper switch. 2. Switch the starter switch to [RUN] and the wiper switch to ON. 3. Measure the voltage between terminal 1of the connector on the harness side and ground on the body.

  • Page 494: Wiper Motor

    KX080-4, WSM CABIN [2] WIPER MOTOR Checking the Voltage 1. Remove the wiper motor connector. 2. Start the engine and turn the wiper switch ON. Measure the voltage based on the table below. Mea- sure- Connector Name Connector Name ment Pin No.

  • Page 495: Cabin Glass Removal And Mounting

    KX080-4, WSM CABIN 8. CABIN GLASS REMOVAL AND MOUNTING [1] COMPONENT SCHEMATIC Part Name Q'ty Part Name Q'ty Striker (door) (16) Bolt Toothed washer (17) Bolt Screw (18) Screw Knob (19) Handle Screw (20) Spring nut Bolt (21) Seal Handle ASSY (inner)
  • Page 496 KX080-4, WSM CABIN Part Name Q'ty Part Name Q'ty Spacer Roof Front glass Glass Rear glass Cushion Hook (10) Glass Sash (11) Spacer Spacer RY9212148CAS0077US0 5-S39 KiSC issued 08, 2015 A...
  • Page 497 KX080-4, WSM CABIN Part Name Q'ty Part Name Q'ty Stopper (11) Lever Linkage (12) Bolt Bolt (13) Cover Bushing (14) Cover Snap ring (15) Clip Linkage (16) Striker Snap ring (17) Bolt Damper (18) Stopper (rubber) Washer (19) (10) Lever...
  • Page 498 KX080-4, WSM CABIN Part Name Q'ty Part Name Q'ty (11) Cover Arm (wiper) (12) Clip (13) Screw Blade (wiper) (14) Nozzle (15) Clamp Washer (16) Bolt Gasket (17) Hose Holder (18) Flange Wiper Motor (19) Washer tank (10) Bolt RY9212148CAS0079US0...

  • Page 499: Necessary Tools

    KX080-4, WSM CABIN Part Name Q'ty Part Name Q'ty Spacer Roof Front glass Glass Rear glass Cushion Hook (10) Glass Sash (11) Spacer Spacer RY9212148CAS0080US0 [2] NECESSARY TOOLS (1) Piano Wire (7) Torx (T50) (2) Scraper (8) Wrench (10 mm)

  • Page 500: Removing The Glass On The Right

    KX080-4, WSM CABIN [3] REMOVING THE GLASS ON THE RIGHT 1. Protect inside cabin from possible glass debris. CAUTION • Take care not to get hurt from shards of glass. (1) Cover RY9212148CAS0037US0 2. Insert the utility knife between the frame of the cabin and the right sash to make an opening to pass the piano wire through.

  • Page 501: Removing The Front Glass

    KX080-4, WSM CABIN 8. Expand the frame of the right sash in direction A and remove the glass in direction B. RY9212148CAS0042US0 [4] REMOVING THE FRONT GLASS 1. Remove the bolts and then the wiper. 2. Remove the cap. (1) Nut...
  • Page 502 KX080-4, WSM CABIN 6. Remove the cap and the cover. (LH/RH 2 places each) (1) Cap (2) Cover RY9212148CAS0047US0 7. With the front glass closed, remove the 4 bolts. (LH/RH 2 places each) (1) 4 × Bolt (M6 × 10) RY9212148CAS0048US0 8.

  • Page 503: Removing Other Panes Of Glass

    KX080-4, WSM CABIN [5] REMOVING OTHER PANES OF GLASS 1. Protect inside cabin from possible glass debris. 2. Insert the utility knife between the cabin frame and the glass to make an opening to pass the piano wire through. CAUTION •...
  • Page 504 KX080-4, WSM CABIN 4. Expand the sash in direction A and install the 1st pane of glass in direction B, then the seal and then the 2nd pane of glass. (1) Seal RY9212148CAS0056US0 5. Put the end of the seal back in place with a slotted screwdriver.

  • Page 505: Installing The Front Glass

    KX080-4, WSM CABIN 9. Use suction pads to install the sash. 10. Use tape or the like to hold it in place until the adhesive hardens. IMPORTANT • Take care not to drop the glass. • After installation, leave to cure for at least 24 hours.
  • Page 506 KX080-4, WSM CABIN 5. Inject adhesive into the gap between the front glass and the frame. IMPORTANT • Take care so the adhesive does not stick out. RY9212148CAS0064US0 6. Put a weight on the glass to the adhesive hardens. IMPORTANT •...
  • Page 507 KX080-4, WSM CABIN 10. Install the wiper motor. 3.5 to 6.5 N·m Tightening torque Bolt (2) 0.36 to 0.66 kgf·m 2.58 to 4.79 lbf·ft (1) Wiper Motor (2) 3 × Bolt (M6 × 25) RY9212148CAS0069US0 11. Install the wiper motor harness, cover and cap.

  • Page 508: Installing Other Panes Of Glass

    KX080-4, WSM CABIN [8] INSTALLING OTHER PANES OF GLASS 1. Use the scraper and the cleaning agent to remove any remaining adhesive, grime or oil on the frame and then apply the trim to the frame. 2. Apply primer and allow to dry for the indicated time.

  • Page 509: Removal And Installation Of Glass

    KX080-4, WSM CABIN 9. REMOVAL AND INSTALLATION OF GLASS [1] PREPARATION Items required • Cleaner : Equivalent of Seeker Cleaner 205 • Adhesive : Equivalent of Seeker Flex 250PC-JM • Primer : Equivalent of Seeker Primer 206 • Scraper • Awl •...

  • Page 510: Installing Glass

    KX080-4, WSM CABIN [3] INSTALLING GLASS 1. Completely eliminate all old adhesive on the frame of the cab. 2. Use the cleaner to clean the cab frame and the surface of the new glass where adhesive will be applied to get rid of any dirt or oil.

  • Page 511: Glass Trim Type

    KX080-4, WSM CABIN [4] GLASS TRIM TYPE (When removing) 1. Lift the rubber core by its seam and remove it. 2. Remove the glass to the outside. (When attaching) 1. From the outside, insert the glass into the glass trim.
  • Page 512 KX080-4, WSM CABIN How to apply primer on the cab side 1. Remove dirt and grease on the opening surface of the glass sash's flange with a cleaner such as white gasoline. Avoid using an alcoholic cleaner. 2. Apply body primer evenly all around of flange from the end.
  • Page 513 KX080-4, WSM CABIN How to install the glass sash 1. Set the glass in the sash on which the adhesive has been already applied and install to attach on the cabin frame. NOTE • Adhesive should not be run off the edge of the sash after the glass sash is set.

  • Page 514: Front Window

    KX080-4, WSM CABIN 10. FRONT WINDOW [1] ADJUSTING THE CLOSING LOCK OF THE FRONT WINDOW (TOP) When water leaks in the cabin or it rattles 1. Close the front window (top) and lock it securely. 2. Remove the trim on the top edge of the front window (top) about half way along the frame and measure the clearance between the glass and the cab frame.

  • Page 515: Adjusting The Open Lock Of The Front Window (Top)

    KX080-4, WSM CABIN [2] ADJUSTING THE OPEN LOCK OF THE FRONT WINDOW (TOP) When it rattles on the cabin 1. Lift the front window (top) and lock it securely to the ceiling. 2. While pulling down on the handle, check whether there is a gap between the glass and the cushion.
  • Page 516 GND4 CRS-ECU(58pin) B-18 CRS-ECU(58pin) GND4 DPF_OUTLET_TEMP_SENSOR CRSD: 0.75 f L/R CRSD: 0.75 f R/B GND4 GND4 to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND CRSD: 0.50 to_J/C-INJ/SLD-GND to_J/C-INJ/SLD-GND J/C-INJ/SLD-GND GND3 to_J/C-SLD-GND CRSD: 0.50 to_J/C-SLD-GND GND4 J/C-SLD-GND Electrical Circuit Diagram (KX080-4 US, CA)
  • Page 517 CAB_WORKLIGHT, E05_1 PUMP) B(-) C_OF02_M iniFuses C_CAM01_1 FUSE(CAB- WORKLIGHT) C_LAF01 C_OF02_M FUSE(WIPER/ _7009-1 iniFuses 836_1 WASHER) C_CAM01_1 C_WF16_7123 -7564-40_1 C_OF02_M FUSE(FUEL_ iniFuses SUPPLY_PUMP) GND4 C_OF02_M iniFuses GLOW,D C_OF02_M iniFuses C_LAF01 _7009-1 836_1 CONNECTOR CHART 1 (KX080-4 US, CA) C_LEF01_ M4_1...
  • Page 518 RELAY 3-209 TRAVEL_ALARM (COMPRESSOR) 0-30_ C_WM02_ C_OF05_M (REAR,GND) C_WF02_7283-2090-30 6187-28 -ISO_1 01_1 SOLENOID RESISTOR_ (TRAVEL_ BLOWER SPEED) C_CAM01_1 C_OF05_M -ISO_1 RELAY C_WF0 C_OF04_6 (CONDENSOR_ 098-0514 2_728 3-209 FAN) 0-30_ ROOM_LIGHT C_OF05_M -ISO_1 CONNECTOR CHART 2 (KX080-4 US, CA) C_OF03_6 130-2330...
  • Page 519 EDITOR: KUBOTA CORPORATION CONSTRUCTION MACHINERY SERVICE TECHNICAL SUPPORT DEPARTMENT 1-1 NAKAMIYA-OHIKE 1-CHOME, HIRAKATA-CITY, OSAKA, 573-8573, JAPAN PHONE : (81)72-840-1195 : (81)72-890-2883 E-mail : kbt_g.ce-sv@kubota.com Printed in Japan 2015. 08, H, EI, EI, engusa Code No. RY911-21601 KUBOTA Corporation Printed in Japan 2013.

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